Abstract
A full-scale test facility is integral during design verification testing of an active Managed Pressure Drilling (MPD) wellbore sealing system as a means to rapidly deploy the technology. The Active Wellbore Sealing System uses a novel sealing element design. Through iterative Finite Element Analysis (FEA) modeling, elastomer composition changes, and immediate feedback from full-scale testing, the first-generation sealing element design performed as intended during its first deepwater field trial in live drilling operations. Further, as the testing took place, the crew was able to prepare and practice planned procedures in a safe environment prior to going offshore.
The test rig facility was upgraded for testing operations with the second-generation Active Wellbore Sealing System. The use of drilling mud combined with simultaneous stripping and rotation of drillpipe under realistic wellbore temperature and pressure enables ‘drilling mode’ testing which exceeds API 16RCD requirements. Use of production equipment at the test rig facilitates automation development to enhance wellbore seal life. Further, trained crews operate the MPD field equipment at the facility and can practice planned drilling procedures. By mirroring the conditions observed in the field, the test rig facility is instrumental in the delivery of project-ready MPD technologies.
This paper will share test data from the design verification testing program to demonstrate how use of the full-scale test center results in a project-ready system by simulating actual drilling conditions. Additional design verification testing of the second-generation Active Wellbore Sealing System is ongoing at the time of publication of this paper.
This paper shares results from the design verification testing. The program resulted in successful performance of the sealing element on its first trial. The continued execution of the program reduces the Non-Productive Time (NPT) and cost compared to conventional pilot projects through offline validation, systems integration testing, and ensuring personnel possess the required competencies to efficiently operate the equipment in the field.
Use of realistic wellbore temperature and pressure with simultaneous stripping and rotating to perform design verification testing was an essential part of the successful first test of the active wellbore seal. Test rig upgrades enable the use of drilling fluid and production equipment to test the second-generation Active Wellbore Sealing System.
