IADC/SPE 164561

Successful Application of Deepwater Dual Gradient Drilling

Robert Ziegler, Paul Ashley, Petronas; Roar Fredrik Malt, Roger Stave, Kjell Rune Toftevg, AGR EDS-ORS

Copyright 2013, IADC/SPE Managed Pressure Drilling and Underbalanced Operations Conference and Exhibition
This paper was prepared for presentation at the IADC/SPE Managed Pressure Drilling and Underbalanced Operations Conference and Exhibition held in San Antonio, Texas, USA, 1718 April 2013.
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
A world first "Controlled Annular Mud Level" type Dual Gradient Drilling (DGD) system was successfully applied on an
ultra-deepwater well drilled in May - July 2012.
Water depth was 2260m and the formation was generally carbonates with potential for severe or total losses. DGD
was applied to prevent losses from occurring. Dynamic circulation pressure effects were eliminated. The DGD topside
system was rigged up offline and when running the riser, the DGD pump was launched and attached to the riser for the
last 400m. During drilling of the 17 " hole section, a Dual Gradient mud weight was selected and the riser level was
maintained between 150 and 200m below flow line most of the time. On connections the riser level was kept
unchanged. The level was decided according to PWD Readings. On several occasions it was demonstrated that
lowering the riser level increased ROP whilst raising it again decreased ROP in hard rock.
In the 12 " hole section, drilled to well TD, the same approach was taken, but here the riser level was raised 50 m
(approximately 75 psi) on connections to account for some of the reduced bottom hole pressure when shutting down
the rig mud pumps. In this section some gas bearing formations were penetrated with a reduced riser level. No gas at
all was seen in the riser top.
During drilling of the reservoir and surrounding formations, no losses were seen and the hole was in good condition
with no indication of fill or drag.
The paper will present the technology applied and analyze the results achieved on this well.

Introduction
AGR Enhanced Drilling Solutions built the EC-Drill system for PC Gulf Ltd. in 2011. This was a pumped riser Dual
Gradient Drilling (DGD) system to be used on Saipems Scarabeo-9 MODU, a new-built 6th generation semisubmersible drilling rig. Based on the previous offset well Y-1, the EC-Drill system was considered a key tool to reach
the planned TD for the C-1 well by maintaining full mud returns should a narrow margin and/or low pressure scenario
be encountered.
This EC-Drill system was designed specifically for the Scarabeo-9 and was built by AGR whilst the rig was in the final
stages of construction and commissioning in the Keppel FELS shipyard, Singapore. Given the challenging metocean
conditions in the area of operation, another major advantage of this deepwater MPD system is that the surface
components of the riser system (telescopic joint, tensioner system etc) are not modified, so the weather capability of
the rig is not changed, which often is a problem with RCD-based systems. Also, due to the fluid level in the riser
remaining constant, there is no masking of influxes or losses by heave.

IADC/SPE 164561

Delivery of the EC-Drill system to the Scarabeo-9 occurred during October, 2011 and installation and site-based
commissioning took place whilst the Scarabeo-9 transited from Singapore to the Gulf of Mexico over a two month
period. The system was first used on the J-1 well for another operator from mid-February to mid May 2012.
Modifications as a result of lessons learned were implemented prior to spud of the C-1 well.
The objectives for using the EC-Drill system on the C-1 well were:

Assist PC GULF Ltd. in drilling to the planned TD for C-1 well without losses or formation related trouble
time.
Prove that ECD can be eliminated and BHP can easily be manipulated as required.
Ensure good hole cleaning in all sections of the well
Increase ROP
Prove that gas in top of the riser is not a problem during drilling with reduced riser level

The DGD system

The EC-Drill technology used is a state-of-the-art DGD technology, designed for drilling post-BOP sections. The
system uses a subsea pump installed on a modified riser joint (MRJ) to manipulate the height of the drilling fluid in the
riser annulus. By manipulating the fluid level in the riser it is possible to alter the hydrostatic pressure seen by the
wellbore, thus controlling the ECD while drilling. The system also adds benefits by making it possible to evaluate pore
pressure/fracture gradient, early kick and loss indication, reducing formation damage, etc.
Its effect is best understood by comparing it to a conventional, RCD (back-pressure) based MPD system: While the
RCD system virtually extends the height of a light fluid column by applying back pressure, leading to a steep mud
pressure gradient, the EC-Drill system reduces the actual height of a heavier fluid column, which allows for a
significantly flatter mud pressure gradient much closer to nature. This leads to a significantly lower pressure at the
weak shoe, while maintaining the required pressure to control moveable formation content deeper in the drilled interval
For this specific operation, a three-stage Subsea Pump Module (SPM) was installed on a modified riser joint to pump
the mud returns back to the surface from a depth of 400m. . Each pump stage was powered by a 300 kW electric
motor. The pumps, motors, and other electrical and hydraulics equipment were integrated into a Subsea Pump Module
(SPM). These disk-type subsea pumps have been field proven in more than 190 Riserless Mud Recovery (RMR) tophole jobs in waters up to 1,500 m deep. The pump can handle drilling mud with drilled cuttings of up to 2.5 and up to
10% free gas. If required for a specific application, it is quite easy to increase available pump pressure by adding a
fourth stage or even add another SPM in series in order to increase the operating envelope of this system.
The DGD system used consists of surface and subsea equipment. The system and rig integration was approved by
DNV according to DnV-OS-E101. The main components in the system are given in Figure 1 and will be described
below.

IADC/SPE 164561

Figure 1
System Overview
Surface equipment:
1. Office/Tool container: This container holds the DGD Controls and monitor interfaces as well as the electrical
equipment to connect the EC-Drill system to the rig and other sensors.
2. Control Container: The control container houses the power supply equipment for the SPM; including a
variable frequency drive (VFD), a step up transformer to increase voltage from 440 V to 3,000 V, sinus filters,
and internal monitoring system. A gas detection system is installed together with ventilation and air
conditioning.
3. Winch with Umbilical: The umbilical is used to transfer power and signals to the SPM.
4. The Hose Handling Platform (HHP) allows safe and smooth deployment of the Mud Return Line (MRL) Hose.
When all hoses are deployed, the last hose is permanently secured at the hang-off point on the HHP.
5. Control & Monitoring System (CMS): The main function of the computerized CMS is to control the SPM to
maintain a desired return fluid rate and a selected mud level in the riser. Monitoring the pressure in the marine
drilling riser and adjusting the VFD to change the speed (rpm) of the subsea motors and pumps allow this level
to be held constant.
Subsea equipment:
6. Subsea Pump Module: The subsea pumps with motors and piping are installed on a module that connects to
the riser. The subsea pump module also contains the necessary valves, sensors and subsea control modules
and is the hub for subsea control signals and sensor input.
7. Mud Return Line (MRL): The EC-Drill system on Scarabeo 9 used flexible return hoses as flow conduit to
transport drilling fluid and cuttings to topside.

IADC/SPE 164561

8. Modified Riser Joint: The modified riser joint acts as the tie in point to the riser. It has isolation valves and
sensors that are operated by, or communicate with the control system via the subsea pump module and
umbilical.

Figure 2 below shows the high level system setup.

Figure 2
System high level P&ID

IADC/SPE 164561

Topside lay-out;
The topside equipment used was standard components from RMR systems, and installed as temporary equipment on
the rig.

Figure 3
Topside equipment layout. Picture shows the Umbilical winch, the control container and the office/tool
container
Subsea Hook-up;
The subsea equipment was purpose built for the Scarabeo 9 operations. The SPM was docked to the riser in the moon
pool and due to time constraint it was not possible to implement wet retrieval / re-dockig. The flexible mud return line
could be disconnected subsea for retrieval and replacement.
The umbilical was attached to the SPM with a "weak link" in order to avoid accidental overload of the umbilical and
umbilical winch during deployment.

Figure 4

IADC/SPE 164561

Left picture shows bottom of the pump with mud return line and riser connection. Right picture shows
umbilical with weak link.

IADC/SPE 164561

Qualification, Verification and Certification

Several design reviews, HAZIDs and FMECAs were performed with AGR, Aker Drilling Risers, Saipem, Frigstad (Rig
designer) and PETRONAS. The EC-Drill concept was also put through a DNV qualification process according to DNVRP- A203 Qualification of new technology. Based on this DnV issued a Statement of Feasibility.
In April 2011 DNV released the newsletter DNV DRILL/DRILL(N) class requirements for Managed Pressure
Drilling systems. A decision was then made to put the EC-Drill system and rig integration through a DNV approval
process according to the requirements stated in the DNV newsletter. As a result, the system, rig integration and drilling
operation was put through a DNV facilitated HAZID & FMECA according to DNV-OS-E101, with participation from DNV
Drill Class, Aker Drilling Risers, AGR, PETRONAS, Saipem and Frigstad. The project document package and rig
integration was reviewed and approved by DNV. The rig integration was also verified by offshore testing. As a result,
the system, rig integration and riser modification was approved by DNV according to DNV-OS-E101 (Drilling Facilities),
DNV-OS-D201 (Electrical Installation) and DnV-OS-D301 (Fire protection), - with a DNV approval letter issued.

Operational Preparation and Training.

Although the main components of the EC-Drill system, including much of the control system, were familiar to the crew,
the application was new and there were important changes compared to the RMR system they were used to. During
the months before operations commenced, several training courses were held to prepare the AGR crew for the new
system.
A one day course, describing the system and its application was held for the entire crew initially.
The next step was to put the AGR crew through a 1 week internal course. The course had three modules;
1. Firstly the course participantswere presented with a module that explained the basics of drilling, formation
pressures and volume control and how these aspects are affected by the EC-Drill system.
2. Second a module describing the equipment, the installation and deployment procedures etc was held. Finally
the control system was gone through in detail. Trouble shooting was a part of this. An onshore WITS
simulator was made in-house to simulate drilling and various challenges that will be encountered during a
normal drilling campaign.
3. The last day the course was finalized with a test involving use of the simulator and trouble shooting. The
operators were set up as normal crew in order to make this test as realistic as possible.

IADC/SPE 164561

The C-1 Well

The C-1 well was spudded on 25th of May 2012 in 2260m water depth. A 24 hole was drilled to 3161 m TVD before
the Riser and BOP were run. The EC-Drill could then be run together with the riser.

EC-Drill System Deployment

The modified riser joint was run as a single joint (50ft) through the rotary table (the other joints were run as 100ft
doubles) without assistance from EC-Drill crew. After preparations were made in the moonpool (creating space
amongst MUX line cables and sheaves), operations to make up the subsea pump module to the modified riser joint
took place. It is important to note that the EC-Drill system only requires minimal additional online time on top of the
normal riser running operation.

Figure 5
From top left (clockwise), Modified Riser Joint being run through RT, preparations being made in moonpool
for pump module, pump module rigged up and function testing pump module with seawater.
Before running the EC-Drill pump, compensators and HPU banks were filled up with Hydraulic oil. The first MRL hose
was then landed in the Hose handling platform.
At 01:00h on the 16th of June skidding of the SPM started. The BOP trolley was fitted with a special handling frame
and used for this operation. Keeping Mux cables clear was an issue all the time. At 01:30h connection to the riser
started. At 04:00h everything was hooked up and tested. MRL hoses were picked up from helideck and running of riser
could continue.
The mud return line was installed as per procedure with protection over the couplings due to concern of damage to the
MUX line. The 30m MRL section lengths were individually picked up from one end using the starboard crane and
lowered into the hose handling platform in the moonpool. The connections were made up manually by an EC-Drill
Operator. New connections were made in parallel with each double riser being installed.
The subsea pump module was lowered approximately 10m below the splash zone prior to activation of the system.

IADC/SPE 164561

Once the subsea pump module was started, it was successfully flow tested with seawater.

Pre drilling Test

These tests commenced on 21st June 2012.
First, a simple function test was performed to verify the system was responding and all valves were lined up correctly.
It was also necessary to verify no spill to the sea in case of wrong line-up or a closed valve on the flow line.
Thereafter a more comprehensive series of tests were performed, first with seawater as described below, then with
mud. These were conducted while drilling out cement:

Lower fluid level in steps corresponding to 25psi bottom hole pressure (BHP) reductions. Reduce riser
level to 150m, increasing the size of the steps until 150m is reached. Maintain this level for 15 min
while drilling.
Test EC-Drill system up to 90% capacity.
Increasing fluid level while stopping pumps for a connection (ie simulating a connection), maintaining
BHP approximately constant.

The PID controller was adjusted while lowering the riser level. The mud pumps were gradually staged up to full drilling
rate (1200 gpm was specified before the test commenced.) The final test on seawater was by increasing flow to 1500
gpm while keeping riser level at 150 m. The EC-Drill pump was then working at 72% and the test was accepted as
good.
Valve
Position
Riser Isolation Valve 1
Open
Riser Isolation Valve 2
Open
SWI Valve
Closed
MRL Isolation Valve
Open
Topside Isolation Valve (Saipem)
Open
Table 1

Confirmation
OK
OK
OK
OK
OK

Valve configuration for testing

After displacing the well to 9.2 ppg mud, a new test of the EC-Drill system was performed. The test stages were the
same as for seawater but in addition kick simulations and fingerprint simulations were performed:

When all parameters were stable, the 1 bbl/min top-fill pump was started to simulate a kick. The time
and volume from pump start until the additional flow was observed by AGR/Geoservices were noted.
This test was repeated 3 times. The first time the EC-Drill operator was not properly prepared and did
not detect the influx after 10 bbl were pumped.
The other two times the influx was detected after 43 seconds. This was detected on pump output and
kick alarm on the system.
Fingerprinting system response when starting and stopping the rig pumps was performed:
o Initial rig pump rate 550 gpm.
o Riser set point at 580 psi BHP reduction
o Stop rig pump
o Riser pressure increased by 7 psi and pump idled off ~30 seconds.
o Startup rig pump
o Riser pressure decreased by 6 psi and EC-DRILL pump rate increased and stabilized.

17 Hole Section

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IADC/SPE 164561

EC-Drill operations commenced on 21st June. The 17 section was started with a mud weight (MW) of 9.2 ppg.
After letting drilling parameters stabilise for a while the riser level was taken down in steps until it was at 150m,
corresponding to an ECD of 9.0ppg. Total flow from rig pumps was 1300gpm when reducing level, and was increased
to 1500gpm after the level was as desired.
Figure 6 below shows riser level reduction and resulting ROP increase.

Figure 6
The figure shows ROP increase when Riser Level is reduced in the 17 " hole section
After drilling for a few hours the level was further reduced to 8.9ppg ECD corresponding to 183m riser level on the ECDrill sensors. This level was maintained until reaching 3213mTVD when an approaching storm necessitated a
temporary stop in operation.
Drilling was resumed and the riser level reduced to 150m then to 200m. ECD measurements from PWD were used to
verify that ECD was at the desired level (8.9 ppg).
Some issues with cooling capacity on the EC-Drill system due to not enough rig water supply necessitated 1500gpm
as max flow with 200m riser level. This was well above the specified 1200gpm, and the EC-Drill pump was only
running at 70% power output.

On several occasions, troubleshooting on suction problems on the rig mud pumps required a stop in drilling. On these
occasions the riser was filled and the EC-Drill SPM isolated. Reducing the level again took 6 12 minutes depending
on the required level reduction and flowrate from the pumps. Once the mud was sheared it was possible to reduce the
riser level with an output from the EC-Drill SPM of 2000gpm without overflowing the shakers.

During drilling, there were variations in flow, but the EC-Drill system maintained the riser level at the desired value, ref
Figure 7.

IADC/SPE 164561

11

Catoche1:171/2"SectionDrillingwithECDrill23/06/2012
8,7

8,8

8,9

BlockPosition(m)
SPP(psi/100)

ECD(ppge)
9,1
9,2

ECD(ppge)

9,3

9,4

9,5

9,6

Av.RiserPressure(bar)

2012062300:00:00

2012062302:24:00

2012062304:48:00

2012062307:12:00

2012062309:36:00

2012062312:00:00

2012062314:24:00

2012062316:48:00

2012062319:12:00

2012062321:36:00

10

15

20

25

30

35

40

45

50

SPP(psi/100),BlockPosition(m)&AverageRiserPressure(bar)

Figure 7
Drilling with 9.2ppg WBM, String Flowrate: 1100gpm BHP reduced by 300psi. ECD: 8.9 9.0ppge

When approaching 3450m TVD, the riser level was increased to 160m to yield 9.2ppg ECD. On connections the riser
level was kept constant. The PID controller was able to keep the riser pressure within a window of +/- 12psi when
stopping and starting pumps on connection. The ECD was then increased to 9.4ppg to balance a potential increase in
pore pressure. This ECD was maintained until 3800mTVD. Due to the ability to keep the ECD at the desired level, the
total circulation rate during drilling was maintained at 1650gpm (1200gpm on string and 450gpm on riser boost pump)
ensuring good hole cleaning.
After passing 3800m TVD without any signs of a pressure ramp, the riser level was again dropped to 200m to increase
ROP. This level was maintained until 3863mTVD where it was increased due to an imbalance in flow in/flow out
readings. The active pit remained stable. At 3866m sectionTD was called.

Figure 8

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IADC/SPE 164561

The figure shows how ROP respond by dropping when Riser is filled
Cementing 13 3/8" casing
During cementing of 13 3/8 casing the EC-Drill system was used to control bottom hole pressure approximately
constant. This technique is called Managed Pressure Cementing.
Figure 9 below shows how this was performed.
A 13ppg lead slurry and 16.27ppg tail slurry was displaced with 9.7ppg mud. Once the cement entered the annulus
and BHP began to rise the riser level was reduced in steps to 300m This level was then maintained for 1.5h after
standing cement before being raised to surface. The EC-Drill pump operated with a power consumption of 70% to
keep the riser level during these circumstances.
One lesson was learned: Because of the abnormally high pressure differential at the casing running tool caused by the
reduced riser level, a much higher set down weight than normal was required to set the seal assembly. This was
initially not taken into account and first attempts therefore failed. After applying sufficient weight, the seal assembly
was successfully set and tested.

Figure 9
The figure shows riser level adjustment during cementing
12 Hole Section
The 12 " section was drilled with 9.7ppg mud. The riser level was initially drawn down to achieve 9.5 ppg ECD
(150m level reduction) but was increased when approaching 4200m TVD due to an anticipated pore pressure rise.
In the upper part of the section, the level was kept constant on connections, but as drilling approached the reservoir
section the riser was filled for each connection to keep constant BHP, similar to the function of the back-pressure
pump on an RCD-based MPD system.
The same effect as in the 17 " section was seen when lowering the level in riser, the ROP increased.
The high flow rate achieved resulted in good hole cleaning in the smaller hole size.

IADC/SPE 164561

13

Catoche1:121/4"SectionDrillingwithECDrill0911/07/2012
0

BlockPosition(m)
Av.RiserPressure(bar)

SPP(psi/100),BlockPosition(m)&AverageRiserPressure(bar)
10
15
20
25
30
35
40

SPP(psi/100)

45

50

ECD(ppge)

2012070822:50:56

2012070910:50:56

2012070922:50:56

2012071010:50:56

2012071022:50:56

2012071110:50:56
9,4

9,5

9,6

9,7

9,8

9,9

10

10,1

ECD(ppge)

Figure 10
The plot above shows relations between ECD readings from PWD, riser level and flow. Note that as flow (and
SPP) is increased, the ECD is decreased due to reduction of riser pressure.
During drilling the top-fill pump was running all the time. This constant flow monopump outputs approx 1 bbl/min, and
serves to remove the effect of gas build up in the riser. It was left to run on connections and was only shut down
during flow checks. Flow checks were performed by stopping all pumps and closing the EC-Drill riser valve. No anti utube valve was used and there was therefore a small u-tube flow from the string that was fingerprinted. This would
stabilise completely within 5 minutes. A continuous circulation system is seen as a very valuable complement to ECDrill in the future, when the SPM is set much deeper and the U-tube effect becomes severe. This would, alleviate the
need for potentially troublesome anti-U-tube valves.
From 4385m TVD ROP increased considerably and gas measurements in the mud (via the mud return line) increased
up to a max of 21%. The rig sensors did not at any time show traces of gas. To further document that the empty riser
does not produce gas under these circumstances, a portable HC detector was used to measure gas in the rotary table.
This detector also showed zero.

Figure 11 below show resuming of drilling after a bit trip in the 12 " section. Note that when the riser level is lowered
the slope of the hook height curve increases. This shows again that ROP increases when the riser level is lowered.

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IADC/SPE 164561

Figure 11
The figure shows ROP increase when Riser Level is reduced in the 12 " hole section
From 4385mTVD to 4407mTVD the riser level was maintained at 138 m, corresponding to an ECD of 9.68 9.69ppg
as read from the PWD. On connections the level was increased to 50m. However drilling was slow and gas readings
below 0.2% so from 4407mTVD the level was further reduced to 170 m, giving an ECD reading of 9.63ppg. Circulation
was maintained at 300gpm on the boost line and 900 gpm on the string in the 12 section.
There were challenges with flow in / flow out balance. This was due to varying rig-pump efficiency and subsequent
improper calibration of EKDS, a known issue in MPD operations.

Pump Effect on Cuttings

The type of subsea pump module used in the Catoche-1 well had previously only been used during top hole drilling in
addition to the previous J1 well, hence it was relatively unknown as to the effect the disk-pump would have on the
cuttings passing through it, although it was assumed that the pump would have little to zero detrimental effect on the
cuttings. Disk pumps are low shear, and are used to pump fragile media in other industries.
On this well it was confirmed that the subsea pump had virtually zero destructive effect on the structure of the cuttings
generated by the bits used when compared to the cuttings collected whilst drilling with a full riser and returns passing
through to the port flow line. It was not possible to differentiate between cuttings drilled with full riser and cuttings
passing through the EC-Drill pump.

Well Control Considerations

The C-1 well was drilled using conventional methods of influx detection (Schlumberger/GeoServices Early Kick
Detection System ( EKDS), PVT readings of the active system, and gas/salinity levels in return flow). The return flow
was into the starboard flow line, gravity fall through the EKDS flow meter and then to the shale shakers. Because the
EC-Drill pump is below the slip joint, the return flow is not affected by vessel motion. In addition, the power
consumption of the SPMs centrifugal (disk) pumps was monitored as it is directly related to the volume (not pressure)
of the mud pumped. Therefore variations of the power consumption are an excellent kick/loss detection instrument with
steady state flow-in.

IADC/SPE 164561

15

During drilling of both 17 " and 12 " sections, the effective ECD was measured using the PWD tool and was at all
times kept above the pore pressure. There were zero incidents relating to influxes into the wellbore whilst the EC-Drill
system was in use.The MW was always maintained high enough to ensure that loss of the mud pumps would not lead
to the wellbore becoming underbalanced.
For flow checks the plan was to use dynamic flow checking using the EKDS ie flow-out equals flow-in. However, due to
variations in rig-pump efficiency affecting the calibration of the EKDS, one had to use trends for the flow in/flow out
relationship and pair this with behaviour of the PVT active system. This is a known challenge of MPD systems relying
on FIFO kick detection with no universal solution yet available. A better way to measure rig mud pump output has to be
found.
The more definitive static flow check method used was to close the Riser Isolation Valve and isolate the EC-Drill pump
(without turning it off) than close down the rig pumps and stop top fill. The string volume would now partially u-tube
back to the riser but with an identifiable reduction in flow to a static level that was finger-printed with an on screen realtime plot on the EC Drill operators control panel..
On dual gradient systems flow anomalies (both small influxes and losses) are best treated dynamically, by adjusting
the riser level instead of shutting the well in at the BOPs, because a major challenge arises if the formation strength
does not allow circulation through the kill/choke line system. A full discussion of potential well control methods for this
and other cases with the pumped riser fluid-gas dual gradient system can be found in OTC paper 22889 (referenced).

Tripping
For each trip, both in the 17 " and in the 12 " section, the riser was filled before tripping commenced. The trip was
then performed conventionally on the trip tank with the EC-Drill system isolated. The contingency plan, that was not
required to be used, was to trip the drillipipe/BHA with the riser level below surface. In this case the riser itself acts as
the trip tank. The pressure sensors on the SPM module are accurate enough to measure a 0.05 bbl variation in the
riser level, which is more than adequate for tripping. This ability to trip the drillpipe with a reduced level by fine tuning
the bottom hole pressure has a big advantage over RCD type MPD systems where the RCD element must be
removed for tripping hence requiring a mud weight increase prior to the trip, which can be difficult to achieve in a
narrow margin environment.

System Recovery
The MRL was disconnected from the Subsea Pump Module and recovery of the hoses at 01:00h on 1st tAugust. At
05:30h the hoses were retrieved. The hoses showed little sign of wear, but all anodes needed replacement. On 2nd
August the Modified Riser Joint was at surface and at 16:25h cables and hoses to the EC-Drill pressure sensors on
riser were removed. At 17:10h the BOP trolley started to skid towards the riser and at 17:47h the pump was
disconnected from the riser. Further work on the pump was performed offline while the rig continued retrieving riser.
The online time attributed to the EC-drill system while disconnecting the pump from the riser was only 1 hour, 22
minutes.

Conclusions

The EC-Drill system was capable of maintaining a riser level of 150 - 200m with 1650gpm flow in the
17 " section. This was above expectations.
No losses or hole instability issues were seen while utilising EC-Drill
ROP could be demonstrated to increase when decreasing BHP.
No gas was recorded in the top of the riser at any stage during the operation.
The EC-Drill system proved to be a valuable tool to avoid losses while cementing the 13 3/8" casing
and the abandonment plugs.

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IADC/SPE 164561

Drawing down the riser level proved to be a fast and elegant way of performing the inflow (negative)
test prior to riser disconnect.
Compared to offset wells, there was no NPT for lost circulation or well control.

IADC/SPE 164561

17

References
SPE 151100-MS- First Application of EC-Drill in Ultra-Deepwater, Proven Subsea Managed Pressure Drilling Method
M. Mir Rajabi, SPE, K. Toftevg, R.S. Stave, SPE, AGR AS, and R. Ziegler, SPE, PETRONAS
OTC 22889-MS A Step Change in Safety: Drilling Deepwater Wells with Riser Margin
Robert Ziegler, SPE, PETRONAS
SPE 130308-MS Deepwater Riserless Mud Return System for Dual Gradient Tophole Drilling
Dave Smith, SPE, AGR Subsea; Warren Winters, SPE, BP America; Brian Tarr,SPE, and Robert Ziegler, SPE, Shell;
and Iskandar Riza and Malik Faisal, PETRONAS
SPE 137319-MS - Deploying the World's First Commercial Dual Gradient Drilling System
J. David Dowell, SPE, Chevron