Advancing MPD operations with integrated riser joint technology

GARRY STEPHEN, Oil States 

Managed pressure drilling (MPD) has become a cornerstone of advanced offshore operations, as it offers unparalleled safety and efficiency advantages when drilling high-risk, complex wells. As MPD matures into a globally recognized practice, innovative systems and techniques are redefining the operational boundaries of subsea exploration. By standardizing MPD processes and integrating advanced technologies, drilling contractors can enhance safety, minimize risk and improve operational efficiency, enabling access to previously inaccessible formations. 

OPERATIONAL CHALLENGES AND COMPLEXITY 

MPD employs a sophisticated closed-loop pressure control system to dynamically manage the wellbore’s annular hydraulic pressure profile. This enables operators to drill safely into challenging reservoirs with precision, which reduces nonproductive time (NPT). Despite its advantages, MPD’s implementation demands a nuanced approach, integrating diverse tools and techniques for precise pressure management. Key activities include: 

• Modulating backpressure and circulating friction 
• Adjusting mud density and annular fluid levels 
• Modifying fluid rheology in real time. 

This level of complexity is essential when working in deepwater pressure reservoirs, such as those off the coast of Brazil, where maintaining wellbore pressure within a narrow, overbalanced range is critical. Excessive mud weight can fracture the formation, and insufficient weight can lead to well control issues. These challenges necessitate robust systems capable of managing intricate workflows, advanced equipment and safety-critical processes. 

INNOVATIVE SOLUTION: INTEGRATED RISER JOINT (IRJ) SYSTEM 

The Oil States MPD Integrated Riser Joint (IRJ) system (Fig. 1) addresses these operational challenges by streamlining pressure control and flow management with a design that enhances safety, reduces NPT and simplifies deployment. Twin retrievable annular seals allow seamless transitions between conventional drilling and MPD operations without removing the system, improving efficiency and reducing downtime. This affords operators greater flexibility in the field. 

Fig. 1. Oil States’ MPD Integrated Riser Joint streamlines pressure control and flow management while enhancing safety, decreasing NPT, and simplifying deployment.

The MPD system works with various riser configurations and topside equipment types, further expanding operational flexibility across diverse rig types. This can help reduce costs, as older assets can be utilized, helping to optimize total cost of ownership. 

Integrated instrumentation facilitates real-time predictive well control, enabling proactive hazard mitigation. By reducing equipment handling and simplifying rig-to-rig transfer of technology and expertise, the system minimizes operational complexity and supports standardization efforts. 

EFFICIENCY AND COST SAVINGS 

The IRJ’s streamlined design enhances operational efficiency, reducing rig time and associated costs. At 40–to-43 ft long, with a tripping weight of 19,000 kg, the compact, lightweight system can be installed in as little as 7 hrs—up to 29 hrs faster than conventional systems—saving approximately $1.2 million per deployment. One of the design elements that helps reduce installation time is a feature that eliminates the need for tandem lifts, which also delivers HSE benefits through reducing site safety risks by removing workers from the red zone, Fig. 2.  

Fig. 2. Removing workers from the red zone supports the industry’s safety commitment while meeting global MPD requirements.

Another advantage is the system’s automated functions—such as the on-deck function and ability to pressure test all pressure paths, including flowline hoses to the manifold—which significantly reduce NPT by reducing in-operation failures. The system enables operators to identify performance issues before deployment and address concerns in an environment that’s much easier for conducting repair work. 

Independent component deployment means the RCD bearing assembly and annular seals can be deployed or retrieved independently. The system design also simplifies the process of making flowline and umbilical connections, by employing a pull-in bridle that reduces complexity and decreases the amount of time required.   

The introduction of a retrievable stripper sealing system replaces bulky spherical strippers, allowing maintenance to be performed without removing the integration joint. This lowers costs further and improves safety. Additionally, a hard-faced integration joint reduces wear and eliminates the need for frequent replacements, enhancing durability. 

Field-proven in challenging environments, such as the North Sea and offshore Newfoundland, the IRJ’s innovative design ensures compatibility with existing infrastructure, while delivering measurable cost and time savings. 

STANDARDIZATION AND KNOWLEDGE TRANSFER 

The flexibility of the IRJ design allows drilling contractors to capture economies in performance, maintenance and safety by broadly employing the system. 

Using the same equipment across rig types enables operational consistency through standardized procedures that streamline operations. Crews trained on a single system can operate that system efficiently on any rig, which reduces the amount of structured training needed and facilitates knowledge transfer among personnel. 

Standardizing the MPD system across a fleet allows for consistent, uniform maintenance cycles, and it also simplifies the transfer of equipment between rigs. When the system is installed on multiple assets, lessons learned can be applied across the fleet to refine methodologies and drive continuous improvement. 

Fig. 3. MPD technology supports greater ultra-deepwater exploration activity. Shown: Oil States MPD IRJ.

An operator operating a high-spec fleet with the MPD IRJ noted that the system offers significant efficiency savings, with respect to deployment and testing. The operator also observed that the pull-in bridle feature eliminates much of the manual work typically required when installing hoses on legacy systems. The retrieval packers also removed the single point of failure related to latch up, which has historically caused contractors weeks of NPT in the past. As the IRJ is smaller and lighter with increased functionality, the operator expects MPD deployment to be reduced from 24 hrs to 6 hrs. 

For an advanced hydraulic control systems provider, the MPD IRJ system supports the company’s proven track record in delivering precise pressure control across complex operations—from HPHT to specialized cementing operations. MPD solutions help the company enhance safety and operational efficiency when conducting real-time wellbore modeling in challenging deepwater environments. 

PIONEERING SUBSEA EXPLORATION 

By enabling more precise reservoir management and safer operations, MPD technologies support the development of energy resources to meet growing global energy demands. As the industry accelerates exploration in ultra-deepwater formations, advanced MPD solutions like the IRJ will be critical for overcoming technical and environmental challenges, Fig. 3. 

Continuous advancements in MPD systems and ongoing standardization efforts are setting new benchmarks for subsea exploration and production, while ensuring that drillers can operate safely, efficiently, and economically in demanding environments. Shared insights gained from MPD deployments will contribute to global advancements in MPD technology and practices. 

ABOUT THE AUTHOR

GARRY STEPHEN is group vice president, UK and Asia, at Oil States, a role he has held since 2019. Previously, he served as the company's managing director from January 2012 to March 2019. Prior to his time with Oil States, he worked with other industry companies, such as Cameron, Expro and Aker Solutions. He is based in Aberdeen, UK.