The Operational Benefit of Testing HPHT/MPD Procedures Using an Advanced Full Scale Drilling Simulator

Abstract

Abstract A challenging HPHT well was drilled with Managed Pressure Drilling. In the preparation phase, an advanced dynamic drilling simulator was used by the operator in order to test and verify operational procedures as well as the HPHT & MPD well control manual. This drilling simulator is based on advanced dynamic models developed from first principles, and will respond very realistically on the operators actions when "drilling", "circulating", "managing the well control problems" etc; like a "Drilling Flight Simulator". All relevant HPHT effects are modeled, like mud density, compressibility and rheology as function of Pressure and temperature; gas solubility in Oil Based Muds, transient thermal interaction in the well and surroundings etc. An MPD module has been developed in the simulator, allowing testing and training of all relevant procedures and operations related to MPD. Also, the drilling rig characteristics (pumps, surface lines, choke and BOP, MPD toolkit etc.) are modeled according to the real rig specifications. The testing lead to several significant changes to the operator's manual and operational procedures. At the same time it allowed the Engineering team to test and rectify the Drilling program prior to deployment of the operation. The MPD technique was tested in the simulator as well, and the various contingency procedures were assessed. It allowed the rig contractor, operator, and the MPD provider to find the operational routine, communication and best practice prior to start operation offshore. The team's decision trees where reviewed and updated during the simulator training. Since the crews actively had a part in the final revision in the manual, the operator experienced that the crews took an ownership in the making of the manual and the offshore operation. As a resultant effect, the drilling crew and MPD operators rapidly adapted to the MPD procedures agreed upon during training, when operation started. This paper will briefly present the advanced drilling simulator, and focus on the testing and verification of procedures and well control manual. The modifications done will be presented, and the operation itself will also be described, highlighting the benefits of utilizing the drilling simulator prior to operation.