PgDip/MSc Energy Programme/Advanced Well Engineering UB Well Control

Well Control in Underbalanced Drilling

Preview
This topic covers the control of underbalanced wells and includes details
of different types of surface equipment and separation packages. It also
introduces borehole stability and hole cleaning.

Primary Well Control

In an underbalanced condition the primary well control of the fluid
column is replaced by a mechanical barrier, ie, the rotating control head
in the jointed pipe option and with the injector head and stripper in the
coiled tubing case. It is therefore essential to maintain the integrity of the
conventional secondary well control system. All additional well control
equipment supplements the existing equipment allowing conventional
well control procedures to be used at all times if necessary.
From the casing head an additional operational blind ram is utilised below
the conventional BOP stack. This provides additional lubrication length
without affecting the conventional well control system. The standard BOP
system is on top of the operational blind ram with two sets of variable
pipe rams and a blind/shear ram, followed by an annular preventer. On
top of this is the snubbing well control system and stripping rams, an
additional annular preventer and the Rotating Control Head, as seen in
Section 2. The snubbing unit will be required for the pipe light condition if
an underbalanced condition is to be maintained at all times. A standard
snubbing unit will have 150,000 lbs push pull capability. It is preferable
to have all of the snubbing equipment below the rig floor to allow for
conventional tripping procedures as soon as a pipe heavy condition is
reached.

Double Barrier Requirements

All well control equipment should have double isolation barriers in place
and any additional well control equipment should be pressure rated to the
pressure rating of the existing BOP system. If an underbalanced condition
is to be maintained at all times with hydrocarbons to surface then two
barriers should be closed against the well when the drill pipe is out of the
hole.

Well Control Barriers

Conventional Drilling:

Primary Barrier Fluid column (Dynamic)

Secondary Barrier BOP’s (Mechanical)

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Underbalanced Drilling:

Primary Barrier Surface System (Mechanical)

Secondary Barrier BOP’s (Mechanical)

Note: At no point should the conventional BOP equipment be

compromised or used as operational barriers.

Surface Separation Equipment

The surface separation package will provide a closed circulating system to
separate the following:
• Injected gas;
• Produced gas;
• Drilling fluid;
• Drilled cuttings.
The package will act as a separation system between the BOP stack and
the rig’s conventional solids handling system. It is intended to utilise the
rig’s shaker system to separate the drilling fluids and drilling solids.
Due to the high flow rates anticipated it is recommended that a high-
pressure separator vessel is placed upstream of the surface choke. This
will reduce the erosion at the chokes by removing the gas prior to the
main pressure drop. The system will provide a separation process for
both underbalanced and low head drilling. For the Low Head or Near
Balance drilling option the equipment will be essentially the same. The
main difference between the two systems is the removal of the first stage
high-pressure vessel utilising the choke manifold upstream of the original
second stage separation vessel. The pressure rating of the equipment will
also be reduced.
NB: see the appendix for a typical underbalanced P&ID A3 diagram.

Typical Process Description

The UB system should be designed for maximum flexibility to handle
varying underbalanced drilling requirements. The proposed system is a
closed loop system designed to supply nitrogen lift gas and accommodate
the worst-case scenario.
Feed air is supplied from 4 feed air compressors to 2 * 1500 scf/m
nitrogen generation unit and 2 high-pressure boosters. Nitrogen is then
mixed with drilling fluid and circulated down the drill pipe and up the
drilling annulus by one of two high pressure drilling fluid pumps.
All well returns initially flow from the rotating BOP and diverter spool,
through a 6” emergency shut down valve and 6” hydraulically activated
operational shut in valve before passing through a 6” data header, 6”
debris catcher, 6”x 4” choke manifold and 6” x 2” sampling manifold.

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Flow can then be diverted to the first stage separator, directly to the
second stage separator (by-passing the first stage separator) or to the
surface separation package by-pass line (by-passing both separators).
The first and second stage separators provide the basis of a compact
surface separation system optimised for solids removal and handling of
slug flow associated with underbalanced drilling well returns
The primary functions of the first stage separator are to remove a high
proportion of gas and solids from the well returns and act as a buffering
chamber to smooth out gas or liquid slug flow, in particular to handle gas
slugs and high gas production associated with flush production. Although
rated at 1,500 psi for slug control, normal operating pressure would be
much lower (100 – 200 psi).
From the first stage separator gas is taken off to the high-pressure flare
and solids slurry to the rig solids handling system. The drilling fluid and
produced oil mixture, along with remaining entrained gas and solids,
flows through to the second stage separator.
The primary functions of the second stage separator are to separate the
drilling fluid and any produced condensate and to remove remaining gas
and solids prior to conditioning the drilling fluid for re-circulation.
From the second stage separator gas is taken off to the low pressure
flare, any remaining solids are taken off to the rig solids handling system,
gas or condensate is removed to stock tanks and drilling fluid is removed
to the rig drilling fluid conditioning tank for re-circulation.

Individual Pieces of Underbalanced Equipment

(Starting from the Return Flowline on the Diverter
Spool)

Rotating Control Head (RCH) and Diverter Spool

The diverter spool below the rotating BOP has a nominal 6” outlet to the
main flow line. The specifications for the different types of RCH are
detailed in the ‘Underbalanced Drilling Equipment’ topic.

Emergency Shut Down (ESD) Valve

The ESD valve is typically a 7 1/16” 5000 psi Hydraulically Actuated Gate
Valve with 6 3/8” through bore. This valve is fail-safe closed and closes
automatically in case of over pressuring of flowlines or vessels and on
high alarms on vessels and stock tanks. It can also be programmed to
close automatically at other process events (loss of power, loss of air
supply etc) as required and can also be shut in manually from remote
ESD stations around the drilling location. The control circuit for the
operation of this valve should be totally independent and tamper proof.

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Figure 1. ESD Valve.

Operational Shut In (OSI) Valve

The OSI valve is identical to the ESD valve but is not connected into the
ESD system. The purpose of this valve is for shut in for non-ESD
purposes (pressure testing, routine shut in etc) to protect the integrity of
the ESD valve for emergency use only. The OSI valve can be shut in
remotely and acts as a manual back up to the ESD valve in case of
emergency.

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Figure 2. ESD and OSI Valves.

Data Header
The two 6” data headers have six data take off points each and are used
to record flowline pressure and temperature data and for chemical
injection (defoamers and de-emulsifiers) and flowline sampling.

Debris Catcher (Optional)

The 6” debris catcher removes debris which is caught in a removable
strainer located in a double block and bleed pressure pot, such that
abnormally large drill cuttings or debris from elastomeric components,
upstream of the choke manifold and first stage separator choke to avoid
plugging of the chokes during drilling. This component also has a bypass
to enable flow past while the strainer is being cleaned.

Sampling Manifold
The high-pressure sampling manifold allows sampling of drill cuttings in
the well returns upstream of the first stage separator whilst drilling for
geological identification. The sampling manifold can be deployed as an
integral part of the choke manifold.

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Figure 3. Cuttings Sample Catcher.

Choke Manifold
The 3000-psi choke manifold incorporates two 4” choke loops from a 6”
main line and each loop has a bag choke and either a second adjustable
or fixed bean choke to allow stepped pressure drop before entry into the
second stage separator. The manifold is pressure rated to 3000 psi and
has a gut line through the centre of the manifold to allow for maximum
flow area.

Figure 4. Emergency Shut Down (ESD) Valve.

Separators
This can be either horizontal or vertical and need only be in one stage if it
is appropriately sized.

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Figure 5. Separators.

First Stage
The first stage separator is a 2,500-psi vertical three-phase unit
separating gas, liquid and solids slurry phases. Features include an inlet
choke for flow control upstream of the vessel, dual inlets with wear
sleeves to minimise erosion damage at the inlet, dual pressure relief
valves, vortex inlet device for improved solids/liquid/gas separation and
pneumatically operated back pressure and liquid level control systems.
Vessel pressure, temperature and gas flow rate are continuously
monitored and recorded.

Figure 6. Separator.

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Figure 7. Mud Gas Separator.

Second Stage Separator

The second stage separator is a 275 psi horizontal four phase unit
separating gas, water based drilling fluid, oil and solids. Features include
an adjustable inlet choke, dual pressure relief valves, vortex inlet device
for improved solids/liquid/gas separation and pneumatically operated
backpressure and liquid level control systems. An optional low gas flow
backpressure control system can be added if very low gas flow rates are
expected. Vessel pressure, temperature, oil flow rate, drilling fluid flow
rate and gas flow rate are continuously monitored and recorded.

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Additional 2” liquid flow meters are provided for low liquid flow
applications.

Figure 8. Second Stage Separator.

Figure 9.

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Figure 10. Horizontal Separation System.

Figure 11. Horizontal Separation Process.

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Figure 12. Four Phase Horizontal Separator.

Automatic Pressure Relief

Automatic Pressure Relief is only activated on failure of level 1 and level
2 safety systems. All pressure vessels have relief valves and relief lines
to allow safe discharge and bleed down of vessel contents in case of
vessel overpressure.

Sparge System
Sparge system is included to both separators to agitate solids in the
bottom of the separator if necessary to create solids slurry for transport
away from the separators. A single Canadian Gardener Denver 2600-psi
triplex sparge pump provides sparging to both separators.

Tore System
This is a small hydroclone driven solids removal system which when
attached to the solids discharge of the separator is capable of removing
the solids very effectively from the separator.

Slurry Pumps
Solids slurry is transported from both separators by eccentric helical rotor
pumps.

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Liquid Transfer Pumps

Transfer pumps for oil/condensate and drilling fluid transfer are 4” x 3”
centrifugal transfer pumps.

Chemical Injection
Chemical injection is provided by Texsteam 5000 psi injection pump.
Chemical injection can be at the HP drilling fluid pump, standpipe, data
headers or other suitable injection point.

Interconnecting Pipework
The package includes necessary interconnecting pipework to connect the
surface equipment together.

Data Acquisition and Process Monitoring/Control

Data acquisition and process monitoring/control is handled via a central
computer system in the ESD/Control Centre. Electronic systems all have
manual override in case of electronic failure. Process data continuously
monitored and collected includes flow line and separator pressures and
temperatures, gas and liquid flow rates, separator and stock tank liquid
levels. Hydraulic chokes, level controllers and back pressure controllers
can all be set and adjusted from the ESD/Control Centre enabling remote
control of the whole process.
Data from other sources can also be incorporated into the data
acquisition system including data from down hole tools and the rig
monitoring system. Specifically the following rig parameters can be
incorporated and monitored if required – tong torque, topdrive torque,
rotary table torque, rotary table RPM, topdrive RPM, mud pump rates,
trip tank level, mud pit levels, ROP, hook load and degasser low level.

Table 1. Data Requirements.

Typical Data Requirements for UBD Process Systems

Time Measure Depth

Gas Injection Rate Total Vertical Depth

Gas Injection Pressure Bottom Hole Pressure

Gas Injection Temperature Bottom Hole Temperature

Liquid Injection Rate Rate of Penetration

Liquid Injection Pressure Motor RPM

Liquid Injection Temperature Cuttings Volume

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Produced Condensate flow rate Exported Fluids Volumes

Produced condensate cum

volume Imported Fluids Volumes

6 hr. Average Gas Production Well head Pressure

Total cum Net Gas Production Wellhead Temperature

Separator Pressures Separator Temperature

Process Monitoring and Manual Intervention

Visual and audio alarms sound in the Data Acquisition/ESD Centre and at
appropriate remote stations in response to separator level one alarms
(Pressure Alarm High, Level Alarm High, Level Alarm Low) and other
preselected parameters detected by the data acquisition system.

Automatic Emergency Shut Down

Automatic full or partial process shutdown in response to level two alarms
detected by the data acquisition system (Pressure Alarm High High in
separators or flowlines, Level Alarm High High in separators or stock
tanks, vessel or flowline rupture, loss of electrical power, loss of air
supply).

Erosion Protection
Erosion Protection Is Provided By The Following:
1. Choke on the first stage inlet separator allows for a pressure step
down upstream of the separator;
2. Choke manifold ‘top down’ design;
3. Chokes and seats replaceable while drilling;
4. Main flow line 6” diameter to reduce flow velocity;
5. Lines as straight as possible with no unnecessary restrictions or
direction changes;
6. Solids removal at first stage separator;
7. Each separator vessel has a vortex inlet device to reduce
velocities;
8. Use of wear sleeves at points subject to high erosion including
separator inlet;
9. Use of erosion resistant materials and coatings;
10.Use of target ‘T’s and flow blocks at direction changes;
11.NDT/erosion monitoring program carried out in the field;
12.System designed to allow staged pressure drop through the
process.

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Flare Line and Flare Stack.

Produced gas from first and second stage separators is diverted via gas
flare lines to 80’ flarestack with self-igniting pipe flare. Both vertical and
horizontal flarestacks are shown in Figure 13.

Figure 13. Vertical and Horizontal Flarestacks.

Figure 14. Offshore Flarestacks.

Borehole Stability
Underbalanced drilling should be carried out in competent formations
only. Highly permeable, and or higher porosity unconsolidated sandstone
reservoirs may collapse under the influence of a pressure draw down into
the well bore. As a rule of thumb, formations with greater than 23%

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porosity cause stability problems. 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 (sandstone/shale 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, 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.

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 and turbulent flow minimises the
formation of cuttings beds. A disadvantage of having a two-phase system
is the reduced carrying capacity of the drilling fluid.
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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Appendix
Figure 15. Typical Underbalanced P&ID diagram.

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