Underbalanced Drilling and Workover Rev 2-5

Underbalanced Drilling
and Workover
1
Outline
» 1. Terms and Basic Calculations

2. Underbalance: Uses and Conditions
3. Surface Control Equipment
4. Downhole Tools
5. UBD fluid column and well control
6. Fluid systems used in UBD
7. Coiled Tubing versus Conventional UBD drilling
8. Control Problem Scenarios
9. Location Equipment and Flaring
2
Terms and Basic
Calculations
UB and Well Control are

very similar
UB Drilling: Drilling into

any formation where
the pressure exerted
by the drilling fluid is
less than the
formation pressure
Underbalanced drilling, completion, and workover are very similar in nature to basic
Well Control: the well is shut-in against pressure in the wellbore, and the well is
circulated through a choke. The basic concepts of UBD are also fundamental to
Well Control.
Underbalanced drilling is defined as drilling into any formation where the pressure
exerted by the drilling fluid is less than the formation pressure. This is also true of
other well operations (such as completion and workover) performed under the same
pressure and circulation conditions.
3
Examples of
Underbalanced Techniques
1. Drilling with Air or Gas, Foams, Mists,

or gas-liquid mixtures
2. Drilling with Cable-Tool method

no mud is used – cuttings are bailed
3. Drilling with conventional Mud

when pressure in the fluid column is less than
formation pressure
4
Types of Pressure
Formation
– Force exerted by fluids in the
formation
Hydrostatic
– Pressure exerted by the fluid
column in the wellbore
Standpipe
– Measured at the top of the drill
stem (DPP)
Choke
– Annulus pressure at the surface
in a U-
U-tube scenario
1. Formation pressure is the force exerted by fluids in the formation. Some

engineers also refer to this as Pore pressure or reservoir pressure. Formation
pressure varies with depth and other geologic conditions. Next slide explains.
2. Hydrostatic pressure is exerted by the fluid column in the wellbore (another slide
explains).
Standpipe pressure is measured at the top of the drill stem.

Choke Pressure is Annulus pressure at the surface in a U-tube well scenario.
5
Types of Formation Pressure
Normal
– Equal to a column of water
– 0.468 psi/ft, 9.0 PPG, or 1.08
SG
Subnormal
– Less than the pressure
exerted by a full column of
water
Abnormal
– Overpressure, geopressure
– Greater than normal pressure
– Up to EMW of 19.9 PPG
Formation pressure varies with the depth of the hole and other geologic conditions.
Formation Pressure can be determined by shut-in drill pipe pressure (SIDPP), or
measured using an MWD recorder or a wireline pressure bomb.
6
Hydrostatic pressure in UBD
Hydrostatic pressure controlled by
crew
– choice of drilling fluid plus pumping
program
Normal drilling
– increase hydrostatic with salt or barite
UBD usually EMW of < 8.3 PPG
UBD drilling
– Decrease hydrostatic with water, oil,
air, or gas
7
Pressure Calculations
Static Pressure
Hydrostatic pressure at any point in the fluid column
P = TVD x MW x K where
P = pressure, psi (kPa)

TVD = true vertical depth, ft (m)
MW = mud weight or fluid density (PPG) (kg/m3)
K = .052 (.0098)
8
Example Static Pressure
Assume:
TVD = 8,202 ft (2500 m)
MW = 11.1 ppg (1330 kg/m3)
P = 8202 x 11.1 x 0.052 = 4,734 psi
= 2500 x 1330 x 0.0098 = 32,585 kPa
9
Hydrostatic Gradient
Gradient (G) expressed as psi/ft of depth (kPa/m)
G = MW x K
G = 11.1 ppg x 0.052 = .577 psi/ft
= 1330 kg/m3 x 0.0098 = 13.034 kPa/m
10
Average Hydrostatic Gradient
Gav = BHP ÷ TVD ÷ K where
Gav expressed as EMW (ppg or kg/m)

BHP = bottom hole pressure, psi (kPa)
Gav = 4734 psi ÷ 8202 ft ÷ 0.052 = 11.1 ppg
= 32,585 kPa ÷ 2500 m ÷ 0.0098 = 1,330 kg/m
11
Mud Weight vs. Gradient
PPG Kg/m3 psi/ft kPa/m
2.0 240 .104 2.353
3.0 359 .156 3.529
4.0 479 .208 4.705
5.0 599 .260 5.880
6.0 719 .312 7.058
7.0 839 .364 8.234
8.0 959 .416 9.410
9.0 1078 .468 10.587
12
Operating Pressures
Drill pipe pressure (DPP)

– required to move drilling fluid down the drill stem
Annular pressure loss (APL)

– pump pressure required to move drilling fluid in the
annulus
– depends on fluid viscosity/velocity, hole roughness
– Normal drilling ~ 200 psi
– UBD ≤ 1,000 psi (high gas velocity at top)
These are the type of pressures defined by Underbalanced drilling.
13
Operating Pressures
(cont’d)
Choke/Separator pressure
– Pressure loss through choke/separator system
– Atmospheric separator, only 1 or 2 psi
– Closed separator, 100 psi or more
Pump pressure
– required to circulate drilling fluid through the entire
hole
– Includes DPP, APL, and choke/separator pressures
14
In UBD, annulus fluid density
VARIES
Difficult to express hydrostatic
pressure at any point in the
annulus
– With decreasing
decreasing depth
Fluid density less
Fluid velocity greater, APL greater
Gas expansion pressure greater
‘Average’ hydrostatic
– Equivalent Circulating Density is
APL expressed as mud weight
Equivalent Circulating Density is an expression of the “Average Hydrostatic

pressure”, and expresses bottom-hole pressure as equivalent mud weight
when the system is circulating. Remember, bottom-hole pressure (especially
Annular Pressure Loss) increases when the fluid system is circulated.
15
Summary and Review
Underbalanced Drilling (UBD)

– drilling into any formation when the pressure
exerted by the drilling fluid column is less
than the formation pressure
– Can be continuous ‘kick’
16
Summary and Review
annulus density
VARIES
17
Outline
1. Terms and Basic Calculations

» 2. Underbalance: Uses and Conditions
4. Downhole Tools
6. Fluids: Mud, Liquid/Gas, Foams and Mist
18
Why Drill Underbalanced ?
Increase the drilling rate

Avoid or limit lost circulation
Limit or avoid reservoir damage
Reduce stimulation costs
Avoid differential sticking
Find potential reservoirs
19
3 to 20 times faster bit

penetration
– Underbalance ‘blows’
blows’ the
cuttings off bottom
ROP begins to increase
at about 500 psi
overbalance
ROP continues to
increase until more bit
speed or weight needed
Drillers know that increasing mud weight slows the Rate of bit penetration (ROP).
What most don’t know, however, is that decreasing mud weight INCREASES bit
penetration. ROP begins to increase at about 500 psi OVERbalance. The increase
continues through equilibrium and into hydrostatic UNDERbalance, until more bit
speed and/or weight is needed or the bit begins to flounder (cuttings aren’t removed
fast enough, bit drills cuttings only).
ROP increases with underbalanced drilling are usually observed at from 3 to 20

times the rates achieved with normal drilling. This translates to fewer bit trips and
lower drilling time and cost.
20
Example: La Paz field Venezuela (SPE 74449)

– Faster ROP, fewer days, fewer bits
ROP increases with underbalanced drilling are usually observed at from 3 to 20

times the rates achieved with normal drilling. This translates to fewer bit trips and
lower drilling time and cost.
21
Avoid Lost Circulation
UBD: flow is into well
Alternative is ‘Lost
Circulation Materials’
– Expensive
– Slows drilling further
– Increase mud solids
Bonus: Foam bubbles

plug LC zones better
than LCMs
Avoiding lost circulation is the number 1 reason that most operators turn to
Underbalanced drilling.
22
Limit Reservoir Damage
Normal drilling
– Filtrate enters target
– Filter cake plugs face
– equals Skin Damage
UBD avoids almost all
Skin Damage
– Reduced or no stimulation
costs
– Bonus: foam has
enhanced lift/cleanout
23
Limit Reservoir Damage
Reservoir damage
affects productivity
and Payout
Recent studies show that
potential to reduce
formation damage makes
UBD economically
attractive despite higher
equipment costs
24
Differential sticking
– Filter cake in normal hole
– Higher pressure in
wellbore pushes drill pipe
toward lower pressure in
formation
UBD: no cake, pressure
inward
– Critical in highly deviated
and horizontal wells
where pipe always on
low side
In a normally drilled hole, the mud system introduces filtrate into permeable
formations exposed in the wellbore. The resulting ‘filter cake’ is deposited along the
outside of the hole, which continues to build up. The drill stem, usually the collars,
are susceptible to coming to rest along the outside of the hole. The lower
‘differential’ pressure in the formation ‘pulls’ the pipe to the side of the hole, and
higher pressure inside the wellbore ‘pushes’ against the pie, and the drillstring
becomes stuck. The strength of the force that holds the pipe depends on how great
is the difference in overbalance between the wellbore and the formation.
In UBD, however, there is no filter cake, and the differential pressure is INWARDS
from the formation into the wellbore. This is particularly important in highly deviated
and horizontal wells where the drill pipe spends most of it’s time in the hole laying
against the low side of the wellbore.
25
Normal Drilling
– filtrate and filter cake
block formation
permeability
– Prevent wellbore
‘shows’
shows’
UBD
– Constant inflow
reveals potential
production
26
When UBD not best
Geopressured shale
– Normal shale
Rock particles support the
overburden
– Geopressured has excess
water; water in pores
supports the overburden
– In UBD, shale sloughs
into the hole
– Requires EMW of 9 to 20
ppg
27
When UBD not best
Salt Formations
– Most salts are ‘plastic’
plastic’,
will flow into borehole
Zechstein (North Sea)
within hours
US mid-
mid-continent within
days
– salt or oil mud, increase
mud weight
– Exception: thin, hard salt
beds: OK with UBD
28
When UBD not best
Coal and other rubble

formations
– Large borehole washouts
– Usually requires mud
– Exception: UBD foam
has enhanced lifting
capability, clears cavings
29
When UBD not best
Unconsolidated sands
– Geologically ‘young’
young’,
never cemented
– UBD: major hole
problems with sloughing
and caving unless mud
used
– Exception: enhanced
lifting capability of foam
supports borehole wall
and cleans the hole
30
UBD and Horizontal drilling
UBD solves major problems:

– Differential sticking
Pipe lies on bottom of hole during connections etc.
– Lost Circulation
Horizontal most often used in fractured and
depleted targets
– Prevents skin damage
Stimulation high % of horizontal well cost
– Fewer bit trips
Increased ROP provides reduced cost of well
31
Differences between UBD and
normal drilling programs
More casing and tighter control of casing

points
More casing to shut off zones that do not respond
well to UBD
– Sloughing shale, coals, unconsolidated, etc.
Typical UBD sets casing immediately above pay

zones
– allows techniques and fluids that further avoid skin
damage
The advantages of UBD are substantial compared to conventional drilling programs,

and provide unique cost savings in a number of areas we have already discussed.
The advantages of UBD, however, are not without increased costs in other areas of
the drilling program. In many cases, additional casing may be required to shut off
zones that do not respond well to UBD, such as coal or unconsolidated zones. In
other cases, casing may be set immediately above a target pay zone, so that the
fluid system may be changed over or other techniques utilized to prevent formation
damage.
32
Tighter
control of bottomhole and surface
pressures
In UBD, the well is continuously ‘kicking’
kicking’
Foams, gas, and gasified liquid drilling systems
require constant pressure monitoring and
adjustment
Higher level of crew training and experience
33
Potential for higher surface pressures

– BUT
Wellborepressures almost always LOWER

than ‘Well Control’ situation
Reduced hydrostatic of fluid column (much
reduced for most UBD fluid systems)
– Provides reduced risk of Underground Blowout
34
UBD emphasis is on surface equipment

Rotary heads, preventers, pressured separators,
gas/foam recovery systems, high-
high- and low-
low-
pressure flares (and more) make UBD work
Design and operation of surface equipment usually

requires 3rd-
3rd-party contractors
Finally, it is the selection and skilled operation of a wide variety of specialized

surface equipment that allows safe utilization of Underbalanced drilling techniques.
We will cover these types of equipment and their safe operation in a later section.
35
IADC Types of UBD
– Gas
Air or gas only
– Mist
Less than 2.5% liquid
– Foam
Continuous liquid phase, 2.5% to 95% liquid, structured
– Gasified Liquid or Mud
Gas bubbles in liquid phase, >95% liquid, unstructured
– Liquid
Liquid phase only
– Near-Balance
Wellbore ~ Formation pressure (usually light mud)
Foam is generated using a chemical additive to promote the integrity and strength
of gas bubbles, and chemical and physical ‘linkage’ between bubbles in the mixture.
This results in a structured mixture of gas bubbles and liquid that is resistant to
bubble merging and eventual breakout. Foams must be ‘broken’ with a counter-
additive to remove the entrained gas.
On the contrary, a ‘gasified liquid’ is a simple physical mixture of gas to liquid,
usually utilizing gas introduced to the fluid system at the rotating head (top of the
drill stem). The gas is free to leave the mixture, usually as pressure is released and
gas bubbles expand and merge.
We will cover each of these types of fluid systems in later sections of the course.
36
Summary and Review
Advantages of UBD
37
Summary and Review
When UBD is poor choice

Geopressured shales, coal, rubble zones, salt,
unconsolidated sand: hole sloughing and caving
Extra costs of UBD

More casing, better control of casing points
Tighter control of operating pressures
Added surface equipment
Added cost of foam or specialized fluid systems
38
Summary and Review
Extra costs of UBD versus Bottom Line

– Average $500,000 savings per well (25%)
Hallettsville TX field-
field-wide program (SPE 13112)
– Reduced drilling days, reduced trouble time (no
estimation for stimulation savings)
– Average 300% - 400% production increase

Hugoton field, USA (Drilling Contractor, July 2004)
– 50 years’
years’ production decline, now 600 psi formation
pressure
39
Summary and Review
Extra costs of UBD

versus Bottom Line
– Higher cost, but more
oil and faster payout
Wayne Field, Williston
basin
40
Summary and Review
Extra costs of UBD versus Bottom

Line
– Lower well cost (much faster drilling)
and 50%-
50%-150% higher gas production
Sajaa field, Sharjah (Emirates)
41
Summary and Review
Example UBD
Economics
– Rhourde El Baguel field,
near Hassi Messaoud
$1853/meter for UBD,
$3520 for conventional
(trouble time)
2 bits/trips for UBD vs. 6
No stimulation for UBD
(cost not included)
300% ROP improvement
SPE 62203
42
Summary and Review
Extra costs of UBD

versus Bottom Line
– Higher production, more
reserves
Shell, 2005 Stockholder’
Stockholder’s
Report
Rotliegendes and Zechstein
formations, southern North
Sea; 1st offshore UBD
6 platforms to be retired in
1997, but still profitable 6
years later
43
Summary and Review
Extra costs of UBD

versus Bottom Line
– General cost and
efficiency improvement
Pemex (SPE 85110 and
59054)
Fractured offshore fields
Averages for 91 wells
– Note: higher UBD
equipment costs give
higher cost/foot BUT
almost $1 million
advantage in production
Note that the equipment and Nitrogen costs provided a much greater cost/foot for
the finished wells, but that advantages in drilling time brought the wells online
sooner at higher production rates. Note that this comparison does include savings
for rig time (72 versus 30 days on average); these were highly fractured, lost-
circulation ‘trouble’ zones, as reflected in rig time. Rather, the comparison focuses
on the time saved in getting production into the pipeline versus economic payout.
44
Outline

» 3. Surface Control Equipment
4. Downhole Tools
45
UBD Surface Equipment
BOP stacks for UBD

Rotating drilling heads and rotating
blowout preventers
Standpipe arrangements
Chokes and choke manifolds
Atmospheric and closed separators
Cutting catchers
Flares and ‘Blooey lines’
46
Barrier Concept
In Conventional drilling, the over-balanced

mud is the primary barrier against a kick
or blowout
In UBD, the drilling fluid is deliberately too

light to control downhole pressure
– Primary barrier is a rotating head or rotating
preventer
– Secondary barrier is annular preventer and
BOP stack
The most important thing to remember is that for conventional drilling, the mud
system is the Primary Barrier against a kick or blowout, and the annular and other
BOP preventers are secondary barriers. Conversely, in UBD operations, the drilling
fluid is deliberately too light to control downhole pressures. For UBD, the Primary
Barrier is a device called a ‘Rotating Head’ or ‘Rotating Preventer’, a sort of annular
preventer that allows rotation and normal drilling operations WHILE CLOSED. We’ll
discuss rotating heads in detail in a few slides.
47
BOP stacks for UBD
For UBD liquid, gas-liquid, and
foam systems: not much different
than for mud drilling
API RP 53
Taller,
Taller, because a rotating head or
rotating preventer is always stacked
above the Annular preventer
Low-
Low-pressure flow line is below the
rotating head but above the annular
preventer
In UBD, at least one of the BOP high-
high-
pressure lines should be 3”
3”- 4” for
normal circulation under pressure
This course is not meant to provide instruction on BOP systems and stack operation
in general; instead, we fill focus only on a comparison of systems used for
Underbalanced drilling with normal systems used for conventional mud drilling. In
general, BOP stack arrangement is usually designed in accordance with the
industry standards set forth in the American Petroleum Institute publication
“Recommended Practice # 53: Blowout Prevention Equipment Systems for Drilling
Operations”.
In general, BOP systems for liquid, liquid-gas, and foam fluid systems are not much
different than those used in conventional mud drilling. These are the primary
differences.
48
BOP stacks for UBD
For gas/air or mist

systems: lighter and
simpler
Rotating head, but no
annular preventer because
well pressures are lower
Rams have 4”4” side outlets
for high-
high-pressure gas
Flow line 300’
300’ long, made
from 7”
7” – 10”
10” casing, called
a ‘Blooey Line’
Line’
49
BOP stacks for UBD
For gas/air or mist

systems: lighter and
simpler
Rotating head, but
sometimes no annular
preventer because well
pressures are lower
Rams have 4”4” side outlets
for high-
high-pressure gas
Flow line 300’
300’ long, made
from 7”
7” – 10”
10” casing, called
a ‘Blooey Line’
Line’
This BOP stack is from a mist system utilizing natural gas and diesel, in Smackover
trend Alabama.
50
UBD Rotating Equipment
Primary barrier
Use: to divert
pressurized drilling fluid
away from the floor to
the flow line, where the
fluid can be recycled,
flared, or disposed
51
Rotating Control Head
Stripper rubbers form a

passive seal against pipe
Annular pressure provides
additional sealing pressure
Stripper assembly is
mounted on a bearing pack
that rotates with the pipe
Tool joints force open the
stripper rubber as they pass
through
Note that bits and collars are not able to pass through the stripper element. To
pass the bit and stabilizers, the carrier is unlatched from the bearing assembly so
that the stripper carrier can be set aside.
Most high-pressure rotating heads have a hydraulic heat-exchanger module that
circulates oil to cool and lubricate the bearings on which the stripper rubber rotates.
52
Rotating Blowout Preventers
Difference: variable hydraulic pressure is required to keep the sealing
element closed
– Higher rated pressure (1500-
(1500-3000 psi)
– Same plumbing as BOP
High-
High-pressure pumps, accumulators, check valves, etc.
53
Common Examples
Those are rotating heads on the left, and rotating blowout preventers on the right.
Remember, the difference is that rotating control heads use a passive seal against
the pipe (although annular pressure provides additional sealing pressure), whereas
RBOP’s are true blowout preventers that utilize positive hydraulic pressure to close
the element against the pipe. RBOP’s are rated for higher pressure than rotating
heads.
It is also important to note that pressure ratings are higher for these units when
used in STATIC mode than when rotating.
54
Advantages of Rotating Control
Heads
Smaller, simpler, and more reliable than

RBOP’s or annular preventers
Always closed
No pressure adjustments; well pressure
makes them tighter
Inexpensive sleeve replacement
Essentially a higher-pressure diverter head
Of course, the disadvantages are that they are USUALLY rated for lower system
pressure (100 to 1500 psi or so), and that the drag of the seal element against the
pipe is fixed and can not be regulated or adjusted. They are also not able to pass
the bit and stabilizers, but must be dismounted.
55
Advantages of RBOP’s
Packer closure to any closing force

Can operate at low closing pressures/low drag
Normally open until hydraulically closed
Manual or automatic operation
Can pass bits and stabilizers
Can close on open hole
The disadvantages are that RBOP’s are more expensive to buy, operate, and
maintain, and feature more complex operation, equipment, and installation.
56
Workover: Stripper Head
most UB workover operations use simple

stripper heads
Rather than rotating control heads or RBOPs
workover pressures not as great as drilling
May be simple passive or hydraulically actuated
57
Secondary Barrier
Annular Preventer used

on most UBD
Except low-
low-pressure gas or
air systems
– Can close around casing,
drill pipe, tool joints,
collars, the Kelly, and
open hole
– In emergencies, can be
used in place of the
rotating head
For extreme-pressure emergencies or for failure of the RBOP or rotating head, the
Annular preventer can be used in place of the rotating equipment. That is one of
the reasons for the 4” flow line required below the annular preventer.
58
Choke Manifold
Critical element in UBD
– Holds back-
back-pressure on the
annulus to control BHP and
gas expansion
UBD chokes subjected to
lower pressures than in
kick-control operations
one choke valve should be
rated same as BOP rams
Non-plugging
Handles surges of liquid, gas,
and cuttings
59
Separators
Holdingtank where water, oil, and gas

separate by gravity-driven methods
Simple gravity, parallel plate, centrifugal, vacuum,
and impact (also called baffle) methods
In UBD:
– Open (atmospheric) vs. Closed (Pressurized)
60
Atmospheric Separators
Mud tanks
‘Gas Buster’
West Texas
style ->
A simple ‘Gas Buster’ type separator is made from a short length of casing. Gas is
separated by a ‘splatter’ or ‘spin’ effect against the opposite wall. Gas separated
from the mud rises into a gas-discharge line and to a flare. Mud is allowed to fall out
the bottom into the mud pits.
West-Texas style drilling separators are slightly more sophisticated, and may utilize
baffles, float controls, and back-pressure controls.
61
Pressurized Separators
Controls gas from the well and sends it to a flare

– H2S safety factor
Instrumented to record pressures and gas,
water, and oil volumes
Closed, or Pressurized, separators utilize technology from Production separators to

control gas from the fluid system.
62
UBD Separator Issues
Non-HC gases (e.g., N2) separate from oil

much faster than HC gases
Foam agents make it difficult to break

foam at the surface
Ideal: Strong enough to clean the hole, weak
enough to break at the surface
Broken: gas to the flare, liquid to the pits
There are a few issues regarding use of a drilling separator in UBD operations that
require more than a simple production separator. For example, in common UBD
liquid systems that utilize nitrogen-gaseated diesel, the nitrogen separates from the
diesel far quicker than will hydrocarbon gases.
In UBD foam systems, chemicals added to the liquid/gas system to create the
structured foam may make it difficult to break the foam into its gas and liquid
constituents. It is not possible to send foam to a flare, and it is very expensive to
re-cycle foam.
63
Standpipe connections
Standpipe connects the mud

line to the Kelly hose
In UBD, many variations

Gas or foam injection line
Relief line back to flow circuit
(gas) or to blooey line
Relief lines allow connections to
be made without pressure in the
Kelly (but no need to shut-
shut-in
compressors)
64
Standpipe connections
Example of an air
surface system
65
Snubbing
Wellbore pressure (upward) is

less than (downward) weight of
drill string: Pipe Heavy
Normal
Wellbore pressure is greater than
weight of drill string: Pipe Light
– Snubbing required, i.e.
– Forcing pipe into the hole against
wellbore pressure
– For UBD, mounted on rig floor
This is one of our own ENSP hydraulic-workover snubbing units. Note that for
workover operations, the snubbing unit utilizes it’s own BOP stack (as in the photo).
66
Review and Summary
Surface components make UBD work

– Rotating control head or RBOP
Primary well-
well-control barrier
Annular and conventional BOP stack as secondary
– BOP stack has extra, large-diameter flow lines
– Choke manifold
– Drilling Separator (usually pressurized)
– Blooey Line/Flare
– Unique standpipe manifolding
67
Outline

» 4. Downhole Tools
68
Typical UBD Downhole
Equipment
Drillpipe (Downhole) safety valves
Downhole motors and Air hammers
Drill bit considerations
Measurement while drilling (MWD)
Whereas surface equipment for underbalanced drilling differs substantially from

normal mud drilling, the downhole tools used for UBD are not much different. There
are a few items unique to UBD, however, that merit a closer look.
69
Drillpipe (Downhole) safety
valves
Essential for UBD

No barrier for flow up the drill pipe (no mud
overbalance)
Drillpipe valves include:

Bit floats
String floats
Retrievable floats
Inside Blowout Preventers (Ibop’
(Ibop’s)
Deployment valves
70
‘Bit Floats’ and ‘String
Floats’
Downhole check valves
– Allow downward but stop
upward flow in drill stem
‘Bit Float’ is spring-
loaded valve ->
– Depending on spring
tension, can cause last
stands to be pulled wet
‘String Float’
– Simple ‘flapper’
flapper’ valve
– Install every 1,000 feet
71
‘Inside’ BOPs
I-bop is pump-down check

valve
– Catcher sub run as part of drill
stem assembly
– Bit float prevents passage
Retrievable I-bop
– Wireline can retrieve and/or set
in higher sub
72
Deployment valves
Casing isolation valve, run on casing or liner
– Control from surface (control line, annular pressure if 2 strings)
strings)
– Full-
Full-opening, shuts in wellbore below valve, allows ‘dead’
dead’ trips
Weatherford design shown here
73
Deployment valves (cont’d)
Usually set at about

3,000 feet
– Below ‘pipe light’
light’ depth
Removes need for
snubbing
– Another ‘barrier’
barrier’ for
well control
Halliburton design
Simple flapper
Open with bit (keeper
drops to hold open)
Bit catches keeper on
way out
74
Deployment valves (cont’d)
Deployment
valves (DDV)
– Set in casing or
liner
– Below ‘Pipe
Light’
Light’ depth
eliminates
snubbing
– Example
Pinnacle Drilling,
Whitney 19
No.1, Louisiana
75
Downhole motors and Air
hammers
Motors work in UBD,

depending on fluid
Light mud, Gas/liquid,
foam fluids work fine
Foam and gas don’
don’t
Air Hammer drills
From mining industry
10x ROP in hard rock
Works with gas and
foam fluid systems
Not in soft formations
76
Bits in UBD
BecauseUBD increases the drilling rate,
tendency is to use more aggressive bits
– BUT
Well can’
can’t be drilled any faster than the hole can be
cleaned
Aggressive bits = large cuttings, maybe too big to
be carried out of the hole with light fluids
– Bit selection: Limit size and amount of cuttings
to what can be cleaned out of the hole with the
fluid system
More fluid volume, not more bit weight
77
MWD Transmission
‘Mud Pulse’
Pulse’ MWD transmission systems will not work
with gas, gas/liquid, most liquid, and foam systems
Steering tools use wireline – not affected
New Electromagnetic (EMWD) not affected
78
Review and Summary
Bit floats and string floats are essential for UBD
Deployment valves: new tool for trips and another

barrier
Bit selection: do not overdrill the fluid system’s

ability to clean the hole
Mud-pulse MWD doesn’t work in most UBD fluid

systems
79
Outline
4. Downhole Tools
» 5. UBD fluid column and well control
80
UBD Fluid Column
UBD means reduced

bottom-hole pressure
Usually by means of gas
A) No circulation: gas
separates from the liquid
B) Circulating: gas
mostly dispersed
through the liquid
81
UBD Fluid Column
Gas bubbles at bottom

are small and do not
displace much liquid
As bubbles travel up the

annulus, they get larger
and displace more liquid
Pressure is less nearer the
surface
Greatest expansion in top
3,000 feet
82
UBD Fluid Column
Annulus Flow patterns in

gas/liquid mixture change
with increasing velocity
Gas expands as it comes
up the annulus
Velocity of mixture increases
Velocity increases friction
Friction pressure increases
bottom-
Complex flow/friction
relationships (non-
(non-linear)
At higher velocities, two-phase flow in the annulus turns to churn and annular flow.
The friction pressure begins to dominate the system, such that adding additional
gas or increasing the pump rate does not actually increase the FLOW rate. The
system is then said to have become ‘Friction dominated’.
83
UBD Fluid Column
Summary:
Two-
Two-phase gas/liquid flow
Gas behavior changes with depth
Flow regime changes with velocity
Velocity increases friction pressure
(non-
(non-linear)
Friction pressure changes BHP
In UBD, computer programs
calculate
– annular pressure loss, BHP,
Equivalent Circulating Density, etc.
In summary, the annulus of a typical UBD well features a complex two-phase flow
regime of gas and liquid mixtures. Because the gas expands as it comes up the
annulus, the gas begins to move faster than the liquid and coalesce into larger and
larger bubbles. As the bubbles get larger, the velocity increases, and as velocity
increases, friction pressure increases. As friction pressure increases, so does
bottom-hole pressure. Even more complex is that as gas velocity increases, the
entire flow regime of the mixture changes with depth, from simple bubble flow to
complex ‘churn’ or ‘annular’ flow.
Therefore, unlike normal well fluid columns where hand calculations suffice, in UBD
specialized computer programs calculate annular pressure loss, equivalent
circulating density, and bottom-hole pressure.
84
UBD Operation IS Well Control
Normal mud drilling: conditions at flow line reflect

downhole conditions
UBD: addition of gas or light fluids changes all
flow rules
UBD Operating Mode: constant ‘Driller’s Method’’
– Maintain constant pump volume
– Standpipe pressure = BHP
– Use the choke to maintain standpipe pressure
– UBD gas in annulus = longer lag times for choke to
change standpipe pressure
In UBD, some flow from the formation is happening at all times. Normal UBD
operation is remarkably similar to the Driller’s Method of well control. IN summary,
maintain a constant pump pressure to provide the bottom-hole pressure appropriate
for the fluid system and formation being drilled. Use the choke to maintain constant
pressure on the standpipe (and constant BHP downhole). When gas-based fluids
are used, the lag time is increased for choke adjustments to be reflected as
increases in standpipe pressure.
85
Normal UBD Operation:

– reducing the size of the
choke opening increases
bottom-
bottom-hole pressure and
standpipe pressure
86
In UBD, a constant ‘kick’

For low-
low-permeability formation, the fluid gain may not be
noticeable. In high-
high-permeability formations, the gain may be
substantial.
Case: Hi-volume fluid gain and/or the annulus fills
with gas
annulus fluid pressure is reduced and the drillpipe tries to U-
U-
tube (which reduces the standpipe pressure)
Use choke to bring standpipe pressure back up and increase
bottom-
In case of large-
large-volume gas flow, kick at surface can be
violent BUT due to UBD and light fluids, overall pressure in
annulus is LOWER than in normal well-
well-control scenario.
In UBD, some flow from the formation is happening at all times. For low-
permeability formation, the fluid gain may not be noticeable. In high-permeability
formations, the gain may be substantial. In either case, normal UBD operation is
remarkably similar to the Driller’s Method of well control. IN summary, maintain a
constant pump pressure to provide the bottom-hole pressure appropriate for the
fluid system and formation being drilled. Use the choke to maintain constant
pressure on the standpipe (and constant BHP downhole). As greater volumes of
formation fluid flow into the wellbore and the annulus fills with gas, the annulus
pressure is reduced and the drillpipe tries to U-tube (which reduces the standpipe
pressure). The choke is then used to bring the standpipe pressure back up and
increase bottom-hole pressure.
87

reducing the size of the
choke opening increases
standpipe pressure and
bottom-
Control of UBD pressure
and flow from the
formation
volume of drilling fluid
fluid density
volume of injected gas
88
Increased ‘Lag Time’

reducing the size of the choke
opening increases standpipe
pressure and bottom-
bottom-hole
pressure
‘Lag Time’: time for change
in choke to show change in
Standpipe pressure
– Increased lag time in UBD
fluid column depends on
Pump rate, volume of gas in
annulus, choke size, BHP
89
Increased ‘Lag Time’
Normal mud drilling:

Lag time 20 sec. in 10,000’
10,000’ hole
UBD lag time increased

– Small gas:liquid ratio - 30 sec.
– High gas:liquid ratio - 10 min.
min.
– Foam: 60 minutes or more!
Best practice: Manual check

of lag time every crew shift
Normal well operations use the rule of thumb that pressure changes travel at about
1 second per thousand feet. In a 10,000 foot well, it would take about 20 seconds
for a change in choke to affect standpipe pressure (10 seconds down annulus, plus
10 seconds up drillpipe). In typical UBD fluid systems, however, the lag time can be
greatly extended, depending mostly on the amount of gas in the system. In the
example 10,000 foot well, Lag times can vary from 30 seconds to over 1 hour in
foam systems with a high percentage of gas. Although it is possible to calculate the
lag time for a given depth, flow rate, and BHP, common practice is for the crew to
manually measure lag time at least once every shift.
90
Stripping and Snubbing
Stripping: running pipe into

the well under pressure
Normal UBD practice
Rotating head or RBOP is primary
barrier
Snubbing: pipe is ‘light’,
must be mechanically forced
into well
Upward-
Upward-acting BHP greater than
weight of pipe
Snubbing is slow and expensive
In UBD, drilling mud is not present to balance BHP, and normal operations usually
require that pipe be stripped into a pressurized well through the packing element of
the rotating head or RBOP. If there is not enough pipe in the hole to ‘pull’ it down
against pressure by using the weight of the pipe, then a ‘Pipe Light’ scenario
occurs. In a ‘pipe light’ situation, BHP is sufficient to force or float the pipe out of
the well. In this situation, it becomes necessary to ‘Snub’ the pipe, mechanically
force the pipe downward into the hole against a greater, upward-acting pressure.
91
‘Mud Cap’
Column (‘plug’) of heavy mud spotted into wellbore
To control BHP during trips (diagram shows bit on bottom)
Keep gas from coming to surface in a well with total lost returns
returns
(fractured zones)
Another unique term in Underbalanced drilling is the use of a ‘mud cap’. A mud cap
is a column or plug of heavy mud that is spotted into the annulus, usually to aid in
controlling bottom-hole pressure during trips, sort of like a ‘deployment valve’
isolates the upper part of the wellbore from conditions in the lower portion. The
diagram shows the bit at bottom, but the usual technique is to circulate a clear, non-
damaging fluid at bottom, and then pull up and spot or ‘float’ a mud cap, either in
casing or open hole.
A mud cap can also be used in drilling situations where returns are lost into a gas-
bearing fractured zone. The mud cap prevents gas from coming to the surface
while drilling continues with total lost returns.
92
‘Mud Cap’
UBD
especially
useful for
H2S zones
Here is an example of a Mud Cap technique used where the operator had a bad
combination of under-pressured pay zone, a lost circulation zone right above it, and
H2S in both zones. He wanted to use UBD techniques for drilling the pay and LC
zones, but try to avoid bringing the H2S to the separator.
93
Review and Summary
The UBD fluid column is very complex and requires

computer calculations for most flowing values
UBD operation is continuous Driller’s Method
‘Lag Time’ increased from 30 seconds (low gas

ratio) to over 60 minutes (foam systems)
Typical UBD operations: ‘Stripping’, ‘Snubbing’, and

‘Mud Caps’
Driller’s Method in UBD: Maintain constant pump volume, Standpipe

pressure = BHP, Use the choke to maintain standpipe pressure, UBD gas in
annulus = longer lag times for choke to change standpipe pressure. Lag
times are increased from 30 seconds to over 1 hour.
Not common in normal drilling, these are typical UBD operations. Stripping
is running pipe into the well under pressure, in a ‘Pipe Heavy’ situation.
Snubbing is mechanically forcing pipe into the well under pressure, in a ‘Pipe
Heavy’ situation. A Mud Cap is a column of heavy mud spotted above the
drilling zone, to allow gas-free trips or when drilling ahead with total lost
returns in fractured zones.
94
Outline
4. Downhole Tools
» 6. Fluid systems used in UBD

95
UBD uses light drilling fluids
Underbalanced fluid systems are usually considered to have an equivalent mud

weight of less then 8.3.
96
UBD uses light drilling fluids
Underbalanced fluid systems are usually considered to have an equivalent mud

weight of less then 8.3, the EMW of water. Here’s another comparison of UBD fluid
systems.
97
Outline
4. Downhole Tools

a) Liquid fluid systems
98
Liquid UBD Fluid Systems
‘Near-balance’ Conventional Light Mud

– Water based (> 10 ppg)
– Oil based (> 8.1 ppg) but expensive
– Mud as Underbalanced fluid depends on formation
pressure
Diesel (EMW = 6.8 ppg)

– Needs additive package (or gaseation)
Depending on the formation pressures to be encountered, conventional mud may

be used as an underbalanced drilling fluid. Due to heavier weights, mud may be
used in the deeper, higher-pressure formations of the drilling section. Diesel oil has
an equivalent mud weight of 6.8, but unless treated with a large volume of additives
or gaseation, works poorly as a drilling fluid.
99
Summary: Liquid drilling
Advantages:
– at ‘near-balance’, all the advantages of UBD
– No gas injection, less expensive than gas UBD
Disadvantages:
– Fluid density > 8 ppg, formation must be high
enough pressure to allow ‘near-UBD’
Liquid-only drilling utilizes light muds, and diesel oil with additives. If near-balance
can be achieved, all or most of the advantages of UBD can be achieved. The
weight of these fluids is limited to densities above about 8 ppg, and so the liquid-
only drilling system only works in formations with high enough pressures to allow
‘near-balance or UBD.
If fluids lighter than 8.3 ppg are required, gaseated fluids are necessary.
100
Outline
4. Downhole Tools

b) Gases utilized in UBD
101
Gases used in UBD
Air
Nitrogen
Exhaust Gas
Natural Gas
102
Air as a gas in UBD
78% nitrogen, 21%

oxygen, 0.03% CO2
Cheap, needs only

compression
Very High corrosion

potential for tubulars
Underground fires
– When drilling into
condensate zones
Underground fires occur when drilling with air into condensate zones below 10,000
feet or at when bottomhole temperature is elevated. Condensate has a low
spontaneous ignition temperature.
103
Nitrogen in UBD
Inert, no corrosion,
does not burn or
support combustion
Types:
– Cryogenic liquid
delivery is primary
cost
Membrane nitrogen is generated on sit. Warm air is pumped into a bundled system
of microscopic membrane fibers. Oxygen and water vapor are stripped out, leaving
90% pure nitrogen gas. Depending on the flow rate, there may be 5% to 10%
oxygen left in the mixture. Oxygen causes downhole corrosion, so an inhibitor
should be used.
104
Nitrogen in UBD
Types:
– Membrane
Generated on site
5%-
5%-10% Oxygen
Corrosion Inhibitor?
Membrane nitrogen is generated on site. Warm air is pumped into a bundled

system of microscopic membrane fibers. Oxygen and water vapor are stripped out,
leaving 90+% pure nitrogen gas. Depending on the flow rate, there may be 5% to
10% oxygen left in the mixture. Oxygen causes downhole corrosion, so an inhibitor
should be used.
105
Nitrogen in UBD
2nd Generation
Membrane Nitrogen
– self-
self-contained units
– 95% Nitrogen @ 650scfm
– Offshore and onshore use
Modern truck- and skid-mounted self-contained membrane units are proving that
Nitrogen can be more economical than air, when safety, corrosion, and fire risks are
taken into account. These 2 units are capable of 650 scfm delivery of 95% nitrogen
at up to 1000 psi.
106
Nitrogen in UBD
2nd Generation
Membrane
Nitrogen
– Cost savings
over cryogenic
nitrogen
$7,500 per
well ->
107
Exhaust-Gas Nitrogen
Compressor engine removes oxygen from air
Propane fuel to run compressor (needed anyway)
Exhaust: ~85% nitrogen, ~15% carbon monoxide
Exhaust-generated nitrogen is a unique way of removing oxygen from air, by using

the process to run the rig compressors. Propane fuel is fed to the compressor
engine. The exhaust is scrubbed with a series of converters and the resulting gas
features about 85% nitrogen and 15% carbon monoxide.
108
Self-contained exhaust-gas nitrogen unit
109
Natural Gas in UBD
Lease gas readily available

Used for drilling since 1930’
1930’s
Safer downhole than air, no corrosion
Cheaper than nitrogen, can be recycled
Dissolved easily in diesel = gaseated fluid
Surface precautions
Gas detectors on rig, cellar, etc
Ventilated cellar
Rotating head packer element checked often
110
Gases used in UBD
Air
Nitrogen
Exhaust Gas
Natural Gas
111
Outline
4. Downhole Tools

c) ‘gaseated liquid’ fluid systems
112
‘Gaseated Liquid’
fluid systems
Gas-cut or gaseated mud or

diesel
– Gas injected at surface
– Gas lightens the hydrostatic
column
– Unstable fluid
The more gas in the system, the
more easily it separates
Range: 5 to 50 parts gas to 1
part mud
The source of gas for gaseated systems may be flow from gas-bearing formations
or gas injected at the surface, or a mixture of both. The injection of gas into a liquid
drilling fluid system serves to lighten the hydrostatic weight of the fluid column.
Simple gaseated systems are unstable because nothing ties the gas and liquid
together. The more gas that is in the system, the more easily it separates. To be
effective, a gaseated system requires at least a 5: 1 ratio is required. The upper
limit is about a 50:1 ratio, or about 670 cubic feet to every 100 gallons of mud.
113
fluid systems
Gas separation in the

annulus
Depends on gas ratio (5-
(5-50:1)
– When circulation stops
Gas rises, forms bigger
bubbles, leaves area below
with no gas
– When circulation resumes
System ‘heads’
heads’: alternate
slugs of liquid and gas
– UBD drilling techniques
avoid heading
114
fluid systems
Some gaseated fluid

systems are temporary
– Gas injected to
underbalance mud
system for a single zone
Usually to avoid lost
circulation or avoid pay
zone damage
115
fluid systems
Advantages
– Simple system, temperature stable
– Easy to operate and maintain
– Inexpensive, readily available liquid and gases
Any mud system, water, and oil
BUT,
BUT, due to surges, Gaseated systems
must operate at very low underbalance
– BHP must be kept low (>200 psi) to avoid
going Overbalanced due to pressure surges
during connections
– Low UB can cause hole caving, makes flow
control difficult
One advantage to simple gaseated systems is that the mixture is not temperature-
dependent, that is there is not a temperature where the system breaks down, as do
some foams and other gas systems. The primary advantage, however, is that the
system is inexpensive and simple.
The primary disadvantage is that gas-heading makes for a very unstable annulus
column and difficult pressure balancing. This is especially true for higher-ratio
systems (> 10:1 gas: mud). The surging actions provides large pressure variations
in the annulus, so that the overall system pressure must be kept low enough (at
least 200 psi underbalance) to avoid overbalancing the system during connections.
The low underbalance, however, can cause hole sloughing and caving and makes
flow control difficult.
116
Jet Subs for gaseated drilling
Reduces pressure surges

– Gas slug comes to surface
Expelled explosively with liquid
BHP drops
BHP rises as next slug builds up
Connections make slugs worse as
pumps started/stopped
Partial solution: drill pipe sub
– Drill pipe sub with 11/32 jet
Set just above surface casing
Poor-
Poor-boy gas-
gas-lift valve
Reduce liquid surges
Helps start circulation
The most widely used solution to pressure-surging in gaseated liquid systems is the
‘Jet Sub’ This inexpensive drillpipe sub is fitted with an 11/32 bit jet, and run on the
drill string. It is usually set just inside surface casing. It acts to continuously bleed
gas into the annulus to balance-out pressure surges. During trips and connections,
it helps to restart circulation without excessive heading.
117
fluid systems
Equipment needed
1. Rotating head or RBOP
2. Choke manifold
3. Pressurized separator
4. Pressurized flow line
5. Standpipe manifold for gas
injection
6-7. Bit and/or string floats
8. Lower Kelly safety valve
9-10 Compressor and lines
118
Gaseated Liquid
Techniques
Unloading the hole

– With no circulation,
gas escapes and liquid
column left behind
– Go to bottom, start
liquid/gas flow
– Pressure builds to limit
of compressor
Shut off gas, just liquid
– Alternate gas/liquid
until well unloads
119
Gaseated Liquid
Techniques
Drilling
– Pump pressure rises and falls as
system surges
No fluid out flow line: pressure
goes up until it unloads liquid;
pressure then goes down
Pump pressure can vary from 200
to 700 psi
– Flow from formation (BHP and
standpipe pressure) is controlled
by the choke
Lag times up to 30 minutes
120
Gaseated Liquid
Techniques
Limit gas surges

– Use a Jet sub
– Increase mud viscosity
but reduce gel strength
– Maintain at least 100 psi
choke pressure
– Decrease gas ratio
– Increase pump rate
– Decrease bit jet
– Smaller hole size
Increasing mud viscosity will tend to keep the gas bubbles from breaking out.
Increasing choke pressure serves to limit expansion of the gas bubbles. The faster
the flow rate, the less the gas will tend to separate. If the underbalance will allow it,
reduce the gas:mud ratio. A smaller bit jet allows better gas/liquid mixing. Lastly, a
smaller hole allows higher velocity and hinders gas breakout.
121
Gaseated Liquid
Techniques
Connections
– During connections, gas and
liquid separate
– Major pressure surge when
circulation re-
re-started
– Limit connection surges
Before connection, fill the drill pipe
with gas (to compressor limit)
Close choke as soon as pump is off
Make connections quickly
122
Summary: ‘Gaseated Liquid’ fluid
systems
Advantages
Any mud system, water, and oil
BUT,
BUT, due to surges, Gaseated systems
must operate at very low underbalance
– BHP must be kept low (>200 psi) to avoid
going Overbalanced due to pressure surges
during connections
– Low UB can cause hole caving, makes flow
control difficult
some foams and other gas systems.
123
Outline
4. Downhole Tools

d) Foam fluid systems
124
Foam fluid systems
Foam terms:
– Ratio : amount of gas to liquid (as surface mixture)
– Quality (%) : amount of gas to liquid at specific depth or
pressure
Increased pressure compresses the gas; foam quality varies with
depth
‘75% Quality’
Quality’ means 75% gas, 25% liquid (by volume); same foam
may be 60% Quality deeper in the hole
– Texture : “viscosity and gel-
gel-strength”
strength” of a foam
– Half-
Half-life : bench test compares break-
break-down of foams when
pumped
The ‘ratio’ of a foam is an expression of the amount of gas to liquid that are mixed
AT THE SURFACE. For example, a 100:1 ratio uses 100 parts gas to 1 part liquid.
Quality of foam expresses the amount of gas to liquid at down-hole conditions of
temperature and pressure. Increased pressure compresses the gas portion, and for
a given volume of foam the gas portion decreases with depth. A foam that is 75%
gas by volume at one pressure may be 60% quality further down the hole. Texture
compares the physical and rheological properties of foams. There are not yet any
standardized measurements or units, but the tests are similar to viscosity and gel-
strength tests for mud.
Half-life compares the longevity of foams and the efficiency of foaming agents when
the mixture is pumped.
125
Foam fluid systems
Foam ‘quality’ varies with

depth
– Increased pressure
compresses the gas; foam
quality varies with depth
– ‘75% Quality’
Quality’ means 75%
gas, 25% liquid (by
volume); same foam may
be 60% Quality deeper in
the hole
126
Foam fluid systems
Foam is an emulsion
– Fluids uniformly distributed; fluids do
not separate easily
– Has structure: bubbles of gas
surrounded by liquid film
– Mixture has strength; water around
gas forms 12-
12-sided structure
(deforms but not shear when
pumped)
– Flows like a sheet or plug
– Does not separate; no pressure
surges like gaseated systems
127
Foam fluid systems
Because it is stable,
large amounts of gas
can be added to
liquid
– Typical 100:1 to
200:1 gas:liquid ratio
– Ratio much higher
than gaseated
systems (1:1)
128
Foam fluid systems
Lightest UBD fluid

– 10 gallons liquid to 133
cu. ft. of gas (100:1)
– 2 to 5 PPG compared to
Water and oil-
oil-based muds
(> 8.3 PPG)
Gaseated gas/liquid
systems (~ 5-
5-8 PPG)
129
Foam fluid systems
Foam Systems
- 450:1 ratio, 1.7 ppg

- 240: 1 ratio, 2.4 ppg
- 170:1 ratio, 2.9 ppg
- 135:1 ratio, 4.0 ppg
- more liquid and
higher flow rate
gives higher BHP
Here is a real-world example of foam systems used in a well in a depleted, fractured

reservoir, the Mission Canyon formation of the Uinta basin, Wyoming USA. At the
base of the Mission Canyon at 13,960 feet, these foam systems provided different
bottom-hole pressures, depending on the ratio of the foam. That is, more liquid and
higher flow rate gives higher BHP. This chart presents the BHP gradient for foams
of different ratios.
From left to right, the first foam system used a 450:1 gas:liquid ratio, solved as
2400 ft3 of gas to 40 gallons (5.35 ft3) of liquid (per minute). The 448:1 ratio foam
provided about 1.6 ppg (equivalent mud weight) at the base of the Mission Canyon,
13,960 feet). From Section 1, psi = depth x MW x .052, or in this case, 1.7 ppg =
1240psi ÷ (13960 ft x .052).
The 240:1 ratio provided 2.4 ppg EMW
The 170:1 ratio foam provided 2.9 ppg.
The 135:1 ratio foam provided 4.0 ppg EMW at 13,960.
130
Foam fluid systems
Foam structure is
reason for high lifting
capacity
Structure deforms but
doesn’
doesn’t shear
– Best lifting: 50% - 90%
quality
– High lifting cap. means
low annulus velocity
No need for high velocities
seen in gaseated systems
Lower overall fluid volume
Compared to water and mud, foam has a much higher capacity to lift cuttings. This
enhanced capacity is probably due to the unique structure of the water molecules in
foams, which deforms during flow but does not shear. A greater capacity to lift
cuttings means that a lower pumping rate and lower annular velocity is necessary to
lift cuttings. Typical pumping rates in foam systems are as low as 20 gallons per
minute of water and 266 cubic feet of gas per minute to achieve normal 120 feet per
minute annular velocity, 10-times better hydraulic performance than a typical mud
system.
131
Foam fluid systems
Foam mixed by pumping

the liquid and foam agent
into the airstream at the
standpipe
– Bit jets provide best mixing
– Typical blend
1 lb/bbl soda ash to soften
makeup water
0.25 lb/bbl caustic soda
0.5% foaming agent
0.5 qt/bbl corrosion inhibitor
132
Foam fluid systems
Lost circulation
– Foam is lightest UBD fluid
AND
– Bubbles enter pores,
slightly expand, and plug
the zone
– Special ‘micro-
micro-foams’
foams’ are
now used in normal
drilling as LCM
LCM = lost circulation material
133
Foam fluid systems
Limits of foam systems

1. Hi-
Hi-ratio foam may ‘break’
break’ in upper
annulus
Becomes ‘mist’
mist’ (unstructured drops in
gas); unstable foam
Mist <3% liquid, >97% liquid (foam
>5% liquid)
Mist = pressure surging as in gaseated
systems, drops cuttings
– Solution: more choke pressure
134
Foam fluid systems

2. Depth affects foam quality
At 12,000 feet, most foams are 95%
liquid (5% quality), EMW ~ 8 ppg
Foam column gets heavier as depth
increases; underbalance depends on
formation pressures
higher gas:liquid ratio makes lighter
but poorer-
poorer-performing foam
135
Foam fluid systems

3. Foam performs poorly in some conditions
Best foam needs fresh or brackish makeup water
– Salt or hard water requires pre-
pre-treatment, more foam agents
Oil (especially light oil) destabilizes foam

– Competes with foam agent to ‘wet’
wet’ the bubbles
– Advances in foam agents
Temperature > 180°

180°F breaks down most foaming agents
Acidic gases (H2S, CO2) destabilizes some foams
136
Foam fluid systems
Equipment needed
1. Rotating head or RBOP
2. Choke manifold
3. Pressurized separator
4. Pressurized flow line
5. Standpipe manifold for gas
injection
6-7. Bit and/or string floats
8. Lower Kelly safety valve
9-10. Compressor and lines
137
Foam fluid systems
Techniques
Unloading the hole

– With no circulation, foam is
stable for ~ 20 to 40 minutes
– If foam separates
Inject gas only
Pressure builds to limit of
compressor
Shut off gas, pump liquid until
pressure comes down, resume
foam
– Trips: circulate out every 20
stands, beginning at 5,000 ft.
138
Foam fluid systems
Techniques
Drilling
– Pump pressure very stable
Slight puffing at blooey line
Pump pressure varies < 150 psi
– Flow from formation, BHP, and
standpipe pressure are
controlled by the liquid flow rate
and the choke
Long term: change liquid flow rate
Short term: adjust choke
Lag time 30 - 60 minutes
139
Foam fluid systems
Techniques
Foam breaking: limit gas

surges
– Increase choke pressure 100 psi
Keeps gas bubbles from expanding
– Increase foaming agent
concentration
– Pre-
Pre-treat makeup water (softer)
– Increase pump rate
– Decrease gas percentage
– Smaller bit jet
Increasing choke pressure will tend to keep the gas bubbles from breaking out.
Increasing choke pressure serves to limit expansion of the gas bubbles. Increase
the concentration of the foaming agent, and/or pre-treat the makeup water to make
it softer.
The faster the flow rate, the less the gas will tend to separate. If the underbalance
will allow it, increase the pumping rate.
A smaller bit jet allows better gas/liquid mixing.
140
Foam fluid systems
Techniques
Connections
– During connections, foam
remains stable
Close choke and/or flow line
– Closed choke causes well pressure
to build, which slows down foam
separation
Make connections quickly
141
Foam fluid systems
Techniques
Surface foam mixing

– Makeup water
Drinking water best
Reduce hardness
mildly alkaline (~ pH 10)
– Foaming agents
Wide variety, mix about 0.5%
Saline water needs different
agent, higher concentration
142
Typical location diagram
RHOURDE EL BAGUEL
This is an example of a complex surface location schematic, for a well using

membrane-generated nitrogen and foam. This well was drilled near Hassi
Messaoud, in the RHOURDE EL BAGUEL FIELD.
143
Foam fluid systems
Techniques
Foam recycling
– foam is broken, gas is discarded, and liquid is recovered to
make up new foam (some additional foam agent needed)
– Mechanical
Water spray and screens
– Alcohol
Applied in flow line, breaks in separator
– ‘Trans-
Trans-foam’
foam’ pH sensitive
Foams when alkaline, breaks when acidic
– No recycling: discharge to pit and make new foam
50% more expensive to make new foam than recycle
It’s about 50% more expensive to make new foam than to recycle. In foam
recycling, the foam must be broken using physical or chemical methods, and then
new foam is generated. The gas is discarded in almost all cases, because it is
more economical to generate new nitrogen than to clean and re-compress the old.
144
Schematic: Foam recycling
pH Method
In the pH method, acid is added in the blooey line to break the foam. The fluid
separator sends gas to the flare pit and liquids to the shaker and then to the pits.
Lime is added to ‘re-make’ the foam and additional agent is added as necessary.
The recovered solution is ready for re-injection and gas addition at the standpipe.
The alcohol method adds alcohol in the blooey line to break the foam, and the
alcohol is evaporated in the separator and sent to the flare pit.
Remember, Recycling saves 50% over the cost of new foam.
145
Schematic: Foam recycling
pH Method
Defoamer
system
La Paz field
Venezuela
146
Foam fluid systems
Summary
Advantages
– Lightest UB fluid
– Structured emulsion
Holds large volume of gas
Enhanced lifting capacity
– Low amount of liquid
– No pressure surges
– Low annulus velocity, enhanced lifting,
low pumping rate: high fluid efficiency
– Plugs lost circulation zones
– Great performance with motors
some foams and other gas systems.
147
Foam fluid systems
Summary
Limits
– Dry, high-
high-ratio foams may break and
pressure surge
– Depth limit: foam column gets
heavier as depth increases
At 12,000 feet, most foams are 95%
liquid (5% quality), EMW ~ 8 ppg
Higher gas:liquid ratio makes
dryer/lighter but poorer-
poorer-performing foam
– Foam performs poorly in some
conditions
Needs soft, alkaline makeup water
Oil, high temperature, acid gases (H2S,
CO2) can break most foams
148
Foam fluid systems
Summary
Example foam UBD

Economics
– Uinta Basin, WY
– completion costs reduced 82%
Fewer casing strings
No lost circulation (usual)
No stimulation cost
– 15 MMCFD (40% increase)
– No H2S to surface (usual)
Foam plugged zone
– SPE Paper 81622
This Uinta Basin well was the BHP example we considered earlier. One important
advantage of UBD was that the foam system not only prevented lost circulation into
several fractured zones, but also prevented H2S from coming to the surface. In
Overbalanced wells, pressure surges during ‘Lost Circulation’ events produced
H2S. The underbalanced foam served in this case to ‘plug’ the fractured zone and
prevent both lost circulation AND production of H2S. This dual-advantage was the
reason for experimentation with foam ratios and BHPs. SPE Paper 81622.
149
Foam fluid systems
Summary
Example foam UBD Economics

– Much higher drilling rate, reduced drilling time compared to
‘gaseated’
gaseated’ systems for LaPaz field, Venezuela (SPE 74449)
150
Foam fluid systems
Summary
Example foam UBD

Economics
– Rhourde El Baguel field,
near Hassi Messaoud
$1853/meter for UBD,
$3520 for conventional
(trouble time)
2 bits/trips for UBD vs. 6
No stimulation for UBD
(cost not included)
300% ROP improvement
SPE 62203
151
Outline
4. Downhole Tools
»6. Fluid systems used in UBD

e) Gas and Mist fluid systems
152
Gas and Mist fluid systems
Air
Gas
– Nitrogen
– Natural gas
Mist
– 1000:1 gas:liquid ratio
– Unstructured mixture
Foamed Mist
– ~500:1 ratio
– Some foam agent gives additional lifting
Remember that a true structured foam has a gas ratio of from 100:1 to 200:1. A
‘mist’ is an unstructured gas/liquid mixture of over 1000:1 gas:liquid ratio, in which
the gas bubbles and liquid are not bound together, and the gas bubbles are free to
coalesce and ‘surge’. In the transition between 200:1 and 1000:1, some operators
use a small amount of foaming agent to create a mist that has a small amount of
structure, primarily for the enhanced lifting capability. Mists and foamed mists are
partly or mostly liquid downhole (depending on BHP and liquid content), but surge in
the annulus as gas on the way up.
153
Air as a gas in UBD
78% nitrogen, 21%

oxygen, 0.03% CO2
Cheap, needs only

compression
Very High corrosion

potential for tubulars
Underground fires
– When drilling into
condensate zones
Underground fires occur when drilling with air into condensate zones below 10,000
feet or at when bottomhole temperature is elevated. Condensate has a low
spontaneous ignition temperature.
154
Nitrogen in UBD
Inert, no corrosion,
does not burn or
support combustion
Types:
– Cryogenic liquid
delivery is primary
cost
Membrane nitrogen is generated on sit. Warm air is pumped into a bundled system
of microscopic membrane fibers. Oxygen and water vapor are stripped out, leaving
90% pure nitrogen gas. Depending on the flow rate, there may be 5% to 10%
oxygen left in the mixture. Oxygen causes downhole corrosion, so an inhibitor
should be used.
155
Nitrogen in UBD
Types:
– Membrane
Generated on site
5%-
5%-10% Oxygen
Corrosion Inhibitor?
Membrane nitrogen is generated on site. Warm air is pumped into a bundled

system of microscopic membrane fibers. Oxygen and water vapor are stripped out,
leaving 90+% pure nitrogen gas. Depending on the flow rate, there may be 5% to
10% oxygen left in the mixture. Oxygen causes downhole corrosion, so an inhibitor
should be used.
156
Compressor engine removes oxygen from air
Propane fuel to run compressor (needed anyway)
Exhaust: ~85% nitrogen, ~15% carbon monoxide
Exhaust-generated nitrogen is a unique way of removing oxygen from air, by using

the process to run the rig compressors. Propane fuel is fed to the compressor
engine. The exhaust is scrubbed with a series of converters and the resulting gas
features about 85% nitrogen and 15% carbon monoxide.
157
Natural Gas in UBD
Lease gas readily available

Used for drilling since 1930’
1930’s
Safer downhole than air, no corrosion
Cheaper than nitrogen, can be recycled
Dissolved easily in diesel = gaseated fluid
Surface precautions
Gas detectors on rig, cellar, etc
Ventilated cellar
Rotating head packer element checked often
158
Air-Gas fluid systems
All UBD advantages

Fastest penetration
Hammer-
Hammer-drills in hard
rock
No skin damage
No concealed
production shows
Spectacular open-
open-hole
completions
Inexpensive
No foam agents etc.
Readily available gases
159
Air-gas volume
required
– Table used for depths
< 10,000 feet
30% more volume for
deeper
– Example:
10,000 ft., 8¾”
8¾” hole, 60
ft/hr ROP
1,700 cu. ft./min. volume
– Mist requires 30% to
50% more volume
160
Limitations
– Caving and washouts
Coal and weak formations
collapse in a dry hole
– Downhole fires in air
Spontaneous ignition of
light hydrocarbons
Nitrogen and natural gas
OK
– Fishing problems
Mud required for fishing,
hole never dries
Spontaneous ignition of light hydrocarbons occurs downhole in the presence of air.

The spontaneous ignition point of diesel, for example, is about 300 degrees F. In a
deep hole, a little heat generated by the bit causes ignition. Downhole fires melt the
bit and often the collars. The holes can only rarely be cleaned of junk, and a fire
usually means a sidetrack.
Nitrogen and natural gas do not support combustion, and are fine for drilling in deep
zones.
161
Air-Gas/Mist fluid systems
Primary Limitation: Water

in the hole
– Cuttings ball up
Solution: MIST
– Concentrated detergent
solution is added to the gas
stream
~ 1000:1 gas:liquid ratio
creates ‘fog’
fog’ downhole for
added lift capacity
Made up in small tank (pH
~10, Rate 3-3-4 gal/min)
When water in encountered and bit-balling occurs, the usual solution is adding
MIST to the system. Mist is created by adding a concentrated detergent solution to
the gas injection stream.
162
Adding mist can help

with balled cuttings,
BUT
– Mist slows drilling rate
– More wetting causes
sloughing
– Chemical/liquid cost can
kill air-
air-gas economics
Remember that mist is unstructured, and although it can help clear the bit, the
additional water slows the drilling rate, causes wetting of dry formations (and
possible sloughing), and adds complexity and cost to a drilling system whose
primary advantage was economics.
163
Next step: Foamed Mist

Add Foaming Agent and more
water (~500:1)
– Objective: foam at the bit,
mist uphole
Foam cleans the bit; water as
foam does not wet the formation
as much as ‘wet’
wet’ mist
– Adds some hydrostatic
pressure
but not as much as an all-
all-foam
column
Surging/heading problems
If Mist does not solve the problem, the next step is the addition of more water and a
foaming agent, to create a ‘Foamed Mist’. Because bottom-hole pressure increases
the ‘Quality’ of a foam with depth, the operator tries to achieve foam downhole, but
a mist column (that is, broken foam) in the upper annulus. This quality objective
depends on depth, but usually occurs at about a 500:1 gas/liquid ratio.
Foam cleans the bit, and the water tied up in a structured foam does not wet the
formation as badly as does unstructured, wet mist. Of course, using foam further
tilts the economics of air-gas drilling.
164
Cutting Size
– Chips ¼” and smaller
– Cutting size decreases
with depth
In deeper holes,
turbulence and collars
break up cuttings
Bit selection
– Don’
Don’t over-
over-drill the
fluid system’
system’s ability to
clean the hole
165
Unique Equipment
– Air Hammers
Free piston forced down
by incoming air, hits anvil
on top of bit
Reversing air valve blows
piston up and down at
~1,800 strokes per
minute
Special flat-
flat-bottom bit
Rotated ~20 rpm
Minimum bit weight
166
Unique Equipment
– Fire Float
Used with air systems
where downhole fires
may occur
Upside-
Upside-down float has
zinc ring
Ring melts, airflow stops
167
Equipment required
– Rotating head
Low pressure diverter head, for pressure < 250 psi
– Annular preventer (usually)
– Bit and/or string floats
– Blooey line with flare and ‘sample catcher’
catcher’ for cuttings
– Atmospheric separator (sometimes)
To suppress dust and noise from blooey line
– Standpipe manifold
Air-
Air-gas bypass to the blooey line
Of course, you also need a compressor and lines, or access to lease natural gas at
pipeline pressure greater than 300 psi. Note the absence of mud tanks, mud pump,
shale shaker, etc.
168
Techniques
General
– Never shut off the air or gas until the hole is
clean
In normal mud drilling, procedure is to turn off the
pump (mud suspends cuttings)
In air-
air-gas drilling, if gas is turned off all cuttings
fall to bottom around bit
About 1 minute per 1,000 feet to clean the hole
– Watch the blooey line
169
Techniques
General
– Never pull on the drill pipe if it sticks
Only jams cuttings tighter around bit/collars/joints
Turn on air and ROTATE
170
Techniques
Connections
Clean the hole (1 minute per 1,000 feet)
Pick up and check for drag
Leave compressor on and bypass to blooey
line
Bleed off drillpipe
Make the connection
Put compressor to drillpipe, allow 150psi
buildup
Pull slips, set down, and drill ahead
171
Summary
Advantages
– Minimal bottom-hole pressure
– Inexpensive, very simple system
– Highest drilling rate by far

Hammers increase ROP further
– Lowest reservoir damage
172
Summary
Limitations
– Needs dry formation
Mist and ‘foamed mist’
mist’ can help, but increase cost
and complexity
– No support to hole
Caving, sloughing, etc.
– Downhole fires if drilling with air

Spontaneous combustion of light hydrocarbons
173
Summary
Example of an air
surface system
174
Air-Gas Mist economics
Hatter’s Pond Field, AL

– Smackover trend,
formation pressure EMW
≈ 2.9ppg
– 400% production
increase
– Using natural gas/diesel
mist
– SPE 62896
175
Outline
4. Downhole Tools
»6. Fluid systems used in UBD

f) Designing UBD fluid systems
176
Which UBD Fluid?
Application of UBD fluid systems involves three

Design Factors:
– Amount of designed Underbalance
– BHP gradient of the target formations
– Type and characteristics of the target formations
There are three criteria used to apply the different fluid systems used in
underbalanced drilling. The first design criterion involves the amount of
underbalance that is desired in the target formations. The amount of underbalance,
considered against the expected formation pressure of the target formation,
provides the design range of Bottom-hole pressures to be achieved in the wellbore
at depth. The third criterion involves consideration of the types and characteristics
of the target formations.
The amount of underbalance depends on 3 factors: 1) whether the target formations
are in the drilling column or represent the target pay zones; 2) the permeability of
the formation, and, if known, 3) whether the primary formation flow will be gas, oil,
or water.
177
1) Amount of Underbalance
Underbalance depends on three factors:
– Permeability of the target zone

Higher k : less underbalance required
– Drilling column or pay zone?

Pay zone: optimum underbalance to avoid damage
Drilling section: 25% - 50% of optimum
– Primary flow gas, oil, or water?

Gas : less underbalance
The first design criterion involves the amount of underbalance that is desired for the
target formations. The amount of underbalance, considered against the expected
formation pressure of the target formation, provides the design range of Bottom-
hole pressures to be achieved in the wellbore at depth.
The amount of underbalance depends on 3 factors: 1) the permeability of the
formation; 2) whether the target formations are in the drilling column or represent
the target pay zones; and, if known, 3) whether the primary formation flow will be
gas, oil, or water.
178
1) Amount of Underbalance
Permeability: more k = less underbalance
Pay: 50% to 100% of optimum; Drilling: 25% to 50%
Flow: Gas = less underbalance
Example:
100md = 550 psi
The amount of underbalance depends on 3 factors: 1) the permeability of the formation; 2) whether
the target formations are in the drilling column or represent the target pay zones; and, if known, 3)
whether the primary formation flow will be gas, oil, or water.
The chart shown here represents the upper ranges of ‘Optimum’ Underbalance. The highest range
(in red) plots the optimum underbalance for perforating. The Green line plots the laboratory work of
King et al, 1985, and is generally accepted as the upper end of design underbalance in target pay
zones, to avoid formation damage and ‘skin’ effect. Note that the scales are logarithmic.
The amount of underbalance is a function of permeability of the pay zone: the higher the formation
permeability, the less the delta-p (underbalance) that is needed to establish flow into the wellbore.
For pay zones, the design underbalance range is from 50% to 100% of the ‘King’ optimum value.
For example, for a pay zone of 100 millidarcy permeability, King considers ‘optimum’ a design
underbalance of about 550 psi. Similarly, for a pay zone of 500 millidarcy permeability, King
considers ‘optimum’ a design underbalance of about 350 psi. Most field applications would consider
a design range for a 500md zone of from 175 to 350 psi underbalance (50% - 100%), depending on
the formation type and the type of fluid flow. For example, a semi-consolidated sand pay zone might
be expected to produce fines, and would probably be designed with underbalance toward the upper,
‘optimum’ end of the range.
For normal drilling of non-pay sections, most operators use a factor of 25% to 50% of King’s
‘Optimum’ value. That is, for an average 500 md section, most field applications would try to achieve
a design underbalance of 90 to 175 psi.
If the primary flow into the wellbore is expected to be gas, most operators use the lower end of the
design range for drilling or pay applications. For oil or water flows, more underbalance (delta-p) is
needed.
179
2) Application of UBD fluid
by pressure gradient
Gas/mist < 2 ppg Foam ~ 2 to 5.5 ppg
Gaseated liquid 5 to 8.3 ppg
Normal mud drilling > 8.3 ppg
The second and most important criterion for application of a UBD fluid involves the
expected BHP gradient in the well, LESS the amount of underbalance designed in
Step 1. For example, air-gas systems provide less than 2.1 ppg EMW in a 10,000
foot well (less than .11 psi/ft). Foams work best where the range of BHP gradients
is expected to be from .11 to about .26 psi/ft (emw of from 2 to 5 ppg in a 10,000
foot well). If additional BHP (and/or less underbalance) is required, gaseated liquid
systems perform best at from .26 to .44 psi/ft (the equivalent of from 5 to 8.3 ppg in
a 10,000 foot well). As we discussed, beyond 8.3 ppg is usually the province of
normal mud drilling (although crude oil and diesel can work at EMWs as light as 7.6
or so)
180
2) Application of UBD fluid by
pressure gradient (cont’d)
Example
Oil Pay zone, consolidated sand
K = 200md
2080 psi @ 5100 feet TVD
1. Optimum UB = ~450 psi

Design range 225 to 450 psi
Say 400 psi (oil flow = higher)
2. 2080 – 400 = 1680 design BHP
1680 psi ÷ 5100 ft = .33 psi/ft
3. .33 psi/ft design gradient
indicates use of ‘gaseated liquid’
liquid’
Let’s consider an example. Using the steps and charts from the previous slides,
choose a fluid based on the design underbalance and BHP gradient of the following
well. Formation: Oil-bearing Pay Zone, consolidated sand; expected BHP: 2080 psi
@ 5100 feet TVD; k = 200md.
Solution: Pay zone, consolidated sand, 200 md: Optimum = about 450 psi
underbalance, design range (50%-100% for Pay) = 225 psi to 450 psi. Choose 400
psi underbalance due to oil flow (higher end of range for oil, water flows, less for
gas).
Expected BHP of target = 2080psi – 400psi underbalance = design BHP of 1680
psi.
BHP gradient = 1680psi ÷ 5100 ft = .33 psi/ft design BHP gradient. From Chart 2
above, .33 psi/ft design gradient indicates the probable use of a simple ‘gaseated
liquid’ fluid system.
181
Application of UBD fluid by
formation type
Some fluid
systems are
best utilized
in certain
rock types
This chart presents the third design criterion, UBD fluids as they are applicable to
different formation types and characteristics. Some fluid systems are best utilized
in certain rock types, although other fluids may also work. For example, air-gas
systems are primarily applied to dry, hard rock types. The rate of penetration can
be 10 times better than could be achieved with ‘wet’ systems. Other fluid types will
also drill hard rock, however, although at a reduced rate.
Unconsolidated and wet zones present a different problem: caving and ‘bit balling’
requires a more competent fluid system such as foam or gaseated liquid, and
air/mist systems work very poorly. The addition of detergent mists can help
performance of air-gas systems in wet zones.
In our example, the use of a ‘gaseated liquid’ fluid system would be appropriate for
an oil-bearing, consolidated pay zone.
182
Summary: Design UBD
fluid system
1. Amount of Under-
Under-balance?
– Range: 25% to 100% of ‘Optimum’
Optimum’
‘Optimum’
Optimum’ UB is a function of k
Upper end (50% - 100%) for drilling/completion of pay zones
– less UB for gas, more for oil and water
lower end (25% - 50%) for normal drilling section
2. Expected formation pressures?

– Target formation pressure minus design underbalance gives
design BHP
Gradient (design BHP psi/ft) indicates best match of fluid system
system
3. Type/characteristics of rocks in the section supports

design fluid system?
183
Counter-example
Yates Field, Texas (2004)

Only 10 psi underbalance due to H2S; used N2/water
gaseated system; Electromagnetic-
Electromagnetic-MWD for real-
real-time data
This example is counter to the design steps we just discussed. The reason is that
the primary design criterion was the presence of 4% hydrogen sulfide, in a fractured
reservoir, the San Andres dolomite in Texas. The primary reason for using UBD
was to avoid lost circulation and stuck pipe, for which the formation is notorious.
Marathon Oil used only a 10-psi underbalance in a nitrogen-water gaseated system,
but were able to achieve and maintain that small UBD offset by using Electro-
magnetic MWD, a very expensive technology. Formation pressure was 660 psi at
1820 feet, or 2.75 psi/ft
184
Outline
4. Downhole Tools
»7. Coiled Tubing versus Conventional
UBD drilling
185
Coiled Tubing versus
Conventional (jointed) drilling
Coiled Tubing unit

– Continuous length of ½”
to 3½”
3½” OD tubing on
reel
– Tubing injector moves
the pipe in or out of the
well
186
Coiled Tubing Unit
Capabilities:
– Continuous pressure control
– Tripping (no connections)
– Circulate
– No rotate BUT downhole
rotating tools are available
Advantages
– Faster, cheaper, self-
self-
contained
187
Coiled Tubing Unit
Advantages (cont’d)
– Because it is not jointed,
coiled tubing can be run at
much faster speeds into or
out of a well
– Fluid can be circulated

through the tubing while it
is being inserted into or
withdrawn from a well
188
Coiled Tubing Unit
Disadvantages of coiled
tubing
– Only light drilling
– Tubing sizes limited
– Tubing collapse and
yield strength low
– In gas and H2S
environments, potential
for gas-
gas-filled tubing on
reel
189
Safety and Surface Pressure Control

– Advantage: Coiled Tubing
smooth and continuous surface of a coiled tubing string and
the built-
built-in stripping mechanism in the CT injection unit
Continuous Maintenance of Underbalance

– Underbalance BHP can be upset during tool joint
connections
No necessity to break for connections
190
Rate of Penetration
– Advantage: Conventional
Limited weight can be applied to the CT bit
Hole Cleaning
Small-
Small-diameter CT string at a disadvantage in holes larger
than 6 inches
CT not able to rotate; breaks up cuttings
191
Total drilling time

No tool joints means 25% faster drilling; CT has much faster
trips
Continuous Circulation
CT has ability to circulate while tripping; better BHP control
and better hole condition
192
Measurement –while-drilling (MWD) Issues

CT allows integrated, internal wireline for telemetry
Conventional must use new electro-
electro-magnetic MWD
Rig site considerations

CT unit is smaller, more portable, and typically requires only
about 50% of the footprint
Quieter
No mud spillage during connections
193
Hole size limitations

CT not able to drill and run large casing sizes (>8”
(>8”)
For many CT wells, conventional rig needed to drill and set
surface casing
Depth limitations
CT limited to less than 10,000 feet under most circumstances
194
Is Coiled Tubing the

Future of UBD?
– Economical technology
meets many unique
needs of UBD

– Not unless casing
diameter and depth
limitations are solved
195
Outline
4. Downhole Tools
»8. Control Problem Scenarios
196
Control Problem Scenarios
Most control problems in UBD have the

same effects and solutions as normal
drilling
Some UBD scenarios have unique well

effects and require different responses
197
UBD Control Problem
Scenarios
Lost Circulation in UBD

Gas or foam systems
No flow from flow line?
– Pump pressure should go up; if not, lost
circulation
– Pump pressure goes down?
Either lost circulation or more gas is entering the
annulus from formation (surging)
– Pump pressure constant?
Either circulating or losing returns; recheck flow line
In case of lost returns in a UBD well, the correct response is to reduce choke
pressure or reduce the amount of liquid being pumped.
198
UBD Control Problem
Scenarios
Lost Circulation in UBD

Gaseated systems
No flow from flow line?
– Gaseated systems constantly surging/heading
When surging, well unloads for a time, then stops
flowing for a similar period (5 – 10 minutes)
If DPP goes down when hole is unloading and up
when not, all probably OK
– If no flow and DPP not rising, lost returns
– Less liquid/mud, more air
199
UBD Control Problem
Scenarios
Large fluid flows from formation

No problem, but may cause high pressures and
large surface volumes
– Throttle back the choke ~100 psi at a time
Reduce flow/pressure to safe value
Choke controls pressures and limits flow to
separator
– More liquid/less gas or higher flow rate
increases BHP
For large gas flows, reduce injected gas but keep
liquid the same to clean the bit
200
UBD Control Problem
Scenarios
Control summary:
– UBD wells constantly
surging/heading or Kicking
to some degree
– Wellbore pressures lower
than in normal ‘Well
Control’
Control’ situation
– Underground Blowout risk
avoided or vastly reduced
Let ‘er Buck!
201
Outline
4. Downhole Tools
» 9. Location Equipment and Flaring
202
Location and
Rigging Up
UBD considerations
– Arrangement of equipment
Larger location than normal drilling
– Size and arrangement of pits
– Gas source (compressor/nitrogen unit)
– BOP stack, rotating head, special lines and
valves
– Choke, blooey lines, separator, and flare
– Standpipe manifold
203
Typical location diagram
RHOURDE EL BAGUEL
This is an example of a complex surface location schematic, for a well using

membrane-generated nitrogen and foam. This well was drilled near Hassi
Messaoud, in the RHOURDE EL BAGUEL FIELD.
204
Flares and Flaring
EPA approves flaring as a

primary method of VOC
disposal
– Flare plan also must
address issues of smoke,
odor, light, and burning
liquids
US Coast Guard and MMS
regulate flares offshore, but
no onshore regulations
Canada regs discourage
horizontal flares
VOC = Volatile Organic Compound
205
Flares and Flaring
Most US operations use

horizontal flare in
reserve pit
Sometimes called ‘Burn pit’
pit’
– Flare line 150-
150-300 feet
from rig
– Pit lined to prevent
seepage
– Primary and secondary
pilot lights
206
Flares and Flaring
Flare concerns
– Far enough and down-
down-
wind
May need 2 lines/flares/pits
– Stake or restrain the flare
line
UBD surges cause line
stress
– Pilot lights a problem in
UBD
Mixed gas/liquid heading
can blow out pilots
207
Flares and Flaring
Proper flare design

– Too large diameter:
flare burns inside
– Too small : flare burns
> 2 feet away from tip
208
Flares and Flaring
Proper flare design

– Too much smoke
means too little
oxygen
209
Flares and Flaring
Vertical stacks used in

Canada, Europe, and
offshore
– Flame, heat, fumes high off
the ground
– safer and better
environmental
– Requires separator and
water knock-
knock-out
210
Outline
4. Downhole Tools
» Overall Summary and Review
211
Overall Summary and
Review
Underbalanced Drilling (UBD)

– drilling into any formation when the pressure
exerted by the drilling fluid column is less than
the formation pressure
Advantages of UBD
212
Overall Summary and
Review
When UBD is poor choice

Geopressured shales, coal, rubble zones, salt,
unconsolidated sand: hole sloughing and caving
Extra costs of UBD

More casing, better control of casing points
Tighter control of operating pressures
Added surface equipment
Added cost of foam or specialized fluid systems
213
Overall Summary and
Review
Surface components make UBD work

– Rotating control head or RBOP
Primary well-
well-control barrier
Annular and conventional BOP stack as secondary
– BOP stack has extra, large-diameter flow lines
– Choke manifold
– Drilling Separator (usually pressurized)
– Blooey Line/Flare
– Unique standpipe manifolding
214
Overall Summary and
Review
Specialized downhole equipment

– Bit floats and string floats are essential for UBD
– Deployment valves: new tool for trips and

another barrier
– Bit selection: do not overdrill the fluid system’s

ability to clean the hole
– Mud-pulse MWD doesn’t work in most UBD fluid

systems
215
Overall Summary and
Review
UBD fluid column

Two-
Two-phase gas/liquid flow
Gas behavior changes with depth
Flow regime changes with velocity
Velocity increases friction pressure (non-
(non-linear)
Friction pressure changes BHP
216
Overall Summary and
Review
UBD Operation
– Addition of gas or light fluids changes all flow
rules
– UBD Operating Mode: constant ‘Driller’s Method’’
Maintain constant pump volume
Standpipe pressure = BHP
Use the choke to maintain standpipe pressure
UBD gas in annulus = longer lag times for choke to
change standpipe pressure
217
Overall Summary and
Review
The UBD fluid column

– complex and requires computer calculations for
most flowing values
– ‘Lag Time’ increased from 30 seconds (low gas
ratio) to over 60 minutes (foam systems)
Typical
UBD operations: ‘Stripping’,
‘Snubbing’, and ‘Mud Caps’
218
Overall Summary and
Review
UBD Fluid Systems

– Liquid
Advantages:
– at ‘near-
near-balance’
balance’, all the advantages of UBD
– No gas injection, less expensive than gas UBD
Disadvantages:
– Fluid density > 8 ppg, formation must be high enough
pressure to allow ‘near-
near-UBD’
UBD’
219
Overall Summary and
Review
UBD Fluid Systems

– Gaseated air-gas/liquid
Advantages
– Any mud system, water, and oil
Disadvantages
– due to surges, Gaseated systems must operate at very low
underbalance (>200 psi) to avoid going Overbalanced due to
pressure surges during connections
– Low UB can cause hole caving, makes flow control difficult
220
Overall Summary and
Review
UBD Fluid Systems

– Foam
Advantages
– Lightest UB fluid
– Structured emulsion
Holds large volume of gas
Enhanced lifting capacity
– Low amount of liquid
– No pressure surges
– Low annulus velocity, enhanced lifting, low pumping rate:
high fluid efficiency
– Plugs lost circulation zones
– Great performance with motors
221
Overall Summary and
Review
UBD Fluid Systems

– Foam
Disadvantages
– Dry, high-
high-ratio foams may break and pressure surge
– Depth limit: foam column gets heavier as depth increases
At 12,000 feet, most foams are 95% liquid (5% quality),
EMW ~ 8 ppg
Higher gas:liquid ratio makes dryer/lighter but poorer-
poorer-
performing foam
– Foam performs poorly in some conditions
Needs soft, alkaline makeup water
Oil, high temperature, acid gases (H2S, CO2) can break
most foams
222
Overall Summary and
Review
UBD Fluid Systems
– Air/gas and Mist
Advantages
– Minimal bottom-
– Inexpensive, very simple system
– Highest drilling rate by far
Hammers increase ROP further
– Lowest reservoir damage
Disadvantages
– Needs dry formation
– Mist and ‘foamed mist’
mist’ can help with water, but increase cost
and complexity
– No support to hole (Caving, sloughing, etc.)
– Downhole fires if drilling with air
223
Overall Summary and
Review
Choose UBD fluid system
1. Amount of Under-
Under-balance?
– Range: 25% to 100% of ‘Optimum’
Optimum’
‘Optimum’
Optimum’ UB is a function of k
Upper end (50% - 100%) for drilling/completion of pay zones
lower end (25% - 50%) for normal drilling section
2. Expected formation pressures?

Gradient (design BHP psi/ft) indicates best match of fluid system
system
3. Type/characteristics of rocks in the section supports

design fluid system?
224
Underbalanced Drilling
and Workover
The End
Thank you for your attention
Let ‘er Buck!
225

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Underbalanced Drilling

» 1. Terms and Basic Calculations

UB and Well Control are

UB Drilling: Drilling into

1. Drilling with Air or Gas, Foams, Mists,

2. Drilling with Cable-Tool method

3. Drilling with conventional Mud

1. Formation pressure is the force exerted by fluids in the formation. Some

Standpipe pressure is measured at the top of the drill stem.

UBD usually EMW of < 8.3 PPG

P = pressure, psi (kPa)

P = 8202 x 11.1 x 0.052 = 4,734 psi

= 2500 x 1330 x 0.0098 = 32,585 kPa

Gradient (G) expressed as psi/ft of depth (kPa/m)

G = 11.1 ppg x 0.052 = .577 psi/ft

= 1330 kg/m3 x 0.0098 = 13.034 kPa/m

Gav = BHP ÷ TVD ÷ K where

Gav expressed as EMW (ppg or kg/m)

Gav = 4734 psi ÷ 8202 ft ÷ 0.052 = 11.1 ppg

= 32,585 kPa ÷ 2500 m ÷ 0.0098 = 1,330 kg/m

Drill pipe pressure (DPP)

Annular pressure loss (APL)

These are the type of pressures defined by Underbalanced drilling.

Equivalent Circulating Density is an expression of the “Average Hydrostatic

Underbalanced Drilling (UBD)

1. Terms and Basic Calculations

Increase the drilling rate

3 to 20 times faster bit

ROP increases with underbalanced drilling are usually observed at from 3 to 20

Example: La Paz field Venezuela (SPE 74449)

ROP increases with underbalanced drilling are usually observed at from 3 to 20

UBD: flow is into well

Bonus: Foam bubbles

Coal and other rubble

UBD solves major problems:

More casing and tighter control of casing

Typical UBD sets casing immediately above pay

The advantages of UBD are substantial compared to conventional drilling programs,

Potential for higher surface pressures

Wellborepressures almost always LOWER

– Provides reduced risk of Underground Blowout

UBD emphasis is on surface equipment

Design and operation of surface equipment usually

Finally, it is the selection and skilled operation of a wide variety of specialized

When UBD is poor choice

Extra costs of UBD

Extra costs of UBD versus Bottom Line

– Average 300% - 400% production increase

Extra costs of UBD

Extra costs of UBD versus Bottom

Extra costs of UBD

Extra costs of UBD

1. Terms and Basic Calculations

BOP stacks for UBD

In Conventional drilling, the over-balanced

In UBD, the drilling fluid is deliberately too

For gas/air or mist