Integrated managed pressure drilling system improves insights for enhanced performance

CHRIS LELEO, JUAN HERNANDEZ, and AUSTIN GROOVER, Nabors Drilling Solutions 

The underlying principles of managed pressure drilling (MPD) have been understood for decades, and drilling companies have been capitalizing on this technology to drill complex wells since the early 2000s. Today, advancements in MPD technology are taking performance to a new level, delivering better results and driving wider adoption. 

THE VALUE OF MPD 

MPD enhances well control and allows drilling operations to continue in difficult conditions through precision pressure management of bottomhole pressure, which reduces the likelihood of wellbore instability and consequent kicks and losses. With fewer incidents of this nature, there is less nonproductive time (NPT) and less lost production. The ability to manage pressure also makes it possible to optimize drilling rates and reduce drilling time, which results in lower drilling costs.  

In addition, MPD enhances wellbore integrity. Maintaining optimal wellbore pressure helps prevent wellbore instability and borehole collapse. Another benefit is that minimizing formation damage and preserving reservoir productivity increases hydrocarbon recovery. Better pressure control also reduces the environmental impact of drilling operations by reducing the amount of drilling fluid used, diminishing the risk of spills and leaks. 

With all the advantages delivered through pressure management, it is not surprising that MPD has achieved broad use globally. Combined, the benefits add up to increased recovery, higher production rates, longer well life and safer operations. 

BARRIERS TO ADOPTION 

Despite the many obvious benefits, however, many drilling contractors are not using this technology because of the impediments they face when implementing traditional MPD solutions. 

One of the biggest reasons drilling companies have yet to take advantage of MPD capability is the difficulties they have encountered installing new systems on older rigs. Technology integration can introduce constraints, and installation complications can lead to costly consequences.  

Another consideration is workforce readiness. A skillset gap can mean that even a system that is installed and ready to go might not deliver value if the crew lacks the training and technical expertise to put the system to work. So, although drillers recognize the potential value of better well management through MPD, investing in an advanced system to help achieve that goal can sometimes be a difficult step. 

A NEW APPROACH 

Based on the premise that drillers are best placed to solve drilling challenges, Nabors undertook the task of designing an MPD system with a focus on how it would be installed and applied in the field (Fig. 1). Conceptualizing the design through the lens of a drilling contractor influenced how every part of the system was developed. The combined experience as a rig builder, experience with instrumentation, and experience with automating rig equipment, such as mud pumps, drawworks and top drives, all contributed to the solution.  

Fig. 1 A Nabors crew working together safely to operate managed pressure drilling.

Nabors began by examining obstacles to installing MPD systems on standard rigs and identified the pain points for drilling contractors. The process started with looking at reducing rigging up and rigging down time and asking questions about how a skid could be designed to move onto the site quickly and be integrated more rapidly than traditional systems. In the end, the skid designed for Nabors rigs was the template for designing third-party skids that enable the shortest, most effective runs for less disruption to the environment.  

Engineers considered the common concerns all drillers have about well control: reducing the footprint of operations, managing drilling fluid usage, increasing drilling efficiency and removing flat time, minimizing the number of workers required on site, and identifying and mitigating operational risks. They also considered practical concerns like how standard operating procedures would need to change and how new guidelines could be distributed easily across drilling programs.  

It became evident that the best MPD solution would need to be comprehensive, integrate with the rig, and interface with other advanced systems to optimize performance. The only way to meet these exacting requirements would be to develop a fit-for-purpose hardware layout and design the correct instrumentation for integration into the rig controls system. In the case of MPD systems, fit-for-purpose hardware means using a single choke integrated with the rig equipment for applications where finely tuned pressure control is unnecessary and using a dual-choke system, with two choke valves used in parallel for more precise and rapid adjustments to flowrate and pressure and to provide redundancy.   

First, and foremost in the system design was the expectation for the new solution to be formulated as an additive service to the rig, rather than a system that was simply installed on it. This meant not adding a lot of equipment on the ground. Instead, the solution would be part of the rig, making it part of the rig ecosystem and transferring responsibility for ownership and management to the crew, who maintains the system in the same way that all rig components are maintained. There was a strong belief that the way the rig crew perceived the MPD system would impact how amenable they would be to learning to use it and how they would implement it. 

The result of this novel thinking is Integra MPD, a proactive system that incorporates advanced intelligence to precisely manage the balance between wellbore pressure and formation pressure to mitigate drilling challenges, maximize reservoir productivity and enable superior pressure control throughout the drilling process. 

The system's physical design is as critical to its functionality as advanced technologies and software upgrades. The modular components have standardized interfaces to expedite equipment installation and removal to reduce rig setup and teardown time and enable seamless integration, not only on Nabors rigs but for third-party assets as well. 

The MPD system integrates with the full rig life cycle and improves transition flat time, reducing rig-up and rig-down time between rig moves and between jobs. Because of its simplified design and operations, fewer people are needed on site. Removing people from the red zone can improve safety without sacrificing efficiency. 

Nabors PACE-F SmartRigs are designed with MPD integrated directly on the rig substructure for rapid rig moves, minimized human intervention, and fewer safety risks. Integrating services in one system eliminates the silos that can hinder efficiency and productivity in traditional drilling operations. This holistic solution seamlessly connects a range of drilling processes, from pressure management to tubular installation and enhances functionality with automation powered by real-time performance data. This reimagines the application of MPD and improves efficiencies, reduces the time between rig moves and requires fewer workers on site. 

HOW IT WORKS 

Intelligence and automation are foundational to this approach to MPD.  

Automation simplifies workflows, reduces manual intervention and enhances readiness, while automated response systems swiftly detect and react to pressure anomalies. Smart pressure control algorithms determine optimal settings for consistent pressure management, eliminating human error by automatically adjusting to maintain safety and efficiency. 

Machine learning (ML) is another essential component of the solution. ML allows the system to learn from historical and incoming real-time data and build predictive models that enable proactive adjustments and finetuning that further enhance operational performance over time. An intuitive human-machine interface (HMI) simplifies the visualization of real-time well conditions for the driller.  

Integra MPD works seamlessly with a proprietary suite of digital solutions to provide comprehensive control. Nabors’ intelligent SmartROS automated rig operating system (Fig. 2) unifies MPD and rig equipment monitoring to optimize operational efficiency and deliver consistent results by minimizing complexity. And its RigCLOUD platform, a central hub for cloud-based data collection and real-time analytics, enables remote monitoring and predictive decision-making. Advanced simulations and pressure modeling provide wellbore stability through precise control, allowing the remote operations engineer to plan ahead with offline tool simulations to improve wellbore stabilization. 

Fig. 2 A driller operating the SmartROS automated rig operating system to gain more accurate insights to drive improved performance.

WHAT IT DELIVERS  

One of the features that simplifies uptake on the rig is the HMI. In a traditional job, drillers can see when a pump is turned on, or a choke is engaged, but there is no clear picture of what is happening downhole. The goal in designing the Integra system was to include the whole scope of rig operations in one system and make it viewable in a way that makes the most sense to drillers. The ability to build dashboards and read KPIs delivers critical insights that give operators and engineers the information they need to make decisions in real time. 

The HMI displays pressure measurements, so the driller can see how the automated system manages bottomhole pressure to prevent kicks and blowouts. The influx management matrix provides structured responses to pressure-related events. Continuous data feeds are measured against optimal drilling parameters, so the system can maintain consistency and reduce nonproductive time by automatically responding to changing conditions. The driller has total visibility and total control of MPD operations from the HMI and can countermand automated commands, if there is a reason to intervene. 

Optimal drilling requires real-time monitoring for early detection of kicks and losses to prevent unnecessary mud treatments. With accurate data collection, drillers have more enhanced insight into wellbore reservoir properties, for example, making it possible to quickly identify high- or low-pressure zones. Precise pressure control minimizes fluid loss into formations and optimizes mud systems, because adjusting pressure allows less expensive and less complex fluids to be used, delivering considerable cost savings over time. Superior well control pays dividends across the board, improving wellbore stability, which reduces incidents like stuck pipe.   

Integra also delivers value for well program management. Access to high-quality data improves reservoir characterization and enhances production forecasting through improved modeling, enabling faster and better decision-making. With real-time performance data and the ability to visualize the consequences of decisions, it is possible to assess outcomes and devise tailored field development strategies to maximize extraction.  

The Integra MPD system has been performing consistently and reliably in the field, but there is always room for improvement. Nabors invests in adding functionality by scheduling continuous code releases yearly, based on customer feedback to enhance performance. Instead of making occasional updates, engineers are challenged to improve on the status quo and continuously develop new features, refining how the logic reads the top drive's position and introducing ways to reduce trip times. 

FIELD RESULTS DEMONSTRATE VALUE  

Recently, Nabors has been using its technology on rigs in Latin America, where most applications are dual-choke systems. Integra MPD systems are deployed in the most complex wells in Vaca Muerta, where they are allowing operators to manage drilling operations more effectively by improving the ability to forecast the number of days it will take to drill problematic sections of a well. This new capability has the potential to improve program management significantly.  

In third-quarter 2024, the Integra system was put to the test to resolve issues encountered by a major operator in northern Argentina. Formation destabilization and wellbore cleaning challenges had led to stuck pipe in an 8.5-in. well, a situation that was compounded by high-temperature, high-pressure conditions downhole and narrow drilling margins. The small operating window required precise control when ramping up and down, which made wellbore stability, safety and drilling efficiency challenging to manage. 

The Integra MPD system provided a stable pressure profile that effectively addressed lost circulation and hole collapse—common challenges in the Vaca Muerta. Superior adaptability to geological variations enhanced both the safety and efficiency of the drilling program.  

With the MPD system integrated directly into the rig alongside an automated drilling activity sequencer operating on the SmartROS platform, it was possible to execute consistent ramp-ups and ramp-downs. The automation allowed for greater wellbore stability, the use of lower mud weights (minimizing formation stress and collapse risks), and the ability to maintain stable bottomhole pressure.  

The result was a 36% increase in rotary rate of penetration, a 40% reduction in weight-to-weight times during connections, and saw 6.5 hours per well saved in flat time and 10 days per overall well cycle (Fig. 3) – the difference in rig-up and rig down time when using an integrated system compared to a conventional MPD system. Furthermore, there was a 28% improvement in integrated MPD related flat time over three years with the automation enhancements in the software.

Fig. 3 Using the integrated MPD system significantly reduced flat time over the drilling program in Argentina.

On a field in Colombia, one of the region’s largest operators faced challenges reaching the production zone because of complex geology. Pressure fluctuations affecting the geomechanical operational window led to stuck pipe issues, wellbore stability problems and wellbore clean-out challenges. These conditions hindered drilling and increased operational risks.  

The single-choke Integra MPD system—the smallest and most cost-effective integration package—performed similarly to a dual-choke system, demonstrating a high capacity to adapt to geological variations, minimize mud circulation volumes, and maintain a stable pressure profile for precise wellbore pressure control. This ensured hole stability, allowing the drilling objectives to be achieved.   

With the integrated approach, rig-up and rig-down took 85% less time than conventional MPD systems from our competitors, decreasing the hours required from 26 hrs to 3 hrs. There was a 40% increase in tripping speed, with a 60% reduction in heavy mud volume. Because of automation and the limited amount of hands-on work required by the crew, the process required only three on-site workers and was completed ahead of schedule.   

In both the United States and Latin America, adoption of MPD systems is increasing, as operators continue to realize efficiency gains by deploying the technology.  

NEXT ON THE HORIZON  

Nabors’ role in Central and South America is evolving with the expansion of services to meet the region’s growing energy demands and the introduction of MPD in more drilling programs, which consistently delivers safety and efficiency in challenging drilling conditions. Integra MPD is revolutionizing drilling in areas with narrow pressure windows, complex formations and stringent environmental regulations. 

These successes lay the groundwork for advancements not only in Latin America but around the world, including imminent applications in the Middle East and Asia Pacific. 

Continuing investment in R&D is pushing the boundaries of advanced drilling technologies that leverage data and automation to enhance operational efficiency and promote sustainable practices by minimizing the environmental impact of operations.  

The elusive objective for the industry is fully automated drilling operations. In pursuit of that goal, engineers are constantly exploring improvements and enhancements that will continue to push the boundaries of what is possible today and move operations into new frontiers. 

ABOUT THE AUTHORS 

AUSTIN GROOVER is the director of Operations for the Nabors Drilling Solutions & Canrig portfolio. He is responsible for customer service, delivery, strategic direction, and value creation in LATAM and Canada.  

Austin has 13 years of experience in the oil and gas sector, holding various product development and operations positions. He holds numerous oilfield patents in directional automation, rotary performance, and optimization. Mr. Groover earned his bachelor’s degree in petroleum engineering from Texas A&M University.  

JUAN HERNANDEZ is the director of Tubular Running Services (TRS) and Managed Pressure Drilling (MPD) business under Nabors Drilling Solutions. He is responsible for the growth and profitability of all products and services for both product lines globally. Mr. Hernandez  

has 15 years of experience in operations across the oil and gas sector, holding various field and management roles. He earned his MBA from the University of Oklahoma and his bachelor's degree in civil engineering from Universidad Santa Maria.  

CHRIS LELEO is the senior manager of global operations for managed pressure drilling (MPD) at Nabors. He has over 25 years of experience at Nabors, holding various roles from field operations to strategic planning, and has been integral in growing our integrated MPD offering globally.  

With years of deep-rooted, hands-on experience in oilfield services, Mr. Leleo has developed expertise in conventional drilling, managed pressure drilling, well control, and other related fields. He has successfully implemented advanced drilling technologies and techniques that have improved operational efficiency and safety in challenging environments.