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SPE/IADC Managed Pressure Drilling and Underbalanced Operations Conference & Exhibition
8-9 April 2014 NH Eurobuilding Hotel, Madrid
Natural Gas Recycle and
Recovery System
Dramatically Reduces
Drilling Cost and
Environmental Impact
1
Alek Ozegovic Weatherford
SPE/IADC Managed Pressure Drilling and Underbalanced Operations Conference & Exhibition
8-9 April 2014 NH Eurobuilding Hotel, Madrid
2
Outline
Recycle & Recovery Process
Equipment Involved
Advantages
Unique Requirements
Case Studies
Economical and Environmental Impact
Conclusions
SPE/IADC Managed Pressure Drilling and Underbalanced Operations Conference & Exhibition
8-9 April 2014 NH Eurobuilding Hotel, Madrid
3
Traditional UBD Layout (Gas Well)
SPE/IADC Managed Pressure Drilling and Underbalanced Operations Conference & Exhibition
8-9 April 2014 NH Eurobuilding Hotel, Madrid
4
Summary of Traditional UBD
On-site nitrogen membrane
40 m3/min N2 consumes 10,000 lpd of diesel
All drilling liquids recycled
All returned lift gas is flared
All produced gas is flared
* Cost of UBD becoming prohibitive in some cases *
SPE/IADC Managed Pressure Drilling and Underbalanced Operations Conference & Exhibition
8-9 April 2014 NH Eurobuilding Hotel, Madrid
5
Something Has to Change
Why do we require generated N2 on location?
We don’t
Why do we need inert gas to drill a well?
We don’t
Is an alternative lift gas available?
Methane!
Can we utilize a neighboring pipeline to “buy” CH4
as our lift gas and “sell” it back to the pipeline?
Yes, but there needs to be an existing pipeline
SPE/IADC Managed Pressure Drilling and Underbalanced Operations Conference & Exhibition
8-9 April 2014 NH Eurobuilding Hotel, Madrid
Natural Gas From Formation
Gas
Drilling Mud
Pipeline
SHUT OFF
SUPPLY GAS
AND OPEN
SALES LINE
Valve
NOT
NECESSARY
TO FLARE
WHILE
DRILLING BY
R&R
BUYING GAS
FROM
PIPELINE TO
START UBD
BOOSTERS
UBD
CHOKE
SEPARATOR
RIG MUD TANKSRIG
PUMPS
SHAKER
ST
AN
DP
IPE
ANNULAR
Flare Stack
H2S SCRUBBER
COMPRESSORS
PRODUCING
NATURAL
GAS WHILE
DRILLING
SPE/IADC Managed Pressure Drilling and Underbalanced Operations Conference & Exhibition
8-9 April 2014 NH Eurobuilding Hotel, Madrid
7
Compressors Scrubber
Booster & Mist
Pump
UBD Choke &
Separator
Flare Stack
MAC Skid
SPE/IADC Managed Pressure Drilling and Underbalanced Operations Conference & Exhibition
8-9 April 2014 NH Eurobuilding Hotel, Madrid
8
Why Recycle and Recover Gas?
Cost Savings Using natural gas as a nitrogen replacement, thereby not requiring the
nitrogen generating equipment
Reduced cost of diesel to run the equipment with bi-fuel modifications
Direct distribution of produced gas for selling to the pipeline rather than
flaring (generate revenue while drilling)
Reduce Environmental Impact
Reduced flaring of gas on location while drilling
Possible carbon tax credit by reducing emissions
SPE/IADC Managed Pressure Drilling and Underbalanced Operations Conference & Exhibition
8-9 April 2014 NH Eurobuilding Hotel, Madrid
9
1st CASE STUDY – UBD
GAS WELL (CANADA)
SPE/IADC Managed Pressure Drilling and Underbalanced Operations Conference & Exhibition
8-9 April 2014 NH Eurobuilding Hotel, Madrid
10
Depleted limestone reservoir
4 – 6 kPa/m [0.18 – 0.26 psi/ft]
Drilled with foam fluid system
water, methane, surfactant
Methane supplied from pipeline until well
produced and then methane was recycled
for drilling with excess sent to pipeline
SPE/IADC Managed Pressure Drilling and Underbalanced Operations Conference & Exhibition
8-9 April 2014 NH Eurobuilding Hotel, Madrid
11
Data reporting compiled on a daily basis
and captured in End of Well Report
Some wells were multi-leg horizontals
0
100
200
300
400
500
600
700
800
900
1000
00:00
02/02
12:00
02/02
00:00
03/02
12:00
03/02
00:00
04/02
12:00
04/02
00:00
05/02
12:00
05/02
00:00
06/02
12:00
06/02
00:00
07/02
12:00
07/02
00:00
08/02
12:00
08/02
00:00
09/02
12:00
09/02
00:00
10/02
Prod
uced
Gas
Vol
ume
(103 m
3 )
1400
1500
1600
1700
1800
1900
2000
2100
2200
2300
2400
2500
2600
2700
Hole
Dep
th (
m)
Cumulative Produced Gas
Cumultive Sales Gas
Cumulative Flare Stack Gas
Cumulative Buy Gas
Hole Depth
911 e3m
3 (36 mmscf) of gas produced
throughout the job.
Produced = Sales + Flare - Buy
SPE/IADC Managed Pressure Drilling and Underbalanced Operations Conference & Exhibition
8-9 April 2014 NH Eurobuilding Hotel, Madrid
12
0
500
1000
1500
2000
2500
3000
2 6 10
14
18
22
26
30
34
38
42
46
50
54
58
62
66
70
74
78
82
86
90
94
98
10
2
10
6
11
0G
as
Pro
du
ctio
n (
e3m
3)
Wellhead Number
Gas Production for R&R UBD Wells
Recovered Gas (e3m3) Flared Gas (e3m3) Produced Gas (e3m3)
Recovered Gas=Sold Gas-Buy Gas
Flared Gas=Produced Gas+Buy Gas-Sold Gas
YEAR 1 YEAR 2 YEAR 3 YEAR 4
SPE/IADC Managed Pressure Drilling and Underbalanced Operations Conference & Exhibition
8-9 April 2014 NH Eurobuilding Hotel, Madrid
13
Flush
Production
Matrix
Production
SPE/IADC Managed Pressure Drilling and Underbalanced Operations Conference & Exhibition
8-9 April 2014 NH Eurobuilding Hotel, Madrid
14
AVERAGE FLARED GAS WAS
~25% OF PRODUCED GAS
SPE/IADC Managed Pressure Drilling and Underbalanced Operations Conference & Exhibition
8-9 April 2014 NH Eurobuilding Hotel, Madrid
15
0
500
1000
1500
2000
2500
3000
2 6 10
14
18
22
26
30
34
38
42
46
50
54
58
62
66
70
74
78
82
86
90
94
98
10
2
10
6
11
0G
as P
ro
du
ctio
n (
e3m
3)
Wellhead Number
Gas Production for R&R UBD Wells
Recovered Gas (e3m3) Flared Gas (e3m3) Produced Gas (e3m3)
Recovered Gas=Sold Gas-Buy Gas
Flared Gas=Produced Gas+Buy Gas-Sold Gas
YEAR 1 YEAR 2 YEAR 3 YEAR 4
Total Recovered Gas = 61,600 e3m3
SPE/IADC Managed Pressure Drilling and Underbalanced Operations Conference & Exhibition
8-9 April 2014 NH Eurobuilding Hotel, Madrid
16
0
5000
10000
15000
20000
25000
30000
35000
40000
45000
50000
55000
60000
65000
$0
$2,000,000
$4,000,000
$6,000,000
$8,000,000
$10,000,000
Cu
mu
latv
e R
eco
ve
red
Ga
s (e
3m
3)
Cu
mu
latv
e R
eco
ve
red
Ga
s M
ark
et
Va
lue
($
)
Market Value for Recovered Gas
Recovered Gas in Dollars
Recovered Gas
CDN $ 9,855,058
61,600 e3m3
PROJECT TIMELINE • The gross heat of combustion of 1 m3 of commercial quality natural gas is around 0.039 GJ • Gas price is based on monthly average gas price in Alberta from http://www.ngx.com/natgas.html
SPE/IADC Managed Pressure Drilling and Underbalanced Operations Conference & Exhibition
8-9 April 2014 NH Eurobuilding Hotel, Madrid
17
0
6000
12000
18000
24000
30000
36000
$0
$1,000,000
$2,000,000
$3,000,000
$4,000,000
$5,000,000
$6,000,000
Cu
mu
latv
e R
eco
ve
re
d G
as (e
3m
3)
Cu
mu
latv
e R
eco
ve
re
d G
as M
ark
et
Va
lue
($
)
Market Value for Flared Gas
Flared Gas Value
Flared Gas VolumeCDN $ 5,261,960
29,983 e3m3
PROJECT TIMELINE
SPE/IADC Managed Pressure Drilling and Underbalanced Operations Conference & Exhibition
8-9 April 2014 NH Eurobuilding Hotel, Madrid
18
2nd CASE STUDY –
SOUR GAS WELL
SPE/IADC Managed Pressure Drilling and Underbalanced Operations Conference & Exhibition
8-9 April 2014 NH Eurobuilding Hotel, Madrid
19
Sour Gas Well Recovery Application
Used to drill a deep horizontal (~3725mTVD, 700m lateral).
Potential for sour gas, estimated to be 13.7% H2S (12% on real test)
The regulatory board issued a flare permit for a maximum of 240 e3m3
cumulative gas flared throughout the entire operation (National Park).
How can we do this?
SPE/IADC Managed Pressure Drilling and Underbalanced Operations Conference & Exhibition
8-9 April 2014 NH Eurobuilding Hotel, Madrid
20
Mitigating H2S Hazards Provided equipment compatible with sour gas, and
resistant to deterioration of all of the flexible elements in
the fluid handling system, i.e. ensured rubber compatibility.
Provided connections to pipeline and directly transported
produced sour gas into pipeline system.
Sour gas level measurements taken with a Gas Tec
monitor while drilling, ensuring safety to all personnel on
location.
Supplied real-time engineering control and data acquisition
system. All drilling parameters monitored throughout the
operation.
SPE/IADC Managed Pressure Drilling and Underbalanced Operations Conference & Exhibition
8-9 April 2014 NH Eurobuilding Hotel, Madrid
21
Pipe line
WFT
4 Phase
Separator
Flare
Stack
Tank Farm
Settling Time
WFT
Control
Manifold
Rigs Choke
Manifold
Standpipe
Manifold
Standpipe Bleed Off
to Separator
Produced
Water
RBOP
Annular
Bleed Off
To Shakers
Bleed Off
Separator
Oil Dump to
Tank Farm
Gas
Oil
Water
Solids
Multiphase Flow
Foam
Defoamer
OPEN FLUID
CLOSED FLUID
OPEN SOLIDS
CLOSED SOLIDS
SCRUBBERS ON TANK VENTS
H2S
Scrubber
H2S
Scrubber
Sample Catchers
Solids Control Tank
Low Volume
Pump
Compressor
Processing
UnitCompressor
Supply gas
Supply gas
from pipeline
Produced gas
to pipeline
Process Flow Diagram – Closed Loop
SPE/IADC Managed Pressure Drilling and Underbalanced Operations Conference & Exhibition
8-9 April 2014 NH Eurobuilding Hotel, Madrid
22
Sour Gas Well Recovery Application - Results
Recovered over 98% of the total natural gas with
12% H2S over a drilling period of 21 days
Total gas flared was 8.5 e3m3 (0.3 MMscf), well
below permit
Reduced environmental impact & increased safety
Sweet gas pipeline for supply; produced sour gas
and returned to a sour gas processing facility
Drilling fluid contamination was mitigated using H2S
scavenger and dump & dilute methodologies
SPE/IADC Managed Pressure Drilling and Underbalanced Operations Conference & Exhibition
8-9 April 2014 NH Eurobuilding Hotel, Madrid
23
Planning for R&R application?
SPE/IADC Managed Pressure Drilling and Underbalanced Operations Conference & Exhibition
8-9 April 2014 NH Eurobuilding Hotel, Madrid
24
QHSE Integrated for R&R Process
Pre-job planning including development of a UB drilling
program with specific SOP’s
HAZOP & HAZID
Site visits to optimize equipment layout and spacing
Auto alarms & shutdowns; intrinsically safe and certified
equipment along with LEL & H2S monitoring
Relief and vent lines tied into a closed loop and not open to
atmosphere
Data monitoring and post well review
SPE/IADC Managed Pressure Drilling and Underbalanced Operations Conference & Exhibition
8-9 April 2014 NH Eurobuilding Hotel, Madrid
25
Unique Requirements for R&R Pipeline Gas Supply
Need to be in a developing field for this to be feasible
Constant pipeline feed pressure & minimal fluid content
Buy & Sell gas specifications
Additional metering equipment with advanced
metering calculations for accurate real-time
measurement data
Equipment modifications to compress natural gas
Adequate lease for equipment and associated piping
SPE/IADC Managed Pressure Drilling and Underbalanced Operations Conference & Exhibition
8-9 April 2014 NH Eurobuilding Hotel, Madrid
26
Reduce/Eliminate Flaring
Safety
Environmental
Economic
Closed-Loop Circulation System
Mitigate H2S & CO2 exposure
Drilling Fluid Compatibility
Oil Wells – Flow Drilling applications
SPE/IADC Managed Pressure Drilling and Underbalanced Operations Conference & Exhibition
8-9 April 2014 NH Eurobuilding Hotel, Madrid
27
Thank you!
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