Chapter 9

SAUDI ARAMCO WORKOVER MANUAL
Drilling Technical Department September 2013

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CHAPTER 9 UNDERBALANCED COIL TUBING DRILLING
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UNDERBALANCED COIL TUBING DRILLING
1. INTRODUCTION
1.1. The Underbalanced CTD Process Back
1.2. Underbalanced Coil Tubing Drilling Selection Criteria

1.2.1. Sidetracks
1.3. IADC UBD Classifications
2. SURFACE EQUIPMENT SPECIFICATIONS

2.1. Specifications of Coil Tubing Rig
2.2. BOPE
2.3. Flowline and Emergency Shutdown Valve (ESD)
2.4. Choke Manifolds
2.5. Solids Sampling System
2.6. Separator System
2.7. H2S Scrubber Systems (Am-Gas Scrubber)
2.8. Data Acquisition System
2.9. Gas Flare Stack
2.10. Condensate Handling System
2.11. Miscellaneous
3. UBCTD DOWNHOLE EQUIPMENT

3.1. Motors
3.2. Non Return Valves (NRV)
3.3. Directional Gamma Sub (DGS)
3.4. Drilling Performance Sub (DPS)
3.5. Electric Disconnect and Circulating Sub (EDC)
3.6. Hydraulic Orienting Tool (HOT)
3.7. Power and Communication Sub (P&C)
3.8. Dual Ball Valve (DBV-Sub)
3.9. Lower Quick Connect (LQC) & Upper Quick Connect (UQC)
3.10. Coil Tubing Connector
4. DRILLING FLUID ADDITIVES

4.1. H 2 S Scavengers
4.2. Demulsifier
4.3. Defoamer
4.4. Caustic Soda
4.5. Corrosion Inhibitors
4.6. Friction Reducer
4.7. Gel Sweeps
4.8. Anti-Freezing Agent
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CHAPTER 9 Underbalanced Coil Tubing Drilling
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5. BASIC PROCEDURES FOR UBCTD

5.1. CTD Planning and Execution Review
5.2. Pressure Testing Requirement
5.3. Xmas Tree Requirement
5.4. Gas Handling
5.5. H 2 S Issues
5.6. Condensate Handling
5.7. Deployment Systems
5.8. Window Milling
5.9. Pre-Khuff Drilling
6. WELL AND SITE LOCATION LAYOUT
Attachment #1A: Saudi Aramco CT-UBD Project Normal Procedures

Attachment #1A: Saudi Aramco CT-UBD Project Emergency Procedures
Attachment #2: Wellhead Schematic and Tree
Attachment #3: Process and Instrumentation Diagram
Attachment #4A: Gas Detection System for Low H 2 S Wells (H 2 S < 1%)
Attachment #4B: Breathing Apparatus Maps for Low H 2 S Wells (H 2 S < 1%)
Attachment #5A: Gas Detection System for High H 2 S Wells (H 2 S > 1%)
Attachment #5B: Breathing Apparatus Maps for High H 2 S Wells (H 2 S > 1%)
Attachment #6: Station Bill
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UNDERBALANCED COIL TUBING DRILLING

1.0 INTRODUCTION
This chapter is designed to provide information on the standards and equipment utilized
during the underbalanced coil tubing drilling (UB-CTD) operations within the SAUDI
ARAMCO drilling organization.
The information contained herein is presented to provide a basis or guideline for UB-CTD
operations. As with any operation, there are exceptions to the rule and considerations
must be given to these exceptions on a case by case basis.
1.1. The Underbalanced-CTD Process
The UB-CTD technique was introduced to Saudi Aramco as a safe and economic
alternative to re-enter Deep Gas Wells, access by-passed reserves and improve
ultimate recovery of Gas reserves. The complete UB-CTD system comprises of the
CT circulating system, a choke manifold, a four-phase separator, high pressure
separator, condensate pump, flare stack and exporting system. In addition, non-
return valves (NRV’s) are installed in the BHA to prevent flow up the CT.
The CTD BOP’s are the primary well control equipment and contingency plans to
return to an overbalanced condition must be in place under certain predefined
conditions or operational problems.
The UB-CTD project is a thru-tubing Coiled Tubing (CT) underbalanced drilling

(UBD) with the objective of increasing production rates and accelerates reserves,
and by accessing inefficiently drained layers which may be at higher reservoir
pressures than the adjoining better drained zones. Drilling into inefficiently drained
layers would develop new reserves.
The approach used is:
• Enter existing wellbore through the tubing and set a retrievable through-tubing
whipstock in the 7”, 4-1/2” or 5” production liner. The whipstock has a flow
bypass area that allows production to continue from the mother-bore after it was
set.
• Mill a window in the production liner using water or 2-phase fluid.
• Exit the milled window and build at a rate as high as 25º/100 ft to reach horizontal
fairly rapidly.
• Drill several horizontal laterals of about 2000 - 3000 ft in length, in all of the
producing zones and produce through existing tubing.
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• The drilling is done underbalanced using water and nitrogen when required as
drill fluid.
• Paleo description is used to steer and identify/confirm location of wellbore in the
Khuff layers.
1.2 Underbalanced Coil Tubing Drilling Selection Criteria
The selection criteria for UB-CTD wells for underbalanced drilling revolve around
problems and issues which occur when drilling these wells conventionally.
For deep gas wells, the main driver is to avoid reservoir damage in tight formation via
well re-entry and drilling without retrieving the completion. In addition, resolving
drilling problems like differential sticking and mud losses are other criteria for
selecting UB-CTD operations.
1.2.1 Sidetracks
One of the most important criteria for selection of sidetrack candidates for
drilling underbalanced is the mechanical integrity of the existing casing
strings and wellhead.
When re-entering a well, consideration needs to be taken of the age,

exposure to corrosive or erosive fluids, and the exposure the casing strings
had to rotary drilling in the original well.
Caliper logs are normally required within the tubing and casing string to
establish inner and outer diameters. This can then be used to determine
casing integrity and determine any issues with respect to casing collapse
while drilling. This is especially important where the casing string being drilled
through has not previously been exposed to production drawdown (monobore
completions etc).
Care must be taken that any casing strings behind the tubing which may be
exposed to the drawdown created through drilling underbalanced (e.g.
packer-less completions) have sufficient integrity to resist collapse. To gain
assurance of this, the previous drilling history of the wells should be carefully
examined. Wellhead voids should be tested as a matter of course.
The table shown in the next page is a score table for selecting the UBD
candidate wells. The table allows one to look at the type of well, its
complexity, offset control among other things to rank the well and then
determine its eligibility for CT UBD operations.
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Typical Score Table for candidate selection

GAS WELL CTD SIDETRACK CANDIDATE SELECTION CRITERIA / KPI
Points Well A Well B Well C Well D Well E Well F Well G
D IS T A N CE B T W
T B G T A IL A N D 10 2,662' 560' 477' 540 H2S > 5% 340 446'
KOP FT
LIN E R ID 0 3.920" 8.435" 6.094" 6.094 6.004 6.004"
ME CHA NI CA L
MON OB OR E
0 YES NO NO NO NO NO
COMP LE T ION
CA LIP E R LOGS 0 NO YES YES Yes Yes YES
LIN E P R E S S U R E
6 650-750 650-750 800 650-750 925 950
PSI
CU R R E N T
6
P R OD U CT ION 8 3 3 6 4 7
(Intermittent)
MMS CF/ D A Y
BHP 10 5900-6100 6000-6200 5600 5900-6100 6000-6300 5700-6000
T A R GE T
0 C4/5 C2 C7 C4/5 C2 C8 C2 C7 C5 C5 C2 C7 C2 C4 C9 C2 C4 C9
R E S E R V OIR
T V D D IS T A N CE
FR OM KOP T O 0 198 150 170 XX 162 160
T A R GE T
R E S E R V OIR
T A R GE T
P OR OS IT Y LOB E 6 32ft 8ft 9ft 28ft 11ft 9ft 11ft 12ft 12ft 16ft 10ft 8ft 14ft 12ft 8ft 14ft 12ft 7ft
RE S E RV OI R A ND GE OLOGY
T H ICKN E S S
R E S E R V OIR
H E T E R OGE N E IT 4 good/fair/good good/fair/fair good/fair/poor good/fair/good good/fair/good excel./fair/fair
Y / QU A LIT Y
S T R U CT U R E / 10 Flank/Medium Crestal/Low Flank/Medium Flank/Medium Flank / V High Crestal/Low

U N CE R T A IN T Y
P R OXIMIT Y T O
Well -X - 0km Well -X - 0km Well -X - 0km Well -X - 0km Well -X - 0km Well -X - 0km
B IOS T E E R IN G
6 Well-Y - 10.2 Well-Y - 10.2 Well-Y - 10.2 Well-Y - 10.2 Well-Y - 10.2 Well-Y - 10.2
CA N D ID A T E
km km km km km km
W E LLS
E XP E CT E D 4 20 20 15 20 20 20
P R OD U CT ION
0 11,102' 11,710' 11,840' 11,690' 12,558' 11,373'

P la nne d KOP
KOP to hit ta rg e t
0 11,354' MD 11,962' MD 12,090' MD 11,942' MD 12,810' MD 11,625' MD
@ 35 d e g / 100ft
D OGLE G 4 35 35 35 35 35 35
S E V E R IT Y
DRI LLA B I LI TY
6 14,500' 15,000' 15,100' 14,900' MD 15,800' 14,600'

T OT A L D E P T H
Inc @ KOP 8 2.08 0.11 3.42 0.5 4.76 0.54
Inc @ S e ns o r 8 2.1 0.1 3.2 0.5 4.4 0.9
W hip s to c k 10 NO NO Yes Yes Installed Yes Yes

a v a ila b le
OTHE R
Othe r 0
Intermittent
Needs to cut
No whipstock No whipstock Scheduled for producer; WHP
N o te s 0 Check KOP window through
available available WO April 2009 - drops quickly
7" and 9-5/8".
when opened.
SUM 100
SCORE 100 24 26 83 85 0 80 85
LATEST RANK 6 5 3 1 7 4 1
Criteria
Eval Weight
Coding
Critical issues-need to be address x -5
Concerns - 0.5
Positive criteria + 1
No assignment ? 0.8
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1.3. IADC UBD Classifications
The IADC has created a naming convention to help classify UBD wells. This is
composed of 3 parts:
Risk Level
Level Description:
5- Maximum projected surface pressures exceed UBO equipment's operating
pressure rating, but are below BOP stack rating. Catastrophic failure has
immediate, serious consequences.
4- Hydrocarbon production. Maximum shut-in pressures are less than UBD
equipment's operating pressure rating. Catastrophic failure has immediate,
serious consequences.
3- Geothermal and non-hydrocarbon production. Maximum shut-in pressures
are less than UBD equipment's operating pressure rating. Catastrophic failure
has immediate, serious consequences.
2- Well capable of natural flow to surface, but conventional well kill methods are
enabled and limited consequences are possible in case of catastrophic
equipment failure.
1- Well incapable of natural flow to surface. Well is "inherently stable" and is a
low-level risk from a well control point-of-view.
0- Performance enhancement only; no zones containing hydrocarbons.
UBD or Low Head

Type Description:
A- Well is drilled with low head, using underbalanced technology
B- Well is drilled truly underbalanced
Underbalanced Technique Used

Type Description:
1. Gas drilling
2. Mist drilling
3. Foam drilling
4. Gasified liquid drilling
5. Liquid drilling
Example
The wells being drilled by Saudi Aramco are classified as 4-B-5.
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2.0 SURFACE EQUIPMENT SPECIFICATIONS
2.1 Specifications of Coil Tubing Rig

The surface equipment provides a means for safely handling the returns and
hydrocarbons being produced.
Fundamentally the CT unit varies slightly from a rig involved in a conventional drilling
operation, the methods of deployment are essentially the same which include the
following:
a) Power system
b) Hoisting system
c) Fluid circulating system
d) Well control system
e) Well monitoring system
The addition of UBCTD included the following:
a) An active choke system

b) 4 phase separator
c) Additional storage if required
d) UBCTD data acquisition system independent of the rigs
e) Transfer pumps
f) High Pressure Separator or Compression/Booster equipment
g) Flaring and export systems to handle the production of hydrocarbons.
The surface separation package is designed to safely permit a well to be drilled in an

underbalanced condition and handle all fluid returns from the well. The fluid returns
from the well come out of the side outlet spool on the flow Tee and down the flowline
through the choke manifold. Here the flowrate and back-pressure are controlled and
the fluid returns fed in a controlled manner to the primary 4 phase separator.
Separation of the fluid into its components of gas, liquids and solids occurs here and
the various fractions are sent to the export line, flare, tanks, or slurry pit respectively.
COIL TUBING UNIT (CTU): Skid mounted CTU capable of safely handling up to
18,500 ft of 2-3/8” coiled tubing including, AC COIL TUBING INJECTOR HEAD
capable of safely pulling up to 18,500 ft of various sized Coil Tubing off bottom in a
deviated horizontal well with up to 10,000 lbs of drag. The following are ratings for
the XTD rigs currently used. Most of the CT rigs have lower specifications:
Maximum pull: 200,000 lbs

Snubbing force: 60,000 lbs
Maximum push: 40,000 lbs
Maximum speed: 110 ft/min
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GOOSENECK: 130” to safely handle the deployment of CT COIL CABIN
HYDRAULIC POWER PACK: The CT power pack provides the hydraulic power
required by the CTU, provide controls and limitations on the hydraulic systems, and
hydraulic accumulator storage for well control (BOP accumulator).
DATA ACQUISITION and RECORDING SYSTEM: with sensors and computer

support. The CTD unit is fitted with Cerberus Data Acquisition System which
employs the Argus coil monitoring system, an integrated depth measurement
system. A mechanical back up is mounted on the reel as a contingency. The depth
measurement System incorporates an encoder mounted on the injector head, below
the chains, utilizing a friction wheel system and the signals sent to the Cerberus Data
Acquisition System.
DROP-IN DRUM SYSTEM: Accommodates a minimum of 18,500 ft of 2-3/8” CT with

15M PSI WP Swivel, Collector, associated fittings and equipment for deployment of
CT including terminal connection at surface for concentric E-line hepta cable. This
system allows quick replacement of the CT reels when required.
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COIL TUBING Mast and Substructure: Including,

No tower required, fewer lifts over wellhead during rig up and less equipment to
move then the conventional Coil tubing tower system, which in turn improves rig
move times
2.2 BOPE
Category II – 10M PSI WP HP CT BOP stack configuration (Attachment #2):

• Tandem Stripper function (2 ea for 2-3/8” Coil)
• Annular Function
• Blind function
• Shear function
• Kill line inlet with double plug valves
• Quick latch Coupler
• Flow Tee with double plug valves
• Lower Shear and Blind function
• Slip function
• Pipe Function
• Tree Adapter
ADAPTER SPOOL: CT BOPE (5-1/8” 10M) to the Saudi Aramco Production tree top
flange
DUAL BOP (Type EH): 5-1/8” 10M PSI WP. This is the primary well control BOP
and will be used for any required closure of the well in event of a well control
situation.
Lower Rams: 2-3/8” Pipe/Slip rams with 5” Actuators
Upper Rams: 2-3/8” Shear/Seal rams with 7” Actuators
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Quad BOP: 5-1/8” 10M psi:
Lower Rams: Combination 2-3/8” Pipe/Slip Rams with 5” Actuators.

Lower Middle Rams: Combination 3” Pipe/Slip Rams with 5” Actuators.
Upper Middle Rams: Combination Inverted 3” Pipe/Slip Rams with 5” Actuators.
Upper Rams: Combination 2-3/8” Shear/Seal Rams with 7” Actuators.
NOTE: The elastomers material to be used in all BOPE components is VITON® due
to its proven performance under constant HC’s flow for UB/CTD operations in Gas
Drilling in Saudi Aramco. Aflas elastomers failed prematurely under constant flow
conditions.
Drilling Flow Cross: For Kill and Choke line; 5-1/8” 10M PSI WP; with one (1) each
3-1/16” 10M side-outlet for one (1) each 2” 10M manual valve and one (1) each 2”
non-return check valve mounted on Kill side-outlet; plus one (1) each 3-1/16” 10M
psi side-outlet for one (1) each 3-1/16” 10M psi manual gate valve and one (1) each
3-1/16” 10M psi HCR valve mounted on choke side-outlet.
Emergency Kill Line Tee: 2-1/16” 10M psi
2.3 Flowline and Emergency Shutdown Valve (ESD)
A detailed P&ID diagram is shown in Attachment #3.
• The flowline is a 4” nominal ID high pressure rated (10M psi) flanged pipe which
conducts the wellbore effluent to the Choke Manifold.
• Elbows used in this line are known as targeted T – they have a lead insert at the
corner of the T to reduce erosion of the pipe body around the corners.
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• The Emergency Shutdown Valve (ESD Valve) is a hydraulically actuated fail-

close valve which is used to isolate the separation package from the well in case
of failure of a major component in the surface layout. It is pumped open by
hydraulic pressure and will close by spring force in the event of loss of hydraulic
pressure either accidentally or by positive actuation of the control panel switch.
Pressure Rating is again 10M psi and 6” nominal ID.
• Emergency Shut-down system: Emergency Shutdown System (ESD) capable of

monitoring all ESD instrumentation and initiating alarm and shutdown events
based on pre-defined and programmed conditions.
• Dual 10M psi ESD valves placed to isolate the 5M flow line / choke from the
UBCTD separation system and divert flow from the well to the 10M choke
manifold (if working with two chokes).
• Single 5M psi ESD valve placed to isolate the Aramco Gas Plant Flow Line from
the UBCTD system. ESD Instrumentation. H 2 S, LEL, high pressure, low
pressure, liquid level, and other sensors mounted on CT/UBD system as defined.
• Dedicated ESD PLC. A Programmable Logic Controller (PLC) dedicated to

monitoring all ESD inputs for the purpose of initiating alarm and shutdown event
are to be strategically located at the well site.
2.4 Choke Manifolds
The Coil Tubing package consists of 2 Choke manifolds, the drilling choke (rated to
5K psi) is used for handling the returns while drilling and the 10K psi choke is part of
the primary well control equipment.
5K Dual Choke Manifold: Dual hydraulic choke manifold for controlling UBD flow
returns upstream of the High-Pressure Gas separation.
• 5,000 psi working pressure, 20-350 ºF, working temperature.
• 5-1/8” API 5M flanged inlet w/ 7-1/16” API 5M adapter, 5-1/8” API flanged outlet
w/ 6” 600# RF adapter outlet.
• Dual hydraulic drilling chokes, E-C type gate and seat, tungsten carbide trim.
• Full opening central by-pass line.
• Equipped with pressure sensors, alarms, and Emergency Shut Down capability.
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• Remote choke control panel, air activated, for full adjustment of the chokes with
instrumentation for: injection pressure, choke manifold pressure, relative choke
position, cumulative stroke counts and air supply pressure.
10K Dual Choke manifold: Dual choke manifold connected to the flare pit for the
purpose of cleaning up, livening, or conducting well killing operations.
• 10 M psi working pressure, 20-350 ºF working temperature
• 3-1/16” API 10M flanged inlet
• Dual manual chokes, one (1) variable with tungsten carbide trim, one (1) positive
fixed bean-type.
• Double-valve isolation upstream and downstream of each choke.
2.5 Solids Sampling System
In-line fluid and solids sampling equipment for analyzing and monitoring UBD return
streams.
• Equipment is able to provide representative sample of drilled solids for well
steering purposes.
• Any bleed off line shall be tied in to the Vapor Recovery System (VRS) to vent
gas safely while bleeding off.
2.6 Separator System
The 4-Phase Separation System is capable of processing 35,000 bpd liquids, 50

MMCF/D gas, 200º F and 1,800 bbl/day of drilled solids. All fluids and gas handling
equipment are H 2 S certified.
Separator are equipped with;
• (i) Automated relief system for pressure and fluid levels, (ii) Pressure, Liquid
level, Toxic gas and LEL alarms, (iii) Vessel Relief Valve to be operated with
ESD system.
• Fluid metering system for interstage liquid, export heavy liquid, export light liquid,
gas flow rate.
• Internal pumps for fluid transfer, fluid export, line flushing and any other transfer
pump needed for proper functioning of the system.
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UBCTD High Pressure Gas Separator
• Capacity for Gas Handling minimum 70 MMSCFD up to 92 MMSCFD maximum

• Capacity for Liquids Handling minimum 10,000 bpd up to 27,000 bpd maximum
• Capacity for Solids Handling minimum 1,000 bpd up to 1,800 bpd maximum
• Working Pressure up to 1,350 psi maximum
• Operating Temperature range minimum -20º F up to 180º F maximum
• Suitable for handling sour gas (H 2 S content equal to 8% maximum and CO 2
equal to 5% maximum)
• Gas Treatment: Mist extractor will remove 99.9% liquid droplets 10 micron and
larger
• Gas metering at the outlet of the separator
• Equipped with (i) pressure, liquid level, Toxic gas and LEL alarms and (ii) Vessel
Relief Valve compatible with ESD system
NOTE: The High Pressure Gas Separator is be able to export dry gas from the
wellbore to the Saudi Aramco Production line (flow line to Gas Plant), with ZERO
solids and maximum 3 bbl/MSCFD of water. The minimum PL exporting pressure is
500 psi.
2.7 H 2 S Scrubber Systems (Am-Gas Scrubber)
Water treatment and gas scrubbing system: To treat the water coming from the
2nd stage separator. The required properties after the treatment are: H 2 S < 0.1 ml/L;
Solids content < 1.0%; Oil Content = 0%; pH > 7. The system consists of;
• Two (2) 400 bbl enclose tank, with internal split for two compartments. These
tanks receive water returns from the 2nd stage separator through a 4” 206 Weco
line.
• Three (3) chemical injection pumps to pump treatment chemical into the inlet line.
• Two (2) AM Gas scrubbers OR equivalent no-back-pressure Scrubbers Vapors
recovered from this tank are routed to a No-Back pressure scrubber for removal
of H 2 S. Neutralized gas is tied-in to the VRS and sent to the flare stack.
• H 2 S Measuring equipment and procedures that accurately determining H 2 S
content in the water.
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2.8 Data Acquisition System
An electronic data acquisition system is fitted to this package to enable all pertinent
surface and downhole data to be collected and presented in one place. Also the
export facility is fitted with a flowmeter and pressure sensors to enable accurate
measurement of the fluid pumped to the Gas plant.
Rig surface data includes all the normal drilling parameters recorded by the rig’s data
gathering system and transmitted via Wellhead Information Transfer System (WITS)
interface. Downhole data includes annular pressure, temperature and the drilling
parameters of the various tools deployed. This is supplied by the directional service
provider.
The data acquisition system is a fully integrated system for collecting, managing,
storing, and distributing data from the Coiled Tubing unit, UBCTD Equipment,
downhole Directional drilling Equipment, and Safety Monitoring/Alarm/ESD system.
The system WITS is compatible and connected to a real time internet based
database system, with real time access for Saudi Aramco Drilling Engineering and
Geologists at the offices in town.
The data acquisition system can accommodate 120 channels inputs with the
following operating parameters being monitored:
• HP Gas separator parameters

• 1st stage separation parameters
• 2nd stage separation parameters
• Fluid Metering and pump skid parameters
• Coiled Tubing fluid pumping/injection parameters
• Wellhead pressure/temperature
• Drilling parameters from the coiled tubing unit
• Drilling parameters from the downhole directional BHA including MWD
• All safety monitoring sensors
• All ESD equipment status
2.9 Gas Flare Stack

50 MMSCFD, 8 in x 60 ft tall mainline stack (capable of being extended to 90 ft) with
free standing base, automatic ignition system, triple guide wires with 5T anchor
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blocks, and associated piping from the UBCTD separation system, sampling
systems, and, if required, from gas compressors. The requirement for the lines are:
• 2 lines from High Pressure 2-phase separator, (1,440 psi)

• 2 lines from 4-phase separator, (1,440 psi), if applicable
• 1 line from 4-phase separator 2nd stage (1,440 psi), if applicable
• Lines are anchored every 30 ft (with 5T anchor blocks specify above)
• There is a dedicated vent line for the Vapor Recovery System (VRS).
2.10 Condensate Handling System

Complete capability for gauging, storing and shipping of produced natural gas liquids
and condensate.
a) 100 bbl gauge tank, with all required transfer pumps (i.e. 2-in mission pump and
3-in condensate pump).
b) Holding Tank: 450 bbl capacity, used as a temporary storage for the condensate,
in case the 100 bbl capacity of the gauge tank is exceeded during the operations.
c) High Pressure Condensate Pump capable of discharging up to 3,500 bpd
condensate at 1,400 psi line pressure.
d) Vapor Recovery System (VRS) to vent gas and vapor emissions from
condensate tanks and water treatment tank to the Flare Stack, with the following
minimum requirements:
• Sufficient piping, 4”, 1,440 psi, 206 WECO or equivalent, with appropriate
connection to the vent hole of the 100 bbl gauge tank and 450 bbl holding
tank and water treatment tanks.
• Proper safety devices on the system to prevent uncontrolled release of gas
and fire.
• One (1) AM Scrubber (or equivalent “no back-pressure” scrubber) to treat the
gas and remove H 2 S. Discharge from scrubber and all Vapor Recovery
System goes through the flare stack.
2.11 Miscellaneous
Generator System: Provide ample power to operate the entire Under-Balanced

Drilling (UBD) equipment package as described allowing safe operations to progress
around the clock 24 hours a day.
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Instrument Air: Air compression sized to provide ample pneumatic air supply for
the entire Under-Balanced Drilling (UBD) equipment package as described allowing
safe operations to progress around the clock 24 hours a day.
3.0 UBCTD DOWNHOLE EQUIPMENT
3.1 Motors
Conventional downhole motors designed for use with relatively incompressible

drilling fluids are not optimized for use in air or foam drilling. For these applications,
the ADM, which has a large chamber volume that results in low bit speed at
increased flow rates. A variety of motors and sizes can be used depending upon the
section of reservoir being drilled.
Rib-Steer Motor (RSM)
The closed loop rib steering technology minimizes tortuosity in the slim hole
wellbore. It allows for smooth, straight trajectories, eliminating the need for the
undulating well paths typically associated with coiled tubing drilling. Therefore
steering inside porous formation is more accurate.
3.2 Non Return Valves (NRV)
Mitigation of flow up the drill string is achieved by utilizing non return valves (NRV’s)
which effectively isolate the string from wellbore pressure by sealing from below.
Pressure from above will open the NRV’s however pressure from below will force the
one way valves closed.
3.3 Directional Gamma Sub (DGS)
This is the MWD module of the CoilTrak® Coiled Tubing BHA, containing the
directional and the gamma sensors. It provides the standard MWD service values
including azimuth, inclination, toolface, temperature and gamma ray. All
measurements are transmitted to the surface control system and are available for
further data processing. It can also send the calculated and raw values for the
azimuth and inclination.
The DGS can be implemented on rigsite depending on application or customer

requirements. The position in the CoilTrak BHA can be at any point between the
Power & Com Sub (P&C) or the BCPM and the Hydraulic Orienting Tool (HOT) or
Rib Assistant Motor (RAM). The mechanical and electrical connections on top and
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bottom are the standard CoilTrak connections. Most likely it is assembled between
the EDC Sub or the DPS and the HPC/HOT
3.4 Drilling Performance Sub (DPS)
This is an optional sub for the CoilTrak® Coiled Tubing BHA. The sub comprises of
the sensors for vibration, stick-slip, bore pressure, annular pressure and downhole
weight on bit (WOB), which can help optimizing CoilTrak performance. All
measurements are transmitted to the surface control system and are available for
further data processing. The DPS can be implemented on rigsite depending on
application or customer requirements. The position in the CoilTrak BHA can be at
any point between the Power & Com Sub (P&C) or the BCPM and the Hydraulic
Orienting Tool (HOT) or Rib Assistant Motor (RAM). The mechanical and electrical
connections on top and bottom are the standard CoilTrak connections. It is usually
assembled between the EDC Sub and the DGS. The DPS has proven to be very
useful in the current operation.
3.5 Electric Disconnect and Circulating Sub (EDC)
This is used as part of a standard CoilTrak BHA to allow hole cleaning in a Coil
Tubing Drilling application. Since there is no string rotation in Coil Tubing Drilling and
the Coil Tubing BHA has limits on flow rates, the EDC provides a means of
overcoming these hole cleaning obstacles. The EDC has ports which allow the flow
to bypass the bit and instead around the BHA to stir up the cuttings to transport. It
also has a feature to disconnect the BHA in an emergency situation or a very bad
case of stuck pipe situation.
The EDC sub has ports around its housing which can be opened or closed from
surface to allow fluid flow through them. The actuator that allows this function also
serves as a means of disconnecting the BHA when needed. The BHA can then be
fished out easily with jars as it has a standard GS fishing head. The commands for
opening/closing the circulating ports and the disconnect feature is sent from surface
electrically. The EDC can be implemented on rig site depending on application or
customer requirements. The position in the EDC in the CoilTrak BHA can be at any
point between the Power & Com Sub (P&C) and the Hydraulic Orienting Tool (HOT)
or Rib Steering Motor (RSM). The mechanical and electrical connections on top and
bottom are the standard CoilTrak connections. It is usually assembled between the
P&C Sub and the DGS/DPS.
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3.6 Hydraulic Orienting Tool (HOT)
The downhole steering device comprises of three main parts, the Hydraulic Power
Control (HPC), the Hydraulic Power Pack (HPP) and the Hydraulic Orienting Unit.
The Hydraulic Orienting Unit, steered by the HPC and HPP, will supply the means of
rotating a high side to the required TF. All parts of HPC, HPP and HOT Unit are
connected together in the workshop and cannot be separated on location.
The HPC with HPP are an electrical-hydraulic system. It contains an electrical motor,
which drives a hydraulic pump supplying the hydraulic power for steering purposes of
the Hydraulic Orienting Tool. The HOT is the downhole orienter, that can turn a tool
(mud motor or whipstock) to its desired direction and it is driven by the hydraulics of
the HPC. The steering direction can be changed bi-directionally and continuously in
a range of 400°(200° left and 200° right) to the desired tool face. The available
output torque will overcome the reactive torque of the Xtreme motor and allows
therefore toolface changes on the fly while drilling on bottom. The HOT also contains
a near bit inclination sensor NBI and a tool face indicator TFI.
The HOT is typically used at the lowest end of the BHA above the mud motor. The
wet connection on top is the standard CTK 2 3/8” HDI thread for the 2 3/8” tool size
and the 3 “CDP thread for the 3” tool size. The bottom connection is the standard 1
½” AMT thread connection for the 2 3/8” CTK and a standard 2-3/8” PAC thread
connection for the 3” CTK without electrical connection.
3.7 Power and Communication Sub (P&C)
The P&C is the main CoilTrak® module, responsible for power transformation and bi-
directional communication within the BHA. The P&C sub transforms the 400 Volt
from the wireline into the M30 volt bus signal. It also handles all data via wireline to
and from the surface system. The P&C sub contains the electronic master which is
necessary to run (all) CoilTrak modules. The Casing Collar Locator (CCL) – two
magnets – can be used to identify larger portions of steel like a Casing Collar
downhole. Main purpose of the CCL is depth correction.
3.8 Dual Ball Valve (DBV-Sub)
The DBVs are used as internal barriers for deployment & un-deployment operations.
The full-bore (or near full-bore) opening permits the use of more complex CT tools,
fluids and operating techniques by allowing balls, darts and plugs to pass through to
the tool string from the CT without restriction.
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3.9 Lower Quick Connect (LQC) & Upper Quick Connect (UQC)
Quick connects are used if it is impossible, or not practicable, to rotate the lower tool
string to make it up to the upper part; e.g., when deploying long tool strings into a
well. For ease of makeup and deployment, the CoilTOOLS quick connect does not
require torque to make up or break out a tool or tool string. Quick connects are
available either in the standard configuration or splined to transmit torque through the
tool.
With the locking sleeve completely uncovering the latch, the stinger mandrel is
stabbed into the latch until the latch fingers fully collapse to their original OD. The
locking sleeve is then made up over the latch fingers preventing them from opening
up. The locking sleeve is made up and then secured with the setscrews. When
disconnecting, the setscrews are removed from the locking sleeve, and then the
locking sleeve is backed off to fully engage the upper thread of the stinger mandrel.
When the latch fingers are fully exposed, pulling on the upper and lower halves will
pull the stinger mandrel from the latch.
3.10 Coil Tubing Connector
The downhole device used to connect the tool string to the coiled tubing string. The
primary requirement is provision of an adequate mechanical connection capable of
withstanding the necessary tensile and compressive forces, while ensuring efficient
hydraulic isolation of the connection between the tool string and the coiled tubing
string.
4.0 DRILLING FLUID ADDITIVES
Operations are conducted in underbalanced mode with the main objective to preserve the
productivity of the reservoir by eliminating any chances of formation damage.
All drilling fluids utilized in this project comply with the Drilling Fluid Program described
below. The drilling fluid program is designed to:
a) Minimize Health Risks associated with the handling of additives
b) Minimize Environmental impact
c) Provide well control when required
d) Avoid any formation damage
e) Protect installed tubular goods against corrosion
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The Anti-corrosion product (SA-193) may be required if H 2 S is encountered in the

reservoir.
A range of chemicals in various quantities are added to both the well effluent and the
return drilling fluid after separation to mitigate undesirable properties in different areas of
the surface process equipment.
The base fluid is fresh water inhibited with pH between 10.0 and 10.5. To prepare one
barrel add 0.5 to 1.0 Lb of Caustic Soda (NaOH) to 0.994 bbl of water OR add 0.5 Lb of
Soda Ash to 0.994 bbl of water. Check pH using pH meter.
A minimum pH of 10.0 is to be maintained at all times. The pH of fluid returns from the
BRT are continuously monitored. At least two (2) hole volumes of kill brine with sufficient
density to control the well plus 250 psi of overbalance, is kept at all times at the location.
The brine is ordered from SDGM mud plant and stored at the location using the Rig Fluid
Tanks.
The kill weight density is calculated based on the Bottom Hole Pressure (BHP) read by the
down-hole pressure sensor. Consideration is given to the effect of down hole temperature
on the brine weight in case of any BHP changes while drilling the lateral.
4.1 H 2 S Scavengers
SourScav (Baroid) are mixed or injected into the fluid stream or separation products
in order to reduce H 2 S exposure of equipment and atmospheric emissions. This is to
protect the integrity of equipment and the safety of personnel working on location.
Both oil soluble and water soluble H 2 S scavengers are used to remove H 2 S from the
fluid stream depending on the well type, drilling fluid or area of process in which it is
applied.
In addition gas processing scrubbers contain an H 2 S scavenging solution which

removes H 2 S from the gas stream.
4.2 Demulsifiers
Demulsifiers are used in the well effluent to aid in breaking down emulsions formed
from the mixing of produced oils and water.
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4.3 Defoamers
Defoamers are used in the well effluents to reduce foaming as they enter the
separator. Foaming may cause inaccurate level control in the separators and
carryover of liquids to the gas flare.
4.4 Caustic Soda
Sodium Hydroxide is used for pH control in the drilling fluids and to neutralize the
acidic corrosive effects of dissolved H 2 S and CO 2 in the mud system.
4.5 Corrosion Inhibitors
CHAMPION 0-3760R (SAP #1000022136) is injected 3 pints / MMSCF of gas

exported in the production lines. See CTUBD Operational Procedure SA-OP-PP-025
(Attachment #1).
A283, a proprietary chemical from Schlumberger, is used for protection of CT reel by

implementation of a corrosion schedule.
Sodium Sulphite is an oxygen scavenger used to reduce the effects of corrosion in

the drilling system, as do corrosion inhibiters in general.
4.6 Friction Reducer
Radiagreen is an environmentally acceptable high-performance lubricant for use with

coiled tubing. The product reduces the sliding friction (metal-to-metal or metal-to-
formation), not the friction pressure of the fluids in the coiled tubing. Initially the
concentration starts at 0.5% until sticking and weight transfer becomes difficult, at
which time the concentration can be increased up to as much as 1.5%. It is assumed
that the Radiagreen will only be used for extended reach portion of the well with a
concentration of 1.5% as a maximum.
Concentration = 1.0%
Base fluid at 80 gpm + 1gpm Radiagreen
Radiagreen is used once weight transfer to bit becomes a problem and helical lock
up of the CT starts to become an issue.
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4.7 Gel Sweeps
Gel (XC-Polymer) sweeps are used as required to aid in hole cleaning. The
recommended procedure is to pump 20 bbl of gel sweep prepare with water and 1.5
to 2.0 ppb of XC-Polymer.
4.8 Anti-Freezing Agent
Glycol and Methanol ordered from Saudi Aramco store house. At least 4 drums of
these additives at all times on location (while conducting gas exporting operations).
5.0 BASIC PROCEDURES FOR UBCTD
Detailed “Operational Procedures” have been developed (Attachment #1) to ensure all
activities and task are performed cost effectively, with safety as upper most consideration.
The procedures are pro-actively maintained through a formal “Management of Change –
MOC” process. These procedures should be available at every rigsite with UBCTD
operations.
Operations are conducted with reference to the “Wellsite Management Plan” which
details the joint policy of Saudi Aramco and the Contractors to conduct their activities in
such a way as to take foremost account of the health and safety of their employees and of
other persons, and to give proper regard to the conservation of the environment. In
implementing this policy all parties shall comply with the relevant legislation and promote
in an appropriate manner measures for the protection of health, safety and environment
for all who may be affected directly or indirectly by their activities.
One of the key advantages of CTD, through its unique pressure control capabilities, is that
it enables safe underbalanced drilling. In preventing or avoiding drilling damage, UB-CTD
is often perceived to be the ideal solution to formation damage, especially in depleted
reservoirs where CTD techniques can be so effectively applied. However, designing and
conducting an UB-CTD operation can be a complex process which requires a thorough
knowledge of the risks (e.g., formation/wellbore collapse) and hazards (e.g., safe handling
of reservoir fluids in the returned wellbore fluids).
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5.1 CTD Planning and Execution Review

This first step in the review process is the responsibility of the CTD engineer and
requires identifying and communicating to all involved parties the reporting
requirements and expectations from each company/individual. Some of the data that
must be requested and furnished to the CTD engineer are:
• Final directional survey and plot of the well

• Final copy of any logs recorded
• Complete record of bottom hole pressure data including date and time
• Completion liner tally
• Revised wellbore sketch
• Bottom-hole pressure records (if data recorded)
• Fluids report
• Cementing data
• Full copy of all daily reports and accident reports
As a general rule, these steps should be followed to drill a well using CT:
a) Clearly define the objectives of the well. Why use CT for this well?
Underbalanced, balanced, or over-balanced fluid? Hole size? Cuttings transport?
Liner or open-hole completion?
b) Review the well history and mechanical condition of an existing well. Well should
be screened in the three main areas of mechanical condition, reservoir quality
and issues, and directional considerations for reaching the target.
c) Perform feasibility study and identify drilling hazards, risks and controls.
Determine what workover operations are required prior to the CTD rig coming to
location and write procedures for this work.
d) Design and prepare a preliminary directional plan.
e) Review and finalize the directional plan for the well. Discuss with the directional
driller and determine the bottom-hole assembly (BHA) that will be needed to
accomplish this plan.
f) Choose a drilling fluid based on formation information provided and run wellbore
hydraulics calculations to determine if fluid and system are appropriate for the
well conditions.
g) Determine type of window-milling operation required for the well.
h) Write final drilling program.
i) Prepare site for the rig and move in rig.
j) Ensure all equipment is inspected and maintenance records are available.
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k) Confirm that all procedures are written and in place.

l) Record and report all required data during the drilling operation.
During UB-CTD operations it is of paramount importance that the plan forward is

clearly defined. Due to the additional equipment, personnel, increased risk due to the
live well nature of the operation and the critical interaction between different
disciplines, work procedures are required.
These procedures will involve planning from the service companies as well as the rig
management including the Saudi Aramco Drilling Forman and the CTD toolpusher.
The end result will be a step by step plan for any operation that deviates from regular
drilling operations.
The issues detailed in the procedures are discussed in the regular meetings on the
rig which are conducted twice daily or as required.
Any deviation from the approved procedures needs to be reviewed and a

supplemental game plan issued for the remainder of the operation.
There may be slight deviation from the contents of this section to allow unique
operational situations to be assessed, risks to be identified and the Written Work
Instructions (WWI) modified to accommodate actual conditions on the specific
wellsite.
Modifications to general procedures will need to be made considering the additional

operational challenges that will arise during drilling operations. The production of gas
presents fundamental challenges that will need consideration while the drilling
operations are ongoing.
5.2 Pressure Testing Requirement

Pressure test procedures for CT BOP and surface line N2 and hydro testing are
described in XTD-LVL5-OPS-008 (Attachment #1). Bi-weekly test procedure for the
CT BOP and surface equipment as per the Saudi Aramco Well Control manual are
described in details in XTD-LVL5-OPS-020 (Attachment #1).
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5.3 Xmas Tree Requirement

A hydraulic actuated tree should be installed on the well before the UBCTD unit is
rigged up. This is to ensure safe operation and integration of hydraulic controls from
the CTD rig.
5.4 Gas Handling

The production of gas requires careful consideration, and the procedures should
reflect allowing sufficient retention time in the separator in order to allow the break
out and subsequent export and/or flaring of gas during drilling operations.
5.5 H 2 S Issues
The presence of H 2 S gas in Saudi Aramco is not uncommon. Hence, for UBCTD
application careful consideration must be given to ensure the high H 2 S content is
identified and that the procedures reflect careful and stringent H 2 S safety guidelines.
Some of the wells recorded more than 50,000ppm H 2 S count in the gas out flow
stream. A detailed gas detection system and breathing apparatus map is shown in
Attachment #4 for low H 2 S wells (<1%) and in Attachment #5 for high H 2 S wells
(>1%). A station bill is attached as attachment #6 which highlights the emergency
procedures, roles and responsibilities of all personnel present on location during
UBD operations.
During the planning stages of the approved procedures, if it is intended to recirculate

the drilling fluid, a complete closed recirculation system is required.
Specific procedures were developed for Wells with high H 2 S levels. Some of the
recommendations from the high H 2 S wells HAZOP/HAZID wells implemented
include:
• Modify and add equipment for drilling high H 2 S Wells
• Extend height of flare stack by 50%
• Move flare stack further away from Well site
• Install extra purging capability throughout the surface equipment
• Install extra H 2 S safety equipment in place
• Minimizing gas rate to ALARP and onsite management of any flaring requirement
• Use of Sourscav for treatment of sour water
• Installation of an additional settling tank and recirculation pump to increase
residence time for chemical action
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• Additional safety personnel

• Further separation of the living camp from the wellsite
5.6 Condensate Handling

Saudi Aramco wells are very rich in condensate (CGRs in the range of 100-160
Bbls/MM are common). The production of condensate may result in the formation of
emulsions. The Condensate after being separated from water in the second stage of
the 4-phase separator, is pumped into the Saudi Aramco flowline to the gas plant.
5.7 Deployment Systems

Pressure Deployment
Probably the greatest feature that CT brings to UBCTD is the ability to maintain a
continuous state of under-balance while drilling and tripping. However, during
operations where the injector must be removed (installing/removing the BHA), the
well must be maintained in an underbalanced condition. Pressure deployment of the
BHA is achieved using techniques developed for CT logging of live wells. The
procedure used depends on factors such as:
• Length and diameter of the BHA

• BOP configuration
• Number of pressure barriers required
Following is a general guide for pressure deployment and should be modified to suit
specific circumstances. Since most wells drilled underbalanced with CTD will involve
directional drilling, these procedures reflect the deployment of a BHA of about 80 ft in
length. Also, since most drilling would be for small hole sizes, the bit is assumed to
be 3-5/8 in. with the BHA having a nominal diameter of 3 inches. The method
employed for deploying is to use a wireline lubricator type deployment riser made up
to the appropriate length.
This requires a set of slip/seal rams and a set of blind/shear rams to be located in the
BOP stack and the use of a deployment bar (a special sub that installs in the BHA
and allows closing of the of the specified slip/seal rams on the correct diameter). The
BHAs are pulled up into the lubricator. With the blind/shear rams closed, the injector
and lubricator are installed on the BOPs and the pressure equalized. The blind/shear
rams are then opened and the BHA run into the well.
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5.8 Window Milling

One of the operations in the CTD project that requires significant planning is window
milling. The use of CTD for through-tubing casing exits provides an economical
means of accessing marginal or bypassed pockets of hydrocarbons, by avoiding the
need to remove existing completions and eliminating expensive workovers.
The whipstock is run through the tubing and set in the cemented liner +/-200 ft above
the perforations. The whipstock is set hydraulically after being oriented with the HOT.
The setting tool is then pulled out of the hole. A milling assembly is run and the
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window is cut. Currently, the whipstock system is suitable for 7 in, 5-1/2 in and 4-1/2
in liners. The following are the sidetrack/re-entry processes that are currently used
during UBCTD.
a) Through-tubing re-entry with completion left in place and sidetracked below

the tailpipe
b) Through-tubing re-entry with completion left in place and sidetracked from
inside the tubing
c) Conventional re-entry with completion pulled and sidetracked from existing
wellbore
Through-tubing re-entries can only be undertaken using mill and bit assemblies
compatible with the minimum ID (restriction) in the tubing string or completion. In
some cases, tubing restrictions can be milled out or cut to allow access for larger
mills and bits.
Through-tubing re-entry techniques have special significance in applications where

completion removal is uneconomical or impractical. The constraints associated with
working within the completion tubular generally preclude conventional rigs and
equipment from this type of operation.
String Mill Diamond Speed mill
Pathmaker mill
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For deep gas well, the typical minimum restriction is found in the “R” nipple, which is
3.688” (for 4-1/2” tubing). For that reason, the maximum OD of the whipstock is
3.625” and the mill OD is 3.65”. The currently available thru-tubing whipstock that
satisfies this requirement is the BAKER OIL TOOL Retrievable Delta Whipstock.
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5.9 Pre-Khuff Drilling

Modification to existing procedures and additional procedures are required for drilling
underbalance with the CTD in the Pre-Khuff reservoir. Special consideration will be
required to address:
• Reservoir Damage (maintain UBD at all times)
• Drilling will follow a pre-defined geometrical trajectory (since reservoir is fossil-
barren, bio-steering is not possible)
• Reservoirs are highly competent, extremely abrasive rock.
Modification of the drilling bit, drive system and circulation system will ensure
success.
6.0 WELL AND SITE LOCATION LAYOUT
Site preparation for the project is an important initial consideration especially for heavy
equipment use for leveling the pad. The equipment layout is vital to a successful operation
and a detailed drawing should be provided as part of the procedure for moving and rigging
up the CTD unit and equipment.
UB-CTD equipment has a smaller footprint compared to the conventional WO rigs. The
fence sections of the location are kept in-place to assist in the control of access for
personnel. The living camp is located towards the west of the location, since the flare
stack is to the east.
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The typical location layout can be seen in the sketch below.
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Attachment 1A: Saudi Aramco CT UBD Project Normal Procedures
TABLE OF CONTENTS
XTD OPERATING AND CONTINGENCY PROCEDURES
TOC VND
G Fudge Date TOC Updated 3/5/2013 Rev # 14 Rev.3
Updated By Drawing #
Re MOC
Procedure # Procedure Title Date Issued
v# Number
XTD-LVL5-OPS-000 Procedure TOC R6 04h Nov 2012
XTD-LVL5-OPS-001 Move In and Spot Equipment R1 04th Nov 2012
XTD-LVL5-OPS-002 Radio Communication and Protocol R1 04th Nov 2012
XTD-LVL5-OPS-003 Cutting Coiled Tubing with a Pipe Cutter R1 04th Nov 2012
XTD-LVL5-OPS-004 Stabbing the Coiled Tubing R1 04th Nov 2012
R2 MOC 59 &
XTD-LVL5-OPS-005 Slack Management 04th Nov 2012
67
XTD-LVL5-OPS-006 Pre Start-Up and Commissioning Checklist R1 04th Nov 2012
XTD-LVL5-OPS-007 Start Up Valve Check Lists R1 04th Nov 2012
XTD-LVL5-OPS-008 BOPE and Surface Line Hydro and N 2 Testing R3 14th Jan 2013 MOC 129
XTD-LVL5-OPS-009 Pressure Deployment R4 04th Nov 2012 MOC 127
XTD-LVL5-OPS-010 Running in Hole and Correlation R3 04th Nov 2012 MOC 59
XTD-LVL5-OPS-011 Whipstock Setting with CoilTrak R1 04th Nov 2012
XTD-LVL5-OPS-012 Flagging the Coiled Tubing R1 04th Nov 2012
XTD-LVL5-OPS-013 Pulling Out of Hole R5 29th Dec 2012 MOC 123
XTD-LVL5-OPS-014 CT String Bleed Down R1 04th Nov 2012 MOC 59
XTD-LVL5-OPS-015 Pressure Undeployment R3 04th Nov 2012 MOC 127
XTD-LVL5-OPS-016 Window Milling R1 04th Nov 2012
XTD-LVL5-OPS-017 Drilling R1 04th Nov 2012
XTD-LVL5-OPS-018 Weekly BOP Ram Check R1 04th Nov 2012
XTD-LVL5-OPS-019 Flaring Decision Tree R1 04th Nov 2012
XTD-LVL5-OPS-020 Bi-Weekly Pressure Test R2 04th Nov 2012 MOC 59
XTD-LVL5-OPS-021 Well Clean Up and Flow Testing R2 04th Nov 2012 MOC 59
XTD-LVL5-OPS-022 Flush and Purge R2 04th Nov 2012 MOC 59
XTD-LVL5-OPS-023 Unstabbing Coiled Tubing R1 04th Nov 2012
XTD-LVL5-OPS-024 Risk Management Plan R1 04th Nov 2012
XTD-LVL5-OPS-025 Inspection of Lifting Equipment R1 04th Nov 2012
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Re MOC
v# Number
XTD-LVL5-OPS-026 Management of Change (MOC) R0 03rd May 2011
XTD-LVL5-OPS-027 Sampling Using Sample Catcher R0 04th Nov 2012
XTD-LVL5-OPS-028 Cleaning out the Junk Catcher R1 02nd Nov 2011
XTD-LVL5-OPS-029 Condensate Export R1 04th Nov 2012
XTD-LVL5-OPS-030 2-Phase Drilling / circulating with N 2 R0 07th Apr 2013 MOC 150
Chemical Cut Coil with Stuck BHA - Cut Above
XTD-LVL5-OPS-031 D1 04th June 2012 Draft
Injector
XTD-LVL5-OPS-032
Chemical Cut Coil with Stuck BHA from the rig
XTD-LVL5-OPS-033 D0 04th June 2012 Draft
floor
CONTINGENCY PROCEDURES
Re MOC
v# Number
XTD-LVL5-OPS-051 UBD ESD Event R2 04th Nov 2012 MOC 59
XTD-LVL5-OPS-052 Circulating Line Failure R2 04th Nov 2012 MOC 59
XTD-LVL5-OPS-053 Rig or UB Package Power Failure R1 04th Nov 2012
XTD-LVL5-OPS-054 Stripper Failure/Change R2 04th Nov 2012 MOC 59
XTD-LVL5-OPS-055 Surface String Failure R1 04th Nov 2012
XTD-LVL5-OPS-056 Downhole String Failure R2 04th Nov 2012 MOC 59
XTD-LVL5-OPS-057 Ball Valve or Flapper Valve Failure R1 04th Nov 2012
XTD-LVL5-OPS-058 BOPE, Production Tree or Wellhead Failure R2 04th Nov 2012 MOC 59
XTD-LVL5-OPS-059 Gas Plant ESD R1 04th Nov 2012
XTD-LVL5-OPS-060 Bullhead Well Kill R2 04th Nov 2012 MOC 59
XTD-LVL5-OPS-061 Window Milling Chrome Liner RO 9th Apr 2013 MOC 151
XTD-LVL5-OPS-062 BHA Plugging/Blockage R1 04th Nov 2012
Securing the Well with Lower 2 3/8” Pipe/Slip
XTD-LVL5-OPS-063 R2 04th Nov 2012 MOC 59
Rams
XTD-LVL5-OPS-064 Emergency Closure of Blind/Shear Rams R1 04th Nov 2012
XTD-LVL5-OPS-065
XTD-LVL5-OPS-066
Chemical Cut Coil w/ Stuck BHA from the rig 15th Feb 2013
XTD-LVL5-OPS-067 R2 MOC 132
floor
th
XTD-LVL5-OPS-068 Stuck CT and/or BHA R1 04 Nov 2012
XTD-LVL5-OPS-069 Hydrate Formation R1 04th Nov 2012
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Accepting Lifting Machinery and Operators on 04th Nov 2012

XTD-LVL5-OPS-070 R1
the Rig Site
XTD-LVL5-OPS-071 Blind/Shear Ram Test R1 04th Nov 2012
XTD-LVL5-OPS-072 Corrosion Management R1 04th Nov 2012
XTD-LVL5-OPS-073 Coil Management R2 29th Dec 2012 MOC 123
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Attachment 2: Wellhead Schematic & Tree
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Attachment 3: XTD-2 VND
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Attachment 4A: Gas Detection System for Low H 2 S Wells (H 2 S<1%)
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Attachment 4B: Breathing Apparatus Maps for Low H 2 S Wells (H 2 S<1%)
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Attachment 5A: Gas Detection System for High H 2 S Wells (H 2 S>1%)
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Attachment 5B: Breathing Apparatus Maps for High H 2 S Wells (H 2 S>1%)
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Attachment 6: Station Bill
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SAUDI ARAMCO WORKOVER MANUAL

Drilling Technical Department September 2013

CHAPTER 9 UNDERBALANCED COIL TUBING DRILLING

UNDERBALANCED COIL TUBING DRILLING

1.2. Underbalanced Coil Tubing Drilling Selection Criteria

2. SURFACE EQUIPMENT SPECIFICATIONS

3. UBCTD DOWNHOLE EQUIPMENT

4. DRILLING FLUID ADDITIVES

CHAPTER 9 Underbalanced Coil Tubing Drilling

5. BASIC PROCEDURES FOR UBCTD

6. WELL AND SITE LOCATION LAYOUT

Attachment #1A: Saudi Aramco CT-UBD Project Normal Procedures

CHAPTER 9 UNDERBALANCED COIL TUBING DRILLING

UNDERBALANCED COIL TUBING DRILLING

1.1. The Underbalanced-CTD Process

The UB-CTD project is a thru-tubing Coiled Tubing (CT) underbalanced drilling

CHAPTER 9 UNDERBALANCED COIL TUBING DRILLING

1.2 Underbalanced Coil Tubing Drilling Selection Criteria

When re-entering a well, consideration needs to be taken of the age,

CHAPTER 9 UNDERBALANCED COIL TUBING DRILLING

Typical Score Table for candidate selection

Points Well A Well B Well C Well D Well E Well F Well G

S T R U CT U R E / 10 Flank/Medium Crestal/Low Flank/Medium Flank/Medium Flank / V High Crestal/Low

0 11,102' 11,710' 11,840' 11,690' 12,558' 11,373'

6 14,500' 15,000' 15,100' 14,900' MD 15,800' 14,600'

Inc @ S e ns o r 8 2.1 0.1 3.2 0.5 4.4 0.9

W hip s to c k 10 NO NO Yes Yes Installed Yes Yes

CHAPTER 9 UNDERBALANCED COIL TUBING DRILLING

1.3. IADC UBD Classifications

UBD or Low Head

Underbalanced Technique Used

CHAPTER 9 UNDERBALANCED COIL TUBING DRILLING

2.0 SURFACE EQUIPMENT SPECIFICATIONS

2.1 Specifications of Coil Tubing Rig

The addition of UBCTD included the following:

a) An active choke system

The surface separation package is designed to safely permit a well to be drilled in an

Maximum pull: 200,000 lbs

CHAPTER 9 UNDERBALANCED COIL TUBING DRILLING

GOOSENECK: 130” to safely handle the deployment of CT COIL CABIN

DATA ACQUISITION and RECORDING SYSTEM: with sensors and computer

DROP-IN DRUM SYSTEM: Accommodates a minimum of 18,500 ft of 2-3/8” CT with

CHAPTER 9 UNDERBALANCED COIL TUBING DRILLING

COIL TUBING Mast and Substructure: Including,

Category II – 10M PSI WP HP CT BOP stack configuration (Attachment #2):

CHAPTER 9 UNDERBALANCED COIL TUBING DRILLING

Quad BOP: 5-1/8” 10M psi:

Lower Rams: Combination 2-3/8” Pipe/Slip Rams with 5” Actuators.

Emergency Kill Line Tee: 2-1/16” 10M psi

2.3 Flowline and Emergency Shutdown Valve (ESD)

A detailed P&ID diagram is shown in Attachment #3.

CHAPTER 9 UNDERBALANCED COIL TUBING DRILLING

• The Emergency Shutdown Valve (ESD Valve) is a hydraulically actuated fail-

• Emergency Shut-down system: Emergency Shutdown System (ESD) capable of

• Dedicated ESD PLC. A Programmable Logic Controller (PLC) dedicated to

2.4 Choke Manifolds

CHAPTER 9 UNDERBALANCED COIL TUBING DRILLING

2.5 Solids Sampling System

2.6 Separator System

The 4-Phase Separation System is capable of processing 35,000 bpd liquids, 50

CHAPTER 9 UNDERBALANCED COIL TUBING DRILLING

UBCTD High Pressure Gas Separator

• Capacity for Gas Handling minimum 70 MMSCFD up to 92 MMSCFD maximum