SPE/IADC 130308

Deepwater Riserless Mud Return System for Dual Gradient Tophole Drilling
Dave Smith, AGR Subsea; Warren Winters, BP America; Brian Tarr and Robert Ziegler,* Shell; and Iskandar Riza
and Malik Faisal, PETRONAS

Copyright 2010, SPE/IADC Managed Pressure Drilling and Underbalanced Operations Conference and Exhibition

This paper was prepared for presentation at the 2010 SPE/IADC Managed Pressure Drilling and Underbalanced Operations Conference and Exhibition held in Kuala Lumpur, Malaysia, 24–25 February 2010.

This paper was selected for presentation by an SPE/IADC 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 Society of Petroleum Engineers or the International Association of Drilling Contractors and are subject to correction by the author(s). The material does not necessarily reflect any position of the Society of
Petroleum Engineers or the International Association of Drilling Contractors, its officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written consent of the
Society of Petroleum Engineers or the International Association of Drilling Contractors 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 SPE/IADC copyright.

Abstract
The paper presents results of a large-scale field trial conducted from a deepwater semi submersible drilling vessel offshore
Sabah, Malaysia, September 2008. A joint industry group comprising AGR Subsea, BP America, Shell, Norwegian Research
Council’s DEMO 2000 program, and supported by PETRONAS undertook this work. The group set out to advance subsea
mud return technology from its established commercial market of shallow water applications, 1800 ft (549 m) or less to
deepwater depths and drilling requirements. Novel equipment and deployment methods were designed, developed, delivered,
tested and proven on a demanding schedule.

The technology is applicable to closed loop riserless tophole drilling, in water depths to ca. 5,000 ft (1500 m), as an
alternative to seabed discharge of drilling fluid and cuttings. The system takes all returns back to the solids control
equipment on the rig where recirculation of drilling fluid minimizes mud consumption thereby enabling the use of higher-
quality fluids otherwise too costly to be continuously dumped. Anticipated improvements, confirmed by field trial results,
are greatly improved control of shallow hazards and, a more-stable, nearly-gauge well bore with benefits of improved hole
cleaning, allowing significantly deeper casing setting depths, and more effective primary cementing of surface casings with
lower cement volumes. Mud logging of formation cuttings and associated drilled gases reveal geologic details of tophole
intervals otherwise lost with seabed discharge methods. The technology facilitates drilling in sensitive subsea environments
subject to strict zero-discharge rules, and in distant locations where resupply of drilling fluids and additives are impractical;
particularly with MODUs that cannot store sufficient quantities of mud to self-support continuous dumping.

The field trial was successful in 4657 ft (1419 m) water depth. Cost-effective use of high-quality drilling mud in tophole
drilling was demonstrated. A near-gauge wellbore, detailed tophole mud logging data and effective primary cementing were
obtained. The unique design and deployment of the deepwater mud return system are first-of-its-kind, and are described.

The field trial results are significant as the first-ever application of subsea mud return technology to deepwater tophole
drilling. Successful integration of topsides equipment and running procedures to the 3rd-generation semi submersible drilling
vessel is an engineering and operational feat. Successful deployment and operation of the subsea equipment at true deepwater
depths is a pioneering technical achievement. This technology finally opens the path for cost efficient deepwater dual
gradient drilling.

Introduction

The tophole intervals of deepwater wells are commonly drilled riser-less with mud and cuttings returns dispersed to the
seabed. Where weighted drilling fluid is required, the economics of non-return and re-use lead to choosing relatively
inexpensive bentonite systems. This involves diluting a dense, typically 16 ppg mud with seawater on the fly to produce the
desired lower density. This is done to reduce the volume of mud shipped offshore to the drilling location, but also presents
challenges in deepwater areas due to rig and logistics limitations and mud quality concerns. 1
2-5
A Riserless Mud Recovery (RMR™) system, Figure 1, has been developed and is in commercial use improving tophole
* now with PETRONAS
2 SPE/IADC 130308

drilling in water depths to 1800 ft (549m). RMR™ uses a Subsea Pump Module (SPM) located near the seabed to pump
fluid and cuttings returns from the well to the rig mud treatment system via a Mud Return Line (MRL). RMR™ enables
treatment and re-use of the drilling fluid allowing economic use of costlier more inhibitive fluid systems, volumetric
monitoring of the well for gains or losses, gas detection, and collection of cuttings for geological evaluation.

The shallow water version of RMR™ has been used commercially use since 2003 on over 100 wells worldwide, Table 1.
The most common reasons for using the system include:

Maintain stability of shallow formations by allowing economic use of an inhibited water base drilling fluid which is
returned to surface, treated and re-used.
Control shallow water and gas by applying a quality weighted mud system and thorough volume monitoring, thus
allowing detection and reaction via mud weight to control the influx.
Extend depth of surface casing by improving the borehole quality through economic use of a more effective drilling
fluid, maintaining appropriate borehole pressure by adjusting mud weight based on gains/losses observed, and
reducing the logistical requirement to transport large volumes of disposable mud.
Conformance to environmental regulations by providing a practical alternative to a riser and pin connector to meet
“zero discharge” regulations.
Prior to establishing the Joint Industry Project (JIP) which developed this system, shallow water RMR™ was limited to
approximately 1800 ft (549 m) water depth by the practical limits of the flexible Mud Return Line hoses and providing
sufficient power to pump fluid returns from deeper water depths.

Shell, BP America, DEMO2000, and AGR formed a JIP to develop a deepwater version of RMR™. This followed an earlier
DEMO2000 JIP 6, which developed a jointed steel tubular as Mud Return Line, and conducted a 2004 field trial in harsh
North Sea winter weather. The Deepwater RMR™ JIP used the same jointed steel return line philosophy and further
improved the pumping power, environmental resistance, and deployment system to lift the return mud and cuttings from
greater depths. Deepwater RMR™, which utilizes two Subsea Pump Modules (SPMs) each with three pump stages, one near
bottom and one near mid-water depth, is shown schematically in Figure 2. System specifications are shown in Table 2.
Pumping capacity is depicted in Figure 3.

A Deepwater RMR™ field trial was conducted in late summer of 2008 on a well in the South China Sea. The field trial was
supported by the original JIP participants and PETRONAS as partner in the well. Deepwater RMR™ offered several
advantages for the South China Sea well:

Overcoming mud logistical limitations – the volume of disposable mud that could be built and transported with the
existing infrastructure limited surface casing depth. Recirculation of the mud allowed extension of shallow casing
depth such that a weak zone traditionally drilled with significant losses of synthetic oil based mud could be cased
and cemented prior to running the BOP and riser.
Safely drill potential shallow hazards – the volume monitoring capability with RMR™ allows safe drilling of
shallow hazards preventing large influxes by adjusting mud weight based on small gains/losses observed. These
shallow hazards included a hydrate zone with possible hydrocarbon accumulation below, and a possible shallow gas
zone.
Provide detailed mud logging through shallow hazards – detailed monitoring of returns for hydrocarbon content
(mud gas spectrographic analysis) aids planning of casing requirements to control shallow hazards in future wells.

Description and Application of Equipment and Processes

Application of Deepwater RMR™ in South China Sea

The casing plan for the Deepwater RMR™ field trial is shown in Figure 4. The plan addressed several challenges including
the following:

Set Surface Casing Across Zone 4 – Placing surface casing across this zone improves economics of the well by
minimizing losses of oil based mud into the weak Zone 4. Using seabed dispersal of water based fluid, the depth to
which the 13 3/8” surface casing could be set was limited by mud logistics.
Control Possible Shallow Gas in Zone 1 – Drill through gas hydrate layer at top of Zone 1 and control possible
shallow hydrocarbons below. The risk of uncontrolled well flow is lowered with RMR™ as volume monitoring and
SPE/IADC 130308 3

precise control over the mud weight in the well is possible. The seabed discharge case for this well included a
contingency shallow set of the 13 3/8” casing to isolate Zone 1.
Control Possible Shallow Gas in Zone 2 – Drill through and control known shallow gas in Zone 2, with a similar
reduced risk due to better volume control and improved control over mud in the well with RMR™.
Control Losses While drilling Zone 3 – Control likely losses while drilling Zone 3 without causing flow from Zones
1 or 2.

Riserless Mud Recovery Equipment

The Deepwater RMR™ equipment used to accomplish the goals on this well is shown in Figure 2:

The Suction Module (SMO) is mounted on the low pressure wellhead on surface and run with the jet and drill ahead
string, Figure 5. The cylindrical open topped SMO receives the return mud and cuttings as they exit the wellhead.
The SMO provides a connection point for the Suction Hose and has provisions for monitoring the height of mud in
the SMO. By controlling the height of the mud in the SMO to a constant level, mud and cuttings are returned to
surface at the same rate they exit the wellbore. The level of the mud is monitored both with redundant lighted
cameras and a pressure transducer sensing the hydrostatic pressure of the column of mud in the SMO.
The Subsea Electronics Package (SEM), Figure 6, houses the SMO electronics in a lightweight frame with
buoyancy to further reduce submerged weight. The SEM is transported to the sea bottom on the Lower SPM, Figure
11, and is moved to the SMO by the ROV. This method avoids exposure of the electronics to possible damage from
vibrations and shock loads while the conductor casing is jetting in with the SMO mounted.
The Suction Hose, Figure 7 provides the flow path between the SMO and the Lower Docking Joint (LDJ). The
submerged suction hose weight is reduced with buoyancy to allow for easy installation with the Remote Operated
Vehicle (ROV).
The Lower Docking Joint (LDJ), Figure 8, is mounted in-line with the Mud Return Line (MRL) and provides for
both structural connection of the lower Subsea Pump Module (SPM) to the MRL and connection of the suction and
discharge lines for the SPM. In addition to allowing for easy mounting of the SPM to the MRL at surface, the LDJ
also provides the connection point between the MRL Anchoring System and the MRL. The LDJ contains a tapered
stress joint at the top end to minimize fatigue damage due to Vortex Induced Vibration (VIV).
The MRL Anchoring System fixes the bottom end of the MRL to the seabed holding the MRL away from the well
and drillstring to avoid clash. The MRL Anchor also allows movement of the MRL with heave of the floating
drilling rig such that a “hard” (uncompensated) hang-off system can be used at surface. The MRL Anchoring
system is not designed to restrain the MRL from vertical movement, only horizontal movement to maintain the
MRL at a constant distance from the wellhead, Figure 9.
The lower Subsea Pump Module (SPM), Figure 10, contains three electrically driven disc pumps that allow for
pumping of the cutting laden return mud with minimal damage to the cuttings. The disc pumps allow for passage of
particles up to 2 in. (50.8 cm) diameter. The lower SPM mounting to the LDJ, which provides both structural and
suction and discharge connections for the pumped fluid, is performed at surface using the SPM Handling Frame.
The Mud Return Line (MRL) provides the conduit from the seabed to surface for the return fluid and sufficient
strength to support the two subsea pump modules and anchor mass and resist forces caused by currents and vessel
movements. A jointed tubular, 7 5/8” casing with Hydril 563 connection for this well, is used for MRL on the
Deepwater RMR™, for this well a 7 5/8” casing was used. The MRL is anchored to the seabed by the MRL
Anchoring System, and is hung off at surface on the Hang of Joint (HOJ) landed in the Hang off Module (HOM).
The Upper Docking Joint (UDJ) is mounted in-line with the Mud Return Line (MRL) near mid water depth and
provides for structural connection of the upper Subsea Pump Module (SPM) to the MRL, connection of the suction
and discharge lines for the SPM, and safe convenient installation of the upper SPM at surface. The UDJ contains
tapered stress joints top and bottom to minimize fatigue damage due to VIV.
The upper Subsea Pump Module (SPM), Figure 11, similar to the lower SPM, contains three electrically driven disc
pumps to boost the cutting laden return mud with minimal damage to the cuttings. The upper SPM connection to the
UDJ , which is performed at surface using the SPM Handling Frame, provides a firm structural and both suction and
discharge piping connection for the pumped fluid.
The SPM Handling Frame, Figure 12, is used to move the SPMs to moonpool center for mounting to the docking
joints. This frame was also used to hang off the MRL Anchor system and the jet and drill ahead conductor casing
during deployment.
4 SPE/IADC 130308

The Hang Off Module (HOM), Figure 12, is used to support the MRL by the Hang Off Joint (HOJ) at surface.
The Hang Off Joint (HOJ), Figure 13, includes a gimbal to reduced bending moment applied to the MRL at surface
due to vessel pitch and roll, and a tapered stress joint to reduce fatigue accumulation due to that bending moment
and VIV.
The Flowhead, Figure 14, provides for valving to isolate the Mud Return Line from the low pressure hose to the
rig’s mud processing equipment and facilitate connection of a contingency line.
A 25 ton winch, Figure 15, was used to store and handle the umbilical providing power and communication to the
lower SPM and SEM.
A 10 ton winch, Figure 16, was used to store and handle the keel hauled umbilical providing power and
communication to the upper SPM.
The Control Containers, Figure 17, house the communication and power equipment used to control the Subsea
Pump Modules (SPMs). This equipment includes Variable Speed Drives (VSDs) to control the pump rate of the
SPM and transformers to increase the voltage of the electricity transmitted subsea.
The Office & Workshop Container houses a workshop and spares storage area and the Computerized Process
Control System that acquires the data from the sensors on the SEM and SPM and sends the signals to control the
VSD’s such that the pump rate of the SPM matches the return rate of the drilling fluid and cuttings.
The Control System provides for operation of RMR™ from a panel on the rig floor during drilling operations,
Figure 18. This panel is mounted in the driller’s cabin to facilitate good communication between the driller and
RMR™ operator. A redundant control panel and additional monitors, Figure 19, are housed in the Office and
Workshop Container. This panel is used to monitor the health of the system during operations, and is used to
control the equipment on deck during rig up and deployment.
Auxiliary diesel driven portable generators were used to provide the electrical power required by the system due to
the limited power on the vessel.
The conductor casing hang off frame, Figure 20, was modified such that cement ports were manifolded together so
that mud and cement could be returned to surface after the surface casing hanger was set. The cement ports were
then connected to the suction port of the SMO with an isolation valve to allow easy changeover of returns when the
surface casing hanger was set. Figure 20 also shows the posts on the SMO for mounting the SEM.

Deployment of the Riserless Mud Recovery Equipment

Deployment of the Deepwater RMR™ equipment was performed as follows:

Deployment of Mud Return Line and Subsea Pump Modules

1) Umbilical from 10 ton winch for powering the upper SPM was keel hauled into the moonpool and terminated to the
upper SPM.
2) Anchor piling was hung off in the moonpool on the SPM handling frame.
3) Anchor mass was run into Anchor piling using synthetic rope and hung off in anchor piling.
4) Lower Docking Joint was run into moonpool, connected to the Anchor Synthetic Rope, and locked to the Anchor.
5) Lower SPM was mounted on Lower Docking Joint.
6) Suction hose was connected to the LDJ and hung off on Mud Return Line.
7) Mud return line was run and the umbilical to lower SPM from 25 ton winch was strapped to MRL to prevent drifting
with current.
8) Upper Docking Joint was installed in the Mud Return Line
9) Upper SPM was mounted to the Upper Docking Joint
10) Additional 7 5/8” casing MRL was run, while the umbilical to upper SPM from the 10 ton winch was run with some
slack.
11) Anchor was test stabbed into seabed, space out was made
12) Hang off joint and Gimbal were installed in Mud Return Line
13) Anchor was stabbed into seabed and the LDJ was released from anchor with ROV assistance.
14) MRL was hung off by Hang Off Joint on Hang Off Module
15) Flowhead, mud flowline and contingency line were connected to flowhead
SPE/IADC 130308 5

Deployment of Suction Module

1) Conductor Casing run and hung off on modified conductor casing hang off frame on SPM Handling Frame in
Moonpool
2) Suction Module (SMO), including loop to allow return of fluids to surface during cementing after casing hanger is
set, was installed on conductor casing
3) Drilling assembly and Cam Activated Drill Ahead (CADA) Tool was installed in conductor casing
4) Conductor casing was jetted in with SMO mounted on Low Pressure Wellhead.

Subsea connections required

1) The ROV was used to install the suction hose to the SMO.
2) The ROV was used to install the Subsea Electronics Module (SEM) and flying lead providing power and
communication for the SMO electronics from the lower SPM.

The RMR™ system is then testing by pumping seawater back to the pits from the SMO.

Operation of the Riserless Mud Recovery Equipment

Initial set up of the equipment requires the well to be circulated to mud. The SMO/SEM is then calibrated with a high and
low level on the pressure transducer using the cameras to observe the mud level.

During operations, the level of the SMO is maintained by the process control system based upon the pressure sensor reading.
During connections, the pumps will automatically slow to maintain the static column of fluid without moving the fluid.
Figure 21 shows the mud/seawater interface during drilling operations, with the smaller screen on the right being displayed
on the rig floor panel and used to control the operation.

For cementing, after the casing hanger is set, the valve to the cement ports is opened, allowing communication of the return
fluids with the SMO sensors.

Presentation of Data and Results

Drilling the well

The conductor casing was jetted in as a routine operation with the SMO mounted on the Low Pressure Wellhead and returns
from the jetting operation taken over the top of the SMO. The cam-actuated drilling tool was tripped out to minimize risk of
plugging the conductor housing with cuttings while the suction hose and SEM were installed on the SMO with the ROV.

The well was circulated to drilling mud and the RMR™ system was calibrated. Drilling of the 17 ½ in. hole section was
performed with returns to the shakers, with full pit volume monitoring in a similar manner on surface to drilling with the
marine riser in place. During the drilling of the 17 ½ in. section, the following events related to return of the drilling fluids
and cuttings and the use of RMR™ were experienced:

Losses/gains were not experienced in the possible faulted section above Zone 1 and drilling proceeded with planned
mud weights, flowrates and ROP.
Hydrates in Zone 1 were drilled without incident. Methane was detected by a gas chromatograph during drilling of
the hydrate zone, free gas was not experienced. Below the hydrate zone, more complex hydrocarbons were detected
in the mud gas on the gas chromatograph, but free gas and high levels of mud gas were not detected confirming the
absence of a significant shallow hazard in Zone 1.
Zone 2 was drilled with planned mud weight. Hydrocarbons were detected in drill gas, but free gas was not seen.
The absence of shallow gas hazard in Zone 2 was confirmed by Logging While Drilling (LWD).
Cuttings during the shale section between Zones 2 and Zone 3 were soft, but effectively separated at the shakers.
Flowrate and drilling rate were controlled to remain within the shaker capacity of the vessel.
During drilling of Zone 3, significant losses of mud to the formation were experienced. Lost Circulation Material
(LCM) improved the losses and the mud weight was reduced below planned mud weight to control losses. The
adjustment of mud weight was performed slowly to avoid influx from Zones 1 and 2.
6 SPE/IADC 130308

More sand stringers than expected were encountered in Zone 3. The return sand caused some blinding of the shaker
screens and whole mud was lost over the shakers. Changing the shaker screens to a finer mesh reduced the blinding
of the shakers and loss of whole mud to a manageable level.
Shortly after the LCM was pumped during losses in Zone 4, a semi-solid mass was observed at the SMO in the
returns from the well. This mass which may have been gumbo, lost circulation material, or a combination of the two
was undesirable to take back over the shakers. The RMR™ pumps were slowed and the mass was dumped to sea
over the top of the SMO. A portion of this mass remained on the top of the SMO partially obscuring the cameras
view of the mud/seawater interface from the cameras mounted on the SMO.
Cuttings from the shale section between Zone 3 and Zone 4 became progressively firmer as the well was drilled
deeper and separated well from the drilling fluid at the shakers.
More sand stringers were experienced in Zone 4 than had been expected. Drilling continued through Zone 4 with
intermittent losses which were cured using LCM and mud weight adjustments. Drilling continued through Zone 4
until a combination of LWD and Cuttings Analysis indicated that an appropriate casing point had been reached. The
surface casing was set according to geologic evaluation at 7404 ft (2256 m), 169 ft (51 m) shallower than planned
depth.
During pre-job planning, there was some concern about build up of Low Gravity Solids (LGS) in the mud.
Significant LGS was not experienced, but this may have been influenced by the amount of fresh mud built due to
losses of mud downhole and whole mud over the shakers during the sand blinding of the shakers.
The inhibition level of the mud was monitored by observing the salt concentration of the KCl/glycol mud. Salt
concentration reduced as the mud was recirculated, but was rebuilt relatively easily during drilling by addition of
KCl to the mud.
The hole was “gauged” occasionally during drilling by pumping carbide slugs and back calculating the average hole
volume based on the volume to detection of carbide gas in the return mud stream. Gas was detected in the return
fluid for about half of the carbide slugs pumped. Slugs of slightly more dense fluid were also used to gauge the
hole, with detection of returns on a densitometer at surface; this method was more reliable than the carbide slugs.
Average hole size at completion of the section was 18.4 in. with use of a 17 ½ in. bit.

Surface Casing and Cement

The excess cement volume for the surface casing cementation was reduced from 200% to 100% based upon the
good condition of the hole.
Surface casing was run routinely with returns during running and circulation to surface.
Losses were experienced during cementing, the loss time and volume was measured by pit volume of returned fluid.
Traces of cement were pumped to surface and detected at the shakers. In this area it is very uncommon to achieve
cement to surface during surface casing cementing.

Following Hole Section

With the surface casing set across Zone 4, the following 12 ¼ in. section was drilled faster than previous wells with
minimal losses of oil based mud.

Performance of Deepwater RMR™

Deepwater RMR™ performed as expected, returning mud and cuttings at the flowrates and mud weights used during the
drilling process without issues. As shown in Figure 3, the pumping demands of the field trial well were well within the
capacity of the Deepwater RMR™ system. Analysis of data gathered during the operation was performed, and showed that
the pressures experienced by the pump units were as predicted by the pumping hydraulic model, Figure 22. The rotational
speed required to perform the pumping during the field trial was slightly lower than that predicted by the modeling, Figure
23, indicating that the disc pumps were generating approximately 2% more pressure head than had been predicted.

Several new items of equipment were developed during the course of the Joint Industry Project to deploy this equipment.
The following section contains comments about these items:

Mud Return Line Anchor System – new development for this system. The anchoring system penetrated the soil very
closely to planned depth which was based on minimal soil information and previous jet and drill ahead experience.
SPE/IADC 130308 7

Figure 24 shows the actual vs. planned penetration of the anchoring system into the soil. There was no unplanned
movement of the anchor observed.
Subsea deployed Subsea Electronics Module for the SMO – this was the first installation of the SMO prior to jetting
of the conductor casing. Vibration measurements were performed on a jet and drill ahead operation in the GOM,
and vibrations in excess of the electronic equipment ratings were experienced. To avoid subjecting the electronics
to this vibration, the electronics were packaged such that they could be deployed on the lower SPM and installed on
the SMO with the ROV. This operation, which required an ROV buoyancy change with the small ROV available,
was performed without incident. The electronics performed well during the operation.
Installation of Subsea Pump Modules to the Mud Return Line using Docking Joints – this operation involved new
design and constructed equipment and was performed as a routine operation.
The deployment of the SPM on the 7 5/8” casing MRL involved running the casing and two power and control
umbilicals simultaneously. This was a new operation, and during the operation there was a communication failure
between the Driller and the RMR™ Operator that resulted in shearing the weak point at the bottom of the umbilical.
This required pulling the SPM back to surface and repairing the sheared weak point. The weak point sheared at the
planned load.
A heavy duty single joint compensator was mobilized to help with making up the casing joints at the lower end of
the 4.5 ton upper docking joint. There were some certification issues that prevented use of the single joint
compensator. The driller was able to lower the UDJ effectively with the drawworks to make up the Hydril 563
casing connection without damage or difficulty.
While the weather during the field trail was generally mild, no movement was observed on the hang off gimbal
during the field trial, including during a small squall. Post operation fatigue analysis indicated that the tapered stress
joint on the Hang off Joint performed effectively and there was minimal fatigue accumulation in both the specialized
RMR™ equipment and the casing used for the mud return line.
There were no cooling issues with the water cooled electrical equipment, but the alarm for high cooling water
temperature on the VSD caused a shut-down of the electrical equipment at the start of the operation. This was
resolved by reprogramming the VSD to account for the higher inlet temperature of the cooling water in the South
China Sea.
Numerous logistical issues were overcome with shipping of equipment to Malaysia and certification of local rental
equipment for offshore operation. Logistics of assembling the equipment and installing it on the rig went very well.
There were no HSE events associated with the deployment, drilling, and recovery of the Deepwater RMR™
equipment.

Conclusions

The main conclusions from development and field trial of the Deepwater RMR™ are as follows:

1) Deepwater RMR™, designed to return drilling fluids and cuttings during tophole drilling, was effectively field
tested from a floating rig in 4657 ft (1419 m) of water
2) Deepwater RMR™ development was accelerated by the formation of a Joint Industry Project that ensured active
participation of each party.
3) Use of a recirculated drilling mud for the tophole section of the well enabled surface casing to be set deeper than
was logistically possible using traditional non-recirculating seabed dispersion of drilling fluid and cuttings.
4) Volume monitoring of the well allowed the mud weight to be adjusted as the well was drilled and, combined with
the more effective drilling fluid provided a more gauge hole, which reduced cementing volumes compared to
historical norms.
5) Tophole geologic information obtained from the return mud and cuttings provided improved information concerning
shallow hazards in the area.
8 SPE/IADC 130308

Acknowledgements

The authors would like to thank Shell, BP America, PETRONAS, AGR Subsea, and DEMO2000 for their support during this
project and for permission to publish these results. The authors would also like to thank the Atwood Falcon rig crew and
management for their assistance and co-operation throughout the field trial planning and operation.

Abbreviations

DKD™ – Dynamic Kill Drilling, trademark of Baker Hughes, Inc.

HOJ – Hang Off Joint
HOM – Hang Off Module
JIP – Joint Industry Project
LCM – Lost Circulation Material
LDJ – Lower Docking Joint
LGS – Low Gravity Solids
LWD – Logging While Drilling
MRL – Mud Return Line
RMR™ – Riserless Mud Recovery, trademarked name of AGR Subsea AS
ROV – Remote Operated Vehicle
SEM – Subsea Electronics Module
SMO – Suction Module
SPM – Subsea Pump Module
UDJ – Upper Docking Joint
VIV – Vortex Induced Vibration
VSD – Variable Speed Drive
™ - Trademarked name

References

1. Scott, Paul; Ledbetter, Sam; Chester, Rick; Powell, Don.: “Pushing the Limits of Riserless Deepwater Drilling”,
AADE-05-DF-HO-30, 2006 AADE Drilling Fluids Conference, Houston, April 11-12, 2006.
2. Alford, S. E.; Campbell, M.; Aston, M. S.; Kvalvaag, E.: “Silicate-Based Fluid, Mud Recovery System Combine to
Stabilize Surface Formations of Azeri Wells”, SPE/IADC 92769, 2005 SPE/IADC Drilling Conference, Amsterdam,
23-25 February 2005.
3. Frøyen, Johnny; Rommetveit, Rolv; Jaising, Hitesh; Stave, Roger; and Rolland, Nils Lennart.: “Riserless Mud
Recovery (RMR) System Evaluation for Top Hole Drilling with Shallow Gas”, SPE 102579, 2006 Russian Oil and
Gas Technical Conference, Moscow, 3-6 October 2006
4. Brown, J. D.; Urvant, V. V.; Thorogood J. L.; Neftegaz, Elvary; and Rolland, N. L.: “Deployment of a Riserless
Mud Recovery System Offshore Sakhalin Island”, SPE/IADC 105212, 2007 SPE/IADC Drilling Conference,
Amsterdam, 20-22 February 2007.
5. Hinton, Andy; Eikemo, Bernt; Tilley, Vince; Nolan, Tom.: “Taming the Grebe Sand – Tophole Drilling Success in
the Ichthys Field”, SPE 121439, 2009 SPE Asia Pacific Oil and Gas Conference, Jakarta, 406 August 2009.
6. Stave, R.; Farestveit, R.; Høyland, S.; Rochmann, P. O.; and Rolland, N. L.: “Demonstration and Qualification of a
Riserless Dual Gradient System”, OTC 17665, 2005 Offshore Technology Conference, Houston, 2-5 May 2005.
SPE/IADC 130308 9

Appendix

Tables

Geo-region No of Wells Water Depth Years Reason for Using RMR

North Sea 35 279 - 1411 ft 2004-2009 New Equipment field trial
(85 - 430 m) Shallow Geohazards
Shallow Water Flow
Avoid Pilot Hole
Build Angle in Shallow Section

Caspian 33 387 - 1723 ft 2003-2008 Shallow Geohazards

(118 - 525 m) Extend Surface Casing Depth
Australia 24 154 - 1004 ft 2006-2009 Shallow Geohazards
(47 - 306 m) Extend Surface Casing Depth
Slumping Sand
Zero discharge Regulation
Russia and 7 249 - 1148 ft 2006-2009 Zero discharge Regulation
Barents Sea (76 - 350 m) Avoid pilot hole and riser & pin connector
Egypt 7 279 - 354 ft 2007-2008 Shallow Geohazards
(85 - 108 m) Eliminate Drilling Liner
Malaysia 1 4657 ft 2008 Deepwater RMR field trial
(1419 m) Extend Surface Casing Depth
US Gulf of Mexico 1 2034 ft 2009 Mud Logistics and Cost
(620 m) Extend Surface Casing Depth

Table 1 – Previous RMR™ Operations

Water Depth 5000 ft (1524 m)

Mud Weight 12.5 ppg (1.5 SG)
Rig Pump Rate 1200 gpm (4550 lpm)
Maximum Hole Size 36 Inch Conductor
Maximum ROP 100 ft/hr (30 m/hr)
Maximum Cutting Pass through size 2” (5.1 cm)

Table 2 – Deepwater RMR™ System Main Specifications

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Figures

Sea Level

Mud Return Line (MRL)

Suction Module (SMO)

Subsea Pump Module (SPM)
Mud Line

Figure 1 – Shallow Water Riserless Mud Recovery System

Sea Level

Mud Return Line (MRL)

Upper Subsea Pump Module (SPM)

Mud Return Line (MRL)

Lower Subsea Pump Module (SPM)

Suction Module (SMO)

Mud Return Line Anchor
Mud Line

Figure 2 – Deep Water Riserless Mud Recovery System

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Deepwater RMR Pumping Capacity

15.5 Operating Envelope
in 5000 ft water depth
15 Planned Capacity
at beginning of JIP
14.5 General Operating
Range during Trial
14
Mud Weight (ppg)

13.5
4000 ft WD rpm limit

13 4000 ft WD power limit

5000 ft WD RPM limit
12.5 5000 ft WD power limit
6000 ft WD RPM limit
12 6000 ft WD power limit

11.5

11

10.5
700 900 1100 1300 1500 1700 1900 2100

Mud Flowrate (gpm)

Figure 3 – Deepwater RMR™ Pumping Capacity

Seabed Shallow hazards

RMR case Dispersion case mitigation case
Seabed 4657’ bmsl

5000’ ss Fault
343’ bml 30” 30” 30”
230’ bml 230’ bml
5414’ ss 757’ bml
Zone 1 (gas ??) 13-3/8” at 5650’ ss
993’ bml
5720’ ss Zone 2 (gas) 1063’ bml

6575’ ss 1918’ bml

Zone 3 (W)
Maximum Depth
With Pump and Dump
13-3/8” at 6900’ ss 11-3/4” SET at 6900’ ss
2243’ bml 2243’ bml
7044’ ss 2387’ bml 13-3/8”
Zone 4 (W) 2243’ bml
7500’ ss /
13-3/8” 7573’ ah
2843’ bml

Zone 5
8400’ ss / Kick-off point
9-5/8” 9-5/8” 8473’ ah 9-5/8”

Well Continues to Reservoir Level

Figure 4 – Casing Plan for Deepwater RMR Field Trial Well

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Cameras and Lights

ROV stab for

communication
and power cable

ROV Friendly
Connection for
Suction Hose Electronics POD

Pressure Sensor

Figure 5 – Suction Module (SMO)

Figure 6 – Subsea Electronics Module (SEM) in operation mounted on SMO

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Figure 7 – Suction Hose with Buoyancy

Figure 8 – Lower Docking Joint Connected to MRL Anchor

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Anchor Set
and
Spaced out

Docking Joint

ROV Emergency
Release

During
Anchor
Set
Synthetic
Rope

Guide Tube

Mud Line

Anchor Mass

Anchor Piling
(approx 15 ft)
Space out

Figure 9 – Mud Return Line Anchor System

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Figure 10 – Lower Subsea Pump Module ready for Mounting on Lower Docking Joint

Figure 11 – Upper SPM (right) on deck with Lower SPM with SEM
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Figure 12 – Hang off Module (left) and SPM Handling Frame (right) in Moonpool

Figure 13 – Hang off Joint and Gimbal at Moonpool level as Anchor is set
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Figure 14 – Flowhead mounted on Hang Off Joint hanging on Hang Off Module

Figure 15 – 25 ton winch for umbilical to lower SPM

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Figure 16 – 10 ton winch for umbilical to upper SPM

Figure 17 – Control Containers

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Figure 18 – RMR control panel mounted in Drillers Cabin

Figure 19 – RMR system monitoring from Office and Workshop Container

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Figure 20 –Casing Hang Off Frame supporting conductor with SMO installed

Figure 21 – Mud Interface at SMO while drilling

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Comparison of Measured and Calculated Pressure for Lower SPM

40

35

30

25

20 Total Pressure Increase of Lower SPM

Pressure (bar)

Calculated Pressure increase at Lower SPM

15 Pressure Boost 1st Stage

Pressure Boost 2nd Stage
Pressure Boost 3rd Stage
10
Calculated Pressure Boost Per Stage
Measured Suction Pressure at Lower SPM
5
Calculated Suction Pressure at Lower SPM

-5

-10
0:43 0:50 0:57 1:04 1:12 1:19 1:26

Time

Figure 22 Pump Performance Comparison (Pressure)

Comparison of Pump Speed for Lower SPM

1800

1700

1600

1500
Pump Speed (RPM)

1400

1300
Calculated Pump Speed
Measured RPM based on Electrical Frequency
1200

1100

1000

900

800
0:43 0:50 0:57 1:04 1:12 1:19 1:26

Time

Figure 23 – Pump Performance Comparison (Speed)

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Figure 24 – Comparison of Predicted and Actual Anchor Soil Pentration