Introduction to

Underbalanced Drilling

By:
Leading Edge Advantage
Old Stoneywood Church
Bankhead Road
Bucksburn, Aberdeen
AB21 9HQ

Telephone 44-1224-716969
Fax 44-1224-712333
Email mailto:enq@lealtd.com
Website www.lealtd.com

Leading Edge Advantage International Ltd 2002 Page 1 of 51 Rev 5

 Table of Contents

1 INTRODUCTION ........................................................................................................................ 4

2 WHAT IS UNDERBALANCED DRILLING? .......................................................................... 5

3 OBJECTIVES OF UNDERBALANCED DRILLING.............................................................. 7

3.1 MAXIMISING HYDROCARBON RECOVERY ............................................................................... 8
3.2 DRILLING PROBLEMS .............................................................................................................. 8
4 TECHNIQUE SELECTION OF UNDERBALANCED DRILLING .................................... 10
4.1 BOTTOM HOLE PRESSURE REQUIREMENTS ............................................................................. 10
5 DRILLING FLUID SYSTEMS................................................................................................. 11
5.1 GASEOUS & COMPRESSIBLE (TWO-PHASE) FLUIDS ............................................................... 11
5.1.1 Gaseous Fluids ............................................................................................................. 12
5.1.2 Mist Drilling ................................................................................................................. 13
5.1.3 Foam drilling................................................................................................................ 13
5.1.4 Gasified Systems ........................................................................................................... 14
5.2 SINGLE PHASE FLUIDS............................................................................................................ 15
5.3 GAS LIFT SYSTEMS................................................................................................................. 15
5.3.1 Drillpipe injection......................................................................................................... 16
5.3.2 Annular injection .......................................................................................................... 17
5.4 PARASITE STRING INJECTION ................................................................................................. 18
6 RESERVOIR STUDIES ............................................................................................................ 19

7 SURFACE EQUIPMENT FOR UBD OPERATIONS ........................................................... 21

7.1 DRILLING SYSTEM ................................................................................................................. 21
7.1.1 Coiled Tubing V Jointed Pipe?..................................................................................... 22
7.2 GAS GENERATION EQUIPMENT .............................................................................................. 22
7.2.1 Natural Gas .................................................................................................................. 22
7.2.2 Cryogenic Nitrogen ...................................................................................................... 22
7.2.3 Nitrogen Generation..................................................................................................... 23
7.3 WELL CONTROL EQUIPMENT ................................................................................................. 25
7.3.1 Jointed Pipe systems ..................................................................................................... 25
7.3.2 Coiled Tubing Systems.................................................................................................. 26
7.4 SNUBBING SYSTEM ................................................................................................................ 27
7.5 ROTATING CONTROL HEAD SYSTEM ..................................................................................... 27
7.6 SEPARATION EQUIPMENT ...................................................................................................... 28
Example of a Modular Vertical Tank Separator System .............................................................. 30
7.6.1 Data acquisition ........................................................................................................... 30
7.6.2 Erosion monitoring....................................................................................................... 30
7.7 THE CIRCULATION PROCESS .................................................................................................. 31
8 COMPLETING UNDERBALANCED DRILLED WELLS................................................... 32
8.1 SNUBBING ............................................................................................................................. 33
8.2 INSTALLATION OF A SOLID LINER .......................................................................................... 33
8.3 INSTALLATION OF A PERFORATED LINER OR SANDSCREEN(S) ................................................ 33
8.4 COMPLETION RUNNING ......................................................................................................... 37
8.5 WORKOVER OF AN UNDERBALANCED DRILLED WELL ........................................................... 37
8.6 UNDERBALANCED DRILLED MULTI-LATERAL WELLS ........................................................... 38

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 8.6.1 Advantages & Limitations for live well deployment ..................................................... 38
9 HEALTH SAFETY AND ENVIRONMENTAL ISSUES....................................................... 39
9.1 ENVIRONMENTAL ASPECTS ................................................................................................... 39
9.2 SAFETY ASPECTS ................................................................................................................... 40
9.3 STEP BY STEP APPROACH ...................................................................................................... 41
10 LIMITATIONS....................................................................................................................... 42
10.1 TECHNICAL LIMITATIONS ...................................................................................................... 42
10.1.1 Wellbore stability.......................................................................................................... 42
10.1.2 Water inflow ................................................................................................................. 43
10.1.3 Directional Drilling equipment .................................................................................... 43
10.1.4 Unsuitable Reservoir .................................................................................................... 43
10.2 SAFETY AND ENVIRONMENT ................................................................................................. 44
10.2.1 Surface equipment ........................................................................................................ 44
10.2.2 Training ........................................................................................................................ 44
10.2.3 Personnel...................................................................................................................... 44
10.3 ECONOMICS ........................................................................................................................... 44
11 CASE HISTORIES ................................................................................................................ 45

12 ADVANTAGES OF UNDERBALANCED DRILLING ..................................................... 46

12.1 DRILLING TECHNICAL ADVANTAGES .................................................................................... 46
12.2 RESERVOIR TECHNICAL ADVANTAGES .................................................................................. 47
13 COSTS..................................................................................................................................... 48

14 FUTURE.................................................................................................................................. 49

15 FURTHER INFORMATION ON UNDERBALANCED DRILLING .............................. 50

16 SUPPLIERS OF UNDERBALANCED DRILLING EQUIPMENT ................................. 50

17 ABBREVIATIONS................................................................................................................. 51

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1 Introduction
This document is intended to provide an overview of current underbalanced
drilling technology and is therefore by no means exhaustive. It should serve as a
guide to current technology, explaining how and why underbalanced drilling is
carried out.

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2 What is Underbalanced Drilling?
When the effective circulating downhole pressure of the drilling fluid - which is
equal to the hydrostatic pressure of the fluid column, plus pump pressure, plus
associated friction pressures - is less than the effective near bore formation pore
pressure. (Definition)

Conventionally, wells are drilled overbalanced, which provides the primary well
control mechanism. Imposed wellbore pressure arises from three different
mechanisms:

1. Hydrostatic pressure of materials in the wellbore due to the density of

the fluid used (mud) and the density contribution of any drilled cuttings
(passive).
2. Dynamic pressure from fluid movement due to circulating friction of the
fluid used and the relative fluid motion caused by surge/swab of the
drillpipe (dynamic).
3. Imposed pressure, with occurs due to the pipe being sealed at surface
resulting in an area with pressure differential (e.g., a rotating head or
stripper element) (confining or active).

Underbalanced drilling is defined as drilling with the hydrostatic head of the

drilling fluid intentionally designed to be lower than the pressure of the
formations being drilled. The hydrostatic head of the fluid may naturally be less
than the formation pressure or it can be induced. The induced state may be
created by adding natural gas, nitrogen or air to the liquid phase of the drilling
fluid. Whether the underbalanced status is induced or natural, the result may be
an influx of formation fluids which must be circulated from the well and
controlled at surface. Underbalanced drilling in practical terms will result in flow
from one or more zones into the wellbore (this is more likely, however, to be
solely from one zone as cross-flow is likely to result) or where the potential for
flow exists.

The lower hydrostatic head avoids the build-up of filter cake on the formation as
well as the invasion of mud and drilling solids into the formation. This helps to
improve productivity of the reservoir and reduce related drilling problems.

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 When comparing underbalanced drilling with conventional drilling it soon
becomes apparent that an influx of formation fluids must be controlled to avoid
well control problems. In underbalanced drilling, the fluids from the well are
returned to a closed system at surface to control the well. With the well flowing,
the BOP system is kept closed while drilling, whereas in comparison to
conventional drilling fluids are returned to an open system with the well open to
atmosphere.

Underbalanced Drilling Conventional Drilling

Under-
pressure
Over-
Over- pressure
pressure

Under-
pressure

Reservoir
formation Reservoir
formation

Drilling Fluid Drilling Fluid

Returns to Closed Returns to Open
Circulation system. Circulation system.

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3 Objectives of Underbalanced Drilling
The objectives of underbalanced drilling can be broken down into two main
categories:
• Maximising hydrocarbon recovery
• Minimising drilling problems
These categories illustrate underbalanced drilling operations are performed.

There are also specific advantages and disadvantages of performing a drilling

operation underbalanced. These can be summarised as follows:

Advantages:
• Increased ROP
• Decreased formation damage
• Eliminate risk of differential sticking
• Reduce risk of loss circulation
• Less weight on bit required
• Improved bit life
• Tight hole problems may be reduced
• Reduced cutting size increasing hole cleaning capability

Disadvantages:
• Wellbore stability
• Wellbore consolidation
• Increased drilling costs (depending on system used)
• Compatibility with conventional MWD systems
• Spontaneous counter current imbibition effects
• Gravity drainage in horizontal wells
• Possible near wellbore mechanical damage
• Discontinuous underbalanced conditions
• Generally higher risk with more inherent problems
• String weight is increased due to reduced buoyancy
• Possible excessive borehole erosion
• Possible increased torque and drag

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3.1 Maximising Hydrocarbon Recovery

The two main objectives of underbalanced drilling can be subdivided as follows:

Reduced formation damage.

No invasion of solids or mud filtrate into the reservoir formation.
Early production
Well is producing as soon as the reservoir is penetrated with a bit. This
could be a disadvantage if hydrocarbon production cannot be handled or
stored on site or if the required export lines are not available.
Reduced Stimulation
As there is no filtrate or solids invasion in an underbalanced drilled
reservoir, the need for reservoir stimulation is eliminated. It has been
noted in wells drilled underbalanced that stimulation with fluids
significantly reduces the productivity of the reservoir. An acid wash
carried out on an underbalanced drilled well, reduced productivity from
20MMscft/day to 2 MMscft/day. The full benefits of underbalanced
drilling were never regained.
Enhanced recovery
Due to the increased productivity of an underbalanced drilled well
combined with the ability to drill infill wells in depleted fields, the
recovery of bypassed hydrocarbons is possible. This can significantly
extend the life of a field. The improved productivity of the wells also
leads to a lower drawdown, which can, in turn, reduce water coning.

3.2 Drilling Problems

Differential sticking.
The absence of an overburden on the formation combined with the lack
of any filter cake serves to prevent the drillstring from becoming
differentially stuck. This is especially useful when drilling with coiled
tubing because of the lack of tooljoint connections. This increases the
stand-off in the borehole.

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 No Losses
In general, a reduction of the hydrostatic pressure in the annulus reduces
the fluid losses into a reservoir formation. In underbalanced drilling, the
hydrostatic pressure is reduced to a level where losses do not occur.
Improved Penetration Rate
The lowering of the overpressure over the formation pressure has a
significant effect on penetration rate. The reduction in the so-called chip
hold down effect also has a positive impact on bit life. The increased
penetration rate combined with the effective cuttings removal from the
face of the bit leads to a significant increase in bit life. In underbalanced
drilled wells, sections have been drilled with one bit where as in
overbalanced drilled wells 3, 4 or even 5 bits were used.
Reduction of ECD in extended reach wells
The drilling of long horizontal or near horizontal sections creates more
and more friction pressure in the annulus. This friction pressure acts on
the bottom of the well and slowly increases the overpressure over the
formation interval. This results in a reduction of ROP and increases the
potential for losses. Underbalanced drilling provides an opportunity for a
reduction in annular friction losses by allowing the reservoir energy to
push fluids out of the hole.

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4 Technique Selection of Underbalanced Drilling
A basic four-step process can be applied to determine the options and
requirements for a well to be drilled underbalanced:
1. Determine BHP requirements.
2. Identify the drilling fluid options.
3. Establish the well design and perform flow modelling.
4. Select the surface equipment.

4.1 Bottom hole pressure requirements

In overbalanced drilling a mudweight is selected that provides a hydrostatic

pressure of 200 to 1000 psi above the reservoir pressure. In underbalanced
drilling we select a fluid that provides a hydrostatic pressure of around 100-200
psi below the initial reservoir pressure. This provides a starting point for the
selection of a fluid system. In the feasibility study this was further refined,
depending on the expected reservoir inflow, with a drawdown of 200 psi. A
closer look at the drilling hydraulics may indicate that 200 psi drawdown is not
sufficient and the well will be overbalanced when circulating. In this case, the
circulation fluid may have to be further reviewed.

Technique Selection
6200
Mud Hydrostatic Pressure

6000

200 psi - 1000 psi

5800
Pressure (psi)

Reservoir Pressure
5600

200 psi
Underbalanced Drilling
5400

5200
Mud Hydrostatic (psi)
Reservoir Pressure (psi)
Underbalanced Pressure (psi)
5000

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5 Drilling Fluid systems
Correct selection of the fluid system used in underbalanced drilling is the key to
the successful outcome of an underbalanced drilling operation. We will
therefore have a closer look at the fluid systems used in underbalanced drilling.

0.

Oil

Weighted Mud
(Barite)

0 Air 150 20.0

SO_00591 2/4/98

5.1 Gaseous & Compressible (two-phase) Fluids

Compressible fluid drilling is, in essence, a drilling technique in which the more
common circulating fluids water or mud, are injected with or replaced by highly
compressible gases. These gases perform most of the same functions as a drilling
fluid, i.e., cool the bit and clean the hole.

Applicability of compressible fluid drilling is limited to a specific set of litho

logical and pore pressure conditions. It is also where significant savings of rig
time and money can be achieved despite the need for additional equipment.
Compressible fluid drilling includes: drilling with air, mist, foam stiff/stable and
aerated mud.

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5.1.1 Gaseous Fluids

These are basically the gas systems. In initial underbalanced drilling operations,
air was used to drill. Today air drilling or dusting is still applied in hard rock
drilling and in the drilling of water wells. The use of air in hydrocarbon bearing
formations is not recommended as the combination of oxygen and natural gas
may cause an explosive mixture. There have been a number of reported cases
where downhole fires have destroyed drillstring with the obvious potential
consequences of the rig burning down if the mixture gets to surface.

To avoid the use of air, nitrogen was introduced. The experience with nitrogen
in well servicing operations made it a first choice for underbalanced drilling
operations. The use of so-called cryogenic nitrogen or tanks of liquid nitrogen
in drilling operations can be restricted. This depends on the logistical issues
involved due to the large amount of nitrogen required for a drilling operation.
Another option is to use natural gas, which, if available, has sometimes proved
a worthy alternative in drilling operations. If a gas reservoir is being drilled
underbalanced, a producing well or the export pipeline may well produce
sufficient gas at the right pressure to drill. This avoids the introduction of
oxygen into the well and, if available, may provide a cheap drilling system.

Characteristics of air-drilling:
• Fast penetration rates.
• Longer bit life.
• Greater footage per bit.
• Good cement jobs.
• Better production.
• Requires minimal water influx.
• Slugging can occur.
• Mud rings can occur in the presence of fluid ingress.
• Relies on annular velocity to remove cuttings from the well.

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5.1.2 Mist Drilling

If gas systems are not suitable the addition of a small amount of liquid will
initially form a mist system. The fluid added to the gas environment will
disperse into fine droplets and form a mist system to drill with. In general this
technique needs to be used in areas where some formation water exists which
prevents the use of complete 'dry air' drilling.

Characteristics of mist-drilling:
• Similar to air drilling but with addition of liquid
• Relies on annular velocity to remove cuttings from the well
• Reduces formation of mud rings
• High volumes required (30%-40% more than dry air drilling)
• Pressures generally higher than dry air drilling
• Incorrect air/gas-liquid ratio leads to slugging, with attendant pressure
increase

5.1.3 Foam drilling

If more liquid and a surfactant is added to the fluid, stable foam is generated.
Stable foam used for drilling has a texture not unlike shaving foam. It is a
particularly good drilling fluid with a high carrying capacity and a low density.
One of the problems encountered with the conventional foam systems is that a
stable foam is as it sounds. The foam remains stable even when it returns to the
surface and this can cause problems on a rig if the foam cannot be broken
down fast enough. In the old foam systems, the amount of defoamer had to be
tested carefully so that the foam was broken down before any fluid left the
separators. In closed circulation drilling systems stable foam could cause
particular problems with carry over. The recently developed stable foam systems
are simpler to break and the liquid can also be re-foamed so that less foaming
agent is required and a closed circulation system can be used. These systems, in
general, rely on either a chemical method, of breaking and making the foam or
the utilisation of an increase and decrease of pH, to make and break the foam.
The foam quality at surface used for drilling is normally between 80% and 95%.

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 The same amount, 80% to 95%, is gas with the remainder being liquid.
Downhole, due to the hydrostatic pressure of the annular column, this ratio
changes as the volume of gas is reduced. An average acceptable bottom-hole
foam quality (FQ) is in the region of 50%-60%.

Characteristics of foam-drilling:
• Extra fluid in the system reduces the influence of formation water
• Very high carrying capacity
• Reduced pump rates due to improved cuttings transport
• Stable foam reduces slugging tendencies of the wellbore
• The stable foam can withstand limited circulation stoppages without
affecting the cuttings removal or ECD to any significant degree
• Improved surface control and more stable downhole environment
• The breaking down of the foam at surface needs to be addressed at the
design stage
• More increased surface equipment required

5.1.4 Gasified Systems

If a foam system is too light for the well, a gasified system can be used. In these
systems, liquid is gasified to reduce the density. There are a number of methods
that can be used to gasify a liquid system and these methods are discussed
within the injection systems section. The use of gas and liquid, as a circulation
system in a well, complicates the hydraulics programme. The ratio of gas and
liquid must be carefully calculated to ensure that a stable circulation system is
used. If too much gas is used, slugging will occur. If not enough gas is used, the
required bottom hole pressure will be exceeded and the well will become
overbalanced.

Characteristics of gasified-mud systems:

• Extra fluid in the system will almost eliminate the influence of formation
fluid unless incompatibilities occur
• The mud properties can easily be identified prior to commencing the
operation
• Generally, less gas is required
• Slugging of the gas and fluid must be managed correctly

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 • Increased surface equipment will be required to store & clean the base
fluid
• Velocities, especially at surface, will be lower, reducing wear & erosion
both downhole and to the surface equipment.

5.2 Single phase fluids

If possible, the first approach should normally be to use a fluid system with a
density low enough to provide an underbalanced condition. If water can be
used then this would be the first step to take. If water is too heavy, oil can be
considered. However, it must be remembered that a well can be kicked off with
a base oil system but, if the reservoir produces crude oil, the circulation system
will become crude oil since base oil cannot be separated from the crude.
Obviously pumping $25 per barrel base oil and producing $15 per barrel crude
oil to drill a well underbalanced does not make economic sense. If a crude oil
system is selected, the rig must be equipped to ensure that the crude can be
degassed before it enters the enclosed pit system. On an offshore rig, a fully
enclosed, vented and nitrogen blanketed pit system must be used to ensure
that gas is not released from the crude.
The use of additives, such as glass beads has been attempted to lighten a fluid
but since the glass beads come out over the shakers in the solids separation
system or get crushed and damaged throughout the whole system, new beads
need to be continuously added. The addition of glass beads is therefore, an
expensive option and not very effective in lightening the fluid.

5.3 Gas lift systems

If a fluid needs to be reduced in density, the use of an injection of gas into the
fluid flow could be an option. This offers a choice into not only the gas used
but also in the way the gas is used in the well.
Normally, natural gas or nitrogen is used as a lift gas, but both CO2 and O2 can
also be utilised. However, gasses containing oxygen are not recommended for
two main reasons. The combination of oxygen and saline fluids with the high
bottom hole temperatures can cause severe corrosion to tubulars used in the
well and drillstring. Also, if during the drilling process, carbohydrates enter the
borehole (expected in an underbalanced environment), then a potentially
explosive situation could arise, resulting in a downhole fire.

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 A number of injection methods are available to reduce the hydrostatic pressure
and these are discussed overleaf.

5.3.1 Drillpipe injection

Compressed gas is injected at the standpipe manifold where it

mixes with the drilling fluid. The main advantage of drillstring
injection is that no special downhole equipment is required in
the well. The use of reliable non-return valves is required to
prevent flow up the drillpipe. The gas rates used when drilling
with drillpipe injection system are normally lower than with
annular gas lift. Low bottom hole pressures can be achieved
using this system.
The disadvantages of this system include the need to stop
pumping and the bleeding of any remaining trapped pressure
in the drillstring every time a connection is made. This results in
an increase in bottom hole pressure. It may then be difficult to
obtain a stable system and avoid pressure spikes at the
reservoir when using drillpipe injection. The use of pulse type
MWD tools is only possible up to 20% gas by volume. If higher
gas volumes are used, the pulse system deployed on MWD transmission systems
will no longer work. Specialist MWD tools such as electro-magnetic may have to
be used if high gas injection rates are required. However, these tools do not
work very well offshore or if significant amounts of evaporites are drilled. One
alternative is to connect the MWD back to surface using an electric cable. This
technique has previously been used very successfully with coiled tubing as the
drillstring. If drill pipe is to be used, wet connects can be utilised, however, the
additional time consumed using this technique can be limiting. A further
drawback for drillstring injection is the impregnation of the gas into any down
hole rubber seals. Positive displacement motors (PDM's) are especially prone to
fail when the rubber components get impregnated with the injection gas and
then tripped back to surface. Once a trip is made, the rubber can explode or
swell as a result of the expanding gas not being able to disperse out of the
stator sufficiently quickly. This effect (explosive decompression) destroys not
only the motors but also affects any rubber seals used downhole, resulting in a
high turnover of motors. This can be very costly to the drilling operation.
Special rubber compounds have been developed and the design of motors is
changing to allow for this expansion. The majority of motor suppliers can now

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 provide PDM’s specifically designed for use in this
kind of downhole environment. But, if drillpipe
injection is an option, the use of all metal turbines
should be considered depending on the operational
demands. Care must be taken at surface when
breaking out the drilling assembly in case there is any
high-pressure gas is trapped in the toolstring.

5.3.2 Annular injection

Annular injection through a concentric string is most

commonly utilised offshore in the North Sea. This
method is worthwhile if a suitable casing or
completion tubing scheme is installed in the well. For
a new drill well, a liner should be set just above the
target formation. The liner is then tied back to surface
using a modified tubing hanger to suspend the tie-
back string. Gas is injected in the casing liner annulus
to facilitate the drawdown required during the drilling
operation. The tie back string is then pulled prior to
installation of the final completion. The alternative is
for an older well to have a completion in place
incorporating gas lift mandrel pockets. These can be
set-up to provide the correct bottom hole pressures
during the drilling operation.
The drawback with this type of operation is that the hole size and tools required
are restricted by the minimum ID of the completion. However, the main
advantage of using an annulus to introduce gas into the system, is that gas
injection is continued during connections thus creating a more stable bottom
hole pressure. As the gas is injected, via the annulus, only a single-phase fluid is
pumped down the drillstring. This has the advantage that conventional MWD
tools operate in their preferred environment, which can have a positive affect on
the operational cost of a project. However, the drawbacks of this system, are
that a suitable casing/completion scheme must be available and that the
injection point must be low enough to obtain the required underbalanced
conditions. There may also be some modifications required to the wellhead for
the installation of the tie-back string and the gas injection system.

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5.4 Parasite string injection

The use of a small parasite string strapped to the outside of

the casing for gas injection is really only used in vertical wells.
For safety reasons, two 1” or 2” coiled tubing strings are
strapped to the casing string above the reservoir as the casing
is run in. Gas is pumped down the parasite string and injected
onto the drilling annulus. The installation of a production
casing string and the running of the two parasite string makes
this a complicated operation. Wellhead adaptation is
required to provide surface connections to the parasite
strings. This system cannot be used in deviated wells as the
parasite string is ripped off with the casing on the low side of
the hole. However, the principles of operation and the
advantages of the system remain the same as above.

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6 Reservoir studies
Prior to an underbalanced drilling operation being undertaken, a significant
amount of work needs to be carried out on the reservoir. Not only is an
accurate reservoir pressure needed but the damage mechanism of the reservoir
must be understood to ensure that the required benefits are indeed possible.
Some wells or reservoirs are suitable for underbalanced operations and result in
an enhanced recovery. Other formations or fields may not be viable for a
variety of other reasons. A summary of those reservoirs that will benefit from
underbalanced drilling include:

• Formations that usually suffer major formation damage during drilling or

completion operations
• Formations that usually exhibit high trends for differential sticking and
lost pipe
• Formations that exhibit regions of high loss circulation or fluid invasion
during drilling or completing
• Wells with large macroscopic fractures
• Wells with massive heterogeneous or highly laminated formations that
exhibiting differing permeability’s, porosities or pore throats throughout
• High production reservoirs with medium-high permeability
• Formations with rock-fluid sensitivities
• Formations with fluid-fluid sensitivities
• Formations generally exhibiting very low ROP’s with overbalanced
drilling

Reservoirs generally not benefiting from underbalanced drilling include:

• Wells in an area of very low cost conventional drilling
• Extremely low permeability wells
• Poorly consolidated formations
• Wells with a low borehole stability
• Wells with loosely cemented laminar boundaries
• Wells containing multiple zones of different pressures

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 Coreflush testing will be required to establish compatibility between the
proposed drilling fluid and the produced reservoir fluids. This is critical if oil
reservoirs are drilled underbalanced. The potential for scale and emulsion
forming needs to be reviewed before drilling operations start. The stability and
UCS of the zone of interest need to be ascertained to determine if the proposed
well path is structurally capable of being drilled with the anticipated formation
drawdown.

Expected productivity with the proposed drawdown must be reviewed. The

objective of underbalanced drilling is to clean the reservoir and not to produce
the well to its maximum capacity. If the reservoir is likely to produce any water
this must be taken into account as water influx can have significant effects on
the underbalanced process. It is important that expected productivity is
analysed with the reservoir engineers, to obtain an accurate indicator as to
whether underbalanced drilling would be of benefit.

When the reservoir issues are understood, it is proven that it would be

advantageous to drill the well underbalanced, and that the proposed well
profile would be also be sufficiently stable, the surface equipment can be
selected.

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7 Surface Equipment For UBD Operations
The surface equipment for underbalanced drilling can be broken down into
four main categories. These are:
• Drilling system
• Gas Generation Equipment
• Well Control Equipment
• Surface Separation Equipment
If the platform process or export equipment is used when drilling
underbalanced then this is considered a separate issue and therefore is not
included in this document.

7.1 Drilling System

Hole size and reservoir penetration as well as directional trajectory will

determine whether coiled tubing or jointed pipe is the optimal drillstring
medium. If the hole size required is larger than 6-1/8", jointed pipe may have to
be used. For hole sizes of 6-1/8" or smaller coiled tubing can be considered. The
size of coiled tubing currently used for drilling operations is between 2" & 2-
7/8" OD. This is due to many factors including the flow rate through the coil,
pressure drop through the tubing, WOB, profile of the well, maximum pick-up
weight, both in hole and the surface equipment and weight of the coiled
tubing itself. Occasionally the ideal coiled tubing for an operation may be
excluded due to such factors as crane or transport limitations or that the life of
the coil may not be feasibly economical.

Generally, coiled tubing has several advantages and disadvantages over jointed
pipe systems. For jointed pipe systems, drill string properties and tripping under
pressure will need to be considered. The installation of a snubbing system on a
platform or rig with a fixed distance between rotary table and wellhead may
cause severe problems. Several previous operations on land rigs had to be re-
designed to accommodate rig assist snubbing systems.

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7.1.1 Coiled Tubing V Jointed Pipe?

Coiled Tubing Jointed Pipe

No connections made during drilling Connections require gas injection shut
down causing pressure peaks.
Higher pressure containment Pressure of Rotating Diverters limited to
3000 psi.
Stiff Wireline makes MWD systems MWD systems unreliable in gasified
simpler in gasified fluids systems
No snubbing system required Pressure deployment requires snubbing
unit
Maximum hole size 6” No hole size limit
Hole cleaning more critical Hole cleaning can be assisted by rotation
Potential for pipe collapse in high Special drillstring connections required for
pressure wells gas fields
Thru tubing drilling work possible Thru tubing work requires special rig floor
tools on conventional rigs
BOP stack smaller BOP stackup requires rotating diverter
system.
Lower costs Higher costs as a result of rig.
Limited with drag for outreach Ability to drill long horizontal sections

7.2 Gas generation Equipment

7.2.1 Natural Gas

If natural gas is used for underbalanced drilling, a natural gas compressor may
be required; this would need to be reviewed once the source of the gas is
known. Most production platforms have a source of high pressure gas. A flow
regulator and a pressure regulator would be required to control the amount of
gas injected during the drilling process.

7.2.2 Cryogenic Nitrogen

The use of tanked nitrogen could be considered on onshore locations where a

large truck could be used for its supply. Cryogenic nitrogen in 2000 gallon
transport tanks provides high quality nitrogen and utilises equipment that is
generally less expensive. Liquid nitrogen is passed through the nitrogen
converter, where the fluid is pumped under pressure prior to being converted
to gas. The gas is then injected into the string. Generally, the requirement is for
the nitrogen converter and a work tank with additional tanks being provided as

Leading Edge Advantage International Ltd 2002 Page 22 of 51 Rev 5

 necessary. For operations in excess of 48 hrs, the requirement for liquid
nitrogen could be quite large, and this can result in logistical difficulties.

The use of cryogenic nitrogen offshore is sometimes not recommended, this

would depend on the application. Pumping 1500 scft/min of nitrogen for a 24hr
drilling period requires 15 tanks of 2000 gal each. Moving this on and off an
offshore platform is a significant task and therefore could present some serious
safety implications. If drilling is ongoing at this rate for several days, then two
dedicated supply boats would be required to maintain supply.

In order to move away from tank transport for large nitrogen dependant
drilling operations, the use of nitrogen generators is often recommended
offshore.

7.2.3 Nitrogen Generation

A nitrogen generator is no more than a filtering system that filters nitrogen out
of the atmosphere. A nitrogen generator uses small membranes to filter the air.
Oxygen enriched air is vented to the atmosphere and nitrogen is boosted to the
required injection pressure.

Nitrogen Generation System

Air Compressors
1500 scft/min

3 x 1000 scft/min Booster

Nitrogen
Generator Compressor

A nitrogen generator is 50% efficient. In real terms, if 1500 scft/min of nitrogen

is required, then 3000 scft/min of air needs to be pumped into the generator. A
fill nitrogen system for 1500 scft/min would comprise of three or four large air
compressors, a nitrogen generator and a booster compressor. This equipment
will take up significant deck space on an offshore rig or platform. Improved
systems are now entering the market and a nitrogen generation package in a
40ft ISO container is now available from several service suppliers.

Leading Edge Advantage International Ltd 2002 Page 23 of 51 Rev 5

 Another issue associated with nitrogen generation is the purity of the nitrogen
itself. Depending on the amount of nitrogen required, the purity will vary. At
95% purity, 5% oxygen will be delivered. Although this is not enough oxygen
to reach explosion levels, it is sufficient oxygen to cause significant corrosion
problems. The corrosion is further worsened when salt brine systems are used at
elevated temperatures.

Leading Edge Advantage International Ltd 2002 Page 24 of 51 Rev 5

7.3 Well Control equipment

7.3.1 Jointed Pipe systems

The conventional BOP stack used for drilling is not compromised during
underbalanced drilling
Typical BOP Stack Up Sketch operations. The
Not to scale for
Information only
conventional BOP stack
Rig Floor
is not used for routine
operations and will not
Snubbing System be used to control the
Potentially required

1.24 m well except in case of

Rotating Control Head

emergency.
system

Primary Flowline A rotating control head

Flow Spool
ESD Valve
system and primary
Annular Preventer
flowline with ESD
Pipe Rams

Variable Rams
valves is installed on
Flow Spool
Secondary Flowline top of the conventional
Drilling spool
Choke / Kill Lines BOP. If required, a
Blind / Shear Rams

Working Blind Ram

single blind ram,

1.00 m
operated by a special
Skid Deck
koomey unit is installed
under the BOP stack to
5.79 m allow the drilling BHA
to be run under
pressure.

Leading Edge Advantage International Ltd 2002 Page 25 of 51 Rev 5

7.3.2 Coiled Tubing Systems

Well control is much

Stuffing Box and
Injector Head
simpler when drilling
with reeled systems.
A lubricator can be
CT Riser Section
used to stage in the
main components of

Stripper Assembly
the BHA or if a
suitable downhole
Blind Rams

Shear Rams safety valve can be

Kill Line
Slip Rams
used then a surface
Pipe Rams
Main Flow line with ESD
valves to choke manifold
lubricator is not
required. The
Blind Ram
injector head can
Tree Connector
then be placed
directly on top of the
wellhead system.
Ground Level

The reeled systems can then be tripped much faster and the rig up is therefore
much simpler. However, one consideration relating to reeled systems is the
cutting strength of the shear rams. Verification is required in order to ascertain
that the shear rams will cut the tubing and any wireline or control line systems
inside the coil. For a stand-alone operation on a completed well an example
stack up is shown above.

Leading Edge Advantage International Ltd 2002 Page 26 of 51 Rev 5

7.4 Snubbing system

If tripping is to be conducted underbalanced, a snubbing system will be

installed on top of the rotating control head system. The current systems used
offshore are called rig assist snubbing
systems. A jack with a 10ft stroke is used to
push pipe into the hole or to trip pipe out of
the hole. Once the weight of the string
exceeds the upward force of the well, the
snubbing system is switched to standby and
the pipe is tripped in the hole using the
draw works. The ability to install a snubbing
system below the rig floor allows the rig
floor to be used in the conventional drilling
way.
The snubbing system is a so called rig assist
unit. This unit needs the rig draw works to
pull and run pipe. It is designed to deal only
with pipe light situations.

7.5 Rotating Control Head System

The rotating control head system will

need to be sized and selected on the
basis of the expected surface pressures.
A well with a reservoir pressure of
1000psi does not need a 5000psi
rotating control head system. A number
of companies offer rotating control
head systems for underbalanced drilling.
The ESD system on an underbalanced
drilling operation closes in the well at the main flowline and shuts down fluid
pumps and gas lift systems. The ESD system can be remotely operated from a
number of locations on the rig when drilling underbalanced.

Leading Edge Advantage International Ltd 2002 Page 27 of 51 Rev 5

7.6 Separation Equipment

Rig Assist
Snubbing Unit
Gas
Gas Injection Drilling Rotating
Fluid Control Head

Choke Snubbing
Manifold BOP

Drilling
BOP

Surface Separation
Package

Solids Disposal Rig

Pump
Drilling Fluid

Oil / Water/ Drilling Fluid

The separation system has to be tailored to the expected reservoir fluids. A

separator for a dry gas field is significantly different from a separator required
for a heavy oil field. The separation system must be designed to handle the
expected influx and it must be able to separate the drilling fluid from the return
well flow in order that this can be pumped down the well once again.

A number of approaches in separation technology have emerged recently, these

include:
• To first separate the gas and then deal with fluids and cuttings
• To separate solids minimising erosion and next deal with the gas

The approach taken is largely dependent on the expected reservoir fluids. It

must be recognised that separation technology for underbalanced drilling may
represent as many a 5 or 6 phases.
• Drilling Fluid
• Cuttings
• Gas
• Oil
• Condensate

Leading Edge Advantage International Ltd 2002 Page 28 of 51 Rev 5

 • Nitrogen

An example of a 4-phase separation system is shown below:

VEN VEN VEN TO ATMOSPHERE

/FLARE

4 PHASE KEY
OIL NITROGEN/GAS
SURGE
WATER-BASED
DRILLING
FLUID
SLUDGE
WATER WATER TWO PHASE
PUMP
SURGE TRANSFER (FOAM)
TANK PUMP
TWO PHASE
AND
OIL TRANSFER UB SOLID
PUMP TO CHOKE
PRODUCTION
OI
SHIPPING LINE
COILED FLOW
TUBIN DIRECTIO
N2 STORAGE G

VEN

DRILLING
CT REEL CHOKE
MANIFOLD

WEL
N2 PUMP SHALE SHAKER
CENTRIFUGE VACUUM
SYSTEM DEGASSER
POOR-BOY
MUD
DEGASSER

FLUID PUMP SAND TRIP

5 4 3 2 1 TRAP TANK
CUTTING
CHARGE S
PUMP

Careful design of the surface separation system is required once the reservoir
fluids are known. Dry gas is much simpler to separate than a heavy crude or a
gas condensate reservoir. However, the separation system must be tailored to
reservoir and surface requirements. This requires a high degree of flexibility and
the use of a modular system helps to maintain such flexibility.

The use of a modular system for offshore operations is often recommended,

because lifting capacity of platform and rig cranes is regularly limited to 15 or
20 Tons. To reduce the total footprint of a separation package, vertical
separators are generally used offshore as opposed to the horizontal separators
used in onshore operations.

Leading Edge Advantage International Ltd 2002 Page 29 of 51 Rev 5

 Example of a Modular Vertical Tank Separator System

7.6.1 Data acquisition

The data acquisition used on the separation system should provide as much
information as possible. This allows the maximum amount of information to be
obtained from the reservoir while drilling. It will also allow for a degree of well
testing during drilling. However, the safety aspect of data acquisition should
not be overlooked as well control is directly related to the pressures and
flowrates seen at surface.

7.6.2 Erosion monitoring

Erosion monitoring and prediction of erosion on pipe work is essential for safe
operations. The use of NDT technology has been found to be insufficient in
erosion monitoring. An automated system using erosion probes is currently
deployed and this allows accurate prediction of erosion rates in surface pipe
work.

The flow velocity limits applied by the industry to control erosion are defined in
the API recommended practice RP14. One drawback, however, of these
guidelines is that the amount of solids in production operations is significantly
lower then in underbalanced drilling operations. The use of erosion probes has
also now allowed prediction of hole cleaning and borehole collapse. As more

Leading Edge Advantage International Ltd 2002 Page 30 of 51 Rev 5

 data becomes available, the behaviour of solids in UBD wells is better
understood and managed. Erosion in surface pipe work is still a problem in
high rate wells and it is a significant cost of the operation. In general, target 'T's
should be used wherever necessary and these should include a method of
quickly releasing them for inspection and change-out purposes.

7.7 The circulation Process

Fluids from the reservoir flow up the wellbore to the surface. The rotating
diverter system ensures that the well remains closed. The fluid exits the well
through the main flow-line; into a well test choke manifold where the chokes
are normally open. Varying the lift gas rate or the liquid rate controls the well.
From the choke manifold, the flow enters the first stage separator where gas is
taken off and the solids are extracted from the fluid flow through a vortex
system. The overflow of the first stage separator enters the second stage
separator where the fluid is further degassed and any remaining solids are
taken out. Drilling fluid is send back to the mud pits. Produced oil is sent to a
stock tank or to the production train. The drilling fluid is then pumped back
down to the well to start the cycle again.

It is currently normal practice to have a first and second stage separator

offshore. This is mainly to ensure that drilling fluid is degassed before it is send
back to the pit system inside the rig. If a gas condensate field is drilled, a third
vessel is often required to ensure that condensate is separated. Further
advances in separation technology are ongoing to ensure that surface
separation packages are smaller and become more automated.

Leading Edge Advantage International Ltd 2002 Page 31 of 51 Rev 5

8 Completing underbalanced drilled wells
The majority of wells previously drilled Underbalanced could not be completed
underbalanced. The wells were displaced to an overbalanced kill fluid prior to
running the liner or completion. Depending on the completion fluid type, some
formation would take place. The damage is not as severe for completion brine
as with drilling mud due to the removal of the drilled cuttings and fines.
However, reductions in productivity of 20 to 50% have been encountered in
underbalanced drilled wells killed for the installation of the completion.

If the purpose of underbalanced drilling is for reservoir improvement, it is

important that the reservoir is never exposed to overbalanced pressure with a
non-reservoir fluid. If the well has been drilled underbalanced for drilling
problems, and productivity improvement is not impaired, then the well can be
killed and a conventional completion approach can be taken.

A number of completion methods are available for underbalanced drilled wells:

• Liner and perforation
• Slotted liner
• Sandscreens
• Barefoot

All of the above options can be deployed in underbalanced drilled wells. The
use of cemented liners in an underbalanced drilled well is not recommended if
the gains in reservoir productivity are to be maintained. Irrespective of the liner
type run, the installation process for the completion is exactly the same. It is
assumed that a packer type completion is installed. The production packer and
tailpipe are normally run and set on drill pipe with an isolation plug installed in
the tailpipe. If the well is maintained underbalanced, well pressure will normally
require the production packer and tailpipe to be snubbed into the well against
well pressure. The use of pressure-operated equipment in underbalanced drilled
wells is not recommended. A mechanically set production packer should be
used.

Leading Edge Advantage International Ltd 2002 Page 32 of 51 Rev 5

8.1 Snubbing

With well pressure acting upwards on the completion, the weight of the
assembly will be less than the upward force. This means that a snubbing system
is required to get the packer assembly in the hole. In an underbalanced drilling
system the well can be allowed to flow via the surface separation package. This
is an advantage over conventional snubbing operations as the surface pressure
of a flowing well is normally lower than shut in pressure.

At no time during the snubbing operations should the conventional well control
BOP stack be compromised. Special snubbing BOP’s and a rotating diverter must
be used in addition to the conventional drilling BOP’s.

8.2 Installation of a Solid Liner

Using solid pipe for the liner is no different than snubbing in drillpipe or tubing.
The shoe track of the liner must be equipped with non return valves to prevent
flow up the inside of the pipe. The liner is normally run with a liner packer and
the liner can be snubbed into the live well. Once on bottom, the liner hanger
and packer are set and the reservoir is now sealed. If zonal isolation is required,
ECP’s must be run at pre-determined intervals. Once the liner is set, the pipe
must be perforated to obtain flow. This can be achieved using the normal
procedures but it should be remembered that any fluid used must maintain the
underbalanced status.

8.3 Installation of a perforated liner or sandscreen(s)

The main disadvantage of running a slotted liner or sandscreens in an

underbalanced drilled well is that isolation is not possible across the slotted
section of the liner or screen with the BOP’s.

The use of plugged slots that dissolve once the liner is installed downhole is not
deemed safe for offshore operations. The pressure integrity of each slot would
have to be tested prior to running each joint and this is not feasible.

Leading Edge Advantage International Ltd 2002 Page 33 of 51 Rev 5

 The use of special blanking pipe in sandscreen also adds further complications
to the installation procedures. Running a slotted pipe or screen into a live well
cannot be done safely, even if all the holes are plugged the potential for a leak
is too great. The only way to install a slotted liner in a live well is by using the
well as a long lubricator and by isolating the reservoir downhole.

There are very few mechanical methods of downhole isolation available for the
running of a slotted liner. The Baker “Underbalanced Liner Bridge Plug (ULBP)
system” is one of the few systems currently on the market. This system allows a
retrievable plug to be set in the last casing. This isolation plug is released by a
retrieving tool which is attached the bottom of the slotted liner. This retrieving
tool unseats the isolation plug and then swallows the isolation plug or packer.
The swallowing action of the retrieval tool ensures that the plug and retrieving
tool are rigid and can be run to TD without hanging up in the open hole. Both
the packer and retrieval tool are specifically designed to be released by the
liner.

If necessary, the well can be lubricated to kill fluid on top of the plug and
displaced via the slotted liner when the drill string is sealed by the rotating
diverter.

The complete procedure for running of a slotted liner and the completion in an
underbalanced drilled well is outlined in the following 12 diagrams.

Leading Edge Advantage International Ltd 2002 Page 34 of 51 Rev 5

 Step 1 Step 2 Step 3
Drilling Out of the Run Underbalanced
Completed Hole Liner Bridge Plug

Production Production Production

Casing Casing Casing

Reservoir Reservoir Reservoir

Step 4 Step 5 Step 6

Underbalanced Liner Run Slotted Liner Trip in with
Bridge Plug Set Slotted Liner

Production Production Production

Casing Casing Casing

Reservoir Reservoir Reservoir

Leading Edge Advantage International Ltd 2002 Page 35 of 51 Rev 5

 Step 7 Step 8 Step 9
Stab into Bridge Run Liner Pull Running
Plug & Unset to Depth String

Production Production Production

Casing Casing Casing

Reservoir Reservoir Reservoir

Step 10 Step 11 Step 12

Run Packer Production Run Completion
Packer Set

Production Production Production

Casing Casing Casing

Reservoir Reservoir Reservoir

Leading Edge Advantage International Ltd 2002 Page 36 of 51 Rev 5

8.4 Completion Running

The main problem with running the completion in a live well is the installation
of the SSSV control line. Once the control line is connected, the BOP’s no longer
seal around the pipe. Once again, therefore the simplest method is to isolate
the reservoir prior to running the completion.

In the case of the completion the production packer with a plug installed in the
tailpipe is snubbed into the live well and the production packer is set on drill
pipe. The packer assembly would be lubricated into the well by utilising the
snubbing well control system.

Once the production packer is set, the drillpipe can be used to pump completion
fluid to provide an additional barrier that can be monitored if required. The
completion is now run conventionally. The isolation plug in the tailpipe will be
retrieved during the well commissioning. Once again, before pulling this plug
the fluid should have been displaced out of the completion string. This can be
achieved with coiled tubing or with a sliding sleeve. Once the completion has
been installed, the well is ready for production. No clean up or stimulation is
required in the case of underbalanced drilled wells.

8.5 Workover of an Underbalanced Drilled well

The workover procedure is a reversal of the completion running, i.e. a

suspension plug is installed in the production packer tailpipe and the well is
lubricated to kill fluid. After retrieving the completion, the packer picking
assembly is run to the packer depth and the well is returned to an
underbalanced condition prior to retrieving the packer. This ensures that
formation damaging kill fluid does not come into contact with the reservoir at
any time.

Leading Edge Advantage International Ltd 2002 Page 37 of 51 Rev 5

8.6 Underbalanced drilled Multi-Lateral Wells

The setting of the production packer with a mechanical plug allows the lower
leg in a multilateral well to be isolated and remain underbalanced whilst the
second leg is drilled. After running the liner in the second leg, the completion
can be run and a second packer can be installed and stabbed into the lower
packer. If leg isolation is required, a flow sleeve can be installed at the junction
to allow selected stimulation or production as required. Re-entry into both legs
is also possible utilising a selective system. However, more detail as to the exact
requirements from a multilateral system will need to be reviewed.

Drilling a multilateral well underbalanced with the main bore producing can be
done but the drawdown on the reservoir will be small. A further setback will be
that cleaning up of the lateral is difficult if the main bore is a good producer.
Getting sufficient flow through the lateral to lift fluids can be a challenge.

8.6.1 Advantages & Limitations for live well deployment

The list below illustrates the advantages and disadvantages for staying with
underbalanced drilling and utilising a mechanical injection system (snubbing) to
install downhole barriers. This allows both the slotted liner and the completion
to be run without the need to be in an overbalanced mode with kill fluid in
contact with the formation.

PROS CONS
1. Reduced formation damage 1. Additional equipment and interfaces
required for snubbing
2. Reduced risk of surface leaks 2. Additional single barriers

3. Possible to run irregular OD completion

assemblies
4. Provides downhole barriers for both the
completion and the slotted liner

Leading Edge Advantage International Ltd 2002 Page 38 of 51 Rev 5

9 Health Safety and Environmental Issues
Because underbalanced drilling involves working on a live well, a Hazard
Operational analysis is required for the full process. To this end a flow chart has
been created that shows all the elements in the underbalanced drilling process.
Using the diagram, each element can be analysed for input and output and the
diagram has also been used to good effect to ensure that all items of an
underbalanced drilling system are reviewed during the HAZOP. It also allows
procedures and documentation to be reviewed for all parts of the
underbalanced drilling system.

HSE System Elements

RIG SYSTEM

7. RIG FLUID
SYSTEM 5. WELL
CONTROL
SYSTEM
1. DRILLING LIQUID
6. SURFACE SYSTEM
SEPARATION
SYSTEM 4. WELL SYSTEM
2. GAS SYSTEM

3. RESERVOIR

8. PLATFORM
PLATFORM SYSTEM
PROCESS SYSTEM

9.1 Environmental Aspects

The underbalanced drilling system is a fully enclosed system. When combined

with a cuttings injection system and an enclosed mud pit system, a sour
reservoir can be safely drilled safely using an underbalanced drilling system. The
pressures and flowrates are kept as low as possible. It is not the intention to drill
a reservoir and produce it to its maximum capacity. A well test can be carried

Leading Edge Advantage International Ltd 2002 Page 39 of 51 Rev 5

 out during drilling underbalanced to provide some productivity information.
The hydrocarbons produced during the UBD process can be routed to the
platform process plant, export or flared. There is work currently being
undertaken to reduce flaring and recover the hydrocarbons for export. In a
prolific well a significant amount of gas can be flared during the drilling
process. Recovering this gas provides an environmental benefit and an
economic benefit. Oil and condensate recovered are normally exported via a
stock tank into the process train.

9.2 Safety Aspects

Beside the full HAZOP a significant amount of crew training is required for
underbalanced drilling. A drilling crew has been instructed during its entire
career that if a well kicks it must be shut in and killed. During underbalanced
drilling the single item to be avoided is to kill the well. This may undo all the
benefits of underbalanced drilling. Working on a live well is not a normal
operation for a drilling crew and good training is required to ensure that
accidents are avoided.

The underbalanced drilling process is more complex when compared to

conventional drilling operations. Gas injection, surface separation as well as
snubbing maybe required on a well. If the hydrocarbons produced are then
pumped into the process train, it is clear that drilling is no longer a stand-alone
operation.

The reservoir is the driving force in the UBD process. The driller must
understand the process and all the interaction required between the reservoir,
the liquid pumprate, the gas injection and the separation and process system to
safely drill the well. When tripping operations start, the well must remain under
control. Snubbing pipe in and out of the hole is not a routine operation and a
specialised snubbing crew is normally brought on to snub the pipe in and out of
the hole.

The extra equipment also brings a number of extra crew to the rig. So besides a
more complex operation a number of service hands are on the rig that now
need to start working with the drilling crew. Yet the drilling crew will move

Leading Edge Advantage International Ltd 2002 Page 40 of 51 Rev 5

 back to conventional drilling once the well is completed. The drilling crew will
need to be trained in this change of operating.
If a number of wells are to be drilled underbalanced in a field, it maybe an
option to consider batch drilling of the reservoir sections. This saves
mobilisation and it also sets a routine with the drilling crew. It must be stated
that few accidents occur during underbalanced drilling, this is mainly believed
to the high emphasis on safety during live well operations.

9.3 Step by Step Approach

It is considered prudent if a number of wells are to be drilled underbalanced

with a new crew to apply a step by step approach to underbalanced drilling.
The first well is drilled underbalanced but killed on trips. The second well is
drilled underbalanced and tripped underbalanced but the well is killed for
completions. The third well is drilled and completed underbalanced. This allows
all crew and service providers to train and prepare the equipment.

Leading Edge Advantage International Ltd 2002 Page 41 of 51 Rev 5

10 Limitations
There are not only advantages to underbalanced drilling. Before embarking on
an underbalanced drilling program, the limitations of the process must be
reviewed. There are technical limitations as well as safety and economic
limitations to the underbalanced drilling process.

Conditions that can adversely affect any underbalanced operation:

• Insufficient formation strength to withstand mechanical stress without
collapse.
• Spontaneous imbibition due to incompatibility between the base fluid
used in the underbalanced drilling fluid and the rock or reservoir fluid.
Use of a non-wetting fluid can prevent or reduce this situation.
• Deep, high pressure, highly permeable wells presently represent a
technical boundary due to well control & safety issues.
• Non-continuous underbalanced conditions.
• Excessive formation water.
• High producing zones close to the beginning of the well trajectory will
adversely affect the underbalanced conditions along the borehole.
• Wells that require hydrostatic fluid or pressure to kill the well during
certain drilling or completion operations.
• Slimhole or drilling conditions that result in a small annulus create high
back-pressures due to frictional forces.
• Wells that contain targets that contain significant pressure or lithology
variations throughout.

10.1 Technical Limitations

10.1.1 Wellbore stability

Wellbore stability is one of the main limitations of underbalanced drilling.

Borehole collapse as a result of rock stresses is one issue to be considered. The
other issue is chemical stability, which is seen in shale and claystone formations.
Both these issues can have serious implications in underbalanced drilling.
Defining maximum drawdown and reviewing chemical compatibility with the
proposed drilling fluids is a key issue in the feasibility of underbalanced drilling.

Leading Edge Advantage International Ltd 2002 Page 42 of 51 Rev 5

 No borehole collapse due to rock mechanics and drawdown has been reported
in underbalanced drilled wells.
A well drilled in Spain in 1996 encountered significant hole problems and was
side-tracked three times and finally produced through the drillstring as a result
of borehole collapse. No further investigations into the causes have been
published but it is one of the published examples of well bore stability
problems.

10.1.2 Water inflow

Water inflow in a depleted reservoir can cause severe problems in an

underbalanced drilled well. If the flow rate is high enough the well will be
killed as a result of the water influx. Gas lifting a well that produces water at a
high rate is almost impossible. Care must be taken that the water leg in a
depleted reservoir is not penetrated when drilling underbalanced.

10.1.3 Directional Drilling equipment

Directional Drilling equipment can have limitations on underbalanced drilling.

Hydraulic operated tools can not be used in UBD wells and if a gasified system is
used the MWD pulse systems may not work. Certain motors and other
directional equipment may be prone to failure as a result of the rubber
components becoming impregnated with the gas used. Explosive
decompression of rubber components is a consideration to be made when
selecting equipment.

The higher Torque and Drag seen in UBD wells (as much as 20%) may also
prevent certain trajectories from being drilled underbalanced. The higher
torque is caused by the reduced buoyancy combined with the lack of filter cake
on the borehole wall. This is a factor that may be of concern in ERD wells.

10.1.4 Unsuitable Reservoir

The reservoir may not be suitable for underbalanced drilling. A highly porous,
high permeable reservoir can provide too much inflow at low drawdown. It is
important that the perceived benefits of underbalanced drilling are kept in
mind when planning for underbalanced operations.

Leading Edge Advantage International Ltd 2002 Page 43 of 51 Rev 5

10.2 Safety and Environment

The HSE issues of an underbalanced drilling operation may prove to be too

complicated to allow underbalanced drilling to proceed. If a safe system cannot
be designed and implemented, underbalanced drilling should be re-considered.
A serious accident in underbalanced drilling operations can cause a severe
setback in this technology. It can be done safely providing that all issues are
addressed.

10.2.1 Surface equipment

The placement of the surface equipment may prove to be impossible on some

offshore locations. There can be problems with rigfloor height and with deck
space or deck loading. Both the wellhead equipment and the surface separation
equipment must be carefully designed to fit the platform or rig.

10.2.2 Training

The entire platform/ rig crew must be trained in underbalanced techniques.

Once the crew understands what is to be achieved, operations will run
smoother and with fewer problems and accidents. The documentation and
policies and procedures should not be forgotten when considering training.

10.2.3 Personnel

The number of crew required for underbalanced drilling is still considered large.
15 to 20 extra crew members are required for full underbalanced drilling and
completing. This number must be brought down for safety reasons. Significant
work is being undertaken in automation of underbalanced systems to reduce
the crew size.

10.3 Economics

The business driver behind the technology must never be forgotten. If the
benefits cannot be achieved then the project must be reviewed. Improvements
seen from underbalanced drilling are:
• Twice the Penetration rate.
• Triple the Production rate.

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11 Case histories

Underbalanced drilling in Europe started with the technology from Canada in

1995. Initially onshore but migrating offshore with the first well drilled
underbalanced offshore by Shell in Lowestoft in June 1997.

Year Country Operator Details

1995 Germany BEB Ulsen
RWE-DEA Breitbrunn gas storage
Australia WAPET
1996 Denmark Maersk Coiled Tubing
Netherlands NAM Coiled Tubing
UK Pentex Oil field onshore
1997 UK Shell First Offshore Well
Mexico Pemex Offshore well GOM
Indonesia Mobil Arun gas field (depleted)
Spain SESA
Algeria Sonarco
Oman PDO
Argentina YPF
1998 UK Shell Offshore Barque & Clipper
UK Edinburgh Oil Coiled tubing gas storage onshore
& Gas
Indonesia Kufpec Oseil
Indonesia Gulf
Italy Agip/SPI Sicily
1999 UK Shell Galleon & Barque
Sharjah BP Amoco

All the above listed underbalanced drilled wells had to be drilled

underbalanced, either because of productivity or for reservoir depletion.

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12 Advantages of Underbalanced drilling
The advantages of underbalanced drilling have been clearly seen during the
wells drilled and completed underbalanced. Early wells were killed for trips and
this clearly showed the benefits of underbalanced drilled wells. One well was
drilled and completed underbalanced and was then stimulated with an acid
wash and this once again proved a reduced productivity.

12.1 Drilling Technical Advantages

No mud losses are encountered during underbalanced drilling.

Simple waterbased fluid systems have been used. If torque and drag are an
issue, then an oilbased mud system can also be used. Gas solubility in oil needs
to be considered when using oilbased mud systems

Penetration rates increase by 2 to 5 fold when drilling underbalanced. This is

still a function of formation and bit selection. The amount of drawdown has a
direct impact on the rate of penetration.

Bit life is increased. Because the well is drilled faster and the removal of cutting
from the bit face is more efficient (Chip Hold down effect)

No differential stuck pipe occurs when drilling underbalanced. There is no wall

cake and no over pressure to push the pipe against the wall of the wellbore. It
does not mean that no stuck pipe occurs when drilling underbalanced. Key
seating and junk as well as hole collapse can still cause stuck pipe even in
underbalanced drilled wells.
Inefficient hole cleaning as a result of the multiphase flow can also cause stuck
pipe in underbalanced drilled wells.

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12.2 Reservoir Technical Advantages

Reduced formation
Reduced formation damage in lower permeability reservoirs leads to an average
increase in productivity of 3 times the production seen in overbalanced drilled
wells. Although the factor of 3 is now been accepted as an average productivity
improvement, significantly larger improvements have been seen on some wells.
Once again reservoir studies and knowledge of the damage mechanism will
quickly indicate the potential improvements.

Reduced stimulation requirements.

The one well that was drilled underbalanced and then acid washed proved
conclusively that acid stimulation does not increase productivity. A well drilled
and completed underbalanced will out perform a stimulated well. Saving the
costs of hydraulic fracture stimulation often offset the price of underbalanced
drilling.
Improved formation evaluation is provided by the ability to test the well while
drilling and to steer the well into the most productive zones of the reservoir.
Intersection of fractures is possible as a large fracture is recognised by an
increase in productivity from the well.

Early Production
Production will start as soon as the reservoir is penetrated. For new field
developments this may require the production train to be ready once the first
well penetrates the reservoir.

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13 Costs
The costs of underbalanced drilling vary greatly with the reservoir encountered
and the sophistication required on the surface separation and data acquisition
system. The reservoir fluids dictate the required separation equipment and the
reservoir pressure dictate the pressure control equipment requirements as well
as the gas lift requirements.

The location and the number of wells to be drilled will to a degree dictate
mobilisation costs. A detailed feasibility study on a multi-well development will
be required while a simple quick look study can be performed on a low pressure
land well in Europe.

Comparing a number of operations in Europe, Canada and the middle East we

can now provide a ball park figure of 10% of the well cost is the additional cost
required for underbalanced drilling. If your well is expensive because of the
complex reservoir geometry, it is likely that the underbalanced drilling
equipment will also have to be suited to the complex drilling systems required.
If a simple vertical well is required in a homogeneous reservoir then the well
costs as well as the UBD costs can be low.

If a multi-well development can be drilled successfully underbalanced the

reduction in well count could be as high as 25% as a result of the increased
productivity. This benefit outweighs the obstacles and cost of underbalanced
drilling significantly.

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14 Future
The future of underbalanced drilling will see a significant increase in
automation and a resulting reduction in crew required.

The use of underbalanced drilling in HPHT reservoirs to avoid or at least

increase the narrow pore pressure / fracture pressure window.

The use of underbalanced drilling from floating rigs and with subsea
developments. There are currently systems and methods on the drawing board
but investment of 2 to 3 million dollars will be required to develop a working
system for underbalanced drilling from floating rigs.

Multiphase flow modelling in the annulus and prediction of hole cleaning and
cuttings transport will further improve UBD operations.

The use of downhole safety systems will eventually eliminate snubbing systems
for UBD wells.

The data acquisition at surface and downhole will improve allowing more and
more wells to be drilled underbalanced more effectively.

Better understanding of reservoir damage mechanisms and their associated

recovery factors and production profiles will lead to a more selective approach
to underbalanced drilling for reservoirs with a real need.

This document provides a flavour of the potential, the drawbacks and the
advantages of underbalanced drilling. It is not intended to provide a
comprehensive answer to all underbalanced drilling questions. It hope fully
provides a guideline and some basic understanding of the technology required
for underbalanced drilling.

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15 Further Information on Underbalanced Drilling
• Gas research Institute. Underbalanced Drilling Manual. Published by Gas
research Institute Chicago Illinois.GRI-97/0236
• Proceedings from 1st International Underbalanced drilling Conference &
exhibition held in The Hague, Holland 1995
• Proceedings from 3rd International Underbalanced drilling Conference &
exhibition held in The Hague, Holland 1997
• Maurer Engineering Inc. Underbalanced Drilling and Completion Manual.
DEA 101 phase 1. October 1996

16 Suppliers of Underbalanced Drilling Equipment

Deutag Northland
Williams
Shaffer
Weatherford
Schlumberger
Halliburton
Alpine

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17 Abbreviations
BOP Blow out Preventors
MMscft/day Million standard cubic foot per day
ROP Rate of penetration
BHP Bottom hole pressure
MWD Measurement While Drilling
PDM Positive Displacement Motor
ESD Emergency Shutdown
BHA Bottom Hole Assembly
NDT Non Destructive Testing
UBD Underbalanced Drilling
HAZOP Hazard Analysis Operations
ERD Extended Reach Drilling
HSE Health Safety and Environment

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