IADC/SPE 136513

Advantages of Managed Pressure Drilling and the Recent Deployment of the

Technology in Vietnam
Steve Nas / Weatherford Solutions; Ben Gedge and Felbert Palao / Weatherford Vietnam; Nguyen Viet Bot /
PetroVietnam Drilling & Well Servcie Corporation
Copyright 2010, IADC/SPE Asia Pacific Drilling Technology Conference and Exhibition

This paper was prepared for presentation at the IADC/SPE Asia Pacific Drilling Technology Conference and Exhibition held in Ho Chi Minh City, Vietnam, 13 November 2010.

This paper was selected for presentation by an IADC/SPE program committee following review of information contained in an abstract submitted by the author(s). Contents of the paper have not
been reviewed by the International Association of Drilling Contractors or the Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessarily reflect
any position of the International Association of Drilling Contractors or the Society of Petroleum Engineers, its officers, or members. Electronic reproduction, distribution, or storage of any part of this
paper without the written consent of the International Association of Drilling Contractors or the Society of Petroleum Engineers is prohibited. Permission to reproduce in print is restricted to an
abstract of not more than 300 words; illustrations may not be copied. The abstract must contain conspicuous acknowledgment of IADC/SPE copyright.


Abstract
Managed Pressure Drilling (MPD) is a technology that accurately controls the annular pressure while drilling and completing
wells. The intention of MPD is to avoid continuous influx of formation fluids to the surface. Any influx incidental to the
operation will be controlled and circulated out and an overbalanced condition will be restored.

MPD can be used to reduce well construction times, which in todays high cost rig market is appealing to any exploration,
appraisal or field development team. The MPD technology can, to a certain degree reduce drilling fluid related formation
impairment, and can through the reduction of the mud weight reduce the cost of mud losses as well as the related non
productive time that is spend in curing losses.

MPD technology is now deployed extensively in the Asia-Pacific Region by many operators, to alleviate a range of pressure
related drilling problems. The main applications for MPD include pressurized mud cap to deal with the kick/loss situations in
fractured carbonates as well as constant bottom hole pressure systems in wells with narrow pore pressure fracture pressure
windows or in depleted reservoirs.

This paper is intended to enhance the understanding of the value delivered through the use of MPD techniques, together with
recommended equipment designs for each application. Some case studies will be used to quantify value delivery for a range of
equipment designs and to better define the operational issues associated with MPD operations.

Introduction
Since 2005, over 200 wells in the Asia Pacific Region have been drilled using MPD techniques by a number of operating
companies. MPD has delivered direct cost and time savings by eliminating the non-productive time associated with losses and
other related well control events. Being able to control wellbore pressures by using a closed wellbore system and introducing
the application of some simple techniques has allowed previously undrillable wells to be successfully drilled to TD.

Operators plan and budget wells for a certain number of days and then find that in the best case some 20% time spent on
curing losses and kicks is added to their well times. Yet other operators have encountered losses and well control issues that
double or even triple their planned well timings. Exceeding planned well times not only pushes drilling budgets past
acceptable limits, but it also has a knock on effect on the rig sequence especially if the rig is shared by other operators in the
region. Rigging up MPD equipment has allowed successful drilling of the fractured carbonates on all of the wells where the
equipment was rigged up. Not all of the wells encountered losses, and on these wells the equipment was rigged up but not
used. On the wells that did encounter the loss / kick scenarios, MPD enabled all of these wells to be drilled to TD without
significant delays.

Reasons for MPD
The main applications of MPD in Asia Pacific are the drilling of fractured carbonate formations. Total losses are often
experienced when fractures and vugs are encountered, and once fluid hydrostatic is lost, gas in the upper part of the carbonate
reservoir migrates rapidly to surface, resulting in a well control situation. Once the losses are cured and the well is brought
2 IADC/SPE 136513
under control, drilling resumes until the next fracture is encountered. At that point, the entire process of killing the well and
curing losses often repeats itself. Curing the losses with LCM, gunk squeezes or cement can be successful, but very often this
has detrimental effects on the productivity of the reservoir. Using underbalanced drilling (UBD) techniques is not suitable as
hydrocarbon delivery from a fractured carbonate reservoir can be large and handling large volumes of hydrocarbons,
especially on an offshore rig whilst drilling, adds to operational complications. Furthermore, crew size and equipment spread
for an offshore UBD operation becomes a further limiting factor in the application of UBD offshore. The ability to drill these
wells using MPD techniques has been proven to be highly successful.

MPD techniques are now also being applied more and more to all kinds of wells. The emergence of MPD techniques in mature
and depleted reservoirs has opened a number of infill drilling opportunities. In the depleted reservoirs the ability to
significantly reduce mud weights and still drill the virgin pressured reservoir provides a real advantage. In the High Pressure
High Temperature (HPHT) wells, the use of a closed wellbore can eliminate problems such as wellbore breathing or
ballooning and influx control. The use of a closed wellbore also allows drillstring movement during well control operations
and this eliminates potential stuck pipe incidents.

MPD Techniques
A total of four (4) MPD variations have been recognized. These variations are listed as:
HSE or Returns Flow Control (RFC)
Constant Bottom Hole Pressure (CBHP)
Dual Gradient (DG)
Pressurized Mud Cap Drilling (PMCD)

Three further techniques are often mentioned with MPD, but these are considered as sub-categories of the four MPD
variations. Floating Mud Cap is considered as a subcategory of the Pressurized Mud Cap technique. Friction Management and
Continuous Circulation Systems are both classified as sub-categories of the Constant Bottom Hole Pressure variation.

HSE or Returns Flow Control (RFC)
This technique does not control any annular pressure, but it can be considered as an essential part of the MPD definition as we
are tooling up to safely and more efficiently react to any downhole surprises. We also positively divert annulus returns away
from the rig floor, to prevent any gas, including and especially H
2
S from spilling onto the rig floor. It is used as a safety
measure. If an influx is taken whilst drilling the well, or trip gas or connection gas spills onto the rig floor, the flow line to the
shakers is closed and flow is immediately diverted to the rig choke manifold, where the influx is safely controlled and
circulated out of the hole. The use of the rotating control device (RCD) avoids the need for the closing of the BOP minimizes
the potential for hydrocarbon release onto the drill floor, and it allows pipe movement whilst circulating out an influx or
dealing with gas cut mud.

Constant Bottom Hole Pressure (CBHP)
The constant bottom hole pressure (CBHP) method is used for wells where the bottom hole pressure needs to be accurately
controlled to maintain the pressure within a narrow pore pressure and fracture pressure window. As circulation is stopped for
connections, the bottom hole circulating pressure reduces as a result of the loss of the annular friction losses or Equivalent
Circulating Density (ECD). Using MPD, this pressure loss can be compensated for by trapping surface pressure in the well.
Once circulation re-starts, the surface pressure is reduced to take the ECD into account and this keeps the bottom hole pressure
constant.

Friction Management
Friction management techniques are used in HPHT or in Extended Reach wells, where the annular pressure is maintained to
keep the bottom hole pressure as constant as possible. In HPHT wells, this is done by maintaining some kind of annular
circulation through the use of a concentric casing string. In ERD wells, the annular pressure loss often needs to be reduced to
achieve the required length and reach of the well. This can now be achieved through the use of an annular pump. The pump is
placed in the cased section of the well and pumps annular fluid back to surface thus reducing the annular friction pressures.
These friction management techniques are considered part of the CBHP variation.

Continuous Circulation Systems
This technique can also be considered under the CBHP variation. It keeps the ECD constant by not interrupting circulation
during drilling operations. The method is used on wells where the annular friction pressure needs to be constant and/or to
prevent cuttings settling in extended reach horizontal sections of the wellbore. The circulation can be maintained during
connections or other interruptions to drilling progress by using a special circulating BOP system or via continuous circulating
subs being added to the drill string.

IADC/SPE 136513 3
Dual Gradient (DG)
The dual gradient (DG) concept is best known for deepwater applications, where the marine riser is displaced to seawater to
avoid the mud column extending all the way from the rotary table to the seabed. Displacing the top of the well to seawater
simulates the rig being placed on the seabed; this avoids the high overbalance and the potential loss of circulation. However,
any application where a second fluid system is used in the same wellbore can be classed as DG drilling. The DG concept is
also applied in many MPD wells where a so called top kill is used to control the well. This is where a low density
underbalanced fluid is used in the bottom of the well and the well is controlled during tripping operations by placing a
higher density fluid at the top of the well. No deepwater DG operations have yet been conducted in Asia Pacific.

Pressurized Mud Cap Drilling (PMCD)
This is the most common MPD method used in Asia Pacific. This method is used to control wells that experience total losses
and kicks in the same well bore. The application of pressurized mud cap drilling (PMCD) is widely used in fractured and
vugular carbonate reservoirs where total fluid losses are experienced. To use PMCD, total losses must be experienced. To use
this technique, the losses must be large enough to take all of the fluids pumped down the drillstring and all of the cuttings
generated during the drilling process. If circulation, even partial circulation, was to be established, the mud cap would be
circulated out of the well. If circulation is possible, a well cannot use the PMCD method, and the CBHP method will have to
be used.

PMCD may be practiced in some situations where a total loss scenario is not encountered, but where total losses can be
induced by increasing the wellbore pressure profile.

Floating Mud Cap Drilling (FMCD)
Floating mud cap drilling (FMCD) is considered as a sub category of the PMCD technique. FMCD operations are used if the
annular fluid cannot be designed to provide surface pressure in the annulus, in which case the mud cap is called floating. In an
FMCD operation, sacrificial fluid (normally water) is pumped down the drillpipe, as in PMCD. The pressure of the reservoir
can be below hydrostatic so that the annulus cannot be kept full of fluid. The annulus fluid level will drop down to a balance
point in the well. The top of the fluid in the well may be too deep to monitor and this will make it very difficult to monitor any
influx or gas migration. The FMCD method is in effect drilling blind and there is only limited annular pressure control.

Some new technology such as wired drillpipe may unlock FMCD techniques by allowing pressure monitoring along the
drillstring, thus providing enhanced well control options. Fluid technologies using lightweight solid additives such as glass
beads are also being considered to achieve mud cap operations when drilling sub-hydrostatically pressured reservoirs.

MPD Requirements
Typically, the following main points will need to be considered:
Installation of RCD, mainly associated with space requirements between the RCD and the bottom of the rotary table.
Return flow line system that allows MPD operations as well as conventional drilling operations
MPD choke manifold and gas handling equipment.
Marine riser issues for MPD operations on floating rigs

It is rare that significant rig modifications are required for MPD operations. On some land rigs, additional space is required
between the annular and the rotary table to fit the RCD. This additional space is normally created by raising the substructure of
the rig. On offshore rigs, the only modifications normally required are the welding of tie-in points for the main flow line to
ensure returns can be taken back to the shakers.

Equipment Requirements
Depending on the MPD method required, the rig up will vary a little. The RCD is required in all of the operations. The rig
Secondary well control equipment should not be used for routine drilling operations. Once that policy is applied the remainder
of the equipment requirements are easily identifiable.

For PMCD operations, a flow spool is normally installed below the RCD to allow fluid to be pumped into the annulus. The rig
up for this set up is shown in Fig 6. The manifold on the left hand side of the RCD is the bleed off manifold that is used to be
able to keep the well full from the trip tank. It also allows any pressure to bled off from the stack should this be required when
changing RCD packers.

For CBHP operations, a separate MPD choke manifold must be installed in the return flow line to allow back pressure to be
applied during the drilling process. If a choke is used and surface pressure is to be applied during connections, then the ability
to energize the choke by pumping across the wellhead may also have to be incorporated. In critical CBHP operations, a flow
meter is often installed as an integral part of the choke manifold to ensure that early kick detection systems can be incorporated
in the MPD equipment.
4 IADC/SPE 136513
Well Engineering Requirements
Planning for MPD operations is not very complex, but most operators will require some engineering to be conducted on their
drilling programs to justify MPD and to gain some assurance that the correct MPD method has been selected. These drilling
program requirements normally include:

A discussion of all drilling concerns and the rationale for using MPD and the selected MPD method.
An overview of any non-conventional circulation methods used in MPD, especially when using PMCD techniques.
Pressure prognosis plots with pore pressures, fracture pressures and, where possible, overburden and hole stability
pressures for all the MPD intervals.
A geological description of the well including uncertainties, and the probabilities of large pore and fracture pressure
variations.
Casing design calculations with safety factors.
A proposed schematic and design considerations for the MPD equipment including gas handling equipment.
Circulation system design specifications and redundancies used in MPD.
Installation and location layout drawings for MPD equipment.
Kick detection methods and a well control matrix.
MPD procedures that will be used, including pressure test requirements for MPD equipment.
Hazard identification (HAZID) / hazard and operability (HAZOP) results.

MPD Projects in Vietnam
A number of MPD projects have already been conducted in Vietnam. The main drivers for using MPD in Vietnam are two
fold:
1. High fluid losses coupled with gas migration in carbonates.
2. Partial or total losses when drilling the fractured granite basement reservoirs.

Cuu Long basin.
In the Cuu Long basin the normal procedure is to fill the annulus with seawater when losses occur. However, periodic gas
migration to surface is still experienced even with high annulus injection rates. The use of a Rotating Marine Diverter Insert
(RMDI) allows continuous drilling while diverting the gas. The Marine Diverter Insert enables the existing marine diverter on
a jackup rig to function as a rotating control device. It seals off the well bore and allows fluid and gas to be diverted below the
rig floor without the need to close the annular preventer.

Nam Con Son Basin
In the Nam Con Son Basin, offshore Vietnam an MPD package was installed to drill through the Nam Con Son Limestone
formation. A previous well drilled the same formation with severe losses and associated gas migration problems and
experienced as a result high NPT was experienced to cure the problems.

The MPD package was rigged up as insurance to enable switching to PMCD when severe losses are encountered. Losses
encountered during drilling the limestone were as high as 400bbls/hour, but the losses were cured with LCM and it was not
required to switch to PMCD. The MPD package was an insurance solution. If the same problem of massive losses and gas
migration in previous wells had occurred in this well, a ready solution would have been available to enable drilling to proceed
without any delays.

Ca Ngu Vang Field
Managed Pressure Drilling was used on a six well development program in the Ca Ngu Vang Field. The primary objective was
to drill the fractured granite basement reservoir. The first three wells in the development program encountered high loss rates
when drilling the basement reservoir. This resulted in very high brine and salt cost and a suspension in drilling operations due
to the interruption of brine and salt supply especially during the monsoon season, and the inability to drill to planned depth
once the loss rate exceeded the rigs mud mixing capacity.

Basement Interval
m
Brine Density
ppg
Loss Rate
bbls/hr
Total Brine losses
bbls
Time Associated with
well control issues
Hrs
4,084 - 6,123 9.6 - 9.8 20 - 160 55,000 298
4,975 - 6,330 9.6 - 10.4 20-60 19,000 82
4,100 - 5,477 9.8 - 10.2 40 - 250 137,000 197

IADC/SPE 136513 5
The application of MPD technology was sought as a solution to the brine management problem. The fluid loss rate in the
granite basement was a direct proportion of the amount of overbalance to the formation, the use of the MPD equipment
allowed the brine weight to be reduced and therefore reduce the fluid loss rate.

The MPD system was designed for drilling with a significantly lighter fluid and holding surface pressures during connections.
The well is drilled overbalanced with the brine weight controlled so that the ECD at drilling rates (450-600gpm) is slightly
above the formation pressure. The amount of overbalance is minimized to reduce the fluid losses to the formation. During
connections, the flow line valve is closed and surface pressure is applied at the RCD to compensate for the loss of annular
friction pressure. This was achieved by pumping fluid slowly down the kill line.

MPD was first used during drilling of the reservoir section for the 4th well in the field development program. Using MPD in
the reservoir reduced the ECD by 350psi or 0.4ppg equivalent (compared to conventional drilling), which resulted in
significantly reduced drilling fluid losses.
A comparison was conducted to optimize the MPD program

Brine weight Losses
9.7 ppg Static losses 35 bbls/hr
9.8 ppg Static losses 60 bbls/hr
10.0 ppg Static losses 95 bbls/hr

Brine weight
ppg
Circulating Rate
gpm
Losses
bbls/hr
9.8 ppg 350 gpm Dynamic Losses 95 bbls/hr
9.8 ppg 450 gpm Dynamic Losses 110 bbls/hr
9.8 ppg 550 gpm Dynamic Losses 120 bbls/hr

The comparison indicated that the loss rates were almost liniar with the pressure applied to the bottom of the well.

With the RCD installed the fluid weight was reduced to 9.2 ppg with a final dynamic loss rate of 6% of the total fluid rate
as compared to a loss rate of 15 to 20% of the total fluid rate without the RCD installed. The loss rate at 9.2 ppg represents a
total loss rate of some 1200 bbls/day as opposed to a loss rate of 4000 bbls/day without the RCD installed. The latter loss rate
being an unsustainable loss rate based on rig mixing and brine supply capacity. The limit for brine supply to the rig based on
the earlier wells was established at 2500 bbls/day.

Further benefits that were realized were efficient hole cleaning and a subsequent reduction in torque and drag. With the higher
flowrates, hole cleaning efficiency improved and the final trip out of the hole encountered significantly less drag.

The penetration rate increased but there are too other many factors, such as bit type and formation issues to conclusively
compare brine weight with penetration rate improvements.

In the previous wells two shocksub failures were encountered. The chromium plating on the mandrell of both tools failed,
which was possibly a result of the relatively high chloride environment while drilling. A reduction in brine density also means
a reduction in chlorise concentration, which could lead to a reduction in tool failures.

Only one bit run was made with the RCD in place and therefore only the final trip out of the hole was made with the
bearing assembly and seal in place. After killing the drillstring with 10 ppg brine, the drillstring was stripped back from TD at
6526m to above the last shoe. It was intended to start pumping trip weight brine at 9.8 ppg down the annulus whilst stripping.
The stripping operation was trouble free and this increased the confidence that stripping could be accomplished without the
need to pump thus realizing further brine savings.

Well Clean up was a short operation and this was accomplished in just 18 hours before a stable flow was achieved.
Nitrogen lifting operations were not required, plus the well clean up benefitted from the reduction in brine volume lost and the
lower mud weight used to drill the well.

This allowed the rig to drill deeper than any previous wells. The well reached a depth of 6,526m, the deepest basement well to
date in Vietnam. The operator also realized a much faster well clean up due the reduction of the drilling fluid lost to the
formation.

6 IADC/SPE 136513
The objectives of MPD in a fractured basement were realized with the ability to drill the well to target using less time. The
more efficient hole cleaning resulted in lower torque and drag and resulted in a much faster cleanup prior to handing the well
over to production. The subsequent 5
th
and 6
th
well in the development program also drilled the granite basement using the
MPD system, with similar successful results.

Conclusions
Knowing what kind of MPD is required is one the most important lesson learned in the many wells drilled in Asia Pacific.
Rigging up for CBHP using an RCD and a choke manifold and then finding out that with total losses, PMCD operations are
required causes significant delays, as now a flow spool and the associated hoses will be required to pump fluid into the
annulus.

The opposite applies to PMCD operations where losses are only marginal. Now the mud cap cannot be maintained and it may
be that a CBHP system with a choke manifold is required. Gate valves cannot be opened with pressure, so rigging up for flow
control and finding that when the flow line gate valves are closed for a connection, surface pressure builds up, causes issues
with opening the system without going through the rig choke manifold.

Rig alignment and drillpipe condition are all important for RCD rubber life. Stripping 20,000 ft of drillpipe through a set of
dual rubbers is possible if the rig is aligned and the drillpipe is in good condition and surface pressures are kept low.

Plugging of the 6 in return line and valves is often raised as a concern, yet this has not occurred in any of the operations
conducted. Even when drilling larger hole sizes, these return lines can be used.

Rig modifications for most MPD operations are minimal. The tie in of the return flow line to the shakers is the most complex
modification that is normally required. On some rigs, additional tie-ins to the standpipe manifold need to be made, but existing
tie-in points often exist and are used. The main modifications required are often additional sub bases on land rigs to raise the
rig high enough to accommodate the RCD.

MPD operations have been conducted on all types of rigs with minimal down time caused by MPD equipment. MPD
operations have resulted in considerable savings by enabling drilling to continue in a kick loss scenario or in wells where well
control issues occur at almost every connection. Drilling with a closed wellbore and simply allowing pipe to be rotated when
killing a well and by so doing, avoiding stuck pipe can already result in large savings.

Glossary
BOP Blow out Preventer
CBHP Constant bottom hole pressure
DG Dual gradient
ECD Equivalent circulating density
ERD Extended Reach Drilling
FMCD Floating mud cap drilling
H2S Hydrogen Sulphide Gas
HAZID Hazard identification study
HAZOP Hazard operability study
HPHT High Pressure High Temperature
HSE Health, Safety and Environment
LCM Lost Circulation Material
MPD Managed Pressure Drilling
PMCD Pressurized Mud Cap Drilling
RCD Rotating Control Device
RFC Returns Flow Control
TD Total Depth
UBD Underbalanced Drilling

IADC/SPE 136513 7
References

Terwogt. J.H, Mkiaho. L.B, van Beelen. N, Gedge. B.J, Jenkins, J. 2005 Pressured Mud Cap Drilling from A Semi-Submersible Drilling
Rig. SPE paper 92294 presented at the SPE/IADC Drilling Conference, 23-25 February 2005, Amsterdam, Netherlands.

Managed Pressure Drilling Projects. 2008. NTL No 2008-G07. United States Department of the Interior Minerals Management Service Gulf
of Mexico Region.

Hannegan. D, Fisher. K, Managed Pressure Drilling in Marine Environments. IPTC paper 10173 presented at the international Petroleum
technology Conference held in Doha, Qatar 21-23 November 2005.

Hannegan. D. Case Studies--Offshore Managed Pressure Drilling. SPE paper 101855 presented at the SPE Annual Technical Conference and
Exhibition, 24-27 September 2006, San Antonio, Texas, USA.

Kozicz. J. Managed-Pressure DrillingRecent Experience, Potential Efficiency Gains, and Future Opportunities. SPE paper 103753,
presented at the IADC/SPE Asia Pacific Drilling Technology Conference and Exhibition, 13-15 November 2006, Bangkok, Thailand.
DOI : 10.2118/103753-MS

Nas, Steve, Wuest, Chad, Toralde, Shaun, Offshore Managed Pressure Drilling Experiences in Asia Pacific, SPE paper 119875 presented at
the SPE/IADC Drilling Conference and Exhibition held in Amsterdam, The Netherlands, 1719 March 2009


Figures

Fig 1. RCD with drilling nipple to allow conventional drilling returns



Fig 2. MPD rig up for Returns Flow Control
8 IADC/SPE 136513


Fig 3. Rig up for Pressurized Mud Cap Drilling operations


Fig 4. Rig up for Constant Bottom Hole Pressure applications
IADC/SPE 136513 9

Fig 5. Riser Cap
TM
installation




Fig 6. Rotating Marine Diverter Insert
















Fig 7 PMCD-RCD 7800 Rig Up on the Jack-up Rig WillBoss Fig 8 PMCD-RCD 7800 Rig Up on a Semi-Submersible in Vietnam