Department of Petroleum Engineering

Indian Institute of Technology (ISM), Dhanbad – 826004

VI Semester B.Tech Petroleum Engineering 2023-24

Lecture 11 / 2023-24
(For internal circulation only)

UNDER BALANCED DRILLING

(AIR, GAS, MIST AND UNSTABLE FOAM DRILLING)

BY
Prof. A.K.Pathak
Department of Petroleum Engineering
Indian Institute of Technology (Indian School of Mines), Dhanbad
E-mail: akhilendra56@iitism.ac.in

Underbalanced drilling is defined as drilling operations where the drilling fluid pressure in the
borehole (Ph) is less than the pore pressure in the formation rock in the open hole section (Pf).
By using light drilling fluids, the driller intentionally keeps the borehole pressure balancing the
formation pore fluid pressure. The light fluids used in UBD are usually air, gas, foam and aerated
water. However un-aerated oil, water and even weighted mud can be used for UBD in areas
where pore pressure gradients are higher than hydrostatic gradient of water.
i. (1920s): Deep petroleum and natural gas wells were drilled using portable air compressors.
ii. (1930s): Aerated drilling fluids have been used to drill bore holes.
iii. (1950s): The more popular use of air as drilling fluid began.
iv. (1970s): The air and gas technology was being used on about 10% of the deep wells drilled
and completed. Stable foam systems first used in production workover operations.

Advantages of Under balanced Drilling:

i. Increased penetration rate: UBD avoids overbalanced pressure to the rock below the drill bit.
Removing this confining pressure makes the rock easier for the bit teeth to cut and frees the
generated cuttings from the bottom of the hole. This helps bottom hole cleaning and increases
the penetration rates (ROP). The ROP can be increased as much as ten times over that for mud
drilling in equivalent formation. An ROP as high as 120 ft./hr can easily be achieved in air and gas
drilling.
ii. Minimized Lost Circulation: Lost circulation occurs due to flow of drilling fluids forced by
hydrostatic head in to the formation with natural fractures or having very high permeability. The
overbalanced pressure can create fractures in depleted petroleum reservoirs and can cause lost
circulation problem. Underbalanced drilling is the means of minimizing lost circulation problem in
drilling naturally fractured formation and pressure depleted reservoirs.
iii. Prolonged Bit Life: Longer bit life is observed in underbalanced drilling than overbalanced
drilling. Rock compressive strength increases due to overbalanced pressure from the drilling fluid.
The pressure confinement imposed on the rock by the overbalanced pressure from the wellbore
fluid during overbalanced drilling does not exist during underbalanced drilling. Therefore the rock
can be fragmented by bit teeth easier in underbalanced drilling than overbalanced drilling. The
pressure confinement generated cuttings become entrained more easily in the drilling fluid, which
minimizes the re-grinding actions to the cuttings by the bit teeth.
iv. Minimized Differential Sticking: Pressure differential is associated with mud cake formed
against permeable zones during overbalanced drilling. Pipe sticking occur when the tool in the
hole can not be pulled out with out exceeding the working load of the equipment or string. There
is no filter cake during underbalanced drilling. Therefore the pipe sticking is not there.

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 Department of Petroleum Engineering
Indian Institute of Technology (ISM), Dhanbad – 826004
VI Semester B.Tech Petroleum Engineering 2023-24
v. Improved Formation Evaluation: UBD provides a means to detect hydrocarbon zone by
directly observing return fluid. Theses productive zones can be bypassed during drilling by using
OBD. Fast return of drilling fluids along with cuttings and reservoir fluids, hydrocarbon pay-zones
can be identified more accurately in depth during UBD. The reduction or elimination of drilling
fluid invasion into formation also improves the interpretation of open-hole logs and pressure
transient tests.
vi. Reduced Formation Damage: Formation damage can occur when drilling fluids enter the
permeable zone during OBD. Drilling fluid invasion can change rock wettability and relative
permeability and can plug rock pores. Pore plugging can be caused by the guest particles from
the drilling fluids, the host materials mobilized by the invading fluid or the host minerals after
swelling. These changes reduce effective permeability of the desired fluid in the reservoir. UBD
minimizes formation damage during drilling. It also reduces stimulation requirements and saves
the cost of well stimulation treatments.
vii. Earlier Oil Production: With suitable surface equipment available, oil can be collected as
soon as a productive zone is opened during UBD. While drilling ahead to penetrate more zones,
the produced oil is accumulated. It is possible for UBD wells to be paid for by the oil produced
during drilling stage.
viii. Environmental Benefits: Air and gas drilling eliminates potential pollution of drilling mud to
environments during and after drilling. Chemicals used in mist and foam drilling are normally
benign, biodegradable surfactants that do not pose significant environmental concerns. Formation
fluids produced during UBD need to be handled with closed surface systems to minimize the
potential for environmental contamination.

Limitations of Underbalanced Drilling:

i. Well Bore Stability Problems: Due to lower well bore pressure in UBD, the wel bore stability is
less as compared to OBD. The lower well bore pressure also increases tendency of tight holes
due to yielding of some formations. Large shale fragments are observed in UBD which are due to
caving in or sloughing shale in well bore wall. This type of problem occur in water sensitive clay
formations. Change in shale water content due to water adsorption or dehydration induces
additional rock stresses near the well bore which can cause destabilizing in well bore. Sudden
sloughing can cause sticking of drill string in bore hole. Use of high volume dry air and gas in
UBD can also result in well bore washout due to erosion against soft rock intervals. Well bore
instability puts a limit on the applicable well bore pressure for UBD.
ii. Liquid Influx Problem: Liquid influx includes water inflow and oil production. Water inflow can
cause mud ring problems during air/ gas drilling. Mud rings can grow to the point where the drill
string I strapped. Excess water inflow significantly increases flowing bottom hole pressure and
reduces gas velocity, resulting lower carrying capacity of air/ gas which in turn can cause stuck
pipe, if not monitored closely. The water inflow problem often requires that mist or foam used to
continue drilling. The disposal cost of the water is additional problem. The other compo0nent of
liquid influx in oil influx (oil production). Oil production during drilling requires the surface
equipments able to handle the produced oil at the production rate. If the oil [production rate is too
high to handle, the drilling technology should be switched over to overbalanced drilling.
iii. Directional Drilling Problems: UBD can be carried out using liquid (oil and water) where
reservoir pressures are not so low. Most UBD operations use aerated fluids that are highly
compressible. Conventional tools used in directional drilling work only for incompressible fluids.
Mud pulse telemetry measurement tools (MWD) tools can not operate with compressible fluids
used in UBD. This is because that the pressure pulses generated by MWD tools do not propagate
through compressible fluid to the surface with detectable amplitude. Electromagnetic MWD tools
are required for drilling directional wells with compressible fluids. Conventional down hole motors

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 Department of Petroleum Engineering
Indian Institute of Technology (ISM), Dhanbad – 826004
VI Semester B.Tech Petroleum Engineering 2023-24
used in directional wells operate on incompressible fluids. Their pe4rformance also deteriorate
while using with compressible fluids.
iv. Safety Issues : Down hole fires and explosions occur under certain conditions during air
drilling and their consequences are severe. The bottom hole assembly can melt or burn away.
Down hole fire can be avoided by using inflammable gas such as nitrogen and natural gas.
Switching from one gas to other gas is not easy so the down hole fire can be minimized by using
mist or foam drilling with sacrificed penetration rate. Vibration and noise also issues of safety in
air / gas drilling. Vibration can cause drill string failure and personnel injury. The high noise level
is detrimental to human health. These problems can be minimized by using mist or foam drilling
with low penetration rate.
v. Economic Considerations: Cost of excessive water and hydrocarbon handling versus gains
in penetration rate and well productivity is measure economical issues increasing cost of well
operations Environmental restrictions make the disposal of produced water expensive. The
savings from increased penetration rate due to underbalanced drilling may not compensate the
cost of liquid handling. The gain in well productivity due to UBD may not justify the drilling cost.
The requirement of hydraulic fracturing, local equipment availability and local logistics are
important economical issues for planning UBD projects.

Basic planning steps of UBD:

i. Identify the geometry of the borehole sections to be drilling with each of the techniques like
open hole diameter, maximum depth, casing size and setting depths.
ii. Determine the geometry of associated drill string for the sections to be drilled with each of the
techniques like drill bit type, drill collar size and length, drill pipe size and description.
iii. Estimate the anticipated ROP in each section based on the type of rock formation to be drilled.
iv. Determine the elevation of the drilling site above sea level, the temperature of the air during
drilling operations and geothermal gradient.
v. Decide whether direct or reverse circulation technique will be used.
vi. Calculate minimum volume requirements to drill each sections like liquid flow rate, gas
injection rate.
vii. Using minimum volumetric flow rates, estimate the bottom hole pressures, surface injection
pressure and compressor power.
viii. Predict pressure unbalanced at the pay zone in order to minimize the formation damage.
ix. Perform bore hole stability analysis.
x. Select the contractor whose compressors will support the drill string operations with
appropriate pressure and flow rate.
xi. Estimate the approximate volume of fuel required by the compressor to drill the well.
xii. Adequate flow rates of gas and liquids are crucial for the success of UBD operations.

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 Department of Petroleum Engineering
Indian Institute of Technology (ISM), Dhanbad – 826004
VI Semester B.Tech Petroleum Engineering 2023-24
SELECTION OF UNDERBALANCED DRILLING TECHNIQUES
Drilling Fluid Improved Ability to Drill in Ability to Drill
ROP Lost Circulation Hard Rock
Zone Formation
Air and Gas ↑ ↑ ↑
Mist and Unstable Foam
Stable Foam
Aerated Liquid
Liquid

Drilling Fluid Ability to Ability to Drill Ability to Drill

Drill in Sloughing High Pressure
Water Shares Zones
Inflow
Zones
Air and Gas ↓ ↓ ↓
Mist and Unstable Foam
Stable Foam
Aerated Liquid
Liquid

Drilling Fluid Ability to Ability to Handle Ability to Handle

Control Pipe Sticking Well Kicks
Bore Hole
Collapse
Air and Gas ↓ ↓ ↓
Mist and Unstable Foam
Stable Foam
Aerated Liquid
Liquid

CRITERIA FOR MINIMUM VOLUME GAS REQUIREMENT

The minimum annular velocity to effective removal of solid particles (dust like particles) from bore
hole is 3000 ft/min or 50 ft/sec under atmospheric conditions (closed to 14.7 psia and 60 0F).
The carrying power of air with velocity of 50 ft/sec can be evaluated based on the kinetic energy
E0 per unit volume of air.
Ego = ɣgo . vgo2 / 2 g (1)
Where-
E0 = Kinetic energy per unit volume of air ɣgo = 0.0765 lbs/ ft3 specific weight of standard air.
vgo = 50 ft/sec minimum required velocity of air under standard condition.
g = 32.2 ft/ sec2 a constant to convert the unit of mass from pounds to slug.

The kinetic energy of 1 ft3 of standard air moving at velocity of 50 ft/.sec is –

Ego = 0.0765 x 502 / 2 x 32.2 = 3 ft-lbf/ft3
It is the minimum value of kinetic energy of fluid required for effective lifting of solid particles.
If the carrying capacity of fluid phase at the point of interest is equivalent to the carrying power of
the velocity of standard air the following relationship will hold-

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 Department of Petroleum Engineering
Indian Institute of Technology (ISM), Dhanbad – 826004
VI Semester B.Tech Petroleum Engineering 2023-24
ɣg . vg2 / 2 g = ɣgo . vgo2 / 2 g (2)
where-
ɣg = Specific weight of air at the point of interest in lb/ft 3
vg = Velocity of gas at the point of interest in ft/sec

The specific weight of gas is in equation 2 can be expressed as a function of insitu pressure and
temperature based on the ideal gas law.

ɣg = Sg . P / 53.3 T (3)
where-
Sg = specific gravity of gas related to the air.
P = pressure at the point of interest in lb/ft2
T = Temperature at the point of interest
The volumetric flow rate of gas at the point of interest in the bore hole is determined based on
gas volumetric flow rate under standard condition using ideal gas law.

Qg = 14.7 X 144 T . Qgo / 520 P (4)

Where-
Qg = Volumetric flow rate of gas at the point of interest in ft3/min
Qgo = Volumetric flow rate under standard conditions in Standard ft3/min (SCFPM)

The gas velocity v at the point of interest in the hole can be determined by dividing equation 4 by
the cross sectional area.
vg = 14.7 X 144 X 144 T . Qgo / 60 X 520 P (5)
vg = 9.77 T . Qgo / P A (6)
where A is cross sectional area of the flow path in inch 2

Substituting equation 3 and 6 in equation 2

P = 23.4 Sg T . Qgo2 / vgo2 A2 (7)

Equation 7 demands a fundamental requirement for the relationship between in situ pressure and
gas injection rate to maintain the carrying power of gas in the hole at the same level of carrying
power of the velocity vgo of air under standard conditions.

MINIMUM VELOCITY CRITERION:

Terminal Velocity: When a solid particle is released in a steady still fluid of lower density it first
accelerates under the action of gravity and yhen decelerates due to the increasing drag force on
the particle from the fluid.. After certain time the variation of the particle velocity is not practically
detectable and the velocity of the particle reaches a constant velocity known as terminal velocity,
free settling velocity and slip velocity.
Terminal velocity is influenced by size, shape and density of particle, density of fluid, flow regime,
particle – particle interaction and particle wall interaction.
For spherical particles following equation is developed by Gray to determine terminal settling
velocity.

Vsl = {4 g DS (ρS – ρg) / 3 ρg CD}(1/2) . {ψ / (1 + DS / DH)} (8)

where-
vsl = terminal settling velocity in fps Ds = equivalent solid particle diameter, ft.
ρs = density of solid particle, pounds mass per cubic feet lbm/ft3

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 Department of Petroleum Engineering
Indian Institute of Technology (ISM), Dhanbad – 826004
VI Semester B.Tech Petroleum Engineering 2023-24
ρg = density of gas in lbm/ft3
CD = drag coefficient accounting for the effect of particle shape : 1.40 for flat (shale and
limestone), 0.85 for angular to rounded (sandstone) particles.
Ψ = sphericity factor DH = hydraulic diameter of flow path, ft.

The gas velocity required to transport the solid particle can be formulated as follows-
vg = vsl + vtr (9)
where
vg = gas velocity in fps. vsl = terminal slip velocity in fps
vtr = required particle transport velocity in fps

The required transport velocity depends upon that how fast the drill bit generates cuttings and the
number of moving particles allowed in the bore hole during drilling. The volumetric flow rate at
which the particles are generated by the bit can be-

QP = (π / 4) (db / 12)2 . (Rp / 3600) (10)

Where-
Qp = volumetric flow rate of particles generated by the drill bit, ft3/sec
db = bit diameter, inch Rp = rate of penetration, ft/hr

The volumetric flow rate at which the particles are transported in the flow path is –

Qtr = Vtr CP ( A/144) (11)

Where
Qtr = volumetric flow rate of transported particle in the flow path ft3/sec
vtr = particle transport velocity fps Cp = particle in the flow path, volume fraction
A = Cross sectional area of the flow path, inch2

Based on the material balance for solid particles, the volumetric flow rate pf particle transport
must be equal the volumetric flow rate of particle generated by drill bit, i.e.-
Qtr = Qp (12)
Substituting equation 10 and 11 in equation 12 we get-

Vtr = (π /4) (db2 / CP A) (RP / 3600) (13)

At solid concentrations in excess of volume fraction 0.04, the tendency for solid in air to slug and
interface materially with each other becomes critical. The assumption of a homogeneous fluid is
wrong at solid concentration higher than Cp = 0.04.
Particle size is required to calculate settling velocity.

Maximum particle size can be estimated based on the maximum cuttings depth per bit revolution.
Ds = Rp / 60 N (14)
Where-
Ds = particle size in ft. Rp = Penetration rate ft/sec N = Bit revolution per min.

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 Department of Petroleum Engineering
Indian Institute of Technology (ISM), Dhanbad – 826004
VI Semester B.Tech Petroleum Engineering 2023-24
Short Answer Questions

1. What is Underbalanced Drilling?

2. What are different types of Underbalanced drilling techniques?
3. What are advantages of Underbalanced Drilling?
4. Under what conditions underbalanced drilling is adopted?
5. What are basic planning steps of UBD?
6. Explain how the better penetration rate is obtained by UBD?
7. Explain how UBD can be used as means to control lost circulation problem?
8. Explain how UBD can be used as means to control differential sticking problem?
9. Explain how UBD can be used as means to control formation damage problem?
10. Explain how UBD can be used to improve Formation Evaluation?
11. Compare the ROP performance between different methods of UBD?
12. Compare the ability to Drill fractured zone by different methods of UBD?
13. Compare the ability to Drill water flow zone by different methods of UBD?
14. Compare the ability to Drill sloughing shale zone by different methods of UBD?
15. Compare the ability to Drill hard rock formations by different methods of UBD?
16. Compare the ability to Drill high pressured zone by different methods of UBD?
17. Compare the ability to control bore hole collapse by different methods of UBD?
18. What are the limitations of UBD?
19. Explain the Well bore Stability condition during UBD?
20. Explain the Safety issues condition during UBD?
21. What are Directional Drilling problems to be encountered during UBD?
22. Compare the economic considerations between UBD and Conventional drilling?
23. What are basic criteria for selection of UBT technique for a field?

TUTORIAL

Q.1: A well is cased from the surface to 7000 ft. with API 8 5/8 inch dia 28 lbs nominal
casing. It is to be drilled a head to 10,000 ft. with a 7 7/8 in dia rotary drill bit using air as a
circulating fluid at an ROP of 60 ft/hr and a rotary speed of 50 rpm. The drill string is made
up of 500 ft of 6 ¾ in OD x 2 13/16 in ID nominal drill collar and 9500 ft of API 4 ½ in dia,
16.6 ppf nominal EU – S135, NC 50 drill pipe. The bottom hole temperature is expected to

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 Department of Petroleum Engineering
Indian Institute of Technology (ISM), Dhanbad – 826004
VI Semester B.Tech Petroleum Engineering 2023-24
be 1600F. Desired circulating density of 0.05 ppg (0.37 lb/ft 3) at the collar top is achievable
using air drilling.
a. Using Minimum Kinetic energy method determine Minimum air velocity, minimum
volumetric air flow rate at the collar top, pressure at the top of drill collar, volumetric air
flow rate at the collar top
b. Using Minimum Velocity method determine Settling velocity, the terminal settling
velocity, cuttings transport velocity, The gas velocity required to transport the solid
particle, volumetric air flow rate at the collar top, volumetric air flow rate at the collar top
under standard condition.

Q.2: A well is cased from the surface to 7000 ft. with API 8 5/8 inch dia 28 lbs nominal
casing. It is to be drilled a head to 10,000 ft. with a 7 7/8 in dia rotary drill bit using air as a
circulating fluid at an ROP of 60 ft/hr and a rotary speed of 50 rpm. The drill string is made
up of 500 ft of 6 ¾ in OD x 2 13/16 in ID nominal drill collar and 9500 ft of API 4 ½ in dia,
16.6 ppf nominal EU – S135, NC 50 drill pipe. The bottom hole temperature is expected to
be 1600F. Desired circulating density of 0.05 ppg (0.37 lb/ft 3) at the collar top is achievable
using air drilling.
Ambient conditions are-
Elevation = 4000 ft. Temperature = 850F Relative humidity = 0.8
0
Geothermal gradient = 0.01 F/ft Dewatering efficiency of water tap = 95%
Mist water rate = 10bbl/hr Formation water influx = 30 bbl/hr
Blooey line pressure = 15 psia.
Drilling solids particle size = 0.1 in diameter specific gravity = 2.8
Determine the minimum required volumetric flow rate of actual air for the operation using
direct calculation method.

Q.3: A bore hole is to be drilled to 2800 ft. with a 17 ½ in diameter rotary drill bit using air
as a circulating fluid at an ROP of 90 ft / hr. The drill string is made of 300 ft of 9 inch x 4
inch drill collar and 6 5/8 inch 27.20 ppf drill pipe (5.9 inch id) of 25oo ft length.
Ambient conditions are-
Elevation = 2000 ft. Temperature = 750F Relative humidity = 0.85
0
Geothermal gradient = 0.01 F/ft Dewatering efficiency of water tap = 95%
Mist water rate = 0bbl/hr Formation water influx = 0 bbl/hr
Blooey line pressure = 14.7 psia.
Drilling solids particle size = 0.1 in diameter specific gravity = 2.7
Determine the minimum required volumetric flow rate of actual air for the operation using
Engineering Charts.