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A Noble DrillingCorporation Subsidiary

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Hollow SphereDual Gradient Drilling

System

Hollow SphereDual Gradient Drilling

System

JIP Kickoff Meeting

Dr. William C. MaurerSeptember 27, 2001

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DOE Hollow SphereUnderbalanced Drilling

Project

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Types of Flow Regimes

MISTFOAMLIQUID GASAERATEDLIQUID

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Lightweight MudLightweight Mud

LIGHT WEIGHTMUDMUD HOLLOW SPHERES

5.84 ppg8.5 ppg 3.17 ppg0.70 S.G.1.02 S.G. 0.38 S.G.

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Glass BeadsGlass Beads

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Particle Sizes in Unweighted, Water-Based Mud

(After Bourgoyne Jr. et al, 1986)

.01 0.1 1 10 100 1000 10,000

Drilled Solids

SILT FINESAND

COARSESAND

GRAVEL

200

100

60 20

MESH

Solid

s Pe

rcen

tag

e

MICRONS

BentoniteSmallHollow

Spheres

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Centrifuge TestCentrifuge Test

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Desilter Tests

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Oilfield Hydroclone(Moore et al., 1974)

Underflow Discharge(Cuttings)

Feed Chamber

Feed Inlet

Vortex Finder

Vortex

Overflow Opening(Hollow Spheres)

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Golden State Drilling Rig Mud System

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Mud ReturnsMud Returns

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Dual Gradient Drilling Systems

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Hydrostatic Gradients for Conventional

and Riserless Drilling(Snyder, 1998)

Surface

Casing

Depth

Seawater (E)hydrostaticpressure

Mud hydrostatic pressure (C) (Conventional)

Mud hydrostatic pressure (D) (Riserless)

Fracture (B)pressure

Pore pressure (A)

Pressure

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Riserless Drilling System(Peterman, 1998)

Mud Returnand Pump

Return LineRiser

MudliftPump

BHA

Wellheadand BOP

Diverter

Drillpipe

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“DGD is estimated to save $9 million per well and increase the

project value by $150 to $250 million at Crazy Horse”

Andy Frazelle, BP (Wellconnected, Dec, 2000)

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“In an ultra-deepwater well, the savings could range from $5 - 15 million in casing running alone”

Conoco, 2001 (Drilling Contractor, May/June)

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Mudlift System

(Conoco/Hydril)

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Mudlift PumpingSystem

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Mudlift Subsea Diaphragm Pumps

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Mudlift Subfloor Module

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Mudlift Subsea Diverter

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Mudlift Drillstring Valve

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(Baker Hughes/Transocean)

DEEPVISION System

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DEEPVISION Subsea Centrifugal Pump

Pressure & volumecompensator

Strainer forcompensator

Isolation valves formotor filters

Main filters

Pump suction

Pump discharge

Electrical connections

Motor cooling loop

Filter for bearing pack

Isolation valves forBearing pack filters

6-Stage pump

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DEEPVISION Subsea Module

5-pump module station Size: 15’ *17’ * 40’ Weight: 350 kips Max. available hhp 4050 ANSI 2500 (6250 psi)

rated Standard riser joint

connection Independent of BOP MUX

control system Self contained power and

control

10,000 ft. Pump Station

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DEEPVISION Drillstring Valve

VALVE SEAT& CONE

VALVEPLUNGER

DISC SPRINGPACKAGE

4-3/4” Flow Stop Sub

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DGD Rock Removal Rates

Drilling Rates (ft/hr)

Rock

Rem

oval R

ate

(to

ns/

hr)

100500 150 2000

4

8

12

12-1/4” Bit

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Shell SSPS System

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Shell SSPS DGD System(Offshore, June 2001)

Power Control Existing Rig PumpsFrom RigPower

Water Depth

Pump Section

Motor & Seal

6 - Pumps Total

NitrogenTank

Check Valve

Level SensorFor Process Control

EductorPump

ControlModule

Element OptionalFor Fluid Sep.

Mud Processing

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SSPS Gumbo Slide & Mud/Gas Separation

Nitrogen Tank

(Back-up)

Mud/GasSeparator

Flowline

Subsea BOP

Cuttings

Eductor

GumboSlide

Nitrogen TankCut Away View

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Dual Gradient Project Participation

CONOCO* HYDRIL* BP CHEVRON

MUDLIFTMUDLIFT TEXACO DIAMOND OFFSHORE GLOBAL MARINE SCHLUMBERGER

BAKER HUGHES* TRANSOCEAN SEDCO

FOREX*

DEEPVISIONDEEPVISION BP CHEVRON

SHELLSSPSSSPS

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Hollow SphereDual Gradient System

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Surface Hollow Sphere System

Riser

Mud Line

BHA

Wellheadand BOP

Drillpipe

Mud

Shale Shaker

Mud

Spheres

Spheres& Mud

Mud Pump(Spheres)

Mud Pump(Mud)

Swivel

Valve

Mud & Spheres

Drill Ship

Mud

Rock

Drill String Valve

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Hollow Glass Sphere Technique

Mixture

Mud

Slurry

HollowGlass Spheres

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New Seafloor Equipment

DeepVision Mudlift

Shell SSPS Maurer

Nothing

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Sea Water Density Mud(50 % Spheres)

LIGHT WEIGHTMUDMUD HOLLOW SPHERES

8.56 ppg14 ppg 3.17 ppg1.02 S.G.1.68 S.G. 0.38 S.G.

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4

6

8

10

12

14

16

18

0 20 30 40 70

Sphere Concentration (Volume %)

Mix

ture

Den

sity

, ppg

181614 12 10

Sphere Sp. Gr. = 0.38

Mud Weightppg

WaterSea Water

Mixture Density vs. Sphere Volume

10 50 60

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Sea Floor

Fracture GradientPore Pressure

Safe Zone

10

12

1416

18

Mud weight (ppg)

Dual Gradient Mud Weights

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Single Injection Point

Valve

Riser Flow Line

Mud& Spheres

Surface

Sea Floor

Mud& Spheres

Wellheadand BOP

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Multiple Injection Points

10,000’

7,500’

5,000’

2,500’

Valve

Riser Flow Line

Sea Water& Spheres

Surface

Sea Floor

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Surface Sphere Separation

ShaleShak

erSeawater

HollowSpheres

Drill CuttingsMud

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Large and Small Hollow Glass Spheres

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Particle Sizes in Unweighted, Water-Based Mud

(After Bourgoyne Jr. et al, 1986)

.01 0.1 1 10 100 1000 10,000

Drilled Solids

SILT FINESAND

COARSESAND

GRAVEL

200

100

60 20

MESH

Solid

s Pe

rcen

tag

e

MICRONS

LargeHollowSpheres

BentoniteSmallHollow

Spheres

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Relative Particle Size (Microns)

50SmallHollow

Spheres

147100 Mesh

Screen

300LargeHollow

Spheres

1700FracSand

(12 mesh)

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Composite Hollow Spheres

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Composite Sphere Densities

WaterDepth (ft) PVC

ThermoplasticMacrospheres

GREMinispheres

Carbon FibreMinispheres

Foam System Density (g/cc)

100020003000400050006000700080009000

1000011000120001300015000

0.250.36

0.280.340.360.390.430.440.480.530.53

0.400.410.450.480.510.550.600.620.65

0.430.450.460.480.500.530.560.590.610.66

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Riser Buoyancy Modules

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Solids Separation

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DGD Sphere Separation System 1100 1000

MESH

MICRONS

100 20

LargeSpheres

20 Mesh

Large CuttingsReturn Mud2000 gpm25% Spheres

Mud 1500 gpm

To Seafloor1000 gpm

50% Spheres

Clean Mud

ShaleShake

r

ShaleShake

rSpheres

Spheres500 gpm

Seawater

Medium Cuttings

Spheres500 gpm

100 Mesh

Spheres

ConventionalMud

System

To Rig Pump1000 gpm

No Spheres

500 gpm

Fine Cuttings

Spheres500 gpm

Mud1500 gpm

+

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Hydrocyclone Separator

Barite (SG = 4.25)Drill Cuttings (SG = 2.65)

Hollow Spheres (SG = 0.4)Water (SG = 100)

Barite, Drill Cuttings

Mud & Spheres

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100 1000

MESH

MICRONS

100 20

LargeSpheres

DGD Sphere Separation System 220 Mesh

Large CuttingsReturn Mud2000 gpm25% Spheres

Mud 1000 gpm

To Seafloor1000 gpm

50% Spheres

Clean Mud

ShaleShake

r

ShaleShake

r

Medium Cuttings(Few Spheres)

100 Mesh

ConventionalMud

System

To Rig Pump1000 gpm

No Spheres

CentrifugalPump

Spheres500 gpm

Mud 1000 gpm

Fine Cuttings

Mud500 gpm

+

SpecialHydrocyclone

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Effect of Spheres on Plastic Viscosity

12.5 12.0

22.5

0

5

10

15

20

25

Pla

stic

Vis

cosi

ty (

cp)

No Spheres Large Spheres StandardSpheres

Water36% Spheres

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Alternative Hollow Sphere

Injection Systems

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Mud Line

Wellheadand BOP

Drillstring Injection DGD System

Riser

BHA

Drillpipe

Mud

Sphere Mixing Tank

Mud Pump(Mud)

Swivel

Mud & Spheres

Drill Ship

Mud

Rock

Casing

Sphere Separator

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Drill String Sphere Separator

Sea Floor

Spheres

Spheres& Mud

Riser

SphereSeparator

Mud

Spheres& Mud

Casing Drill Bit

Drill Pipe

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Carrier Fluid Dual Gradient System

Riser

Mud Line

BHA

Wellheadand BOP

Drillpipe

Mud

Shale Shaker

CarrierFluid

Spheres

Carrier Fluid& Spheres

Mud Pump(Spheres)

Mud Pump(Mud)

Swivel

Choke

Mud & Spheres

Drill Ship

Mud

Rock

InjectorPump Screen

Valve

Flow Controller

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Mud

Injector Pump(Moineau)

Carrier FluidPlus Spheres

Screen

Return Line

Valve

CarrierFluid

Carrier Fluid Dual Gradient System

Mud

Choke

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Seawater Transfer System

Mud

Seawater andSpheres

Seawater

Mud

Injector Pump(Moineau)

Mud andSpheres

Screen

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Spreading Pore Pressure/Frac Curves Apart

Surface

Depth

Fracturepressure

Pore pressure

Pressure

Increased Frac Pressure

Seafloor

Flow Drilling

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Curved Gradient Drilling

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Fracture Gradient

Riser

Pore PressureGradient

Sea Floor

Conventional Deep Water Drilling

Safe Zone

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Fracture Gradient

Riser

Pore PressureGradient

Sea Floor

Dual-Gradient Deep Water Drilling

Safe Zone

SubseaPumps

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Fracture Gradient

Riser

Pore PressureGradient

Sea Floor

Curved-Gradient Deep Water Drilling

Safe Zone

Gas or SphereInjection Points

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`

DRILLING FLUID

SPHERESOR GAS

PARASITE

INJECTIONPORT

Fluid Injection Techniques

GAS ORSPHERES

`

Concentric Drill Pipe Parasite String

Tie-Back Casing

SPHERESOR GAS

MUD

`

MUD

SPHERESOR GAS

Jet Sub

`

MUD

SPHERESOR GAS

Nozzle

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Seafloor Sphere Injection0

6000

10000

15000

2000015,00010,0005,0000

Well D

ep

th (

ft)

Riser

Sea Water Density (8.6 ppg) (50%)

4470 psiSea Floor

11,750 psi

8110 psi

Annulus Pressure (psi)

Casing

Seafloor Sphere Injection

14 ppg (0%)

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Sub Seafloor Sphere Injection0

6000

10000

15000

2000015,00010,0005,0000

Well D

ep

th (

ft)

Riser

10.4 ppg (33%)

Sea Floor

14 ppg (0%)

11,750 psi

8110 psi

Annulus Pressure (psi)

Casing

Sub Sea FloorSphere Injection

5410 psi4470 psi

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Sub Seafloor Sphere Injection0

6000

10000

15000

2000015,00010,0005,0000

Well D

ep

th (

ft)

Riser

11.3 ppg (25%)

Sea Floor

14 ppg (0%)

11,750 psi

8110 psi

Annulus Pressure (psi)

Casing

Sub Sea FloorSphere Injection

5876 psi4470 psi

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Lightweight Brine Drilling Fluid

Sea Water(8.56 ppg)

Salt Brine(12 ppg)

Salt Brine + 39% Spheres(8.56 ppg)

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Major Questions

• Will Hollow Spheres Survive?

• Can Spheres Be Pumped Reliably?

• Can Spheres Be Separated From Mud?

• Can Sphere Circulation Be Initiated after Shutdowns?

• Maximum Sphere Concentration Achievable?

• How to Detect and Handle Kicks?

• Can Constant Seafloor Pressure Be Maintained?

• System Cost and Reliability?

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