World Oil Webcast Q&A
What the static/dynamic pressure rating for active wellbore sealing system?
The static pressure rating of the ACD is 2000 psi. The dynamic pressure rating, as tested per API 16RCD, is 1500 psi at 160 RPM.
How long does it take to change out the seal sleeve, and can downhole pressure be maintained when changing the sleeve?
Seal sleeve change out takes 25-30 minutes when running in the hole, and 25-30 minutes when retrieving. ASBP can be maintained during both operations. The seal sleeve assembly is designed to account for stack misalignment as well as reducing any surge or swab during running and retrieval operations.
Is 160 rpm the maximum rpm for the ACD?
No, 160 RPM was the rotational speed used for the API monogram test program. It achieved a 1500 psi dynamic rating at this rotational speed. Additional qualification testing is planned for 220 RPM. The limit of the AFG test rig is 310 RPM.
Can the same sleeve be used for 6 5/8 and 5 DP? Which is the range of usage?
As with RCD elements, we make different seal sleeves sizes based on the specified drill pipe OD. We currently have 2 sizes of seal sleeves. The first has an ID of 8.75 inches and the second has an ID of 7.25 inches. For 5-in. drillpipe, we would recommend using the 7.25-in. seal sleeve so that the longest run time can be achieved. It is possible for the 8.75-in. seal to close on 5-in. pipe, but this would reduce the operational time of the seal sleeve and should only be done as a contingency.
Are your drilling-mode tests in excess of API 16RCD requirements?
Yes, the drill mode testing that occurs at the AFG test facility is in excess of API requirements. API 16RCD allows the use of two different test benched to qualify equipment. The first test bench is a stripping test bench that is only used for pipe reciprocation. The second test bench is a dynamic test bench that is only used for rotation. Although this is good testing, the true test of the equipment is when actual drilling conditions are simulated. The AFG test rig allows for this by providing the ability to test ACD at up to 310 RPM while simultaneously reciprocating at up to 2 ft per second. When we perform drill mode testing, we do this with the client in mind. We collaborate with either the contractor or the operator to determine a set of tests that will mirror what they predict to see in the field. Once these parameters are set, we can input them into the test rig and run the tests on actual seal sleeves. The results will give the client a great prediction of what to expect when field drilling begins.
Is there the possibility of having the ACD and DSIT in the same AFGlobal integrated riser joint?
Yes, we call this the unitized MPD joint and we have a customer who has purchased this configuration.
As sleeves wear, is there any risk of wearing packer element?
Because of the condition-based monitoring (CBM) feature, there is no risk of wearing the packer elements. During operation, the packer elements do not make contact with the drill pipe. The only time that they would contact the drill pipe is if the seal sleeve was completely worn through. There will be several indications before this would ever occur. The first in the real time CBM feature of the system, and the second would be a significant pressure change or unexpected large flow rate to the trip tank.
Is the urethane seal poured internally?
Yes, all elastomers associated with the ACD are manufactured at our internal elastomer facility. Each poured elastomers has an associated test coupon for traceability. Instead of batch testing, each individual elastomer is tested.
Can the element cartridges be serviced on the rig?
Yes, the seal sleeve cartridges can be serviced on the rig, with minimal tooling, in the horizontal or vertical orientation. They do not need to be shipped to a service center like RCD bearings.
Is the test rig available for third-party testing?
Yes, the test rig is available for third-party testing. We are currently testing for 2 operators.
As you move forward, where else will this system be deployed?
Three systems will be integrated in drilling by Q1 of 2020. All three of these systems will be drilling in the Gulf of Mexico.
Let's talk about system integration - to what extent was the system integrated on this project?
The system was fully integrated into the driller's chair. All communication was transferred via AFGlobal OPC server. All parties connected to this network for open communication.
Justin, how important will condition-based monitoring of the drill pipe seal be to future MPD operations?
Condition-based monitoring of the seal sleeves will allow the driller to properly plan for seal sleeve change out. This will bring efficiency to the operation by having the ability to schedule the retrieval of the seal sleeve assembly during a drilling operation that makes sense, instead of having to react immediately when it may be inconvenient.
Justin, what are key advantages of the ACD seal sleeve?
There are multiple advantages to the ACD when compared to an RCD. The first major advantage is the real time condition based monitoring that the ACD offers. This allows the drilling contractor to efficiently plan seal sleeve change outs so that it is done at a convenient time during the drilling sequence. Secondly, the ACD is an active system. The driller always has the ability to modify parameters of the system to maintain control over the operation. This is a major difference versus a passive RCD system. Lastly, when a seal sleeve assembly is not installed, the ACD provides two additional barriers to wellbore during conventional drilling operations.
What provisions are there for removal of debris plugging?
After retrieval of the seal sleeve assembly, it is recommended to run a jetting sub to clean the MPD joint. This is good practice offshore and is typically done, regardless of what MPD system is in service.