The offshore East Java laid numerous carbonate formation, where depending on area, carbonate formation is exercised as the reservoir. The carbonate exploration drilling campaign, which is naturally fractured, risks the operation not just from safety aspect but also deliverability of well objective to explore uncovered reserve in the area.
In this well, total loss circulation was experienced while drilling, despite no record of similar event from offset wells data. The field operator determined to call out Rotating Control Device (RCD) and installed prior to drilling 12.25in. hole section. The Pressurized Mud Cap Drilling (PMCD) method is prepared in advance as mitigation plan to overcome the exploration uncertainties. PMCD is one of the Managed Pressure Drilling (MPD) variants used in oil and gas wells that experience severe to total loss circulation. PMCD method involves drilling with closing flowline valve completely while using RCD system to seal the annulus.
While drilling the 12.25in section, absence of return fluid observed as drill string penetrates the carbonate reservoir section (target formation). Activation of the annulus flooding system enables to pumps seawater through annulus, continued with pulling out the string to last casing shoe, and then installation of RCD bearing assembly to convert drilling strategy into PMCD method. As the PMCD components required such as RCD and drill string Non-Return Valve already equipped and all associated procedures prepared in advance, swift transition to PMCD mode results to lesser drilling flat time. After reaching target depth, the PMCD setup also assists in the deployment of open hole logging operation by installing RCD logging adaptor.
With the successful PMCD implementation, the field operator managed to reduce drilling risks, reach exploration target successfully, reduce flat times and increase in ROP. This paper present success story of PMCD well drilled and lessons learned as the operator evolves to improve PMCD execution further.