Simulated Drilling Testing of an Active Wellbore Sealing System on a Full-Scale Test Rig

An active wellbore sealing system has undergone simulated drilling tests in a full-scale, purpose-built test rig facility. The active wellbore sealing system contains wellbore pressure during all drilling operations with an active, direct-hydraulic control system to actuate the dual non-rotating seal sleeve elements. The test rig facility enables simulated drilling testing including the use of drilling mud, simultaneous drillpipe stripping and rotation, production topside equipment, and application of wellbore pressure. The active wellbore sealing system test program operates the equipment under realistic field conditions and enables control parameter optimization. Test procedures have been developed based on historical well data with careful consideration given to the application of test results. Analysis of the test data is provided and discussed. This paper shares test results from the active wellbore sealing system test program. An overview of the system and test environment will be shared. Test procedures and technical considerations will be discussed. Data and analysis from the test program will be shared. The active wellbore sealing system offers distinct operational advantages over passive systems in deepwater. An active control system enables extended seal life and active seal integrity management. Rigorous simulated drilling tests provide a technical basis for comparison to real wells. Seal element condition monitoring allows the rig to replace the seal assembly only as required, saving rig time. The active wellbore sealing system is operated with the chamber pressure between the seal elements higher than the wellbore pressure, forming three mechanisms to ensure wellbore pressure is contained. Further, testing demonstrates that minimal human input is required to operate the system.