Rock failure is one of the major concerns of drilling operation, especially in the formation with narrow drilling window, which may lead to several technical issues and even endanger the operation safety, such as wellbore collapse, stuck pipe, formation breakdown, lost circulation, etc. A new technology is proposed in this paper to prevent rock failure and maintain wellbore stability through controlling the annular pressure profile.
A new managed pressure drilling equipment named pressure control drilling system (PCDS) is developed which combines the constant bottom hole pressure technique and micro-flux control technique to quickly create overbalanced, near-balanced and underbalanced wellbore condition in the whole process of drilling operation. Based on the proposed MPD equipment, a novel technology is developed to maintain the annular pressure within the range of formation fracture pressure and formation collapse pressure, ensuring the formation rock to be neither shear failure nor tensile failure. Hydraulic calculation is performed before and during the drilling operation to predict the pressure profiles inside and outside the drill pipe, frictional pressure and equivalent circulating density, providing reference to the maintenance of wellbore stability. Real-time monitoring of multiple parameters such as properties of drilling fluid, bottom hole pressure and circulating flow rate as well as logging data is conducted to detect any minor change of down hole circulating system, minimizing the potential of wellbore collapse and formation breakdown.
The proposed technology has been applied in several onshore and offshore wells with a great success. Generally, a relatively low density of drilling fluid is used to cooperate the application of this new technology, due to its advantage of fast response to down hole conditions, minimizing the possibility of formation breakdown and formation damage as well as enhancing the rate of penetration. The easily collapsed formation is successfully drilled through with the assistance of the proposed technology by maintaining the annular pressure profile to be constant as pre-designed and eliminating the pressure fluctuations. Several incidences of early phase lost circulation are detected in time, and the annular pressure would be modified, avoiding the failure of the borehole wall rock, therefore prevent the serious losses.
On the basis of specific MPD equipment, this new technology gives drilling engineers a fast and effective way to ensure the borehole wall stability, thus eliminate the potential of multiple technical issues due to shear and tensile failure of borehole wall rock. Application of this technology could significantly improve the operation efficiency and enhance the economic benefits of drilling operation.