08.05. Underbalanced Drilling

Contents
References
Objectives
Resume
Topic 1 Introduction to underbalanced drilling
1 Introduction to underbalanced drilling
1.1 What is underbalanced drilling?
1.2 History
1.3 Why drill underbalanced?
1.4 IADC underbalanced well classification system
1.5 Mud cap drilling
1.6 What formations to drill UB?
1.7 Disadvantages and limitations of UBD
Topic 2 How to drill underbalanced - type of rig
1 How to drill underbalanced - type of rig?
1.1 Conventional rig
1.2 Coiled tubing unit
Topic 3 The drill string
1 The drill string
1.1 Introduction
1.2 Choking drill collars
1.3 Non return valves
1.4 Hydrostatic control valves
1.5 Pressure measurement tools
Topic 4 The underbalanced drilling fluid
1 The underbalanced drilling fluid
1.1 Introduction.
1.2 Types of liquid
1.3 Type of gas
2 Air, airlmisr and foam
2.1 Air drilling
2.2 Air mist drilling
2.3 Foam drilling
3 Drilling with gasified liquids
3.1 Drill string injection
3.2 Annulus injection
4 Fluid selection for underbalanced drilling operations
Topic 5 The circulation system
1 Introduction
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2 Dominating regime
3 Back pressure and choking
4 Modelling of a circulation system
5 Connections and drill string movement
5.1 Connections
5.2 Drill string movement
Topic 6 Borehole stability and hole cleaning
1 Borehole stability
2 Hole cleaning
Topic 7 Well control in underbalanced drilling
1 Primary well control
1.1 Sealing mechanism around the drill string
1.2 Surface safety valve
1.3 Choke manifold
1.4 Surface separation system
2 Secondary well control
2.1 BOPS
2.2 Kill fluid
Topic 8 Data acquisition
1 Data gathering
2 Down hole data transmission
Topic 9 Health, safety and the environment
1 Planning
2 Training
2.1 UBO procedures - overview and safety concerns
3 General work-site safety
3.1 Site safety management
3.2 Housekeeping
3.3 Communication
3.4 Logistics and transportation
3.5 UBO hazards and PPE requirements.
4 Hazard communication and materials handling
4.1 Hazards specific to UBO.
4.2 Transportation of hazardous materials
4.3 Uncontrolled /accidental release of hazardous material
5 Occupational health
5.1 Employee's HSE responsibilities
5.2 Work-permit requirements.
Appendix 1 : Abbreviations
Questions
Page 8 / 5 / 6 WOLP - Underbolonced drilling

I References
Bennion, B., et al, 'Underbalanced Drilling, Praises and Perils', First Underbalanced
Drilling Conference and Exhibition, The Hague, Netherlands, Oct. 2-4, 1995
Bennion, B., Thomas, F.B., 'Underbalanced Drilling of Horizontal Wells: Does it really
Eliminate Formation Damage?', 1994 SPE International Symposium on Formation
Damage Control, Lafayette, Louisiana, Feb 7 -10.
Bieseman, T., Emeh, V., 'An introduction to Underbalanced Drilling', RKER.95.071
Curtis, F., 'Two Day - Hands On Underbalanced Drilling Seminar Manual', prepared for
NAM, 1996
Dorenbos, R.B., 'Investigation of parameters influencing undesirable foam formation and
stability in surface facilities during underbalanced drilling operations', STUDREP.96.014,
Shell Research Rijswijk, 1996
Kardolus, C., 'Underbalanced equipment and services overview', SIEP 98-5054
'Project to Develop and Evaluate Air/Mist/Foam and Underbalanced Drilling Technology',
Maurer Engineering Inc., Houston, Texas, May 1995
Saponja, J., 'Challenges with Jointed Pipe Underbalanced Operations', SPE 37066
Stone, C.R., Cress, L.A., ' Blowout Preventer Testing for Underbalanced Drilling', Signa
Engineering Corp., Houston, Texas
Francis, I.P., ' Root Causes of Drilling-Induced Formation Damage ' SIEP 97-7024
Bourgoyne Jr., AT., et a1 'Applied Drilling Engineering' SPE Textbook Series 1986,
ISBN 1-55563-001-4
Acknowledgernerzts:
Photogrupks atzd sketches have hen corztribz~tedby tbefOllowirzg compurjies: BJ ServicesJ Blade Errergy
Purtrzers, EXPRO North Sed, Hal1ib1crtorz Energy Services, N A M , Nortblatzd, SIEP, Shaffq Sbeii
Expro, and Weutbe@t.d Utzderbaiarzced Seruices.

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I
Objectives
After studying this Part, consulting other relevant documents and, if necessary, discussions
with your mentor, you will be able to:
Explain the drivers behind drilling underbalanced
List the advantages of underbalanced drilling
Explain the disadvantages of underbalanced drilling
Define the range of operations1 well conditions in which underbalanced drilling is applica-
ble
Classify a underbalanced drilling operation according to the IADC well classification sys-
' tem
Outline the type of rig that can be used in underbalanced drilling
Explain the ways in which underbalance is achieved in a well
Explain how trips can be safely accomplished during underbalanced drilling
Explain how control of underbalance is achieved.
Outline the surface equipment set up for the circulating system
Explain the key components of the BHA
Explain the surface well control equipment set up within a well
Understand and outline how data is acquired during two phase flow conditions
Explain the key health safety and environmental considerations that must be taken into
account during underbalanced drilling.
Page 8/5/8 WDLP - Underbalanced drilling

The purpose of this Part is to provide an introduction to underbalanced drilling. The case for
drilling underbalanced is presented, indicating when it is beneficial t o drill underbalanced.
The equipment used in terms of rig type, downhole tools, the different underbalanced drilling
fluids, including methods of initiation of underbalance, and the surface circulation system are
all discussed. Drilling problems such as borehole stability and maintaining well control dm-
ing underbalanced drilling operations are covered, as are the complications of data acquisition
in two phase flow. Lastly, health, safety and environmental considerations during underbal-
anced drilling operations are presented.
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Topic 1
intlrodluction To Underbalanced
INTRODUCTION TO UNDERBALANCED DRILLING

1.1 W H A T IS UNDERBALANCED DRILLING?
Underbalanced drilling (UBD) is a drilling technique in which the both the hydrostatic and
dynamic pressure in the circulating down-hole fluid system is intentionally kept below the
pressure of the formation being drilled. As a result, production of formation liquids and gases is
induced during the drilling phase.
In conventional drilling, primary well control is obtained by the hydrostatic pressure (mud weight)
that exceeds the formation pressure. In underbalanced drilling, primary well control is achieved by
a mechanical barrier - the rotating control device, stripper ram or stripper in coiled tubing.
1.2 HISTORY
UBD is not a new technique. All wells drilled up until the design and acceptance of the rotary
drilling rig were drilled underbalanced. The introduction of the rotary rig meant mud could now
be circulated to the bit and with the mud column; overbalance drilling became the normal
practice.
In the 19501s, drilling with air became popular when it became known that this drilling
technique could increase drilling rates in hard rock by up to three times. In the early 1970's
stable foams were developed for use in underbalanced completion operations. In the 1990's the
interest in underbalanced drilling increased again largely due to work done in North America
using the UBD technique coupled with the development of the closed circulating system. In
addition to increased drilling rates, UBD appeared to significantly improve productivity because
of the reduction of formation damage.
Current developments in the oil and gas industry have again revived interest in UBD. Most of the
world's mature hydrocarbon reservoirs ate in the lower end of the depletion phase. In addition, the
increasing number of horizontal wells with un-cemented completions has resulted in a shift in
emphasis towards impairment-prevention, as opposed to impairment removal. Also,
improvements to the rotating control devices, which ensure an effective seal against a rotating
drill string, and the success of coiled tubing drilling, make it possible to drill safely in the
underbalanced mode.
Most recently, UBD techniques combined with multi-lateral horizontal wells, and the ability to
run expandable sand screens in the underbalanced mode, have increased the portfolio of UBD
candidates to include previously un-economic very tight gas reservoirs and reservoirs with sand
production problems.
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1.3 WHY DRILL UNDERBALANCED?
Underbalanced drilling is used primarily to prolong the life of older reservoirs and allow the
development of new fields by reducing the life cycle costs.
There are several reasons for drilling underbalanced.
During
Reduction in Formation Damage.
overbalanced drilling
operations, formations are exposed
- ---
- -
Solids-lnva61miqfo a
Homogenous Porn Sysl;em
to several types of potential
formation damage. For example, Effactlve
invasion of solids from the mud into

I External -
the formation matrix and adverse
reaction between invaded filtrate
and formation fluids often lead to Internal 10 micron porn throal
1 micron &srnsllersdlds
plugging of the pore throats,
swelling clays and wetability
alterations. Generally, formation lneffeclive
External seal
10 micronpore tiareal
damage due to invasion is 10 micronsdi& L oome
and Filtrate mnallsr solids
irreversible. Figure 1, Figure 2 and
Figure 3 illustrate reservoir
impairment due solids invasion.
Figure 1 - Solids Invasion into a Homogenous Pore System
fflgh Velocity (210 cmlmin Interstitial)
Figure 2 - Mechanism of
suspended solids entrainment
ExternalFllter Cake lnlernalFiller Cake Non-BridgingSolids

33%<kcl4%dpore k414Kdpare
In UBD operations, the risk of damaging the formation is significantly reduced by preventing the
invasion of drilling fluid and drilled solids into the formation. This often translates into a decrease
in the cleanup time after drilling, increase in the productivity of the wells and most importantly,
recent data suggests an increase in ultimate recovery; all of this equates to incrusedasset value.

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Mechanism of'sollds
Entrainment in Fractures
Hlgh Losses
Minimal Damage
I
Sealed Fracture
I
depth of lnvaslon
dependent on solld
slze distribution I
100 micron fracture
10 - 100 micron solids I
and overbalance
Poor Seal,
potentlal for
continued
leakoff of
1 I""
A n cnn -2 ---- --,:.r.
llllClYll lldCL"lti
l
flltrateand
small sollds
Figure 3 - Mechanism of Solids Entrainment in Fractures
Increased Reservoir Knowledge.
The value of information is oken underestimated in the drive to reduce unit cost. Recent
improvements in the tools and techniques for reservoir evaluation while drilling underbalanced
have provided an opportunity to gain reservoir informarion previously unavailable until after the
well was drilled, completed and tested. This information ran now enable faster and more cost-
effective optimisation of the field development plan based on real time acquisition of reservoir
knowledge.
For example, the ability to test the well while drilling provides real time infofmation previously
available only from extensive production logging programmes. If the flow of the produced liquids
and gases is properly monitored at surface it can provide a good indication of the presence and
location of productive reservoir zones. Equally, zones believed to contain recoverable hydrocarbons
have proved to be non-productive during UBD operations. In order to evaluate formation
properties and the productive capacity of the formation, high permeability features, water flood
profile and zones of water break through can now be identified while drilling and single or multi-
rate draw down tests can be conducted during the drilling phase.
This inbrmation can be used as a valuable aid in geo-steering the (horizontal) well into the
productive intervals. In addition, the completion and/or the drilling plan can be modified
appropriately while the well is still being drilled.
111. Reduced Drilling Problems / Improved Drilling Performance.
Avoidance of Lost Circulc~tion - In overbalanced drilling, fluid losses may occur while drilling
through fractures, highly permeable, low-pressured formations, depleted reservoirs and
unconsolidated porous sandstone formations. Figure 4 and Figure 5 illustrate how losses in
permeable and fractured zones occur.
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Figure 4 - Lass Circulation in a Highly Permeable Zone
In conventional drilling, total losses when hitting a major fracture may mean that the planned
total depth (TD) cannot be achieved since it is not an accepted practice, nor safe to drill "blindly"
in a hydrocarbon reservoir. In addition to the incremental cost of drilling fluid associated with lost
circulation, which can be significant, a loss of well control can also occur. This can result in
substantial rig time and cost trying to cure the losses.
During the initial production phase of the well, there may be a requirement to separate the
recovered drilling fluid from the produced hydrocarbons. Since it can take up ro several months to
recover the lost drilling fluid, this may result in incremental operating cost and lost revenue being
incurred.
Figure 5 - Drilling to the First Fracture - Total Losses (Conventional)

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Figure 6 - Drilling Beyond the First Fracture - No Losses (UBD)
Lost circulation is avoided in UBD because the dynamic bottom hole pressure due to the mud
column is less than the pore pressure of the rock. This also enables drilling past that "first"
fracture to TD, in a safe and controlled manner and increases the chances of intersecting multiple
fractures in a low-permeability, fractured reservoir as illustrated in Figure 6.
Diff~mtialsticking - illustrated in Figure 7; occurs in conventional drilling if the differential

pressure, acting across the filter cake (into the formation), generates a side force that pushes the
drill string and the bottom hole assembly (BHA) into the mud cake. The mud cake acts as a seal
(creating the differential pressure) against the pipe, causing it to stick in place.
Oiverbalanced Drilling Underbalanced Drilling
Figure 7 - The Mechanisms of Differential Sticking

In UBD a net force is acting cowards the centre of the borehole and no filter cake is present to act
as a seal and therefore differential sticking does not occur.
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Improved drdliitzg pe.fom~itzce - resulting from UBD, is obtained mainly from increased rate of
penetration (ROP) and prolonged bit life.
In UBD, ROP can be considerably higher than in conventional drilling due to the disappearance
of the "chip hold down effect" illustrated in Figure 8. In conventional drilling, the dynamic bottom
hole pressure due to the mud column is designed to be greater than the pore pressure of the rock.
The "chip hold-down pressure" is the difference between the borehole pressure and the pore
pressure, acting to keep the drilled cuttings in their original position. This means that the
dynamic forces required at the bit-tooth 1 chip interface to remove the chip which is greater with
an overbalanced fluid, is lower with an underbalanced fluid in the hole, and &€en results in
increased bit life. This is why a "drilling break" is an indicator of a potential over-pressured
formation.
pzq- Forehole Pressure I

, e
I B. Wedge Formation I
I
Figure 8 - Chip Hold Down Effect
In Summary, underbalanced drilling was originally introduced to help solve "drilling" problems
but as the above UBD Value Diagram illustrates, there is more to it than the solution to a
technical problem. The real vulue ofthe technology is its impact on the Company3 bottom line.

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1.4 IADC UNDERBALANCED WELL CLASSIFICATION SYSTEM
In order to standardize nomenclature used for UBD operations, the IADC have adopted the
following Underbalanced Well Classification System (2001).
0
1 &sj$iE,,,A
Performance enhancement only; no hydrocarbon containing zones.

1 Well incapable of natural flow to surface, inherently stable, and a low-level
risk from a well control point of view.
2 Well capable of natural flow to surface but enabling conventional well
control methods and has limited consequences in the case of catastrophic
equipment failure.
3 Geothermal and non-hydrocarbon production. Maximum shut-in pressures
are less than UBD equipment operating pressure rating. Catastrophic
failure has immediate serious consequences.
4 Hydrocarbon production. Maximum shut-in pressures are less than UBD
equipment operating pressure rating. Catastrophic failure has immediate
serious consequences.
5 Maximum projected surface pressures exceed UBO operating pressure
rating but are below BOP stack rating. Catasrrophic failure has immediate
serious consequences.
UBO Term Description
Application
Type
A Low-head or near Condition where the hydrostatic head of the well
balanced drilling. bore fluid column is reduced to be either in
balance or slightly greater than the formation
pressure, thus not planning to induce
hydrocarbons or formation fluids into the well
bore.
B Underbalanced Planned condition where the bottom-hole
drilling (UBD). pressure exerted by the hydrostatic head of the
fluid column is less than the formation pressure
being drilled.
1 Gas drilling. Drilling process using only gas as the drilling

medium; no intentional fluid added.
2 Mist drilling. Drilling with liquid entrained in a continuous
gaseous phase; typical mist systems have < 2.5 %
liquid content.
3 Foam drilling. Drilling with a two-phase fluid and a continuous
liquid phase generated from the addition of
liquid, sunfactant, and gas; typical fwms range
from 55% to 97.5% gas.
4 Gasified liquid Drilling with a gas entrained in a liquid phase.
drilling.
5 Liquid drilling Drilling with a single liquid phase
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Example:
Horizontal gas well, predicted reservoir pressure of 4700psi and potential surface shut-in pressure
equal to 2700 psi. Reservoir will be drilled underbalanced with Diesel - hydrostatic head less than
reservoir pressure. The BOP rating will be 10k stack and the Rotating Diverter is rated to
5 OOOpsi static and 2500 dynamic
1.5 MUD CAP DRILLING

Strictly speaking this is a complementary application of the underbalanced drilling technique used
to drill through highly fractured loss zones but no reservoir fluid flow to surface is intended.
Drilling fluid (usually water), is pumped down the drill pipe (DP). A higher density fluid is also
pumped down the annulus at a controlled rate to overcome gas migration. All of the pumped
fluid, produced fluid and cuttings are pumped into the fractures. It is the safest method for
drilling sour reservoirs with a loss zone above because there are no returns to surface. Figure 9
illustrates the mud cap drilling technique.
There are two types of mud cap drilling techniques:
Floating mud cap - Annular fluid density is high enough to force fluid and cuttings into
loss zone. This requires large volume of mud materials.
Pressurized mud cap - Utilizes annular pressure and fluid column, to divert drill fluid and
drilled cuttings into the loss zone. This allows lower density annular fluid (gas can also be
used in highly depleted zones) to be used and annular injection rate to be optimised and
annular pressure provides direct indication of what is happening down-hole. Therefore,
less fluid is lost co formation and viscosifiers can be added to slow gas migration up the
annulus. However, a rotating control device is required for pressurized mud cap drilling.
d at suff~cientdensity and rate
m P w M
hWlCaP,
Lower density mud @miarcat surface)
Rotatiqg Head required
-
Figure 9 Mud Cap Drilling

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1.6 WHAT FORMATIONS TO DRILL UB?
UBD is not a technique to be applied in all formations. In some reservoir formations for example,
other techniques such as acidising or fracing may be more effective since UBD is not a stimulation
technique. However, research and field observations have been used to identify the types of
formations likely to benefit from the application of the technique. These include:
Low permeability reservoirs - less than 800 mD in oil and less than 5 mD in gas reservoirs
based on the research work done by Paul Francis SIEP-RTS (Reference Figure 10). When
Shell first started drilling underbalanced, this work was used as the basis for candidate
selection. However, based on recent competitor research and field results from wells
drilled by Shell, oil reservoirs with less than 1000 mD and gas reservoirs of less than 100
mD are now considered candidates.
X
x X 0
90% X X
X X
0
&a%-
X x i x
xX IT X 0
70% - X x 0 0
0
1:--
i w/a
1L
- -
'GOOD'
'BAD'
x
x
X 0
2m -
0 0
10%
W' , X X
X
--
0
0 01 0.1 1 10 1w 1000 1WW

Initial Penneahlllty. mu
Figure 10 - Return permeability after testing as a function of initial core permeability
11. Low permeability (0.1 to 10 mD) reservoirs with potentially open micro fractures.
(Impairment prevention)
111. Highly fractured reservoirs. (Enable drilling beyond first fracture)
IV. Depleted or under-pressured reservoirs. (Prevent losses to reduce / limit impairment)
Hard, competent overburdened fbrmations. (Increase ROP, reduce problem time)
VI. High-pressure reservoirs. (Control flow - This technique has been used in other parts of
the world, but it is only recommended as a solution to a specific problem and not as the
primary means to drill the reservoir). This thinking may change with time, as advances in
UBD tools and equipment allow us to safely handle these reservoirs.
In addition, analysis of data from reservoirs where both conventional and underbalanced drilling
techniques have been used, allow us to make the following observations:
UBD wells often produce significantly better than convenrionally drilled wells in similar
quality formations.
Conversely, conventionally drilled wells in "good" quality formations often produce better
than UBD wells in "poor" quality formations.

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1.7 DISADVANTAGES AND LIMITATIONS OF UBD
Underbalanced drilling has several potential disadvantages and limitations:
Borehole Instability
When drilling UB through shale streaks in the reservoir a large draw down might aggravate
borehole instability as illustrated in Figure 11. This risk exists especially when knowledge of the
reservoir characteristics and reservoir pressure is poor.
Figure 1 1 - Formation Sloughing

11. Formation Damage
Formation impairment may still occur if the underbalanced condition is not maintained
continuously during the drilling, tripping and completion phases.
NOTE: B s a t l e &6re i s ~ o cahpfese~u dscfii#g,UBDan. owrba1tt:n~:dsitr;ctatim,

eweF jrqv a h mfzbu'tes,can cauSe imwirsil$e &mag? t o t&epjba res~wo:ii.
n - - -
1
The underbalanced condition can be lost in several ways:
Inadequate design due to lack of knowledge relative to reservoir characteristics. This

could result in reservoir pressure being (temporarily) exceeded by the dynamic well-
bore pressure. This can also occur in gas wells due to localized depletion from
producing while drilling
b. Equipment and/or lift-gas supply problems can cause a temporary overbalanced

situation, e.g., if gas injection is terminated due to supply problems.
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If gas injection is terminated while making pipe connections. Maintaining a flowing
condition (non drill pipe gas injection) or circulating the open-hole clean to pure gas
prior to each pipe connection tends to minimise the effect of overbalanced pulses.
While making pipe connections on high viscosity, low pressure oil wells. Due to the
influx of high viscosity formation crude during the connection, an overbalance
condition may occur as the slug is circulated out. Using clean low viscosity drilling
fluid and or gas injection down drill pipe for a short period may prevent this.
If a concentric or parasite string is used to inject gas, an overbalanced condition may

still exist directly at the rock-bit interface. This is because the full hydrostatic pressure
due to the mud column inside the drill string will be present at the drill bit.
Spontaneous imbibition (formation wetting) and counter current imbibition effects

may occur. Due to adverse capillary pressure relations, water based fluids may imbibe
into the near well-bore region of the formation. This may cause a reduction in
permeability of the formation due to rock-liquid and liquid-liquid incompatibility
effects or a reduction in flow capacity due to aqueous and hydrocarbon phase trapping
and its relative permeability effects.
111. Corrosion
Underbalanced drilling in a sour environment may cause stress corrosion cracking of the drill-
string. The use of HB resistant drill pipe andlor the use of corrosion inhibitors can control the
problem. Corrosion can also be a concern if nitrogen produced by membrane units is used as the
lift gas. Most membrane units will produce a nitrogen stream with 3% to 5% oxygen content. If
membrane generated N2 is to be used and depending on the type of fluids and the specific
conditions, the project team should ensure that either the pipe is coated with the recommended
coating and/or a corrosion inhibition program will be in place. It is also important that some form
of QAIQC inspection be conducted to ensure the condition of the coating and/or the drill pipe is
known before the job. Typically in Southern North Sea (SNS) operations, if a membrane nitrogen
system is required, a base oil fluid system will be specified, to avoid oxygen corrosion issues.
IV. Application of UBD in zones of extreme pressure and permeability.
Drilling high permeability formations, especially in the offshore sector, may become problematic
since large volumes of produced fluids and gases will have to be safely handled and disposed. If in
addition these formations are also high-pressured, higher surface pressures may need to be
controlled. The development of higher pressure rated surface control equipment and high
pressure, fit for purpose surface fluidsisolids handling equipment, are extending the operating
envelope for application of UBD in the offshore sector. To date UBD systems have been designed
to handle up to 7,000psi surface gas pressure.
Costs.
UBD is usually more expensive than a conventional drilling operation since additional effort in
planning (UBD design and HSE), an extensive training program and additional onsite equipment
and personnel is required. During the planning phase of the well a UBD engineer, an HSE person
and a UBD equipment engineer will be required to do the multi-phase modelling, size
equipment, prepare procedures plan and conduct HSE studies etc. Training is not an option; the
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thought process and the procedures required to properly execute a UBD operation are different
from conventional drilling operations. In addition to the conventional tools and equipment
requirements, a pressure while drilling (PWD) tool, rotating control devices, snubbing
equipment, mud/gas/solids handling equipment, and a gas supply unit may be required. There
will be additional costs incurred to transport the UBD equipment, critical path time will be
required to rig up and commission the equipment and to train personnel onsite
VI. Other Limitations and Risks.
The planning and execution of UBD requires additional specialised equipment, engineering and
field support. UBD operation is itself a concurrent operation - a simultaneous drilling and testing
operation. UBD is still considered a new technology in some areas and personnel may be
unfamiliar with the technique. Therefore, detailed planning, properly designed equipment,
training and the implementation of specific UBD procedures are required to reduce the risk to
personnel, equipment and the environment.
The key to deciding whether to drill underbalanced is proper candidate screening to evaluate
whether UBD can be physically and safely accomplished, whether the benefits are greater than
the disadvantages and if the limitations of the technology that are specific to the project can be
overcome. However, there will always be a tendency to focus on cost; the increased drilling cost
has to be weighed against the lower completion costs (no perforation/stimulationl clean up
requirements), the potential for reservoir drainage with fewer wells therefore less capital
investment, and as recent data suggests the potential to increase ultimate recovery. The bottom
line is that UBD projects should be screened and evaluated based on added value rather than
incremental drilling cost.

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HOW TO DRILL UNDERBALANCED TYPE OF RIG? -
Underbalanced drilling operations can be performed using a conventional drilling rig, work-over
rig, or with a snubbing unitlhydraulic work-over unit, all using jointed pipe. Figure 12 illustrates
a land operation rig up showing the layout of an UBD operation utilizing a conventional drilling
rig. A coiled tubing or hybrid rig can also be used. Each method (jointed pipe or coiled tubing)
has its own niche applications and is described below,
1.1 CONVENTIONAL RIG

Very few modifications are required to adapt the rig for underbalanced drilling. The development
of rotating control devices and non-return valves in the drill string enable underbalanced drilling
with jointed pipe to be conducted in a controlled and safe manner.
Two of the advantages of using a conventional rig are its significant mechanical strength
(generally limited by pipe strength) and the capability to rotate the string. This makes the rig
capable of handling operational problems like stuck pipe (mechanically stuck rather than
differentially stuck) and drilling larger hole sizes: 6%'' - 8%". In addition, only the reservoir
section is usually drilled underbalanced. Therefore, if a conventional rig is used to drill to the top
of the reservoir, it is often cost-effective to continue with jointed pipe operations in UBD mode in
the reservoir.
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One of the main disadvantages of using conventional rig / jointed pipe in UBD mode, is the fact
that fluid circulation has to be interrupted while making connections. This may lead to
undesirable down-hole pressure fluctuations.
On many of the wells using underbalanced techniques there will be a point where a "pipe light"
situation will exist. This occurs where the force inside the well-bore acting to push the string out,
is greater than the force tending to keep it in the well bore (primarily the weight of the string). In
a wire line operation, a lubricator long enough to completely contain the weighted tool-string is
installed at surface on top of the wellhead, in order to shut in the well and allow safe removal of
the tools. In a UBD operation, designing a "down-hole lubricator" into the casing or completion
string can be used to the same effect; by installing a full-opening valve set down-hole at a depth
where the force due to the weight of the string is greater than the forces acting to push the string
out. The drill pipe is stripped out (or run in) to just above the valve. The well can then be shut in
at this depth to allow tripping
v out (or stripping in) to continue
Westherlord
in a normal or conventional
manner. To prevent impairment
of the reservoir, the well bore
below the down-hole valve must
contain only reservoir-induced
fluids (no drill fluid) prior to
shutting in. This is because the
closed system below the valve
can "pressure invert" driving
u After lnslallatlon
stripping out Trlpplng out
fluids into the formation. In gas
wells the well is blown to gas
prior to closing the downhole
Figure 13 - Weatherford's Down-hole Deployment Valve

HALLIBURTON
valve. Figure 13 and Figure 14 illustrate two of the
valves currently on the market.
A snubbing unit is often installed above the rotating

control device. It utilises reverse acting slips and
hydraulic jacking rams to push (or pull) the drill string
into the well against well pressures. Snubbing BOP pipe
rams and a surface lubricator is used to break the string
into smaller, easier to handle sections as required. The
use of the slips and jacks, in combination with the rams
and the lubricator allow safe and efficient removal of the
drill string in a 'hipe light" situation while the well
produces continuously. However, tripping is much
slower in a snubbing operation. Figure 15 illustrates rig
assists snubbing units in use on an offshore Jack-up and
on a conventional land rig.

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Off
Figure 15-Snubbing Unit Applications Offshore and Onshore

Figure 16 illustrates a push pull
machine that operates similarly to a
snubbing machine.
Most of Shell's experience in UBD has

been in North America, land
operations and in the offshore
environment of the Southern North Sea
region utilizing conventional rigs and
jointed pipe techniques. Recently,
UBD operations using convenrional
rigs and jointed pipe have been
introduced in the Middle East and Far
East regions.
Figure 16 - Texo's Push / Pull Machine

Each region has its own requirements and challenges to the implementation of the technology.
The Middle East region, for example, has its own unique equipment requirements due to the
extreme heat and sandy environment, while in the Far East, the UBD operation in Malaysia was a
world's first, using a floating tender assist rig. The primary language used by the rig crews may
not be English and therefore communication and training are critical. However, with a project
team approach and committed resources (including a competent project manager as the leader),
and proper planning, these operations can be and have been safely and successfully conducted.
Figure 17 illustrates the equipment and environment in PDO's operation in Oman, whilst Figure
18 illustrates the equipment and operating environment from Shell Malaysia's UBD operation on
the E l 1 platform in the South China Sea.
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1 Figure 17 - UBD Operations with
I Conventional Rig in Oman

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Figure 1 8 - Offshore UBD OperaUions in Malas/sia I
1.2 COILED TUBING UNIT
CT has been in use for underbalanced well interventions and workovers since the 1970's.
However, as Figure 19 illustrates, today's CTD rig with its specially designed mast can be used in
any area and in all types of conditions. In addition to the potential for reduced environmental
impact, the lack of pipe connections in coiled tubing gives it many advantages over jointed pipe
UBD:
There are no bottom-hole pressure fluctuations due to connections.
Personnel are not required to work directly above the well bore.
The ability to transmit continuous data with the use of electric line inside the coil.
Continuous injection of gas through the drill string (CT).
Underbalanced tripping is relatively routine and much faster than with jointed pipe.
Disadvantages of coiled tubing are:

The inability to rotate the string.
Limited pulling or pushing power (surface equipment limitations).

Limited coil life due to fatigue cycles (bending I straightening).
Depth control limitations (depends on equipment selected).
Limitations in reach and hole size (3%" - 6%").
Logistical limitations relative to the coil (especially critical offihore).
In summary, coil tubing drilling and underbalanced drilling appear at first glance to be a
"marriage made in heaven". In addition to the obvious advantages over conventional jointed pipe,
CTD technology brings other benefits to the table; because of its small outer diameter, coiled
tubing can also be used for underbalanced deepening, or side-tracking of a well through the
existing completion. Because there are no connections to be made, the use of coiled tubing in
underbalanced drilling provides a very safe and efficient circulating conduit, especially when
drilling sour gas wells; making the underbalanced drilling process much simpler and easier. The
decreased personnel activity adjacent to the well bore also means less exposure and therefore less
risk for personnel on location. It can handle much higher surface pressures than currently available
rotating control devices and the ability to hardwire the survey and pressure tools back to surface
allows for faster data transmission. However, the technology currently has limitations in hole size,
depth, horizontal section length, controllability, crew experience in drilling activities, and it is
difficult to fish. These limiting factors must be taken into account when planning to use coil as a
drilling conduit. At present, the best application is to drill to the reservoir with a conventional
drilling rig and use the CT rig to drill in the reservoir section only, playing on the strengths of
both systems.
Nevertheless, CTD technology is continuously improving and the potential for increased use and
versatility is very good especially with the development of the Hybrid Rigs. The Hybrid rigs of
the future may combine all of the strengths of the rotary rig with the strengths of the CT rig. A
forward-thinking Well Engineer would design a CT friendly well utilizing mono bore designs
typically 7" to 4" with current CT BHA technology. In addition, landing the casinglliner shoe at a
high exit angle into the top of the reservoir would make the well an ideal candidate for future
CTD.

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HYBRID UNIT
Figure 19 - UBD Operations with Coiled Tubing Rig
WDLP - Underbalanced drillinn Pane 8/5/29

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Topic 3
The drill str~ng
THE DRILL STRING

1.1 INTRODUCTION
A simple drill string design can be used for UBD operations. Components used in a conventional
drill string to reduce the risk of drilling related problems can be left out. For example, spiral drill
collars; differential sticking is no longer a problem and deployment through the rotating control
device may be a problem in a live well. Another example is that drilling jars also have to be left
out of UBD BHAs where snubbing will take place.
The drill string tool joints should be slick to prevent damage to the sealing element of the rotating
control device; therefore drill pipe with raised-face hard banding, or identification groves cur in
the tool joint should not be used and during the operation, excessive tong marks should be
removed for the same reason.
All BHAs must be checked to see whether they can physically be snubbed into and out of the
well. If non-uniform tool exteriors exist over lengths greater than the stroke of the snubbing jack
(typically loft), then the slips will be unable to grip the tool, and it would be ejected from the
well. For this reason, snubbing pipe conveyed logging tools into the well poses significant
challenges. Each tool combination must be analysed for its "snubbabilty", preferably by the
snubbing contractor.
Many of the early UBD operations had tremendous cost overruns due to drill pipe failure and/or
failure of internal plastic coating. As mentioned earlier and repeated here for emphasis, QAIQC
pre-inspection of the drill pipe must be conducted to ensure the condition of the coating and/or
the drill pipe is known before the job to reduce the potential for failure. All downhole tools must
be inspected dimensionally, and from a design viewpoint to try and eliminate all potential leak
paths to gas from external to internal.
For most applications conventional drill pipe connections can be used. However, for
underbalanced drilling in high-pressure gas wells, a gas tight connection is highly recommended
and a drill pipe inspection process should be put in place at the rig site to reduce the potential for
washouts occurring and having to kill the well, negating the benefits of UBD.
Figure 20 illustrates a drill string configuration showing components that could be required in an
UBD operation. These are described below:
WDLP - Underbalanced drilling Pane 8/5/3 1

Version 2.0.0
Choking drill collars
Drop-in check valve
Drill collars (slick)
Memory pressure recorder
MWD + annular pressure sub
Non return valve (flapper type)
Non return valve (plunger Npe)
Figure 20 - Drill string Configuration
1.2 CHOKING DRILL COLLARS

Although no longer commonly used, choking drill collars were an early solution to controlling high
gas rate wells. Flush production is a phenomenon that occurs when a high-pressure high
permeability feature is encountered while drilling underbalanced. It becomes a serious erosion
issue on high pressure, high volume gas wells, when the chokes are used to try to control the
pressure and flow rates at surface. In order to continue drilling in underbalanced mode, drill pipe
at surface is swapped out for large diameter drill collars (DC). The effects of these large diameter
collars are to create a high friction gradient and a corresponding large pressure drop in the
annulus; thus providing a down-hole choke effect. The use of choking drill collars reduces the
required surface backpressure and decreasing the surface backpressure will minimise erosion of
the surface choke.

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In fact due to the additional problems encountered in getting the choking drill collars into the
well, and the improvements in the surface separator package, choking drill collars are no longer
used in high rate gas wells.
1.3 NON RETURN VALVES

Non-return valves (NRV's) are essential components in the UBD drill string. The valves are
installed in the BHA to prevent (reservoir) flow up the drill string and are also installed in the drill
string near surface when using gas injection down drill string to reduce blow-down volume at
connection time.
There are a number of different valve types on the market. The most commonly used NRV's are
the flapper type and the dart type valves illustrated in Figure 21. These are installed in tandem,
within a specially manufactured BHA sub. There are also wireline run check valves that can be set
in profile nipples that are installed throughout the drill string.
P1apper Style ~ a r t . " ~ ~ ~ e
Figure 2 1 - Non-return Valves Used in UBD Operations

The advantages of the flapper style valve over the plunger or dart type valve are that the flapper
type erodes less, and it is not easily plugged with drilled solids. However, the plunger valve tends
to seal more effectively than the flapper valve especially in the horizontal sections of the well;
therefore this type is frequently used at the bottom of the string.
As mentioned before, non-return valves are usually run in tandem to provide double barrier
redundancy. The placement position in the drill string depends on the purpose of the valve:
Just above the motor (preferred) or in the last stand of the drill string to allow full drill
string deployment. These are installed for "well control" purposes.
Neat surface (to minimise the time required to bleed down the drill string pressure above
the float prior to making a connection). These are installed for "drilling" purposes and are
often referred to as "near surface" NRVs.
WDLP - Underbalanced drillina Poae8/5/33
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Figure 22 - An example af a Plunger Type Won-Return Valve with Pressure Relief Tool
-
Note conventional drill string float subs are not suitable for UBD operations. I n
conventional subs, the float inserts are not mechanically locked in place, but held in place
by the friction between the float seal and the polished bore sealing area. This friction might
be exceeded by pressure trapped below the float while pulling out of the hole. In this case, the
float insert might be propelled from the sub when breaking the connection at the float sub.
Special modified float subs have been developed for UBD operations, where che float insert is
mechanically locked in place with a snap ring.
A special tool is required to relieve the trapped pressure below a non-return valve during tripping
operations. Figure 22 illustrates the NRV, the specially manufactured NRV sub and the pressure
relief tool assembly and describes the components. Figure 23 shows actual tools used in the field.
Page 8 / 5 / 3 4 WDLP - Underbalanced drilling

Version 2.0.0
Figure 23 - NRV's, NRV Subs and Pressure Relief Tool
In addition to the subs for NRV's, landing nipples for wire line set tools are sometimes also
installed in the BHA. Plugs or check valves can be run on slick line and installed in these profile
nipples to provide string integrity in case of a failure below the landing nipple.
In extreme circumstances, for example with a leaking drillstring, a bridge plug can also be set
inside the drillpipe and cement dumped on top, to provide a seal whilst pulling out of hole.
1.4 HYDROSTATIC CONTROL VALVES

The Hydrostatic Control Valve (HCV) illustrated in Figure 24 can be installed on top of the mud
motor. The purpose of the valve is to maintain a fluid column above the MWD tools ensuring
WDLP - Underbolonced drillins Page 8/5/35

Version 2.0.0
proper detection at surface after a connection. Drill pipe screens should be run whenever possible
in UBD, to minimise the chances of plugging off the MWD tools (or the HCV if installed) with
debris. The consequence of an inoperative MWD is often more severe in UBD wells since round
trips take considerably longer (up to 5 days). In addition, the HCV should be function tested at
surface several times to check the opening pressures and the consistency of these pressures. While
running in, the drill string should be filled every 10 to 15 stands. If this is not done, the
differential pressure from the annulus to the drill pipe will cause serious problems opening the
valve.
Figure 24 - Hydrostatic Control Valve - Fully Open / Opening / Fully Closed Positions
1.5 PRESSURE MEASUREMENT TOOLS

PWD tools are now an integral part of the MWD component. Most of the PWD tools currently in
use can provide real time temperature and pressure inside and outside of the drill pipe, just above
the bit. This inlbrmation can be used to:
Optimise the under balanced conditions.
a Verify computer model simulations.
Characterise the reservoir.
As well, this data is also recorded continuously while drilling and tripping and can be used for
detailed post job analysis.
Prior to the advent of real time PWD tools, sunlace annular pressures were monitored and used as
an indication of what was happening down-hole. Surface annular pressures may or may not
indicate down-hole problems, whereas from bottom-hole pressure (BHP) readout, problems can be
clearly identified. Figure 25 illustrates where a borehole cleaninglpack-off problem, evident in the
BHP data is not reflected in the surface pressure data.

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TIME
I
1 @TechnicalServices
25 - Comparison BHP Readout vs. Surface Pressure Readout
The absence of accurate real-time pressure draw down information may result in accidental
creation of an overbalanced condition or to undesirable high production rates.
WDLP - Underbalanced drilling Poae 8/5/37

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Topic 4
The Underbalanced Drilling Fluid
THE UNDERBALANCED DRILLING FLUID

1.1 INTRODUCTION.
In conventional overbalanced drilling, the drilling fluid fulfils several basic functions; for example,
lubrication, cooling, cuttings transport, bottom hole pressure control, power fluid for mud motors,
filter cake to control fluid and solids invasion. To fulfil these functions several materials or
chemicals are added to the basic fluid such as:
Weighting materials, to ensure primary well control.
Filter cake material, to minimise fluid losses.
Chemicals and viscosifiers, to ensure good hole cleaning characteristics.
The drilling fluid design for UBD operations differs from the conventional design in that the basic
functions of the fluid are different. Since underbalanced drilling prevents fluid losses, filter cake
material is not required. Hydrocarbon production from the reservoir combined with the drilling
fluid, generally increases the annular velocities. The increase in annular velocities consequently
enhances hole cleaning and therefore the addition of viscosifiers is less critical. In fact low PV/ YP
muds are preferred in gas wells as they enable faster break out of gas at surface. Weighting
materials may or may not be required depending on the reservoir pressures and the degree of draw
down desired. The following table compares characteristics of a conventional mud system with an
underbalanced mud system.
Conventional Fluids UBD Fluids

Rely on Viscosity to carry cuttings Rely on Velocity to carry cuttings
Uses wall cake to controlf l ~ i dlosses to the Underbalanced condition is maintained to
formation preventflzxid losses (no wall cake)
Density is used to control bottotn holepress~tre Density is used to control sfkt$acepressure
and prevent inflow from formation
Generally, no compatibility issues Compatibility with produced fluids can be a
major issue for srsrface hczndling
1.2 TYPES OF LIQUID

UBD fluid systems usually consist of basic liquids, such as seawater, fresh water, brine, crude,
diesel or base oil, occasionally combined with gas injection.
The types of fluid systems, which can be used vary, ranging from 100% gas as in air drilling to
100% liquid as in flow drilling. In between these two extremes are mist fluids, (gas is in the
continuous phase and the liquid is suspended as droplets in the gas); stable foams (created by
adding surfactants and other chemicals to the liquid phase). Two-phase fluids, where the liquid is
WDLP - Underbalanced drilling Pane 8/5/39
Version 2.0.0
the continuous phase, are classified as faams or gasified liquids. The following chart illustrates the
range of densities available.
Airtgas 0.1 - 0.2

Mist 0.1 to 0.3
Foams 0.3 to 0.5
GasifiedtAerated Liquids 0.5 to 0.8
Single Phase liquids > 0.7
Oil l diesel 0.7 - 0.9
Seawater 1.04
KCl britze 1.33
Formute fines 2.0
In conventional drilling the bottom hole pressure is controlled by the equivalent circulating
density of the mud. The same principle applies in underbalanced drilling. However, the
equivalent circulating density of a gasified liquid depends on the liquid, the circulating liquid rate
and the injection1 production rate of the gas.
1.3 TYPE OF GAS

Air, natural gas, nitrogen (cryogenic and membrane generated), exhaust gas and recovered gasses
are all used as injected gasses in underbalanced operations.
Air - It is readily available and relatively inexpensive to use. Usually used in performance drilling
applications to improve ROP in non-hydrocarbon bearing zones or in applications where a pure air
system can be safely used. Safety - Combustion is a major concern. Air should not be used if coal
or liquid hydrocarbons are likely. Corrosion to drill pipe and casings is also a major concern
especially in the presence of brines. Inhibitors are required, which may cause reactive problems
with formation and formation fluids.
Natural Gas - Availability is location dependent. Where fuel gas supply, with required rate and
pressure is available on-site, this will be a very cheap option. However if the gas must be
transported, this is not a viable option. An advantage of using this type of gas is that it can be
recovered and recycled but compression can be a problem if inappropriate compressors are used.
Safety - When supplied in pure form (methane), it is not readily combustible.
Nitrogen - Nitrogen can be generated by the cryogenic process or by membrane technology.

Cryogenic process is used to super-cool air and produce liquefied nitrogen. Cryogenic nitrogen is
the gas most frequently used for gas injection in UBD operations. Figure 26 shows the cryogenic
Nitrogen system in use. However, this is because most UBD operations have been conducted
onshore and in areas where liquid Nz was easily available. A major advantage is its 99% purity but
in more remote areas and in offshore operations, storage and logistics becomes a problem,
especially where vast quantities of nitrogen are required. Safety - The effects of a liquid spill on
personnel and the environment must be considered. Proper personal protective equipment (PPE)
such as gloves and coveralls must be used, and the nitrogen system must be bunded to prevent
spills from damaging the rig deck (&hore).
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Figure 26 - Cryogenic Nitrogen System
Membranes have been developed to filter the nitrogen gas from the oxygen, carbon dioxide and
water vapout in air. The membrane technique is based on the process of selective permeation
across a membrane wall. Figure 27 illustrates the process and size of the membrane tubes used in
the fibre bundles.
HOLLOW F~BER
FEED AIR
Figure 2 7 - Fibre bundle from N2 generating process

Membrane units are capable of separating approximately 50% of an inlet feed volume to 95%
nitrogen and 5% oxygen. Since the system is only 50% efficient, feed compressors must be capable
of providing twice the volume of gas required for injection. The disadvantages of this system
include high mobilization cost, the size of the equipment, the number of components and the
maintenance that is required, and the presence of oxygen in the gas stream. Figure 28 illustrates
the membrane process used in a UBD operation and Figure 29 is an overview of the equipment
used.
WDLP - Underbalanced drillinn Page 8/5/4 1

Version 2.0.0
-
4
QHii$w
Rig,
I
-la?,+!
.-I,
,l<S
b0dQt:
Figure 28 - UBD membrane process

8
I I-
Process Flow
IbmBZae
F w d AIr
l ~ ~ ~ p r ~ ~ a r
..
.-.--..---
&
--
. pi\
,
a 3 w e ? r , =
Safety - Injected gas mixtures containing oxygen can result in down-hole explosions, down hole
fires and potential corrosion problems. The concentration of oxygen that can safely be allowed in
injection gas with regard to combustion risk depends on down-hole pressure, temperature and
hydrocarbon composition. As a rule of thumb, oxygen concentration up to 5% by volume can
generally be accepted. However, the presence of high concentrations of H2S may increase the risk
of down-hole combustion even with 5 % 0 2 by volume and additional well-specific testing may be
required.
Figure 29 - Overview of membrane system equipment

Exhaust Gas - Exhaust gas recovery process that was recently patented by Northland Energy for
use in oil and gas well intervention. The supply package takes the exhaust gas from the gas
compressors converts it and uses it as the feed gas. The compressors are normally driven by
propane so that the exhaust gas is relatively clean and easy to convert. Figure 30 illustrates the
process.

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-
-
Flow Path ?
Propane
. Byled Engine I
i
PROPANF -
I
1
I
Comprmot
-- - --
- -
-
-
Figure 30 - Exhaust gas recovery and injection process
The system is capable of producing 1500 standard cubic feet per minute at 2000 to 2500 psi and
with approximately 20 ppm Oxygen. Mobilization cost, availability of equipment and adequate
propane supply may be a concern. Figure 31 shows some of the equipment used for exhaust gas
recovery and injection.
Figure 31 - Equipment uwd in exhaust Bas sysfm
AIR, AIR/MIST AND FOAM

As nrentimed before, rhe types of fluid systems, which can be used in underbalmcd drilling,
vary, ranging fmm 100%gas s in air drilling to 100% liquid, Figwe 32 illwmtes the commm
fluid systems used and the bffect on bo& h d e cleaning. The fallawing axtion describes haw each
of these fluid sysrem evolved and is currently used in UBD pmurw,
WDLP - Underbalanced drillina Page 8/5/43
Version 2.0.0
Air or Gas Mlot Aerated Uquid Foam
Figure 32 - Common Fluid Systems

Used in UBD
Increasing Cutting Carrying

Capacity
2.1 AIR DRILLING

Air Drilling is the process where compressed air is used as the drilling fluid rather than mud. It
first came into commercial usage in the early 1950's as a technique to increase penetration rates
while drilling overburden formations. The increased ROP's were considered phenomenal at the
time and consequently operators started experimenting with its use in reservoir sections. Some of
the limitations to the technology were quickly discovered:
1. The compressors available at the time were relatively small and therefore hole sizes
and depths were severely restricted.
Water flow would result in stuck pipe due to lack of borehole cleaning. In the worst
cases, the fine cuttings when mixed with water would form a type of cement that
would adhere to the inside of the casing strings. This situation resulted in many long
and arduous back-reaming jobs and in some lost boreholes.
Air drilling in coal beds resulted in down hole fires that had s&cient heat to melt
drill collars.
Reservoir sections that contained hydrocarbons were also subject to down hole fires
due to the "diesel effect".
Techniques and equipment were developed to overcome the inherent shortcomings and to
improve the technology:
Larger compressors were designed and built, to provide the operator with a high
volume / high-pressure air supply. This improved hole cleaning and made the
technology more versatile.
The "air hammer" was re-designed and developed for use in the drilling industry.
Page 8/5/44 WDlP - Underbolonced drilling

Version 2.0.0
It is still not recommended to drill coal or reservoir sections with air, but changing to an inert gas
(such as nitrogen, COz, or exhaust gas) eliminates the fire hazard while retaining the benefits of air
drilling.
Some of the advantages of air drilling are its relative cost, its simplicity and the fact that very low
BHP can be attained. This enables surface holes to be drilled far above the water table for example
in mountainous regions. Recent innovations in motor and hammer technology have allowed air
drilling to break through the directional control barrier where long high angle tangent sections
can now be air drilled.
2.2 AIR MIST DRILLING

Another technique developed to increase the hole cleaning capacity of air was airlmist. Lifting
cuttings out of the well-bore when drilling with a dry gas depends on velocity alone as the gas
itself has no carrying or lifting capability. I t was discovered that the addition of a very small
amount of liquid (usually water) greatly improved the hole cleaning of the gas. Air/Mist drilling
was seen as a major improvement in the technology. Improvements to the air supply and the "air
hammer", coupled with the development of airlmist technique, have allowed hole sizes to increase
to the point where it is not uncommon to see air drilling used in 17%'' hole sites. The technique is
generally used when water influx is encountered during gaslair drilling for ROP improvement in
overburden sections.
Advantages of this technique are its higher tolerance to minor water influx and it generally
eliminates the formation of mud rings.
The main disadvantages are its higher gas requirements, corrosion and its impact on exposed
shale.
2.3 FOAM DRILLING

Although airimist drilling was seen as an improvement over straight air drilling in some cases,
water flows still caused major problems because the switch from water-in-gas to gas-in-water
reduces the hole cleaning ability of the resulting fluid. However, as the technology continued to
develop, it was discovered that the addition of a surfactant to the airlmist system resulted in the
formation of stable foam. This system known as foam drilling was capable of absorbing large
amounts of water and also improved the hole cleaning capacity relative to the airlmist system.
With the advent of the stable foam, it was now viable to start to downsize compressors with the
resulting savings in fuel and still have all the benefits of drilling with gas.
The stable foam is comprised of gas bubbles uniformly dispersed in a continuous liquid phase.
Mixing water, gas and a foaming agent in a closed chamber creates the basis for the foam, which
is then generated as the mixture exits the bit nozzles. Typical foam quality ranges from 60% (gas
content by volume) to 80%; with 75% foam quality considered the optimum.
An advantage of drilling with foam is the significant cutting carrying capacity of the foam.
Cuttings can be suspended for long periods after circulation has stopped. In addition, if the
reservoir pressure is too low to obtain an underbalanced condition with a gasified liquid, stable
foam generated with air or nitrogen can be used.
The major disadvantage of this circulation system is the destabilisation (with chemical additives)
that is required of the foam returns from the well. The destabilisation process sometimes hinders
re-circulation of the drilling fluid in a closed loop system and can be a source of combustible
Version 2.0.0
material if used in an open system. However, recent developments in foam technology appear to
have overcome recycling problems by using pH control of the base fluid.
It is of interest to note that many of the same ideas and procedures used in the past are still being
used today. Improvements in both surface and down-hole technology allow us to control the
drilling process and create underbalanced conditions intentionally and safely. Many of the
concerns and conditions not fully resolved in previous decades are now being tackled anew;
rethinking and applying the best possible drilling practices and optimising reservoir conditions
and conservation methods, allow us to maximise hydrocarbon recovery.
3 DRILLING WITH GASIFIED LIQUIDS

The simplest UBD fluid system is a single-phase fluid. Often referred to as flow drilling, the
dynamic bottom hole pressure due to the mud column and frictional losses of the selected fluid is
less than the formation pore pressure. However, this is not always possible and in order to reduce
the hydrostatic head sufficiently to obtain or maintain an underbalanced condition, gas injection
may have to be utilised. Depending on the reservoir pressure, permeability and the type of
reservoir fluid (oil, water or gas), continuous or temporary gas injection may be required.
There are two methods of introducing gas into the fluid stream: drill string injection and annulus
injection. These concepts are illustrated in Figure 33.
Figure 33 - Methods of Gas lniection (UBD mode) and Flow Drilling

"Flow drilling" generally refers to a system used in high-pressure wells where the bottom-hole
pressure exerted by the drilling fluid column is less than the pore pressure of the reservoir and
hydrocarbons produced from the reservoir will lower the hydrostatic head sufficiently such that no
gas injection is required to maintain flow from the reservoir under dynamic conditions.
3.1 DRILL STRING INJECTION

In drill string injection, gas is injected into the drilling fluid at the standpipe manifold.
Advantages:

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Simple method, which does not require an additional injection string to be run.
The full annulus drilling fluid column can be lifted since the gasified fluid is circulated
into the annulus at the bit (well depth). Under these conditions, the lowest bottom-hole
pressure can be achieved.
Disadvantages:
Injecting a 2-phase fluid down the Kelly hose must be properly managed from a safety
perspective. Normally, nitrogen resistant kelly hoses are fitted prior to circulating with a
2-phase fluid.
Conventional mud pulse telemetry (MPT) cannot be used to transmit MWD data to
surface beyond *20% gas volume in the drill string.
Gis injection needs to be stopped while making a connection and while tripping. During
these operations, the underbalanced state might not be properly maintained resulting in
possible impairment of the reservoir.
No immediate effect on the bottom-hole pressure when adjusting the gas injection rate.
The effect only takes place after drill string volume has been displaced and the expansion
of gases in the annulus takes place.
Multi-phase flow down the drill string reduces the efficiency of down-hole motors.
Multi-phase flow down the drill string can cause an increase in drill string vibrations.
Multi-phase flow in the drill string can lead to a significant increase in friction and
consequently increased standpipe pressures.
Multiphase flow in the annulus can also cause increased friction factors so torque - drag
planning must take into account offset UBD experience.
3.2 ANNULUS INJECTION

In annulus injection, the gas (or low-density fluid) is injected into the annulus via a fixed
subsurface point. The deeper the injection point (to a certain depth), the lower the bottom-hole
pressure that can be achieved. Gas injection below approximately 2000m will have very little
effect in reducing bottom hole-pressure due to compression of gas below this depth.
There are 3 different methods for annulus injection:

Parasitic string injection.
Parasitic casing injection.
Gas lift mandrel injection
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3.2.1 PARMITICSTRING JNJ~CTION
An externid tubing string is run tdgether with the prducrioh casing. These strings ilre then
cemented in place. The rubing is e%snnect& to a &Id@e;ntry sub in the rasing. D u r i e UBD
operarkns, gas is i m j d via che tubing wing into the produetion casing driIl pipe annulus.
Figure 34 illustzs~testhe equipmmt used in parasitic string injection.
Figure 34 - Equipment used in parasitic $!ring injection

Dis9dmtncages:
Difficuicies while turning the tubiqg 1 &sing Strings.
Implementing a side entry sub, introduces a weak point or leak path in the surface casing
or production casing design.
3.2.2 PARASITIC
CASING INJECTION
A smaller diameter casing string is temporarily hung-off inside the production casing. The gas is
injected down into the annulus between the casings. The casing can be run open ended and gas
can simply be circulated out the bottom. However, bottom hole pressure control can be very
erratic and there is a high possibility of going overbalanced because of this. A better design is to
run the casing with an injection valve in the string and pack it off at landing point (with either a
packer or PBR assembly).
Disadvantage:
An obvious disadvantage is the increased rig time required to run and pull the temporary
casing string.
Implementing the smaller ID parasitic casing string may also decrease the hole size that
can be drilled. This is not the case in the Southern North Sea, where a 7" parasitic
(concentric) string is used to tie back from the top of the 7" liner.

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3,2,3 GASLIFT MANDREL INJECTION
If the reservoir section can be drilled through an existing completion (e.8. deepening with coiled
tubing or a properly sized drill string) and a side-pocket mandrel (SPM) exists as a part of the
completion, the SPM can be used for gas injection. In effect, the completion is used in the same
way that the parasite casing is used but it is a permanent installation and the gas lift valve can be
retrieved with wire line.
4 FLUID SELECTION FOR UNDERBALANCED DRILLING

OPERATIONS
In selecting the fluid to be used for an UBD operation, there are many issues that must be
considered before the final selection is made. The following is a list of criteria for fluid selection:
Compatibility with formation fluids
Creation of emulsions down hole and at surface
Borehole stability and hole cleaning
Compatibility with formation
Ease of defoaming
System stability
Degree of Underbalance required
Adequate bit and BHA Cooling
Surface separation of drilling fluid from produced fluid
Friction and casing wear
Inhibitive properties
Corrosion
Temperature
Health, safety and environmental factors.
The fluid selected is usually a compromise solution that addresses all of the needs of the mud
system and minimises potential problems. The mixing of the drilling fluid, injected gas and
produced hydrocarbons under high pressures can often lead to undesirable phenomena such as
down hole emulsification and foaming in surface facilities. Shell Canada for example, experienced
severe emulsion formation, which created a bottleneck while drilling one of the early Harmatten
wells in underbalanced mode. Foam formation in surface facilities was observed while drilling
NAM well Dalen-2 and was identified as a ~ r o b l e mdrilling some of the Shell Canada and Pan
Canadian wells in Saskatchwan. Figure 35 is a table showing some of the possible fluidlgas
interactions.
WDLP - Underbalanced drillinn Page 8/5/49
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, Formation Component
l ~ r i l l i fluid
n~ Crude Formation Gas Solids
Water
GAS Foam Foam Combustion -
APr/Nitrogen
FOAM Foam Foam Combustion -
Air/ Water
CRUDE +N2 Emulsion & Emulsion & Foam Emulsion
Foam Foam
DIESEL +N2 Emulsion & Emulsion & Foam Emulsion
Foam Foam
BRINE +N2 Emulsion & Precipitation Foam Emulsion
Foam
WATER +N2 Emulsion & Change in mud Change in mud Emulsion
Foam rheology rheology
Figure 35 - Underbalanced drilling compatibility problem chart.

When the potential of foaming problems exist, anti-foaming additives can be added to the drilling
fluid. However, it should be noted that increased viscosity and the presence of fine solids and
nitrogen might stabilise the foam and therefore compatibility testing of chemical additives is
recommended.
Page 8 / 5 / 5 0 WDLP - Underbalanced drilling

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Topic 5 I
The Circullati'onSystem
I INTRODUCTION
The circulation system is considered the most critical element in underbalanced drilling.
The circulation system must:

Achieve and maintain an underbalanced state.
Provide adequate borehole cleaning.
Deliver power to the BHA 1 motor.
Provide well control.
The control of bottom-hole pressure and the design of a suitable circulation system are key to
successfully drilling underbalanced. In the planning and design phase of the project, two phase
flow modelling will be done by the project UBD engineer. The results of the modelling and other
design parameters will be used to size equipment and develop procedures prior to the start of
operations and within these procedures the bottom-hole pressure operating envelope will be set
based on best available data. However, the actual well and reservoir conditions will determine the
optimal operating parameters used during the execution phase and real time phase behaviour
modelling on location will be required.
The bottom-hole pressure is influenced by many interrelated parameters such as:

Reservoir inflow
Gaslliquid type, method and rate of injection

Well configuration
Drill string movement
Bottom-hole pressure = pressure exerted by the hydrostatic head of the annular column + the
pressure drops created by friction in the annulus + the inertial pressure of fluid acceleration.
DOMINATING REGIME
A circulation system can be hydrostatically dominated or friction dominated as illustrated in
Figure 36.
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Figure - BHP vs. Gas Inflow Rate
Gas Inflow Rate
Figure 37 - Effects of Varying Pump Rates on BHP vs. Gas Inflow Rate
In Figure 36, the bottom-hole pressure is plotted against the gas inflow rate for a certain fluid
rate. The bottom-hole pressure rapidly decreases as the gas inflow rate increases from zero. This is
due to the reduction in hydrostatic pressure as the gas lightens the annular fluid column.
Annular friction losses do not behave linearly. At low gas-inflow rates, friction loss is small and
does not really influence the bottom-hole pressure. However, as the gas inflow rate increases,
annular friction losses increase which reduces the rate of change in bottom-hole pressure caused
by the increased gas inflow rate. Ultimately, a point is reached where the effect on bottom-hole
pressure due to reduced hydrostaric pressure is balanced by the effect caused by increased annular
fiiction losses. This optimal point is the minimum achievable bottom-hole pressure for a given
liquid rate. If the gas idlow rate is increased beyond this point, the bottom-hole pressure will

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marginally increase; the bottom-hole pressure is said to be "friction dominated". The area to the
left of the optimum point where the bottom-hole pressure is decreasing with increasing gas rates,
the bottom-hole pressure is said to be "Hydrostatically dominated". Figure 37 illustrates the effect
on BHP and the shifiing of the optimum point by varying the pump rates.
A circulation system operating o n t h e friction-dominated side is more stable and less

affected by changes i n gas injection rates or reservoir inflow. Increased gas flow from the
reservoir will cause an increase in bottom-hole pressure and consequently the reservoir's ability to
inflow gas will be reduced. The friction dominated circulation system controls the i d o w of gas
from the reservoir and hence the bottom-hole pressures. A positive effect of stable bottom-hole
pressures is increased borehole stability.
3 BACK PRESSURE AND C H O K I N G

Annular bottom-hole pressure can also be controlled by choking and applying backpressure at
surface. However, this type of control is usually kept to a minimum since it enhances the erosion of
chokes and other surface equipment significantly.
4 MODELLING O F A CIRCULATION SYSTEM

As stated earlier, two phase modelling is critical to the success of the UBD operation since the
underbalanced circulation system usually consists of multiphase flow.
Multiphase flow in a well-bore is very complex and it can have many co-existing flow regimes.
Therefore an advanced computer simulation model is required to model multiphase flow.
However, most available models are static and interpret steady state flow only at a point in time.
The effects of starting and stopping circulation, and fluid interaction during connections must be
modelled by dynamic simulators, which are much more complex. Recent improvements in this
area now allow training and real time multiphase modelling with PC based dynamic simulators.
CONNECTIONS AND DRILL STRING MOVEMENT

Drill string connections and pipe movement, influence the circulation system. Due to drill string
movement and connections, the bottom-hole pressure fluctuates almost continuously. These
pressure fluctuations should be minimised to ensure efficient underbalanced drilling.
Special connection and tripping procedures exist for UBD. Effective communication prior to
making connections is crucial to ensure the proper procedural steps are taken.
5.1 CONNECTIONS
Drill string connections interrupt the steady state of a circulation system. Initially the bottom-hole
pressure drops due to the loss of the friction gradient when circulation is stopped. Then, fluid and
gas in the annulus separate resulting in the formation of slugs of liquid. As well, gas influx from
the reservoir forms a bubble in any high angle lateral section. When circulation is restarted the
bottom-hole pressure increases due to fluid acceleration inertia, the lifting of the liquid slugs
formed during the connection and the annular friction losses. As soon as the liquid slugs are
produced from the annulus, the bubble formed in the lateral by the reservoir gas influx
significantly decreases the bottom-hole pressure. This results in a flow rate surge at surface.
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This cycle is repeated every time a drill string connection is made and any time circulation is
stopped for orher reasons a shown in Figure 38 and Figure 39. If this phenomenon is considered a
problem with respect to the underbalanced objectives in the reservoir, then the amount of
connections per bottoms-up cycle s h d d be controlled (reduce the ROP).
6L.U DWR €1
TlME (min)
-
Figure 38 Effects OF Drill String Connections on BHP (UBD Mode - Liquid Slugging)
TlME (rnin)
Figure 39 - Effects of Drill String Connections on BHP (UBD Mode -Gas Surge)
5.2 DRILL STRING MOVEMENT

Drill string movement may also induce surge and swab pressures. These pressure fluctuations can
lead to an overbalanced situation causing reservoir impairment. However, this is no different than
in a close margin conventional well and the driller needs to be aware of the consequences of
sudden jerky pipe movement.

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Topic 6 I
1 BOREHOLE STABILITY
Underbalanced drilling should be utilised in competent formations only. Highly permeable
unconsolidated sandstone reservoirs may collapse under the influence of a pressure draw down into
the well bore. Also, over-pressured shale is likely to start sloughing when a pressure differential
into the well bore is applied; this usually occurs in a depleted, layered (sandstonelshale sequences)
reservoir. These situations need to be thoroughly evaluated if UBD is planned in such reservoirs.
Borehole stability can also be affected by unstable fluctuations of bottom-hole pressures due to
changing reservoir inflow, rapid drill string movement, drill string connections and circulation
system adjustments. This "cycling" effect can mechanically destabilise a formation. To reduce the
potential for borehole instability, draw down pressures should be minimised and significant
fluctuations in bottom-hole pressure should be avoided. If the UBD circulation system can be
operated as a friction dominated regime, a more stable bottom-hole pressure can be achieved. In
addition, as mentioned before the driller needs to be aware of the consequences of sudden starts
and stops of the drill pipe, and fast tripping speed and be encouraged to handle his equipment
appropriately.
During the execution phase, it is important to monitor the cuttings mass balance continuously, for
indications of borehole stability problems. However, in practical terms this is often difficult to
achieve with any accuracy, and so trend analysis may be more realistic.
2 HOLE CLEANING
Hole cleaning efficiency depends mainly on:
Velocities of the liquid phase
Concentration of solids
Hole cleaning is more efficient in a two-phase circulation system. The presence of a gas phase
increases annular velocities and can result in the generation of a turbulent flow regime. Turbulent
flow minimises the formation of cuttings beds.
To optimise hole cleaning prior to making a connection, circulation should be maintained
for several minutes while reciprocating and/or rotating the drill string.
The carrying capacity of the liquid phase determines the maximum allowable ROP that
can be achieved.
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Topic 7
Well Control in Underbalanced
Drilling
I PRIMARY WELL CONTROL

In conventional drilling, primary well control is obtained by creating a hydrostatic pressure with
the mud column, which exceeds the pressure in the formation being drilled. In underbalanced
drilling, the primary well control function of the mud column, has been replaced by flow and
pressure control. The bottom-hole pressure and consequently the reservoir influx is monitored and
controlled. Flow control is achieved by means of a closed loop surface system.
The main components of the closed surface system are:

A sealing mechanism around the drill string
Surface safety valve (ESD valve)
Choke manifold
Surface fluids / solids handling system
1.I SEALING MECHANISM AROUND THE DRILL STRING

At surface, well-bore pressures are contained by means of a sealing mechanism around the drill
string. Well-bore pressure should be continuously restrained while allowing drill string rotation
and pipe movement. Pipe strippers in CT drilling and a snubbing annular or a rotating control
device (RCD) in jointed pipe UBD operations provide the sealing mechanism around the pipe.
There are two types of RCD systems, passive systems and active systems. The passive system
depends on a friction fit between the drill pipe and the rotating pack-off and well bore pressure to
effect a seal. Examples of the passive system are the Weatherford-Williams RCH, Drilco Grant's
low-pressure heads and Stacy's medium pressure heads. The active system uses hydraulic pressure
to effect and maintain the seal around the drill pipe. Some examples of RCD that have been used
on Shell's operations are:
Rotating Control Head (RCH - Weatherford-Williams Tool Company Inc.)
Rotating Blowout Preventer (R-BOP - Northland Energy.)
Pressure Control While Drilling (PCWD - Shaffer Pressure Control)
Despite the names used for the various rotating control devices, other than the PCWD, none are
certified by the API as Blow-out Preventers and cannot be used as a replacement for the annular
in the BOP stack. Although the PCWD and others in the future may be certified as API annular
BOP'S and may be part of the BOP stack, a second RCD is required for underbalanced drilling
operations. This is a regulatory requirement in most jurisdictions and as a company requirement
within Shell.
The published pressure ratings are based on testing the manufacturer has performed or
commissioned on their units. However, some of these units have been certified for use to their
rated pressures by agencies such as Lloyds of London and DNV. There is currently a plan to have

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an API 16-A-UBD standard for rotating control devices but this is still at committee stage. It is
also worth noting that an RCD is not a diverter although it diverts flow as one of its
functions. Diverters refer to a specific piece of equipment and are used in low-pressure
applications only.
1.1.1 PASSIVE - ROTATINGCONTROLHEAD

SYSTEM WEATHERFORD-WILLIAMS
The Williams RCH uses one or two stripper rubbers, which are designed typically for 0.5 inches of
interference between the inside diameter of the rubber and the drill pipe. The initial seal comes
from this interference fit and is supported by well-bore pressure, not by active pressure. Low-
pressure leakage may occur when worn rubbers are in place. However, low pressure sealability
testing conducted by the Alberta Research Council in Edmonton Canada, did not find low-
pressure leakage to be of concern. NAM's SimWell has a model 9000 in use as part of the UBD
rig-up and Model 8000 units have been used in the offshore environment for drilling the chalk
with seawater. If the manufacturer's recommended maintenance and inspection procedure is
followed, there should be very little problems with this type of unit.
After Technical reviews, NAM also selected the Williams Model 7100 RCH illustrated in Figure
40 for UBD in gas reservoirs. This unit is rated for 5000 psi in static (non-rotating / non-stripping)
mode. The unit is rated for 2500 psi in dynamic mode (stripping and rotating). It has also been
used by Shell on UBD operations in Venezuela and Oman and is planned for use in Syria. The tool
has also been used by Shell in offshore well control situations and has functioned as planned in all
situations to date.
A disadvantage of the RCH is that staging large diameter tools (refer to Figure 43) through the
stripper rubber is not possible. Therefore, the bearing assembly must be removed which eliminates
the primary well control device from the system during the staging operation. One solution to this
problem is a proper design of the drill string / BHA / completion to remove the requirement for
staging. A snubbing adapter is also available but the bearing assembly and pack off rubbers are
first removed disabling any rotating or stripping capability of the tool.
5
Kelly Driver
Top Rubbe~
Bottom Rubbe
-'
w
Bowl
RofaLg Head
Figure 40 - Williams 7100 RCH and accessories

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I . I .2 ACTIVE
SYSTEMS - ~CHAFFER'S PCWD AND NORTHLAND'S
R-BOP
RCD's should always be used in conjunction with the conventional blowout preventer stack, even
if the name implies that it is a rotating blowout preventer. These devices are used to control and
divert the flow from the well in an underbalance drilling operation, secondary well control
however, is still provided by the conventional stack. One of the obvious differences between these
units and the RCH is the active system RCD uses hydraulically actuated packing elements to seal
around the drill pipe. The hydraulic closing pressure can be varied automatically as the well-bore
pressure varies. The packing elements are able to close on open hole. When the packing element
is open, these devices allow full access to the well-bore (up to a max. of 11"). The pack-off
elements on both devices remain closed at all times when in underbalanced drilling mode.
The Shaffer PCWD Rotating BOP illustrated in Figure 41 is rated to 5000 psi working pressure
in static (non-rotating) mode. The working pressure in dynamic mode varies from 3500 psi at 50
RPM to 2000 psi while rotating up to 200 RPM. After Technical evaluation Shell Expro selected
the PCWD for their UBD operation in the Southern North Sea. The difference between the NAM
and Shell Expro operations was the requirement for snubbing in Shell Expro. The PCWD is best
suited for continuous rig up of a snubbing stack since it has a studded top connection and can be
opened and closed for staging tools without the removal of the pack-off assembly. So far only the
11" version has been used by Shell.
4dapter Ring
""PI
-
Figure 41 - Shaffer PCWD Rotating BOP
WDLP - Underbalanced drillina Poqe 8/5/59
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I
1
Outer Packer-
Inner Packer -
Bearing,
B-
-
Figun 42 - Nsrthlafids RBOP

Nairthlgnd's RTI 11-3 R-BCXP illusmced in Figure 42 can handle a maximum a t ~ i pressure
c d
2000 pi and a m ~ m u m prjeasuse while drilling k>f 1500 psi. The maximum maciolnaf speed is
1m PPM.The wrkirrg pressme white tripping is 1000 psi. This unit has been u s ~ dby Shell
Can& fix rnmy cpf their early UBD pi~jeztsinc1ding their saur p;as und$rtbaEancled drilling
aperatims on wells containing up ta 30% H&. A snubbing adapter L vim available far this unit.
Narthland also hm a 3$0.(S[lppsi rared RBQP on the m r h t dthpugh Shell has not 4 this unit.
RBOP
l r
Tool Below
RBOP
71
Close Annular
Open RBOP
IF
Strip Tool
CloseRBOP ,
Open Annular I
Figure 43 - Staging Large Diameter Tool through RCD (R-BaPor PCWD)
All of the rotating control devices must be inspected periodically to monitor the condition of the
sealing element. On both the RCH and R-BOP, the element must be removed from the system
for proper inspection. The inspection process can usually be accomplished in 15 minutes and a
complete change-out, if required, takes approximately 30 minutes. However, the sealing element
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cannot be removed fbr inspection on the PCWD, and it will take 2 to 3 hours for a change-out.
NAM designed and tested a rotating pressure monitor for the Williams 7100 RCH. The use of
this device allows the operator to monitor the condition of the bottom seal element without
pulling the assembly. When the bottom rubber wears out, the assembly is pulled and replaced.
Figure 43 demonstrates that if part of the BHA exceeds the RBOP operating ID, then another
annular (e.g. rig annular) below must be closed first, before the RBOP is opened. The large O D
tool can then be staged through the RBOP, and when it is above the RBOP, the RBOP can be
closed again and the other annular opened.
1.2 SURFACE SAFEN VALVE

A surface safety valve (fail close) provides an additional barrier between well-bore pressure and the
surface separation equipment. A surface safety valve is usually installed between the wellhead and
the choke manifold and controlled by an emergency shut down system (ESD). The ESD system
used in UBD operations is usually a combination Manual/Automatic system. Releasing control
line pressure if an unsafe condition is detected activates the system enabling the valve to fail close.
It is critical that when the system is hooked up to an executive shut down alarm or device that a
visual/audible alarm is triggered whenwer the manual override is activated. To reduce the risk of
solids build-up preventing the valve from closing, only valves that close and seal in the up
direction are generally used in a UBD operation. Figure 44 shows an ESD valve and a redundant
manual gate valve being installed in an offshore UBD operation and illustrates the location of the
ESD valve relative to the RCD.
Figure 44 - ESD Valve Location

In an Underbalanced Drilling operation, the rigs kill system remains lined up per normal drilling
operation. If the ESD system is activated, the driller (and crew) must ensure that the rig's HCR
valve to the choke manifold remains closed since opening the HCR valve will bypass the closed in
ESD valve and allow well-bore fluids to enter the UBD surface system.
1.3 CHOKE MANIFOLD

The UBD choke manifold is used for controlling flow rate and reducing the well-bore pressute to
acceptable levels before it enters the separation equipment. The choke manifold is composed of
gate valves, a variable choke box, a f ~ e dchoke box and measuring points for upstream and
downstream pressures as illustrated in Figure 45. Choke manifolds are typically 4 inch or 6 inch,
single or double block valves with inserts. For high pressure / high flow rate applications, a 6 inch
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choke manifold is recommended. The choke manifold is a high-risk area for erosion and washout to
cxrcur. Because of this, double blocking is recommended where WOM inserts cannot be used. It is
critical that equipment wear due to erosion be modelled and monitored throughout the system
especially ar the choke manifold.
Figure 45 - 4" UBD Choke Manifold for OilJGas Reservoir

Depending on the requirements of the Project Geologist, sample catchers will be required to
enable cuttings samples to be taken during underbalanced drilling. Although it is not part of the
flow control equipment, the pressure rating and set up of the system will depend on whether
samples are taken upstream or downstream of the choke. The process in either case is simple:
some of the flow stream is diverted to the catcher manifold. The manifold is usually designed with
dual catchers, isolation valves and bleed-off valves to allow samples to be retrieved while drilling
and sampling continues. Figure 46 shows a high-pressure unit in use.
Figure 46 - High pressure sample catcher

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1.4 SURFACE SEPARATION SYSTEM
There are two types of UBD systems currently on the market. The systems differ in how oil, gas,
solids and liquids are handled and at what stage of the process.
The first system, which is still the most used, allows all of the well effluent (gas, liquids and
cuttings) to flow through the UBD choke manifold, where the well pressure is reduced through a
choke. The flow is then piped through to the surface separation equipment where oil, gas, solids
and drill fluids are separated in a large horizontal separator. This is the system described in the
section on separators below.
For high-pressure high volume gas wells, there are two designs. Well-bore fluid is returned to a
high-pressure vertical separator or to a high-pressure hydro-cyclone upstream of the choke. In one
of the designs, the solids are separated and stored at this stage. The gas and solids free fluids are
then handled as in a conventional well test system. In the other design, gas is separated by
cyclonic action and piped directly to flare or to the production facility. A liquid level controller in
the separator controls the choke and the fluid and solids are then separated by a hydro-cyclone
either before or after the choke manifold. This can result in less erosion of the choke manifold.
Figure 47 is a schematic example of this system.
Figure 41 - An txample or a UBU aurrace rru~a/ ~OIIUS nanaling system

Whichever surface separation system is used, it must have the pressure and flow-rate capacity to
handle high instantaneous flows. Phenomena referred to as "flush production" have been observed
on a number of wells. Flush production is an abnormally high rate of reservoir production caused
by rapid depletion of local high permeability or deliverability regions near the well bore and it is
likely to occur when drilling underbalanced.

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Demands on surface equipment can be reduced by:
Increased fluid flow rate
Decreased gas injection
Use of choking drill collars high in the string (no longer commonly used)
In addition to the choke manifold and sample catcher, other components of the UBD fluids
handling system are as follows:
Steam heat exchanger - is used to increase the temperature of the returns from the well.
Increased temperature will prevent formation of hydrates, reduce viscosity, breakdown emulsions
and foams and stabilize oil and condensate (make less volatile).
Separator - There are two basic designs for separators vertical and horizontal. Vertical separators
are the optimum design for separating gas from liquid and horizontal separators are the optimum
design for the separation of liquids of various densities. The type and design of the separator will
be influenced by the well design and a number of well parameters such as: the type of drilling
fluid and the pump rate, expected production rate and type of reservoir fluid, hole size and length
of reservoir to be drilled, and the environment (oghore or onshore). By far the most used type of
separator is the horizontal four-phase design shown in Figure 48 and Figure 49. It allows
separation, metering and sampling of all phases of the well returns. The separator pressure is
maintained at a pre-set level by an automatic control valve on the gas outlet. The liquid level
within the separator can be monitored through sight glasses. The separator can be protected from
overpressure by a relief valve and/or a rupture disc system. Oil is metered out to the storage tanks
or pipeline system via the oil dump line. Excess water (produced water) is also metered out via the
water dump line. Measuring oil, warer and gas and conducting mass balance calculations allow an
accurate account of production data at drilling depth to be maintained real time.
11Pressure Hellef
Figure 48 - Cutaway of a Horizontal 4 Phase Separator

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Figure 49 - Separation Process Horizontal 4 Phase Separator
Gas Handling 1 Flare system - Gas produced during UBD operations is either fed to the
production facilities or is flared off. The mandate to reduce flaring andlor the impact of
flaring in our operations make this part of the UBD process more challenging. Large gas
recovery compressors, and "green" burners (silent, enclosed system) add to the complexity
of the system process. However, we need to understand that some flaring capability will
always be required in an underbalanced operation. For safety and environmental reasons a
properly designed and maintained flare system is important. Large diameter flare lines
and/or booms should be used (6-12"). Knockout vessels can be installed to reduce the risk
of liquid carry-over to the flare head. The stack height must be sufficient to disperse
plume and an automatic electric igniter or continuous pilot is required. To avoid flash
back the equipment must be purged to remove all oxygen and a flame arrester and in
some cases a submerged flare head should be installed. Finally, tie-in of storage tank vents
to the flare stack should be avoided or done with extreme caution. Figure 50 illustrates
some of the equipment used in the flare system.
Figure 50 - Flare system equipment

Storage - After separation, the drilling fluid will be re-routed back into the active system.
Oil or condensate is pumped into storage tanks andlor transported off location (tanker
trucks, pipe line or by boat) to the production facilities. Storage tanks must be properly
grounded, must vent to a safe area (not tied into the flare system) and should be placed
within a dykedl bunded area in the event of a leak.
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SECONDARY WELL CONTROL
BOP'S
In conventional drilling, well control procedures are put into immediate effect whenever a kick is
detected. Similar principles are used in UBD operations. Well control procedures are p u t into
immediate effect whenever bottom hole or surface pressures and/or flow rates are
detected which could lead to the pressure rating of the RCD (static o r dynamic) or the
capacity of the surface separation equipment being exceeded.
A conventional BOP stack provides secondary well control in underbalanced drilling - same
function as in conventional drilling. Kill fluid is also kept on site as a secondary means of well
control.
Conventional BOP'S are designed for secure, high-pressure containment of the well bore for a low
number of cycles, Underbalanced drilling operations, however, demand a high number of function
cycles. The increase in cycles can lead to high repair and maintenance cost. Shop inspection and
scheduled BOP maintenance should not be neglected. In addition, conventional BOP function
testing, required by regulations, may not be adequate for UBD. Each BOP stack configuration
should be considered unique to the application in which it is used. Special considerations might be
required for some of these unique applications and, if so, additional test procedures should be
used.
Examples of a conventional BOP stack and a coiled tubing drilling (CTD) BOP stack suitable for
underbalanced drilling are given in Figure 5 1 and Figure 52
Figure 5 1 - BOP Stack Configuration Rotary Drilling

A pressure equalisation line is recommended between the kill spool and the RCD on the
conventional stack to equalise pressure across BOP devices prior to opening. All of the valves are
numbered to match the process and instrumentation diagram (P&ID) and these numbers are
referred to in the detailed work procedures.
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The coiled tubing drilling stack is similar to the conventional stack except for a couple of
additional specialized items required for pressure deployment of the EHA and the hook up of the
injector and coil tubing pack off head to the top of the BOP. Numbering of the stack is still
recommended but less critical, since the CT driller operates and is in control of all the wellhead
equipment.
CT-
STRIPP:
RUBBB
Figure 52 - CTD BOP and Injector Equipment
17SA mm. 35 MPa
t Flow spool
Conventional
179d mm, 35 MP
Figure 52 - CTD BOP and lniector Equipment - continued
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2.2 KILL FLUID
Enough kill fluid of sufficient density should be available on site at all time to enable killing the
well in an emergency for IADC UBD well level 3 and above.
The kill fluid should be weighted up to the lowest density requirement that can be
expected since weighting up is easier to accomplish than weighting down
It is recommended that 1.5 times the hole volume be always available.

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1 DATA GATHERING
To properly drill underbalanced, relevant data should be collected and displayed on screens on a
continuous basis.
Proper data acquisition is required to enable:

Oprimisation of the underbalanced state. For example, adjustments to the bottom-hole
pressure.
Observation of trends
Correlation and fine-tuning of computer model simulations to actual data.

Characterisation of the reservoir
Key data to be monitored includes:

Annulus/choke pressure
Bottom-hole pressure
Standpipe pressure
Active surface system fluid volume
Drilling fluid pump rate
Returned gas rate
Returned liquid rate
Gas injection rate (if any)
Surface equipment pressure
Surface and down hole temperature
Gas sensors should be installed to monitor for any leakage in the closed surface system. Sensors
should also be insralled near the drill floor, close to the rotating head I BOP stack, on the active
surface system tanks, near the separator unit and at the choke. Cameras placed in strategic
locations will allow the driller and supervisors to quickly identify problems without having to send
personnel to check.
2 DOWN HOLE DATA TRANSMISSION

Conventional mud pulse telemetry can be used if a single-phase fluid will be pumped in the drill
pipe, an for two phase systems up to 20% gas volume fraction pumped into the drillstring.
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However, if gas injection is required at higher rates, a parasitic casing string will be required.
Alternatively, if concentric string injection is not possible, the drill string will have to be displaced
to a single-phase liquid prior to taking a survey or Electro-magnetic MWD (EM-MWD) has to be
used.
EM-MWD is basically a radio transmission system. Down hole measured parameters are
transmitted to surface through Electromagnetic Waves emitted by the MWD tool. The tool can
Transmit data to surface with two-phase flow inside the drill string. However, it does have its
limitations. It is Lithology sensitive, depth sensitive (due to signal attenuation) and has ofTshore
limitations. Limiting factors such as depth and formation conductivity can be overcome with the
extended range system, which uses an electromagnetic transceiver with an extended antenna
utilizing an electric cable. These can be installed at regular intervals in the drill string. This
system, Illustrated in Figure 53, allows two-way communication with the down hole tools which
can be quite useful. It allows data transmissionlcommunication in all drilling phases; it is
independent of the drilling fluid, mud characteristics and circulating system hydraulics. However,
the use of repeater antenna (cables) within the drillstring will restrict access in the event of stuck
pipe, and may not be possible depending on BHA and1 or near surface NRVs.
Figure 53 - EM/ER MWD Technology

In coiled tubing drilling, MWD data can be transmitted using wire line telemetry with rhe
electric line installed inside the string. Many of the advantages of EM telemetry also apply to
CTD with E-Line coil.
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Topic 9
Health Safetv and Environment
I PLANNING
The potential for HSE problems increases whenever a new operation that is different from the
normal activity is introduced. Such is the case with UBO on a drilling rig site. UB operations are
significantly different from the conventional drilling approach and the supervisors and crews
executing these operations have to be familiar with the process, the equipment and the
procedures, to ensure a safe and efficient operation. Therefore, in planning a UBD project, it is
essential that HSE issues are considered and planned for in the very early phases of the planning
cycle. A complete HSE study including HAZID (Hazard Identification) and HAZOP (Hazard and
Operability study) reviews should be conducted prior to underbalanced drilling operations. These
should be reviewed relative to the rig's safety case. HSE Bridging documents and procedures
should address the various contractors / service interfaces for the UBD operation.
In UBD, new crews are inserted into an existing effective functioning team (the rig crew).
Acceptance of the new members to the team is critical for the success of the operation. Team
building exercises and joint planning sessions are two methods to quickly integrate the new crew
into the team and get them talking to each other and these type of sessions should be planned for.
TRAINING
Training of personnel on a rig site has long been recognised as critical to a safe operation. In an
UBD operation, training becomes even more important because of the number of interdependent
services and personnel involved. Failure to recognise the impact of their actions or decisions on the
overall process can have potentially serious consequences.
2.1 -
UBO PROCEDURES OVERVIEW AND SAFETY CONCERNS
Once detailed procedures are available, supervisors and crews need to be trained to execute them
properly, since only trained, competent personnel should be allowed to work on a UBD site.
Personnel in the process of becoming competent must be properly supervised by trained,
competent staff. In the course of planning a UBD well many procedures will be prepared.
However, there are a few procedures considered critical to not only the technical and economic
success of the job, but also the HSE success. These include:
Kicking off the well - In a flow-drilling situation, this is not a problem since the base fluid is
already UB. After breaking circulation, keeping the equivalent circulating BHP within the UB
design envelope by choking or with circulating rates is easily accomplished. However, in depleted
reservoirs and drilling with a 2-phase fluid, this can a bit more complex. It can be accomplished in
ehe higher pressured higher permeability formations in a single circulation by displacing the well
to the 2-phase fluid and inducing the well to flow. However, this will usualIy require high-
pressure injection equipment. If the pressure rating of the injection system does not allow kick-off
in a single circulation, then a technique, usually referred to as rocking can be used. This is
WDLP - Underbalanced drillinq Pwe 8 / 5 / 7 1

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accomplished by alternating pumping of 2-phase fluid and liquid slugs to gradually reduce the
head in the annulus and induce flow. In the highly depleted, lower permeability reservoirs, gas
lifting in stages may be required to unload the well and induce flow. Initial gas injection depth
and subsequent staging depths will depend on the injection gas supply pressure capability.
Making Connections - The exact procedure will depend on the design of the well but in general
with the bit off bottom the drill pipe is cleared of 2-phase fluid to the top NRV (if required). The
drill pipe pressure is bled off and monitored for potential NRV failure. The top drive or Kelly is
disconnected once it is confirmed that the NRV's are holding pressure, and the connection
proceeds as in conventional drilling. This procedure can be quite complex if 2-phase injection
down drill string is required; therefore good coordination and communication will be required. A
key operational decision is whether to shut-in the well to keep the well from unloading fluid or to
keep the well flowing to maintain underbalanced conditions. Multi-phase flow modelling during
the planning stage of the well with results reconfirmed by additional multi-phase flow modelling
during actual operations will drive this decision. Figure 54 illustrate simulator-generated output
of the bottom hole pressure profile that will occur while making a connection with the well closed
in and Figure 55 the profile with the well open. With the recent development of UBD training
simulators, the effect of a certain procedure can be simulated and crews can be trained to
recognise transient behaviour and react accordingly,
BHP \Ps. Time: CloxcclWell
. . .a< -. .,-- ,.-

!ma&
F#aQI
l
-1rWWV
L
Figure 54 - Bottom hole pressure profile during connection - choke closed

Safety Tips: The floor crew must be vigilant during connections for potential NRV failure and
Kelly Cocks must be available on drill floor at all times in event of an NRV failure or leak. For
obvious safety reasons, personnel should not put themselves in a position where they can be
exposed to fluid discharge up the drill pipe in the event of a catastrophic NRV failure.

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BHP Vs. Time: Open Connection
-
5 -Traget BHP
Pmssw Ims due Ressuregah due to

to loss h friclim h b w and gas migram
The
Figure 55 - Bottom hole pressure profile during connection - choke open

Live well tripping - As mentioned before, the well design will dictate the precise tripping
procedure that will be used. If down hole shut-in as illustrated in Figure 13 and Figure 14 is
available, drill pipe will be stripped out to a depth above the isolation valve with pressure below
the RCD and with no pressure after the valve is closed; pressure above it is bled off and the well
above the valve is circulated to fluid. TWOother options for live well tripping above the pipe light
depth discussed earlier are to utilize a snubbing unit illustrated in Figure 15 or the pushlpull
machine illustrated in Figure 16.
Another method used on low or medium GOR, depleted oil wells is to circulate the well clean of
cuttings and drilling fluid, then blow the well down with gas and allow clean reservoir fluid to
flow into the open hole section and continue to flow until it kills itself with reservoir fluid. Once
the well is dead (cod~rmedby monitoring annulus fluid levels with a sonic echo-meter), stripping
and tripping can continue to surface with the annulus venting via a line equipped with a venturi;
to create suction and keep any gas blow away from the floor.
The final method available is not recommended, since it involves killing the well with a kill
weight fluid which defeats the principle of "underbalanced for the life cycle of the well".
However, it has been used to implement the UBD technology in a staircase of complexity
approach.
Safety Tip: As discussed before, while tripping a live well, personnel should never put themselves
in a position where they can be exposed to fluid discharge up the drill pipe in the event of a
catastrophic N R V failure. In addition, while stripping or tripping, personnel should avoid looking
down and through the rotary table opening as illustrated in Figure 56.
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Figure 56 - Looking through the rotary table (not recommended in UBDI!)
In addition to the above procedures for planned events, there will be operating procedures,
procedures for maintenance, unplanned events and there will be procedures for contingency
events. These will be communicated and training provided to appropriate personnel as required.
3.1 SITE SAFETY MANAGEMENT

During execution of the underbalanced drilling operation as in any drilling operation, site safety
management is very important. An Emergency Response Plan (ERP) should be in place and
communicated to all personnel. On-site hazards need to be clearly identified. Some of the items
requiring planning and attention for good site management are as follows:
Pre-job planning meetings - should be conducted for all non-routine operations. The discussions
and plans should be fbcused on the underbalanced operation and the interfaces between the
different functions. Strict attention on how the interfaces will be managed and the interface
communications scheme must be addressed. In addition, UBD drills should be planned and
conducted until the supervisors and crews are comfortable with emergency response requirements.
Analysis and feedback sessions at the end of each drill are very important to the learning process.
Site-specific orientations - these can also be used as an effective means of onsite safety
communication for visitors and arriving crews. Site specific organisation - chain of command, site
layout, hazardous areas, location of Emergency response (ER) equipment, station bills and alarm
system, muster areas and escape routes are just a few items that should be included in the
programme. During the orientation, Safety Management System interfaces and how they will be
managed should be discussed. In addition, discussions around the current operations, associated
hazards and Personal Protective Equipment (PPE) required are a good way to end the
programme.
Safety meetings and toolbox briefings - must be conducted to ensure everyone involved knows
what is planned, who does what and when, the hazards involved and the risk mitigation methods

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to be used. These sessions do not have to be boring affairs provided they are properly planned and
everyone is allowed to and actively participates.
Storage of produced hydrocarbon Liquids - hydrocarbon storage on a UBO location also needs
to be properly managed. The tanks should be placed within an impermeable bermed area, at least
50 metres away from the wellhead and the flare stack. It is important that the volume within the
berm or dyke can contain any spill from the storage tanks without spill over. In addition to the
issue of containment, awareness and communication of the following issues is also important:
Electrical grounding of the tanks - It is important that all equipment on location is

electrically bonded to each other and earthed. This prevents build up of electrical
charges that could lead to sparking which could potentially set the stored fluids or
leaking hydrocarbons on fire. Facility for bonding tank trucks to the storage tanks
must also be available. Load lines should be at least 10 metres in length and be
equipped with dry break connection on load end outside of the berm.
Venting - atmospheric venting from tanks or trucks should be to an safe area. If the
produced fluid is sour (contains low amount of HS), ammonia scrubbers should be
fitted to the vents and the area around the vent must be managed as a hazardous area.
In some areas where ambient temperatures are above the flash point of the stored fluid
a continuous Nz purge above the hydrocarbon fluid has been used to alleviate concerns
about venting pure methane to atmosphere.
Venting tanks to a flare stack - This should be approached with extreme caution due
to the risk of a flash back. If the produced fluid is high in HB content, a pressurized
(402s) N2 blanket is maintained in the storage tank and the vent line is tied in to the
flare stack with an isolation valve in the line. Whenever the tanks need to be opened
to atmosphere (to gauge for example), the operator must first close in the vent line to
the stack using the isolation valve and the operator needs to ensure there is positive
pressure upstream of the valve before re-opening it. An alcohol manometer upstream
of the valve can be used as a positive pressure indicator for the operator.
Zone changes - The placement of UBO equipment may affect the rig's zoning classification.
Areas previously designated "zone 2 or zone 3 may have to be temporarily designated as zone 1 or
zone 2 for example. These areas must be defined and clearly identified and communicated to all
personnel on location. All equipment within these areas must be rated for the zone designation,
isolated and locked and locked out or moved out of zoned area. During the planning phase this
must be taken into consideration especially for offshore jobs since a lot of the UBO equipment
available was designed for use on land and may not be rated for offshore use.
3.2 HOUSEKEEPING
Spills - Hydrocarbon spills can have major consequences for a UBD operation. It can affect the
health and safety of personnel on location as well as having an environmental impact. Spills must
be contained as soon as possible with a temporary berm and must be cleaned up as quickly as
possible in an environmentally friendly method. The ERP should require that oil absorbent
materials be easily available to the operation. A liquid Nitrogen spill is a very dangerous event.
The extreme cold can freeze skin on contact, crystallize metal (causing cracks in rig deck plates
for example) and the evaporating gas cloud can be toxic (cause suffocation). In an offshore
environment, Nz manifolds and N2 line connections should have drip trays filled with water placed
beneath them.
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Leaks - Leaking flow lines and pipe connections can be dangerous. Report leaks to supervisors
immediately since a small leak can escalate into a large leak quite rapidly. Most lines in an UBO
will contain toxic or flammable material. Many of the chemicals used in an UBO including
corrosion inhibitors are highly toxic and correct PPE should be used when handling fluids or
attempting to repair leaks. Pressurized lines can contain a tremendous amount of stored energy.
Do not ever attempt to repair a leaking line or connection under pressure. A break in a high-
pressure line containing an energised fluid (gasified fluid) will cause severe whipping of the pipe.
If the well also contains the energised fluid and a line tied into the well fails, the well will behave
like an accumulator and will continue to supply energy to the failed pipe. Movement of unsecured
pipe will be towards the wellhead (opposite direction to the jet force) and could result in serious
damage to the wellhead equipment. To reduce the risk of this occurring, a check valve should be
installed on the line, as close to the wellhead as possible and the pipe should be secured in a way
to prevent this movement.
Tripping Hazards - In a UBO additional lines will be installed on the location that is not normal
to a conventional drilling operation. These create additional hazards for personnel to be aware of
and to be managed properly. Lines should not be run across emergency escape routes if at all
possible. Stairways and platforms constructed over top of lines in work areas and walkways will
mitigate the tripping hazard as depicted in Figure 57.
Visible Hazard Identification - High-pressure lines and vessels should be clearly identified with
caution signs and this type of equipment should be kept away from emergency escape routes. The
use of other signs (for example: Pressure testing in progress-Do not enter), high visibility flags on
guy wires and overhead lines, and physical barricades to a hazardous area, visually alerts workers
to a potential hazard. Figure 58 Illustrates a walkway that has been physically barricaded and
signed due to overhead lift operations.
Figure 57 -Walkway over piping

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Figure 58 - Signed and barricaded walkway
3.3 COMMUNICATION
Communication is essential to the proper execution of an underbalanced drilling operation. Key
personnel like the DSV, UBD supervisor, the RCH technician, the data acquisition engineer, the
driller, the surface equipment supervisor and the tool pusher must have direct communication
with each other. Passing on relevant information and observations is of utmost importance. An
effective method of on-site communication is via portable radios.
Site orientation and regular safety meetings are also effective means of communicating with the
crews. Organisational chain of command and management of communication interfaces need to be
clear to all personnel. The site orientation is a good vehicle for doing so.
Chain of command - In general the company representative (Drilling Supervisor) is in overall

charge of the UBD operation. Reporting to him1 her for their functions are the supervisors
responsible for the other services on location. For example the rig contractor supervisor (Tool Push
or onsite Rig Manager) is responsible for rig operations and the UBD contractor Supervisor is
responsible for separation equipment, gas injection, rotating control device and snubbing. The
exceptions to this are in the offshore sector, where the Offshore Installation Manager (OIM) is
responsible for the safety of the installation and onshore within a production complex where the
complex manager is responsible for the safety of the facility. In most drilling operations within an
operating complex a concurrent operations coordinator will be appointed and will be responsible
for the safety of the joint installations.
Communications Interfaces - Due to the amount of interplay that takes place between the
various independent service-providers in a UBD operation, experience has shown that a central
command and control structure functioning from within a central command centre or control
room is a critical success factor. In physical terms this means that all tour supervisors sit in the
same room. All activity related communication between the various services, requests for
information, clarification of instructions, activity control, is done via the supervisors within the
control room. On a practical level, it is business as usual. Which means the driller is responsible
for normal drilling activity such as pipe manipulation, well integrity; including emergency well
control, wellhead equipment such as BOP'S and the RCD and for the direct supervision of his
Version 2.0.0
crews. Likewise the separator, snubbing and gas injection supervisors are responsible for their
equipment and the physical operation of it including the direct supervision of their equipment
operators.
3.4 LOGISTICS A N D TRANSPORTATION

Logistics and transportation are key issues usually left to the last on the UBD planning cycle. Yet,
due to the lack of UBD equipment and support infrastructure in many areas outside of North
America, it can have significant impact on project cost and timing. Therefore, effective
coordination of this function is a key ingredient for project success.
Once all of the equipment and personnel are on location, the following need to be considered.
Parking - O n land locations, non-essential cars and trucks should not be allowed on location.
Engine heat and exhaust material are potential ignition sources and therefore designated parking
areas should be located outside of hazardous areas.
T r u c k Lanes - Truck traffic on location needs to be restricted during UBO operations and should
be controlled under the Permit to Work system. (PTW) During pre-rig up planning, the need to
bring fuel on to location and the removal of produced fluids and waste product off of location must
be considered. Truck lanes that stay outside of hazardous or zoned areas, away from high-pressure
lines and vessels, and no closer than 10m from hydrocarbons storage tanks must be designated.
Heavy Lifts - Heavy lifts have an impact on other operations and therefore need to be properly
planned and executed especially in an offshore environment. Heavy lifts should be controlled
under PTW system and are not allowed over pressurized tanks or lines. Ensure lines and vessels
are shut in and pressure bled off if a heavy lift is required. Ensure proper lift equipment (certified
lift slings and lift points) and procedure are used.
Flare Placement - Flaring operations also have an impact on other operations and therefore, this
also needs to be considered in planning where to place the flare. Flare placement must not impact
helicopter landings offshore, access to location or egress from location and emergency response
activity. Consider the effect of wind on flare placement. Local knowledge of the prevailing wind
direction during planned project period will help in the lease preparation for access and
emergency egress roads. It will also help in the selection of appropriate and alternative escape
routes and muster areas depending on wind direction. In an offshore, underbalanced operation,
dual flare booms will be installed with the ability to switch and/or isolate one or the other to allow
a safe helicopter landing regardless of the wind direction. Personal Protective Equipment (PPE)
The safety of personnel on any oil and gas operating location is of primary concern to all of the
companies involved. The use of appropriate PPE is one of the tools used to make the work
environment a safer place. The basic PPE set includes coveralls, hard hat, steel toed boots, and
safety glasses. In addition, some tasks conducted on the work site may require the use of specific
PPE.
3.5 UBO HAZARDS A N D PPE REQUIREMENTS.

An underbalanced drilling operation is basically a concurrent operation involving conventional
drilling equipment; equipment normally associated with well testing; equipment normally
associated with well stimulation work and all combined with the sights and sounds of a production
operation. The personnel that work in these disciplines are quite familiar with the PPE
requirements for their work. For an UBO, we need to make others recognise hazards that may not
Page 8/5/78 WDLP - Underbolonced drilling

Version 2.0.0
normally be associated with their disciplines and ensure the appropriate PPE is available and is
used.
Natural gas - Leaking gas is a potential source for a flash fire or explosion. Crews working around
the natural gas compressors and gas separation equipment should wear fire recardant coveralls.
Noise - Hearing protection is required when working or passing through an area with a noise
level greater than 85dB. An underbalanced drilling operation will have more noisy areas
associated with it than a conventional one. Compressors, flaring operations, high flow rates of gas
through small piping and additional pumps are the primary ones to consider. These areas must be
identified and well signed that hearing protection is required. Radio headsets for communication
will be also required.
Liquid Nitrogen and Membrane Nitrogen Generation - Until it is converted to a gas, any un-
insulated pipe and leaking product is a hazard to exposed skin due to the extreme cold and the Nz
operators must wear long sleeve coveralls and good quality gloves to protect against getting cold
contact burns. In addition, pure nitrogen atmosphere is toxic and workers cleaning up a liquid
nitrogen spill in a confined area must test the atmosphere and may have to wear special footwear
and use breathing air equipment. The equipment used to pump either cryogenic or membrane
nitrogen is very noisy and noise protection and radio headsets will be required for communication.
The zone inside an enclosed membrane generation unit should also be classified as a confined
space hazardous zone. Either a continuous air quality monitor with visible and audio alarm must
be in place or personnel working in the area should wear personal air quality monitors or
respiratory protection. The exhaust from the membrane unit is pure oxygen and the exhaust fumes
from the compressors and engines can be toxic. These should be vented to a safe area as illustrated
in Figure 59, where it can dissipate into the surroundings as illustrated in the following picture.
Figure 59 - Venting exhaust fumes to a safe area

Formation fluid storage - Hydrocarbon storage and associated hazards hqve already been
discussed. Hawever, produced water can also contain toxic products, Sour produced water will
release H2S vapours and therefore must be handled accordingly. The use of wind direction
indicators (wind socks) an the tanks is recommended and the storage area must be treated ss a
controlled entry area. Personnel expected to work in the m a must be trained in the use of
personal bre~thingair equipment. Breathing air equipment (cascade system] and respirators must
W L P - Underbalanced drillinn Poae 8/5/79

Version 2.0.0
be available in a designated safe zone close to the storage tanks. The Rules of Conducr must be
clear to all and all personnel on location must know the location of safety equipment.
Flare by-products - SO2 is a by-product of the flaring process. It is extremely toxic to living
organisms. The area around a flare stack must be treated as a hazardous area. The use of wind
direction indicators (wind socks) at ground level is recommended. Because of the heat generated,
workers may want to hang around the base of the stack during coffee breaks especially in colder
climates. This is not allowed and must be discouraged.
HAZARD COMMUNICATION AND MATERIALS
4.1 HAZARDS SPECIFIC TO UBO.

Because of the nature of the operation, drilling underbalanced lends itself to situations that
personnel must be aware of.
Pressure release from drill pipe - In conventional drilling a drill pipe leak or a washed out float
may take some time to discover. However, in a UBD environment a drill string NRV failure or a
drill pipe connection leak will be quickly identified since the well will start to flow up the drill
pipe.
Pressure build u p in annulus - In conventional drilling a pack off will be detected by the driller
very quickly because pressure increase in drill pipe andlor lack of pipe movement. However, in a
UBD environment, the driller may not detect a solids bridge in the annulus since a compressible
fluid is in the annulus and possibly in the drill pipe as well. The driller will observe sticking pipe,
the MWD engineer will observe bottom hole pressure increasing and the annulus surface pressure
may drop off quite quickly. A plugged line at surface will give similar symptoms except the
annulus surface pressure will increase quickly as the well backs up but the driller will not have
any problems with the drill pipe movement. These situations will cause the well to go over balance
if not detected. However, BHP monitoring is a key success factor in UBD, so these events should
be seen immediately.
Rotating Control Devices - These devices have rubber elements that will wear out from the
drilling operation or from stripping pipe under pressure. In the process, the well will spit and burp
effluent especially when a D P connection is moving through the element. It is important that
crews be aware of this and do not put their heads directly over the rotary table when pipe is
moving. Procedures have been prepared to change out these elements with pressure below the
BOP and crews have to be trained to execute them safely.
Trapped pressure in equipment - In the process of operating the different BOP elements, ESD
valve etc. on a live well, pressure can become trapped between two closed-in pieces of equipment.
Always ensure that procedure to check for pressure behind a valve or below a closed in BOP
element is followed before opening.
4.2 TRANSPORTATION OF HAZARDOUS MATERIALS

At the conclusion of the UBD operation equipment will be returned to base for cleaning and
refurbishment, repairs etc. and fluids will be shipped off location. Some simple rules to follow may
prevent colleagues at base stations from getting a nasty surprise.

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1. Flush and purge all equipment before returning to base. Attach a dangerous goods label to
individual tanks or containers as appropriate. Indicate that the equipment was flushed
and purged but it was exposed to hazardous well fluids.
2. Attach an information label or a dangerous goods label (if appropriate) to individual parts
or containers as appropriate. Indicate if the equipment was flushed and purged or not.
Indicate what environment the equipment was used in and if there is a potential for
trapped pressure; for example sealed RCH bearings can potentially have trapped pressure.
3. Dangerous goods manifest is required for shipping liquid Nz containers, produced fluid
and purged tanks and vessels exposed to hazardous well fluids.
UNCONTROLLED /ACCIDENTAL RELEASE OF HAZARDOUS

MATERIAL
Some times even with the best planning accidental release will occur. These should be reported to
supervisors immediately. D o not attempt to handle o n your own. Shut down all operations and
assess the situation. Senior Supervisor will put the ERP into action and will try to contain on
location using available materials and will report to senior management and authorities as
appropriate.
OCCUPATIONAL HEALTH
5.1 EMPLOYEE'S HSE RESPONSIBILITIES
All employees on location have responsibilities not only for themselves but for fellow workers as
well. They need to attend all safety briefings and all safety meetings relative to their job function.
They need to understand work instructions and ask questions ro clarify if they don't. If a PTW is
required, they need to read, check and ensure they fully understand the requirements of the
permit and not just sign it on receipt. They need to be aware of all site-specific hazards and report
to supervisor if they observe a health hazard on location. They need to report all incidents; actual
or near misses. They need to let fellow workers know if they are working unsafely and stop the
work immediately. Finally, they should try to recognise a potential problem before it becomes a
problem for themselves or fellow workers. Figure 60 illustrates two situations observed and
reported.
Figure 60 - Safety nonconformances
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5.2 WORK-PERMIT REQUIREMENTS.
Each operating company and/or service contractor will have a Permit to Work system that will
detail when a work permit is required. The PTW system is a formal authorisation process used to
control certain types of work that have been identified as being potentially hazardous. It is a
written means of communication between the personnel in charge of a facility and the personnel
carrying out the work. In general, the objectives of the P T W system are to:
Authorise a specific task and outline the scope of work
Identify the hazards of the task
Specify the precautions to be taken; for example check of the air quality, PPE
requirements etc.
Ensure that area supervisors are aware of all the work within their areas of responsibility
and in other areas that may impact them.
Provide a system of continuous control to ensure that matrix of allowable concurrent
operations is not violated.
The following are requirements specific to an UBO and are not intended to be inclusive.
Pressure Testing - Vessels and lines with gas. Testing of Rotating Control Device, the BOP
stack and valves.
Confined space entry - To enter vessels, mud tanks or storage tanks, to work within an engine
enclosure, the membrane unit enclosure or the cellar.
Hot work - around pressure vessels, mud tanks, produced fluid storage tanks, on or around the
rig and around the nitrogen membrane units. It is a generally accepted practice not to issue Hot
Work Permits while the operation is live (drilling with the well flowing hydrocarbons).
Scaffolding - is usually required especially in the offshore environment to reduce the risk of slips,
trips, and falls, resulting from all of the additional equipment on location. Only qualified personnel
can perform the erection and dismantling of scaffold and work to be undertaken from the scaffold
cannot begin until it is declared safe by a qualified inspector.

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Appendix 1 - Abbreviations
Glossary:
RCD Rotating Control Device

RCH Rotating Control Head
ROP Rate of Penetration
RTS Research and Technology Support (Shell International - Den Haag)
Sg Specific gravity
SPM Side Pocket Mandrel
UB Underbalanced
UBD Under Balanced Drilling
UBO Under Balanced Operation
WOB Weight on bit
GIT Shell UBD Global Implementation Team
PTW Permit to work

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Contents

WDLP - Underbalanced drilling Page 8/5/5

Page 8 / 5 / 6 WOLP - Underbolonced drilling

WDLP - Underbalanced drilling Page 8/5/7

Page 8/5/8 WDLP - Underbalanced drilling

WDLP - Underbalanced drilling Page 8 / 5 / 9

INTRODUCTION TO UNDERBALANCED DRILLING

WDLP - Underbalanced drillina Paae 8/5/11

There are several reasons for drilling underbalanced.

invasion of solids from the mud into

fflgh Velocity (210 cmlmin Interstitial)

ExternalFllter Cake lnlernalFiller Cake Non-BridgingSolids

Page 8/5/12 WDLP - Underbalanced drilling

Figure 3 - Mechanism of Solids Entrainment in Fractures

Increased Reservoir Knowledge.

111. Reduced Drilling Problems / Improved Drilling Performance.

WDLP - Underbalanced drillinn Paae 8/5/13

Figure 5 - Drilling to the First Fracture - Total Losses (Conventional)

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Diff~mtialsticking - illustrated in Figure 7; occurs in conventional drilling if the differential

Oiverbalanced Drilling Underbalanced Drilling

Figure 7 - The Mechanisms of Differential Sticking

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pzq- Forehole Pressure I

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Performance enhancement only; no hydrocarbon containing zones.

1 Gas drilling. Drilling process using only gas as the drilling

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1.5 MUD CAP DRILLING

There are two types of mud cap drilling techniques:

d at suff~cientdensity and rate

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0 01 0.1 1 10 1w 1000 1WW

Figure 10 - Return permeability after testing as a function of initial core permeability

WDLP - Underbalanced drilling Page 8/5/19

Figure 1 1 - Formation Sloughing

NOTE: B s a t l e &6re i s ~ o cahpfese~u dscfii#g,UBDan. owrba1tt:n~:dsitr;ctatim,

The underbalanced condition can be lost in several ways:

Inadequate design due to lack of knowledge relative to reservoir characteristics. This

b. Equipment and/or lift-gas supply problems can cause a temporary overbalanced

P a ~ e8/5/20 WDLP - Underbalanced drilling

If a concentric or parasite string is used to inject gas, an overbalanced condition may

Spontaneous imbibition (formation wetting) and counter current imbibition effects

IV. Application of UBD in zones of extreme pressure and permeability.

VI. Other Limitations and Risks.

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1.1 CONVENTIONAL RIG

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Figure 13 - Weatherford's Down-hole Deployment Valve

A snubbing unit is often installed above the rotating

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Figure 15-Snubbing Unit Applications Offshore and Onshore

Most of Shell's experience in UBD has

Figure 16 - Texo's Push / Pull Machine

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Disadvantages of coiled tubing are:

Limited pulling or pushing power (surface equipment limitations).

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Figure 19 - UBD Operations with Coiled Tubing Rig

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THE DRILL STRING

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