UNDERBALANCED DRILLING PROGRAM

OMOZ 22 Horizontal New Well

D1 Formation
Hassi Messaoud Field

Sonatrach

ALGERIA

WEATHERFORD CONTROLLED PRESSURE DRILLING

& TESTING SERVICES

Author: Cherif Mohamed Mazouz Reviewed By: Ayman Marei

Position: CPD Engineer Position: Project Manager
Date: February 27, 2009 Date: July 8th, 2009

Prepared for:
Position:

Document Reference No:

DISCLAIMER & PROPRIETARY INFORMATION

Weatherford International (“Weatherford”) warrants that the information contained in the within report has been compiled using sound engineering principles
and judgment and employing currently available technology. However, the conclusions reached are based in whole or in part on information and data provided by
the named recipient, its employees or authorized agents, the accuracy and completeness of which are beyond the control of Weatherford. Weatherford provides
no warranty as to the quality or usefulness of the reported results and no guarantee whatsoever regarding its fitness to the purpose of the recipient or the outcome
of operations, which it explicitly or implicitly recommends.

This report is intended for sole use of the named recipient, and should not be relied upon to reach conclusions other than those expressly stated herein. The
recipient warrants that it will keep this report confidential and will limit its disclosure, on a need to know basis, to persons within its employ or from whom it seeks
advice. The recipient further warrants that it will not provide this information to any company or persons who provide services competitive to those provided by
Weatherford or any of Weatherford’s subsidiaries or affiliates.
 Sonatrach – Algeria
Hassi Messaoud Field – Well OMOZ 22 (D1 Formation)

Table of Contents
1 EXECUTIVE SUMMARY ............................................................................................................................. 4

2 OBJECTIVES .................................................................................................................................................. 6

3 WELL DATA ................................................................................................................................................... 7

3.1 WELL SCHEMATIC ...................................................................................................................................... 7
3.2 GEOLOGICAL AND RESERVOIR DESCRIPTION............................................................................................. 8
4 UNDERBALANCED DRILLING DESIGN PARAMETERS ................................................................. 13
4.1 CASING DESIGN ........................................................................................................................................ 13
4.2 BHA AND DRILL STRING DESIGN ............................................................................................................ 13
4.3 DRILLING FLUID SELECTION .................................................................................................................... 13
4.3.1 Liquid Phase .................................................................................................................................... 14
4.3.2 Gas phase......................................................................................................................................... 15
4.4 FLOW MODELING, OPERATING ENVELOPE, PRODUCTION SENSITIVITY AND OPTIMUM RATES .............. 15
4.4.1 No Production Case Evaluation...................................................................................................... 17
4.4.1.1 Case 1 (Concentric Injection)...................................................................................................... 18
4.4.1.2 Case 2 (Drill Pipe Injection)........................................................................................................ 18
4.4.2 Production Case Evaluation............................................................................................................ 19
4.4.2.1 Case 1 (Concentric Injection)...................................................................................................... 19
4.4.2.2 Case 2 (Drill Pipe Injection)........................................................................................................ 20
4.5 HOLE CLEANING ....................................................................................................................................... 22
4.5.1.1 Case 1 (Concentric Injection)...................................................................................................... 22
4.5.1.2 Case 2 (Drill Pipe Injection)........................................................................................................ 23
4.6 MOTOR PERFORMANCE ............................................................................................................................ 24
4.7 SURVEY REQUIREMENTS .......................................................................................................................... 24
4.8 DATA ACQUISITION SYSTEM .................................................................................................................... 24
4.9 PRODUCTIVITY INDEX WHILE DRILLING ................................................................................................. 25
4.10 FLOW CONTROL MATRIX ......................................................................................................................... 26
4.11 SURFACE EQUIPMENTS EROSION MANAGEMENT..................................................................................... 27
4.12 STRIPPING SYSTEMS ................................................................................................................................. 29
5 SPECIAL CONSIDERATIONS .................................................................................................................. 31
5.1 QHSE ....................................................................................................................................................... 31
5.2 WELLHEAD CONFIGURATION ................................................................................................................... 31
5.3 DRILL PIPE REQUIREMENTS ..................................................................................................................... 31
5.4 CHEMICALS ............................................................................................................................................... 31
5.5 TOP DRIVE ................................................................................................................................................ 31
5.6 BOREHOLE INSTABILITY ........................................................................................................................... 32

List of Figures
Figure 1: OMOZ 22 Horizontal Wellbore Schematic – Hassi Messaoud Field ..................................... 7
Figure 2: Hassi Messaoud Field Location............................................................................................ 8
Figure 3: OMOZ 22 Location ............................................................................................................... 9
Figure 4: OMOZ 22 Stratigraphy ....................................................................................................... 11
Figure 5: CPD Operating Window – CCI (no production) – WHP 100psi.......................................... 18
Figure 6: CPD Operating Window – DPI (no production) – WHP 100psi .......................................... 19
Figure 7: CPD Operating Window – CCI (with production) – WHP 100psi ....................................... 20
Figure 8: CPD Operating Window – CCI (with production) – WHP 100psi ....................................... 21

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 Sonatrach – Algeria
Hassi Messaoud Field – Well OMOZ 22 (D1 Formation)

Figure 9: Fluid Velocity vs Measured Depth (CCI 850 lpm Crude and 53 sm3/min N2) ..................... 23
Figure 10: Fluid Velocity vs Measured Depth (DPI 730 lpm Crude and 26 sm3/min N2) ................... 23
Figure 11: Various PIWD curves ...................................................................................................... 25
Figure 12: BHCP vs. Measured Depth ............................................................................................. 33

List of Tables
Table 1: offsite wells to OMOZ 22 ...................................................................................................... 10
Table 2: Reservoir Parameter for OMOZ 22....................................................................................... 12
Table 3: OMOZ 22 Casing Design .................................................................................................... 13
Table 4: OMOZ 22 BHA Design........................................................................................................ 13
Table 5: Minimum liquid velocities criteria.......................................................................................... 22
Table 6: UBD Operations Acquired Data ........................................................................................... 24
Table 7: Flow control matrix (Liquid Inflow)........................................................................................ 26
Table 8: Flow Control Matrix (Gas Inflow) .......................................................................................... 27
Table 9: Recommended stripping limits ............................................................................................. 30
Table 10: RCD remaining life calculation example............................................................................. 30

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 Sonatrach – Algeria
Hassi Messaoud Field – Well OMOZ 22 (D1 Formation)

1 EXECUTIVE SUMMARY
Weatherford’s Controlled Pressure Drilling (CPD) team has more than 40 years of
worldwide experience in all aspects of Underbalanced Drilling services. Weatherford is
dedicated to supply the most reliable CPD equipment through an aggressive application
of new “cutting-edge” technology and continuous dedicated efforts of research and
development to improve equipment reliability. Weatherford is the only global provider of
fully integrated CPD products and services. Weatherford is committed to offer its
customers the most comprehensive, safe, and effective drilling solutions in order to
meet today’s growing demands of oil and gas production worldwide.
Sonatrach is the Algerian National Oil and Gas Company, which explores, develops,
produces, and sells crude oil, natural gas, and natural gas liquids. The company is
headquartered in Algiers, with operations in various oil and gas fields in Algeria and has
invested in the development of the Hassi Messaoud field using Weatherford’s advanced
Controlled Pressure Drilling and Testing Services.
The Hassi Messaoud field, discovered in 1956, is the largest oilfield in Algeria covering
about 2000 km2 and currently including over 1000 wells. Production is from thick,
Cambrian age sandstone at a vertical depth of approximately 3400 m. This sandstone is
extremely hard, abrasive, and slow to drill. And that has inspired Sonatrach to utilize the
Underbalanced Drilling (UBD) technology to drill wells in Hassi Messaoud field with the
objectives of improving the rates of penetration, eliminating drilling problems, minimizing
formation damage and improving productivity. These objectives were successfully
accomplished by utilizing Weatherford’s integrated CPD products and services.
This drilling program illustrates the technique that will be applied to drill the D1 drain
section of the Cambrian with the well OMOZ 22 underbalanced, with the main objective
being reducing formation damage caused by the invasion of drilling fluids and cuttings
into the formation while minimizing bore hole stability problems. The proposed solution
is to drill this section using concentric casing injection (CCI) or Drill Pipe Injection (DPI)
with a minimal bottom hole pressure drawdown of 5% to 10% (never creating more than
1000 psi drawdown).
Based on the provide reservoir pressure and depth, a gasified fluid system is required in
order to achieve a controlled bottom hole pressure drawdown leading to stable
underbalanced drilling conditions. Comprehensive hydraulic simulations were carried
out in order to determine the required gas and liquid injection rates and back pressure
on the choke manifold to ensure safe and continuous underbalanced drilling operation
conditions. The simulations were also used to predict the anticipated circulating
pressures and ensure adequate hole-cleaning with the appropriate equipment.
The horizontal section direction should be designed based on the magnitude and
direction of the minimum and maximum in-situ horizontal stresses and their relation to
the overburden value. If the maximum horizontal stress is smaller in magnitude than
the overburden or the vertical stress then the well should be orientated in the direction
of the minimum horizontal stress. However, if the maximum horizontal stress is greater
in magnitude than the overburden or the vertical stress then the well should be
orientated in the direction of the maximum horizontal stress.

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 Sonatrach – Algeria
Hassi Messaoud Field – Well OMOZ 22 (D1 Formation)

Weatherford has been enlisted to provide underbalanced drilling services for the Hassi
Messaoud Field. This underbalanced drilling program outlines the technical aspects of
the application of UBD technology in this well.

Underbalanced drilling requires the integration of diverse services and equipment. All
aspects of the operation must be organized in a cooperative fashion to increase the
success and the productivity of the project. Distinct and very specialized services must
be integrated to form a coherent operating entity.

The program was drawn with input from Sonatrach’s drilling, reservoir, geology and
production engineering team. It should be noted that any significant deviation from the
well profile assumed and the reservoir data supplied by Sonatrach may have an effect
on the accuracy of the conclusions contained within this program.

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 Sonatrach – Algeria
Hassi Messaoud Field – Well OMOZ 22 (D1 Formation)

2 OBJECTIVES

Weatherford will provide its integrated Controlled Pressure Drilling (CPD) services to
drill well OMOZ 22 in the Hassi Messaoud Field underbalanced. The plan is to drill a 6”
horizontal lateral section underbalanced. The drain hole will be drilled into the Cambrian
Formation drain section of D1.

This underbalanced drilling program outlines the processes, equipment, personnel,

procedures and operations necessary for the application of Underbalanced technology
for drilling, logging and completing the Horizontal Well.

The primary objectives of the Sonatrach UBD project include:

• Drill 1000 m of 6” open hole out of 7” production casing through the D1 formation
in underbalanced conditions.
• Minimize formation damage (maximizing the reservoir productivity).
• Reservoir characterization, evaluating the oil/gas production while the well is
being drilled and during flow test and Build up test process.
• Increasing rate of penetration.

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 Sonatrach – Algeria
Hassi Messaoud Field – Well OMOZ 22 (D1 Formation)

3 WELL DATA

The wellbore schematic data and the reservoir information received and proposed for
the UBD operation is summarized in this section. The diagram presented below
(figure 1) is the wellbore schematic for well OMOZ 22 planned to be drilled in the Hassi
Massoud field.

The casing program planned for this well includes running and setting the 18 5/8” casing
at 495m TVD, the 13 3/8” casing at 2334m TVD, the 9 5/8” casing at 3273m TVD, a 7”
casing set at the top of the payzone at 3354m TVD. The producing section will be
drilled 1000 m horizontally into the D1 formation.

3.1 Well Schematic

Label Description MD (m) TVD (m) Incl(deg)

1 18"5/8 Casing Shoe 495 495 0
2 7" Tie back 0-2540 0-2540 0
3 13"3/8 Casing shoe 2334 2334 0
4 Circulating sub 2530 2530 0
1 5 7" Liner 2540-3490 2540-3354 0-88
6 KOP 3000 3000 0
7 9"5/8 Casing shoe 3296 3273 40
2 8 Landing point 3490 3354 88
9 7" Liner shoe 3490 3354 88
3
10 6" Open Hole 3490-4490 3354-3379 88
11 TD 4490 3379 88

6
5

9 10 11

Figure 1: OMOZ 22 Horizontal Wellbore Schematic – Hassi Messaoud Field

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 Sonatrach – Algeria
Hassi Messaoud Field – Well OMOZ 22 (D1 Formation)

3.2 Geological and Reservoir Description

The Hassi Messaoud field is a flattened anticline located in the Oyed Mya Basin of
Algeria, about 800 km southeast of Algiers, in the northern part of the Sahara desert
(as shown in Figure 2). Discovered in 1956, it produces from Cambrian age, quartzitic
sandstone with a gross thickness of 60-150 m.

The field is divided aerially into 25 separate zones that are separated from each other
by low permeability, usually faults, though this isolation is not complete. Four
producing formations have been identified, the Ra being the primary producer and the
R2, Ri, and R3 also contributing in some zones. The Ra is further divided into four
“drains” that vary in productivity and are classified based on percentage of permeable
sandstone present versus discontinuous shale lenses relative to the overall package.

Figure 2: Hassi Messaoud Field Location

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 Sonatrach – Algeria
Hassi Messaoud Field – Well OMOZ 22 (D1 Formation)

OMOZ 22 is situated South of Zone 07 (Interzone OMO) as illustrated in Figure 3.

The geological correlation was based on nearest UBD wells (OMOZ 322 and
OMOZ 222).

Figure 3: OMOZ 22 Location

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 Sonatrach – Algeria
Hassi Messaoud Field – Well OMOZ 22 (D1 Formation)

Table 1 summarizes information about UBD offsite wells OMOZ 322 and OMOZ 222

Table 1: offsite wells to OMOZ 22

OMOZ 222 OMOZ 322

Well No. 28 36
From 22/07/2006 13/04/2007
Duration
to 05/08/2006 19/05/2007

Rig ENF21 ENF21

UBD Method CCI / DPI DPI

Target Ra(D1R2) Ra(D1)

Planned Depth (m MD) 4150 4107

Real Depth (m MD) 4116 4107

Meters Drilled 773 774

Average ROP (m/hr) 10.65 5.97

Avr. Production (m3/hr) 16 9

Avr. GOR (sm3/m3) 208 180

UBD Days 12.34 29.33

Estimated Reservoir
2963 3225
Pressure (psi)

Real Reservoir Pressure

(psi) 2963 3024

Average BHCP (psi) 2750 2885

Average Drawdown (%) 5-10 10.5

No. of flow tests 2 3

Remarks Down hole losses TD

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Hassi Messaoud Field – Well OMOZ 22 (D1 Formation)

The sandstone is naturally fractured though most of the fractures are filled through
secondary deposition and are not conductive. The geological prognosis of well OMOZ 22 is
shown in the stratigraphic column (Figure 4), which illustrates the formations of interest, D1
and the planned casing program and well profile.

SONATRACH PED GISEMENT DE HASSI-MESSAOUD

DEPARTEMENT POLE HASSI MESSAOUD FICHE DE PREVISION DU FORAGE HORIZONTAL
EN UBD (OMOZ22)

COORDONNEES,
LSA UTM (m)
X= 812 517,72 X= 783 956,089
Y= 132 806,52 Y= 3 515 986,087
ALTITUDE
Zsol= 170,86 m Ztable= 180 m

AGE PROF STRATIGRAPHIE LITHOLOGIE DESCRIPTION Carot, TUBAGE DIAGRAPHIES

test
0-242 MIO-PLIOCENE sable , calcaire et marne sableux

26" X18"5/8
242 EOCENE sable calcaire à silex

361 CARBONATE calcaire + dolomie et anhydritique

C
455 SENONIEN ANHYDRITIQUE anhydrite + marne et dolomie
495 m
R 663 SALIFERE
L- L- L- L- L- L- L
sel massif et traces d'anhydrites
L-L- L- L-L- L

E
808 TURONIEN calcaire tendre crayeux

T
928 CENOMANIEN anhydrite marne et dolomie

Phase 16 X CSG 13" 3/8

A
1087 ALBIEN Grès et Argile Silteuse

C 1422 APTIEN Dolomie cristaline et calcaire

1447 BARREMIEN
E Argile et sable + Grès

1688 NEOCOMIEN Dolomie , marne et Grés + Argile

1903 MALM Argile , Marne et Dolomie + Grès

2123 ARGILEUX Argile, Marne et Dolomie

DOGGER
J
2224 LAGUNAIRE Anhydrite , Dolomie et Marne
U
R 2334 m
2446 L.D.1 Dolomie , Anhydrite et Argile
A
S L-L-L-L-L-L-L-L-L-
2517 L.S.1 Alternance Sel , Anhydrite et Argile
S L-L-L-L-L-L-L-L-L-
Phase 12" 1/4 X CSG 9"5/8

CBL/VDL (1/200 ET 1/500)

2609 LIAS L.D.2 Anhydrite et Dolomie cristalline

Gamma Ray / CALIPER

Q
U L-L-L-L-L-L-L-L-L-
2661 L.S2 Alternance de Sel et d'Argille
E L-L-L-L-L-L-L-L-L-

2714 L.D.3 Alternance de Marne et de Dolomie

L-L-L-L-L-L-L-L-L
2752 TS1 Alternance Sel , Anhydrite et Argile et dolomie
L-L-L-L-L-L-L-L-L

T
2800 SALIFERE TS2 Sel massif à intercalation d'anhydrite et d'argile

R L-L-L-L-L-L-L-L-L-
2936 TS3 Sel massif et traces d'Argile
L-L-L-L-L-L-L-L-L-

I Argile rouges Dolomitiques ou silteuses

3194 ARGILEUX G35=3279
injectée de sel et d'argile. G35= 3279 m
A
3322 GRES SUPERIEURS Grés fins à ciment Argileux abondant
ARGILO-
S GRESEUX ARGILO-
Argile Dolomitique Et Niveau Dolomie
& CARBONATE
CARBONATE Grès Fins à Grossiers avec Passeés
GRES INFERIEURS
argileuses et friables.
Complexe volcano-sédimentaire
ANDESITIQUE
Phase 8" 3/8 x 7''

O Quartzites gris beiges fins àTigillites

QUARTZITES DE HAMRA
R
Grés Glauconieux fins à Tigillites
D avec passées d'argile noire
GRES D'EL ATCHANE
O
V
ARGILES D'EL GASSI Argile noire micacée et niveaux de grès blancs
I
C
I ZONE DES ALTERNANCES Alternance de Grès et d'Argile
E
N Grès quartzitiques fins
Réservoir Ri
isométriques à Tigillites
C ... Grès quartzites et Quartzites Grés
3332 Réservoir Ra (DH) 3335 m
A ....... anisométrique avec passées de Siltstones
Gamma Ray / Neutron /

M ......................
CBL/VDL (1/200 ET 1/500)

Résistivité/ Densité /

3390 Réservoir R2 Grès quartzitiques à ciment argileux

B .................
AU 1/200-1/500

R ......................
IMAGERIE

Grès quartzites à ciment Argileux

Réservoir R3
................. abondant à éléments très gossiers
Infracambrien Grès argilo-carbonatés rougeâtres,
galets de granite Arrêt @ 3395 m TVD (-
3395 TD -3215 3215 mTVDSS)
3480 OWC -3300
PRESSIION DE GISEMENT PREVUE: 220 Kg/cm2

Figure 4: OMOZ 22 Stratigraphy

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 Sonatrach – Algeria
Hassi Messaoud Field – Well OMOZ 22 (D1 Formation)

The average permeability ranges from 0.5-10 mD but can reach up to 1000 mD in
cases where open fractures are encountered. Original oil in place for the entire field
was estimated at about 2 billion cubic meters (12.6 billion barrels) making this a true
giant among oilfields. Production is a 43.7 - 45°API oil with a current average GOR of
about 200 m³/ m³, and a formation temperature of approximately 120°C.

Original reservoir pressure in Hassi Messaoud field was 473 bars and now ranges
from 140-250 bars. Bubble point pressure of the crude varies across the field from
142 to 196 bars.

The reservoir information for a well OMOZ 22 is presented in Table 2. The data
summarized in Table 2 was deduced from Sonatrach, and deviation from this data will
result in a significant effect on the accuracy of the conclusions contained within this
program.

Table 2: Reservoir Parameter for OMOZ 22

Parameter Description

Formation D1
Fluid Type Oil & Gas

Oil Gravity 43.7 – 45o API

Lithology Sandstone/Quartizite

Permeability 0.5-10 mD

Reservoir Pressure 3190 psi

TD MD / TVD 4490 m / 3379 m

Reservoir Temperature 120 (oC)

GOR 200 m3/m3

H2S None

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 Sonatrach – Algeria
Hassi Messaoud Field – Well OMOZ 22 (D1 Formation)

4 UNDERBALANCED DRILLING DESIGN PARAMETERS

4.1 Casing Design

Casing design from the general Sonatrach Drilling Program was utilized in preparing
this UBD document. The casing configuration used in the design process as well as
the drilling injection and production fluid points are illustrated in figure 1. The casing
setting depths used to prepare this drilling program and perform the hydraulics
calculations are summarized in Table 3.

Table 3: OMOZ 22 Casing Design

Depth Interval Length Weight OD ID
Casing m m m lb/ft inch inch
(MD) (TVD)
18 5/8” 495 495 495 N/A N/A N/A
13 3/8” 2334 2334 2334 N/A N/A N/A
9 5/8” 3296 3273 3296 53 9.625 8.535
7” Liner & Tieback 3490 3354 3490 29 7 6.18

4.2 BHA and Drill String Design

The BHA and drill string configuration provided by Sonatrach was used to prepare this
UB drilling program as well as perform the hydraulics calculations, and is summarized
in Table 4.

Table 4: OMOZ 22 BHA Design

Drill String OD ID Weight
Type
Inch Inch lb/ft
Drill Pipe 3 1/2 2.76 13.3
DC 4 3/4 2.25 47.0
HWDP 3 1/2 2.06 25.3
DP 3 1/2 2.76 13.3
Motor+MWD 4 3/4 N/A N/A

4.3 Drilling Fluid Selection

The selection of the appropriate drilling fluid system as well as the selection of each of
its phases is crucial in the application of a successful underbalanced drilling operation.
Whichever fluid is selected, it must be evaluated on the basis of its effect on the
formation, the hole-cleaning capability, general hydraulics, and the surface separation
equipment.

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 Sonatrach – Algeria
Hassi Messaoud Field – Well OMOZ 22 (D1 Formation)

Based on the reservoir data provided by Sonatrach, for the D1 formation in the Hassi
Messaoud Field, the reservoir pressure requires the injection of two phases drilling
fluid (Nitrogen and Crude) to achieve underbalanced conditions during the initial stage
of drilling. Concentric casing gas injection method will be utilized to inject the gas
phase (Nitrogen) downhole due to the small bottom hole pressure operating window
available.

Based on the projected production rates and the GOR, the Nitrogen injection rates
can be reduced and the well could then be drilled utilizing flow-drilling techniques
once a continuous stable production from the well is encountered.

The following topics need to be considered during the drilling fluid selection process:

• General hydraulics (ECD, hole cleaning, equipment).

• Mechanical wellbore stability.
• Chemical wellbore stability.
• Surface and downhole temperatures.
• Fluids compatibility.
o Interaction with the formation (wetability).
o Interaction with the formation fluids (emulsions).
• Fluid separation and handling at surface.
• QHSE related issues (Cuttings treatment, water disposal, contaminated
fluid disposal, etc.).

The use of crude as the liquid phase and Nitrogen as the gas phase and controlling
the injection rates and the choke back pressure allows the optimal BHCP to be
achieved.

4.3.1 Liquid Phase

Liquid phase selection for an underbalanced drilling operation should be mainly

based on formation fluids, rock compatibility, and fluid density. At the initial stages
of the simulation, a liquid phase with a density value similar to that of the produced
crude (0.82 s.g) was chosen to simulate the multiphase flow modeling. The
results from the simulation showed that nitrogen will have to be injected in order to
achieve underbalanced drilling conditions.

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 Sonatrach – Algeria
Hassi Messaoud Field – Well OMOZ 22 (D1 Formation)

4.3.2 Gas phase

Many different gases are used in underbalanced operations. These include natural
gas, membrane generated nitrogen, cryogenic nitrogen, exhaust gas, and carbon
dioxide. Each system has its own distinctive advantages and disadvantages.

Injected gas mixtures containing oxygen could result in downhole fires and
explosions when a set of conditions is present (i.e. hydrocarbons, oxygen,
pressure, and temperature). High oxygen contents can also create potentially
serious corrosion problems with both drill string equipment and surface separation
equipment. It is for these reasons that Weatherford do not recommend using
aerated fluids (i.e. high quantities of oxygen content) for this project.

To simplify the drilling fluid system, Weatherford will use membrane generated
nitrogen as the gas medium to drill the reservoir section. Membrane generated
nitrogen is cost effective, less corrosive, safer to use, and more environmentally
friendly than other gases with a higher oxygen content.

4.4 Flow Modeling, Operating Envelope, Production Sensitivity and Optimum

Rates

Weatherford uses rigorous multiphase flow simulation software to determine the

response of the well to changes in downhole conditions. The flow behavior in the
wellbore during underbalanced drilling is very complex. Using this software, circulating
pressures and hole cleaning parameters can be evaluated, and appropriate
equipment and injection rates selection can be determined.

The hydraulic and multiphase flow modeling software utilized has been validated on
many underbalanced drilling operations worldwide, including all the well drilled in
underbalance in Hassi Messaoud by Weatherford, and is widely considered the
industry-leading package.

When designing the drilling circulating system, specific criteria must be met in order to
satisfy all of the objectives of a properly drilled underbalanced section. While
considering these criteria, it is sensible for the selected UB system to be the simplest
possible that can achieve all of the required objectives.

The design of an underbalanced drilling circulating system must consider the following
criteria:

• Bottom Hole Pressure: the bottom hole circulating pressure must be controlled
and maintained in underbalanced conditions during the drilling and completion
phase operations.

• Hole Cleaning: Drilling fluid systems should guarantee the hole cleaning at any
given depth or inclination.

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 Sonatrach – Algeria
Hassi Messaoud Field – Well OMOZ 22 (D1 Formation)

• Motor Throughput (ELV): the equivalent flow (Crude oil plus Nitrogen) through
the downhole motor must be within the operational specifications to achieve
maximum motor efficiency.

• Surface Separation Equipment: the reservoir inflow must be controlled in order

to remain in the safe operational envelope of the surface equipment’s flow
containment capacities, rated pressures, and pipe work erosion limitations.

Based on these criteria, an underbalanced drilling window is defined and an

acceptable circulating system is developed.

Modeling Considerations
The following considerations were assumed in performing the hydraulic flow modeling
simulations:

• A two phase system, Crude (with a weight of 0.82 S.G) as the liquid phase and
Nitrogen as the gas phase.
• Minimum vertical liquid velocities of 55 m/min and 65 m/min for vertical and
horizontal sections of the well respectively are required to ensure the drilled
cuttings are effectively removed from the wellbore and to achieve adequate hole
cleaning.
• The 7” production casing extends to the surface. Circulating ports @ 2530 m
TVD.
• Density of cuttings of 22.6 ppg, cuttings diameter of 0.05” and rate of penetration
of 10 m/hr.
• 10% Drawdown (never more than 1000 psi drawdown from the real reservoir
pressure).
• A positive displacement, medium speed downhole motor (4 ¾” OD) with a
throughput between 378 lpm to 950 lpm (100 gpm to 250 gpm).
• A 700 psi pressure drop through the BHA (PDM+MWD).
• A 6” Bit with nozzles of 3 x13/32”.

Basic specifications for the PDM volumetric flow rates requirements, drill string
dimension, BHA (PDM and EM – MWD) pressure drops, bit total flow area and well
trajectory were considered for preliminary flow modeling purposes. Adjustments to
the modeling parameters should be carried out if equipment specifications vary
considerably from the values assumed in this study.

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 Sonatrach – Algeria
Hassi Messaoud Field – Well OMOZ 22 (D1 Formation)

4.4.1 No Production Case Evaluation

Hydraulic simulations were carried out considering the “no production” scenario,
which means no reservoir influxes were considered while modeling the envelope.
Figure 5 and Figure 6 show plots of the BHCP induced by a variety of nitrogen and
liquid injection rates. These plots are referred to as the “operating envelope”. Also
plotted on the operating envelope are the various constraints that must be
considered during underbalanced drilling operations. The purpose of plotting this
envelope (No Production Evaluation) is to obtain the liquid and gas injection
parameters that will be required while initiating the UBD operation.

Prior to the start up and during the UBD phase of the well, adjustments of these
parameters will become necessary in order to maintain the optimum operational
conditions (ECD, hole-cleaning, motor requirements, BHCP, and DD). On site
monitoring of all hydraulic parameters will be performed by the Weatherford CPD
Engineer, such as accounting for any production encountered, hole enlargement or
any other issues which modify the drilling profile examined in this program.

The following two cases (concentric casing injection and Drill Pipe Injection) were
modeled to provide increased flexibility in starting the conditioning of the well to
achieve underbalanced conditions.

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 Sonatrach – Algeria
Hassi Messaoud Field – Well OMOZ 22 (D1 Formation)

4.4.1.1 Case 1 (Concentric Injection)

Flow modeling performed indicated that Underbalanced conditions are achievable

for the OMOZ 22 horizontal well to be drilled to 3379 m TVD / 4490 m MD in
Hassi Messaoud field. An operational window exists for crude injection rates
ranging between 750 to 860 lpm and Nitrogen rates from 18 to 58 sm3/min with
100 psi of back pressure applied. To obtain the optimum underbalanced drilling
initiation pressure drawdown, 850 lpm crude injection rate with 53 sm3/min
Nitrogen is recommend to reach a 9.7% or 303 psi drawdown (2827 psi at bottom
hole) for the planned casing/hole configuration (Figure 5).
3600
Recommended Parameters:
3
850 lpm crude, 53 sm /min N2
3500 WHP=100 psi
BHCP=2827 psi
DD=9.7%
3400 Min.Horz.Liq.Vel.=73 m/min
ELV=934 lpm
SPP=1020 psi
3300
Bottom Hole Circulating Pressure (psi)

3200
Reservoir Pressure 3130 psi

3100

3000
5% DD

2900

10% DD
2800 Max
Moto
Mi r ELV
nH 9 50 lp
rz. m
Ve
2700 lo cit
y6
5m
/m
in
2600
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60
N2 Injection rate (sm3/min)

600 lpm 650 lpm 700 lpm 750 lpm 800 lpm 850 lpm
Reservoir Pressure 10% DD 5% DD Max Motor ELV Min Horil Velo. 55m/min

Figure 5: CPD Operating Window – CCI (no production) – WHP 100psi

4.4.1.2 Case 2 (Drill Pipe Injection)

An operational window exists for crude injection rates ranging between 650 to
780 lpm and Nitrogen rates from 13 to 27 sm3/min with a 100 psi applied back
pressure. To obtain the optimum underbalanced drilling initiation pressure
drawdown, 730 lpm crude injection rate with 26 sm3/min Nitrogen is recommend to
reach a 10% or 313 psi drawdown (2817 psi at bottom hole) for the planned
casing/hole configuration (Figure 6).

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Hassi Messaoud Field – Well OMOZ 22 (D1 Formation)

pp j @ p
3600
Recommended Parameters:
3
730 lpm crude, 26 sm /min N2
3500 WHP=100 psi
BHCP=2817 psi
DD=10%
3400 Min.Horz.Liq.Vel.=74 m/min
ELV=936 lpm
SPP=1424 psi
3300
Bottom Hole Circulating Pressure (psi)

3200
Reservoir Pressure 3130 psi

3100

3000
5% DD

2900

10% DD
2800 Max
Moto
Mi r ELV
nH 9 50 lp
rz. m
Ve
2700 lo cit
y6
5m
/m
in
2600
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34
N2 Injection rate (sm3/min)

600 lpm 650 lpm 700 lpm 750 lpm 800 lpm 850 lpm
Reservoir Pressure 10% DD 5% DD Max Motor ELV Min Horil Velo. 55m/min

Figure 6: CPD Operating Window – DPI (no production) – WHP 100psi

4.4.2 Production Case Evaluation

From an operational point of view, the underbalanced condition can be achieved.

However, as soon as reservoir production is encountered, the underbalanced
drilling operation becomes more challenging. The oil production rate along with a
GOR invading the wellbore reduces the equivalent circulating density of the
weighted mud system. The results are a high wellhead pressure, along with a high
return fluid rate that can cause erosion problems on the flow line especially when
cuttings are entrained in the fluids stream. Finally, managing a large volume of
fluid production at surface requires the specific planning for each case.
As this hydraulic evaluation is highly related with the reservoir properties (depth,
oil production, GOR, formation pressure, etc.), hydraulic simulations will be carried
out considering the specific case or set of data supplied by Sonatrach.
The following two cases (concentric casing injection and Drill Pipe Injection) were
modeled to provide increased flexibility in starting the conditioning of the well to
achieve underbalanced conditions.

4.4.2.1 Case 1 (Concentric Injection)

Flow modeling performed indicated that Underbalanced conditions are still
achievable for the Hassi Messaoud well OMOZ 22 even when production is
encountered. An operational window exists for crude injection rates ranging
between 670 to 850 lpm and Nitrogen rates from 0 and 37 sm3/min (as shown in
Figure 7), however, with a stable oil and gas production from the well, less crude

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 Sonatrach – Algeria
Hassi Messaoud Field – Well OMOZ 22 (D1 Formation)

and nitrogen will be required since the this hydrocarbon influx will assist in
achieving the underbalanced drilling conditions.
3600

3500 Recommended Parameters:

3
750 lpm crude, 0 sm /min N2
WHP=100 psi
3400 BHCP=3028 psi
DD=3.2%
Min.Horz.Liq.Vel.=72 m/min
3300 ELV=824 lpm
Bottom Hole Circulating Pressure (psi)

SPP=970 psi

3200
Reservoir Pressure 3130 psi

3100

3000
5% DD

2900

10% DD
2800 Max Mo
Min to r ELV 9
50 lpm
Hrz
. Ve
2700 lo city
65
m/m
in
2600
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60
N2 Injection rate (sm3/min)

600 lpm 650 lpm 700 lpm 750 lpm 800 lpm 850 lpm
Reservoir Pressure 10% DD 5% DD Max Motor ELV Min Horil Velo. 55m/min

Figure 7: CPD Operating Window – CCI (with production) – WHP 100psi

To obtain the optimum underbalanced drilling bottom hole pressure, 750 lpm liquid
injection rate (with no Nitrogen injection) is recommend for the planned casing
configuration with a 100 psi applied back pressure. At that liquid rate, a bottom
hole circulating pressure of 3028 psi will be achieved which is equal to a 3.2% or
102 psi drawdown from the reservoir pressure. Note that the operating window
shown in Figure 7 was obtained assuming a 200 m3/m3 GOR and 240 m3/D oil
production.

During the UBD phase of the well, adjustments to these parameters will be
necessary in order to maintain the optimum operational conditions (ECD, hole
cleaning, motor requirements).

4.4.2.2 Case 2 (Drill Pipe Injection)

Flow modeling performed indicated that Underbalanced conditions are still
achievable for the Hassi Messaoud well OMOZ 22 even when production is
encountered. An operational window exists for crude injection rates ranging
between 650 to 850 lpm and Nitrogen rates from 0 and 17 sm3/min (as shown in
Figure 8), however, with a stable oil and gas production from the well, less crude
and nitrogen will be required since the this hydrocarbon influx will assist in
achieving the underbalanced drilling conditions.

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Hassi Messaoud Field – Well OMOZ 22 (D1 Formation)

pp j @ p , ,
3600

Recommended Parameters:
3500 3
700 lpm crude, 0 sm /min N2
WHP=100 psi
3400 BHCP=2995 psi
DD=4.3%
Min.Horz.Liq.Vel.=67 m/min
ELV=769 lpm
3300
SPP=815 psi
Bottom Hole Circulating Pressure (psi)

3200
Reservoir Pressure 3130 psi

3100

3000
5% DD

2900

10% DD
2800

2700

2600
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34
N2 Injection rate (sm3/min)

600 lpm 650 lpm 700 lpm 750 lpm 800 lpm 850 lpm
Reservoir Pressure 10% DD 5% DD Max Motor ELV Min Horil Velo. 65m/min

Figure 8: CPD Operating Window – CCI (with production) – WHP 100psi

To obtain the optimum underbalanced drilling bottom hole pressure, 700 lpm liquid
injection rate (with no Nitrogen injection) is recommend for the planned casing
configuration with a 100 psi applied back pressure. At that liquid rate, a bottom
hole circulating pressure of 2995 psi will be achieved which is equal to a 4.3% or
135 psi drawdown from the reservoir pressure. Note that the operating window
shown in Figure 8 was obtained assuming a 200 m3/m3 GOR and 240 m3/d
producing oil.

During the UBD phase of the well, adjustments to these parameters will be
necessary in order to maintain the optimum operational conditions (ECD, hole
cleaning, motor requirements).

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 Sonatrach – Algeria
Hassi Messaoud Field – Well OMOZ 22 (D1 Formation)

4.5 Hole Cleaning

A well-accepted criteria utilized in underbalanced drilling operations to ensure hole
cleaning of a multiphase system is the "Minimum Liquid Velocities Criteria" shown in
the table below.

Table 5: Minimum liquid velocities criteria

. Liquid Velocities

Well Trajectory Oil Based Mud Water Based Mud

Horizontal 65 m/min 55 m/min

Vertical 55 m/min 45 m/min

The “no-production” case is often referred to as the “worst case scenario” for hole-
cleaning in UBD operations. This is because any production encountered increases
the flow rate in the wellbore and consequentially the annular velocity. In a high GOR
well, gas can be expected to significantly increase the annular velocity in the wellbore
geometry and hence enhance hole-cleaning. For this reason modeling has not been
performed to examine hole cleaning after production has been encountered.

Based on the past experience from the drilling underbalanced wells in the Hassi
Messaoud field, high viscous pills are pumped and circulated prior to making
connections in order to insure that the cuttings are efficiently removed.

The following two cases (concentric casing injection and Drill Pipe Injection) were
modeled to confirm a good hole cleaning.

4.5.1.1 Case 1 (Concentric Injection)

Figure 9 represents the change in annular liquid velocity over the entire wellbore. This
graph illustrates the changes in the liquid velocities as the return fluids encounter the
various wellbore geometries. As shown in the graph, the velocity is above the
minimum acceptable thresholds for adequate hole cleaning.

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Hassi Messaoud Field – Well OMOZ 22 (D1 Formation)

500

450
4 3/4" DC 4 3/4" PDM
3 1/2" DP 3 1/2" HWDP 3 1/2" HWDP

400

350
Annular liquid Velocity (m/min)

7" Csg Tie Back 6" open Hole

7" Liner
300
Circulating Sub

250

KOP
200

150

100

50

0
0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200 3400 3600 3800 4000 4200 4400
Measured Depth (m MD)

Figure 9: Fluid Velocity vs Measured Depth (CCI 850 lpm Crude and 53 sm3/min N2)

4.5.1.2 Case 2 (Drill Pipe Injection)

Figure 10 represents the change in annular liquid velocity over the entire wellbore.
This graph illustrates the changes in the liquid velocities as the return fluids encounter
the various wellbore geometries. As shown in the graph, the velocity is above the
minimum acceptable thresholds for adequate hole cleaning.
500

450
4 3/4" DC 4 3/4" PDM
3 1/2" DP 3 1/2" HWDP 3 1/2" HWDP

400

350
Annular liquid Velocity (m/min)

7" Csg Tie Back 6" open Hole

7" Liner
300

250

KOP
200

150

100

50

0
0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200 3400 3600 3800 4000 4200 4400
Measured Depth (m MD)

Figure 10: Fluid Velocity vs Measured Depth (DPI 730 lpm Crude and 26 sm3/min N2)

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Hassi Messaoud Field – Well OMOZ 22 (D1 Formation)

4.6 Motor Performance

The 6” hole will be drilled with a 4 ¾” OD positive displacement motor. The acceptable
UBD operational range was designed with the minimum and maximum downhole
motor equivalent flow rates of the selected motor in mind. From the preliminary
engineering study performed, the modeling results indicate that injection rates ranging
from 700 lpm to 950 lpm of crude are anticipated to create the BHCP’s required for
underbalanced drilling.

4.7 Survey Requirements

During underbalanced drilling operations, the basic logging requirements include the
pressure while drilling (PWD) and measurement while drilling (MWD) tools to provide
real time bottomhole circulating pressure, gamma ray, and directional data needed for
orientation. Sonatrach will specify any additional logging while drilling (LWD) tools
required if needed. The MWD/LWD Company will supply the downhole tools with
appropriate accessories for directional control requirements for this well.

4.8 Data Acquisition System

Weatherford’s DataProTM data acquisition system is an industry-proven data

acquisition system that is used worldwide. The CPD data acquisition system is
compatible with all other data acquisition systems and can be used to acquire, store
and display the data provided by most logging companies.

Table 6: UBD Operations Acquired Data

Parameters
WEATHERFORD MUD LOGGERS MWD
Liquid Injection Rate Standpipe Pressure Bottom Hole Pressure
Gas Injection Rate Bit Depth Bottom Hole Temperature
Gas Injection Pressure Total Depth
Choke Inlet Pressure TVD
Choke Inlet Temperature ROP
Separator Pressure Pump Strokes
Separator Temperature Liquid Injection Rate
Separator Gas Flow Hook Load
Transfer Fluid Rates WOB
Tank Level Indicators RPM
Fluid Export Torque
Wellhead Pressure
Rig Choke Pressure

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Hassi Messaoud Field – Well OMOZ 22 (D1 Formation)

4.9 Productivity Index While Drilling

In order to characterize the productivity of the reservoir and the relative performance
of each productive feature, the Productivity Index While Drilling (PIWD) will be
calculated throughout the underbalanced drilling operation.

[
PIWD m 3 / day / kPa = ] [
Oil Inflow Rate m 3 / day ]
⎛ P [kPa] + Pheel [kPa] ⎞
Pres [kPa] − ⎜ toe ⎟
⎝ 2 ⎠

The PIWD data points are to be collected as often as possible during underbalanced
drilling, even at the same depth if no new hole was drilled and the well has been
flowed for a period of time in order to characterize flush production depletion behavior.

For every PIWD data point, the circulation system should be as stable as possible.
The heel pressure must be obtained from a flow model and should be the first point of
hydrocarbon production along the horizontal section.
Figure 11 illustrates six PIWD type curves and the associated formation porosities that
are reflected with the curves.

Increasing
quality

Matrix Fracture Compartmental

Negative Slope

Channel Sand Vugular Non-Productive

Figure 11: Various PIWD curves

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Hassi Messaoud Field – Well OMOZ 22 (D1 Formation)

4.10 Flow Control Matrix

Manageable wellhead pressures and returning liquid and gas flow rates must be
determined to ensure continuous and safe drilling operations. The Flow Control
Matrix defines these parameters for drilling operations.

A risk based approach to the design of the flow control matrix is required and must be
based on:
• A safety factored maximum flow capacity of the surface separation system
• The pressure rating of the flow control equipment, such as the ESD valve, the
UBD choke manifold, and the primary flow lines
• Erosion rates of the surface flow lines and manifolds
• Maximizing the service interval for the rotating diverter

Safety Critical Design Notes:

• Rotating Diverter: Weatherford 7100, Dynamic = 2,500 psi, Static = 5,000 psi
• Surface Separation: Max Liquid Rate (separator) = 40,000 bbl/d
• Gas Rate: Max Gas Rate (flow line erosion) = 40 MMscfd (standard cubic meters
per day)

The Flow Control Matrix establishes flow control actions as functions of fluids flow
rates and flowing wellhead pressure. Color indicates hazard assessment risk level.
The adjustment regions (yellow areas) are established to allow safe reaction time to
return operations to a green condition. The red shaded areas indicate well control
events.

Table 7: Flow control matrix (Liquid Inflow)

WELLHEAD FLOWING PRESSURE

0 – 1,250 psi 1,250 – 2,250 psi + 2,250 psi

Adjust system to increase BHP:

0 – 24,000 Shut-in on rig’s
Manageable • Increase liquid injection rate
bbls/day BOP.
• Decrease surface backpressure
INFLOW RATE

Increase BHP:
Adjust system to increase BHP:
• Increase liquid
24–36,000 injection rate Shut-in on rig’s
• Increase liquid injection rate
bbls/day • Decrease Gas rate BOP.
• Decrease gas injection rate
• Increase surface
backpressure
+ 36,000 Shut-in on rig’s
Shut-in on rig’s BOP. Shut-in on rig’s BOP.
bbls/day BOP.

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Table 8: Flow Control Matrix (Gas Inflow)

WELLHEAD FLOWING PRESSURE

0 – 1,250 psi 1,250 – 2,250 psi + 2,250 psi

Adjust system to increase BHP:

0 – 24 Shut-in on rig’s
Manageable • Increase liquid injection rate
MMscf/day BOP.
• Decrease surface backpressure
INFLOW RATE

Adjust system to
increase BHP:
Adjust system to increase BHP:
24–36 • Increase liquid Shut-in on rig’s
• Increase liquid injection rate
MMscf/day injection rate BOP.
• Decrease gas injection rate
• Increase surface
backpressure
+ 36 Shut-in on rig’s Shut-in on rig’s
Shut-in on rig’s BOP.
MMscf/day BOP. BOP.

The flow control matrix design parameters are as follows:

1. Maximum surface operating pressures on the x-axis are specified as
follows:
• GREEN LIGHT: 50% of the lesser of the rotating diverter’s dynamic
rating, the underbalanced choke manifold’s rating or primary flow line’s
maximum working pressure
• YELLOW LIGHT: 50% to 90% of the lesser of the rotating diverter’s
dynamic rating, the underbalanced choke manifold’s rating or primary
flow line’s maximum working pressure.
• RED LIGHT: Above 90% is a well control event

2. Maximum operating fluid flow rates on the y-axis are as follows:

• GREEN LIGHT: Up to 60% of the surface separation system's
maximum liquid flow rate capacity or the upper erosion limit of the
surface flow lines and manifolds
• YELLOW LIGHT: 60% to 90% of the surface separation system's
maximum fluid flow rate capacity or the upper erosion limit of the
surface flow lines and manifolds
• RED LIGHT: Above 90% is a well control event

4.11 Surface Equipments Erosion Management

The erosion process is variable and makes it very difficult to develop definitive best
practice recommendations that will apply to surface flow line equipment in
underbalanced drilling operating conditions. There are numerous erosion mechanisms
and factors that influence them.

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Potential mechanisms that could cause significant erosion damage are:

• Particulate erosion
• Liquid droplet erosion
• Erosion-corrosion
• Cavitations
It is generally accepted that particulates (cuttings) are the most common source of
erosion problems in UBD operations. However all of the other mechanisms are
equally aggressive under the right conditions. Regardless of erosion mechanism, the
most vulnerable parts of the UBD flow process systems tend to be components in
which:
• The flow direction changes suddenly (turbulence)
• High flow velocities occur caused by high volumetric flow rates
• High flow velocities occur caused by flow restrictions
Components and pipe work upstream of primary separators carry multiphase mixtures
of gas, liquid and cuttings. Consequently, these components are more likely to suffer
from particulate erosion, erosion corrosion and droplet erosion.

The vulnerability of particular components to erosion heavily depends on their design

and operational conditions. In UBD operations the following is a list of components
most vulnerable to erosion:
• Chokes
• Sudden constrictions
• Partially closed valves, check valves and valves that are not full bore
• Elbows or turns
• Weld intrusions and pipe bore mismatches at flanges
• Blind tees
• Straight pipes downstream and in close proximity to elbows

Erosion has been long recognized as a potential source of problems in UBD

operations. The variable nature and complexity of the erosion process makes it
impossible to completely eliminate. However, procedures, practices and safety
measures can be put in place to help identify components and reduce factors that
exacerbate the problem. One important aspect of managing erosion is to establish
the scale of the problem and hence, the amount of effort required to avoid failures
thus protecting personnel and equipment.

The particle erosion rate is highly dependent on the particle impact velocity. It is
generally accepted that the erosion rate is proportional to the particle impact velocity
raised to a power. Particle size, shape and hardness (reservoir geology) are factors.

A number of measures/procedures can be taken to monitor and avoid erosion:

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Hassi Messaoud Field – Well OMOZ 22 (D1 Formation)

1. Reduction of production rates: Reducing the production rate reduces the flow
velocity through the flow line

2. Design of flow line: Flow lines should be designed to minimize flow velocities
and avoid sudden changes in flow direction. The use of full bore valves and
blind tees in place of elbows can also reduce erosion problems. The distance
between elbows must be at least 10 internal diameters to allow the flow to
“straighten” prior to the next turn

3. Reduction of slugging: Slugging flows can be particularly damaging by

generating periodically high velocities that may significantly enhance the
erosion rate. Application of backpressure during connections mitigates the
effects of slugging

4. Use of thick walled pipes to increase the wear life of pipe work: However,
care should be taken when doing this as increasing wall thickness reduces the
pipe bore, elevating flow velocities and increasing the erosion rate particularly
with small-bore flow lines

5. Specially designed ‘target tees’: used in which the dead leg of the tee
includes a layer of soft material (usually lead) that absorbs the energy of
particle impacts

6. Pumping liquid: the practice pumping liquid into the surface flow line after the
rotating control head can reduce the erosion rate significantly

7. Design of injection rates: Using higher liquid injection rates helps reduce the
erosion rate significantly

8. Operating the primary separator at a higher backpressure: doing so

reduces the velocity by inducing lower pressure drops through the flow lines,
as a rule of thumb, increasing the pressure by a factor of 2 reduces the erosion
by a factor of 4

9. Monitoring for erosion: this can be achieved by using available Ultra Sonic
testing in probable locations

10. Solids concentration in the liquid phase: In general, the greater the solids
concentration in the liquid phase, the greater the erosion (i.e. the higher the
ROP the greater the erosion rate)

4.12 Stripping Systems

Weatherford employs a no-leak policy with regards to rotating diverter element

maintenance. As such, a preventative replacement matrix has been developed in
order to allow the safe replacement of the diverter elements before failure.

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Hassi Messaoud Field – Well OMOZ 22 (D1 Formation)

The following matrix defines the recommended stripping limits for underbalanced
drilling and tripping with jointed drill pipe, in good condition and minimal hard-banding,
through a passive rotating diverter:

Table 9: Recommended stripping limits

WHP RANGE OF WHP RANGE OF WHP RANGE >
WHP < 10% OF 10% TO 40% OF 40% TO 70% OF 70% OF
DYNAMIC DYNAMIC DYNAMIC DYNAMIC
RATING RATING RATING RATING

MAXIMUM
ALLOWABLE PIPE 3,655 2,435 1,525 610
STRIPPED (METERS)
MAXIMUM
ALLOWABLE
600 500 200 150
OPERATING TIME
(ROTATING HOURS)

The consumed element life must be calculated based upon a weighted average of
time or meters stripped and wellhead pressure. For an example calculation for a
rotating diverter, with a 2500 psi dynamic rating, see Table 10:

Table 10: RCD remaining life calculation example

Meters
Pressure Calculation Life Remaining
Stripped
345 kPa 50 psi 365 365/3,655 = 10% 100% - 10% = 90%
6,205 kPa 900 psi 485 485/2,435 = 20% 90% - 20% = 70%
9,650 kPa 1,400 psi 610 610/1,525 = 40% 70% - 40% = 30%
13,100 kPa 1,900 psi 180 180/610 = 30% 30% - 30% = 0%

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Hassi Messaoud Field – Well OMOZ 22 (D1 Formation)

5 SPECIAL CONSIDERATIONS

5.1 QHSE

The Weatherford UBS QHSE department in liaison with Sonatrach’s QHSE

department will address all QHSE matters associated with the underbalanced drilling
phase of the Hassi Messaoud well. Weatherford considers safety to be of paramount
importance. Hazid and Hazop process identification will be conducted prior to
underbalance drilling operations. Security of personnel on location, rig camp and
during transport from and to location needs to be included in the safety scheme of
Sonatrach.

5.2 Wellhead Configuration

Weatherford does not intend to alter the current wellhead to carry out underbalanced
drilling operations. The design as per Sonatrach will be retained.

5.3 Drill Pipe Requirements

It is strongly recommended that drill pipe should have minimal hardbanding and
identification grooves. Hardbanding and identification groves shorten the life of the
Rotating Control Head sealing element.

5.4 Chemicals

Chemicals might be used for corrosion mitigation and de-emulsification (if water
influxes are encountered). This will be discussed with the fluids Engineer before
underbalanced drilling operations and appropriate contingency plans will be put in
place. The injection points of the various chemicals will be at the UBD choke
manifold. The addition of other chemicals will be up to the mud engineer and
Sonatrach’s discretion.

5.5 Top Drive

Depending on the rig to be used to drill the Hassi Messaoud wells a top drive or a
kelly might be used. The use of a top drive will greatly enhance underbalanced
drilling operations on this well by:

• Eliminating two-thirds of connections, drilling with triple stands. Reducing

precautionary hole-cleaning time for connections.
• Maintaining directional orientation for up to 30 m.
• Reducing survey time and improving directional control.
• Continuously drilling 30 m horizontal sections thus, allowing for stability and
accurate reservoir characterization.

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• Allowing for improved underbalanced drilling efficiency.

• Tripping - Ream and circulate on trips in minutes - with stands.
• Circulating and rotating while tripping horizontal sections in case of hole
problems.
• Improving pipe-handling safety.
• Improving well-control response time.

Top drives will no doubt prolong the life of the RCD sealing elements and therefore
enhance QHSE for the UBD operations.

5.6 Borehole Instability

The presence of numerous shale breaks has been well documented for many years.
These shale breaks pervade the field and while their frequency of occurrence can be
predicted and has been mapped, their exact location cannot be predicted. Even the
ability to forecast frequency of occurrence is of no help at this point since the specific
subject wells have not yet been identified. These shale breaks or lenses are
variously referred to in the literature as shales, clays, and siltstones, and are reported
to be typically less than a meter in thickness. When these lenses are drilled
underbalanced, they are more likely to either deform plastically or to slough than
when drilled overbalanced, especially if those encountered happen to be thicker than
average. The lower the BHCP, the more severe the problem is likely to be. The
calculation of how much underbalanced the wellbore is, usually is based on the
difference in current formation pressure and the pressure in the borehole. That is
accurate when drilling a permeable formation like sandstone. However the shales,
being relatively impermeable, must be treated as having original reservoir pressure
contained within.
The presence of numerous, randomly located shale breaks poses a risk of borehole
instability when they are drilled underbalanced. The lower the bottomhole circulating
pressure, the greater is the risk of bore-hole instability of occurring.
The fluctuations in the BHCP should be controlled in order to reduce the tug and
push effect on the formation caused by those fluctuations. The more stable the
BHCP the lower is the chance of borehole instability occurring
Another approach that can be adopted to minimize the effect of borehole instability,
besides controlling the bottom hole pressure oscillations, is to carefully design the
horizontal section direction (azimuth). The horizontal direction should be designed
based on the magnitude and direction of the minim and maximum in-situ horizontal
stresses and its relations with the overburden value. If the maximum horizontal
stress is smaller in magnitude than the overburden or the vertical stress then the well
should be orientated in the direction of the minimum horizontal stress. However, if
the maximum horizontal stress is greater in magnitude than the overburden or the
vertical stress then the well should be orientated in the direction of the maximum
horizontal stress.

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 Sonatrach – Algeria
Hassi Messaoud Field – Well OMOZ 22 (D1 Formation)

4000

3500

3000

ReservoirPressure=2845 PSI
BHCP (psia)

2500
10 % DD

20 % DD

2000

1500

1000
3300 3400 3500 3600 3700 3800 3900 4000 4100 4200 4300
Measured Depth (m)

PWD Values

Figure 12: BHCP vs. Measured Depth

Figure 12 shows a typical well drilled UBD, which is a good example of controlling
thee BHCP while drilling with N2 injection. The amount of pressure spikes is
infrequent and the amplitude of the spikes is also small ensuring that minimum stress
is applied to the formation.
Typically a drawdown of 5-10% is applied while drilling UBD in the Hassi Messaud
field’s reservoirs. To minimize any risk of collapse, the maximum amount of
drawdown acceptable to drill the R2 should be 2-5% (and never more than 500 psi
difference between the real reservoir pressure and the BHP). An accurate account of
the reservoir pressure will be required once drilling has commenced. After 50m of
formation has been drilled, a pressure build up test will need to be performed to verify
the correct amount of drawdown is applied.

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