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UNDERBALANCED OPERATIONS
DISSERTATION SUBMITTED
IN PARTIAL FULFILMENT OF THE REQUIREMENT
FOR THE AWARD OF THE DEGREE OF
MASTER OF TECHNOLOGY
IN
PETROLEUM ENGINEERING
By
PRAVEEN PATHAK Roll No. 08MT1004
SCHOOL OF PETROLEUM TECHNOLOGY
PANDIT DEENDAYAL PETROLEUM UNIVERSITY
GANDHINAGAR, GUJARAT, INDIA 18
th JANUARY 2010
UNDERBALANCED OPERATIONS
DISSERTATION SUBMITTED
IN PARTIAL FULFILMENT OF THE REQUIREMENT
FOR THE AWARD OF THE DEGREE OF
MASTER OF TECHNOLOGY
IN
PETROLEUM ENGINEERING
By
Praveen Pathak Roll No. 08MT1004
Under the supervision
of
Prof. S.S.P. Singh
SCHOOL OF PETROLEUM TECHNOLOGY
PANDIT DEENDAYAL PETROLEUM UNIVERSITY
GANDHINAGAR, GUJARAT, INDIA 18
th JANUARY 2010
ii
18/01/2010
CERTIFICATE
This is to certify that the dissertation entitled “ Underbalanced Operations” submitted by
Praveen Pathak (Roll No: 08MT1004) in partial fulfillment of the requirements for the award of
the degree of Master of Technology in Petroleum Engineering, from School of Petroleum
Technology, Pandit Deendayal Petroleum University, Gandhinagar was carried out under my
guidance and supervision. No part of this dissertation has been submitted for the award of any
degree or otherwise elsewhere to the best of my knowledge.
(Prof. S.S.P.Singh)
School of Petroleum Technology, Gandhinagar
Forwarded by:
(Dr. Shrikant J. Wagh)
School of Petroleum Technology, Gandhinagar
iii
ACKNOWLEDGEMENTS
I would like to take this opportunity to express my deep sense of gratitude and profound feeling
of admiration for Prof. SSP Singh, Ex.GM (Prod.) and Head Well Stimulation Services ONGC
Ltd. His student friendly attitude, involvement and guidance has provided me good atmosphere
to develop my research capabilities. Also his regular assessment and feedback helped me to
complete my project within timeframe.
My heartiest thanks to Mr. V.K Jain (ED-Ex. Head IDT) and Mr. S.K. Dutta (GGM- Head IDT)
for providing me an opportunity to work at the Institute of Drilling Technology, ONGC,
Dehradun.
Very sincere and honest thanks to Dr. Vinod Sharma (GM- Chemistry), for granting permission
to work and utilize the laboratory facilities at R&D Lab Chemistry division at IDT Dehradun. I
also like to acknowledge Mr.A.K.Barthwal (CC), Dr. V.K.Singh (CC) and all other personal at
IDT for their kind support and continuous motivation during my experimental work.
I would like to express my appreciation to all members of PG committee, School of Petroleum
Technology, Gandhinagar for their regular evaluation and guidance. I would also like to convey
my thanks to the whole PDPU members who helped me directly and indirectly during my project
work.
I am heartily grateful to my family members for their blessings and motivation.
iv
(Praveen Pathak)
ABSTRACT
Formation damage to some extent occurs in all wells. As a result the objective of drilling, completion and workover designers is to reduce the effects of damage to economically acceptable levels. The underbalanced operation is one such technology to exploit the formation to its full potential.
At present many of the onshore reservoirs of India are in depleted conditions with good amount of recoverable reserves. Various issues involved in the underbalanced operations have been investigated. Laboratory screening procedures for evaluating the effectiveness of underbalanced operation for a specific application has been elaborated. Benefits and limitations of underbalanced operations are identified. Appropriate candidate selection for underbalanced operations is elaborated. Fluid operations used in underbalanced techniques are also discussed.
The project provides a detailed study in how to plan for underbalanced operations to achieve success in drilling, completion and workover to the oil field. The study emphasizes advantages of this technology, formation stability, well control, environmental restrictions, minimize / avoid formation damage with employing non-damaging fluid and the development of water based low gravity workover fluid formulations for sub-hydrostatic reservoir field. It is very difficult to maintain the underbalanced condition during horizontal well operations due to poor hole cleaning. In that case formation damage occurs when underbalanced condition is lost, for such condition laboratory experiments and evaluation of non-damaging fluid at bottom hole environment is performed which will provide guaranteed economic incentives.
The technology implementation would minimize formation damage, reduce requirement of subsequent stimulation/activation jobs, and would result in higher productivity gain.
Objective of the project is to improve the productivity from sub-hydrostatic Indian reservoirs.
v
CONTENTS
Title ……………………………………………………………………………………………….i
Certificate ………………………………………………………………………………………..ii
Acknowledgements ……………………………………………………………………………..iii
Abstract .........................................................................................................................................iv
List of Tables …………………………………………………………………………………..viii
List of Figures …………………………………………………………………………………...ix
Abbreviations …………………………………………………………………………………...xi
Nomenclature …………………………………………………………………………………..xii
CHAPTER 1 Introduction of Underbalanced Operations 1
1.1What is Underbalanced Operations? 1
1.2 History of Underbalanced Operations 3
CHAPTER 2 Literature Survey 5
2.1 Underbalanced Operations 5
2.1.1 Underbalanced drilling 5
2.1.2 Underbalanced perforation 14
2.1.3 Underbalanced workover 17
2.2 Underbalanced Fluid System and Techniques 20
2.2.1 Selection of an underbalance operations fluid 20
vi
2.2.2 Underbalanced operational fluid design aspects 20
2.2.3 Fluid system selection 22
2.2.3.1 Gasified (Aerated) fluid operations 22
2.2.3.2 Foam fluid operations 30
2.2.3.3 Mist fluid operations 37
2.2.3.4 Air and gas fluid operations 39
2.3 Candidate Screening and Selection 43
2.3.1 Drivers to consideration of underbalanced operations 43
2.3.2 Reservoir aspects of underbalanced operations 44
2.3.2.1 Good candidate indicators for underbalanced operations 44
2.3.2.2 Bad candidate indicators for underbalanced operations 45
2.3.3 Assessing rock potential for formation damage 46
2.3.4 Assessing lost circulation potential 53
2.3.5 Assessing pipe sticking possibility 54
2.4 Well Control Aspects in Underbalanced Operations 55
2.4.1 Blow out prevention system 55
2.4.2 Sub-surface control system 55
2.4.3 Well control equipments 56
2.5 Problem Identified 58
vii
CHAPTER 3 Methodology & Experimental work 59
3.1 Development and Evaluation of Low gravity, Non invasive Fluids for
Sub- hydrostatic Underbalanced Workover Operation 59
CHAPTER 4 Results and Interpretations 76
CHAPTER 5 Conclusion and Recommendations 80
5.1 Conclusion 80
5.2 Recommendations 80
5.2.1 Recommendations for underbalanced drilling 80
5.2.2 Recommendations for underbalanced workover 82
5.2.3 Recommendations for underbalanced perforation 82
APPENDIX
REFERENCES
viii
LIST OF TABLES
2.1 IADC fluid classification…………………………………………………………………….22
2.2 IADC UBO Committee classification system for UBD wells……………………………….46
2.3 Main components of various clay and fine particles………………………………………...47
2.4 Damage indices for pure clays……………………………………………………………….49
2.5 Distribution correction factors……………………………………………………………….49
2.6 Damage mechanism vs. formation type matrix……………………………………………...52
ix
LIST OF FIGURES
2.1 Conventional Overbalanced Vs Underbalanced Operations……………………………….5
2.2 Pseudo-steady-state depletion condition near well bore region during underbalanced
drilling condition…………………………………………………………………………..9
2.3 Invasion during an overbalanced/reduced underbalanced condition phase in the near
wellbore depletion region………………………………………………………………….9
2.4 Gravity induced invasion in horizontal well UBO………………………………………..10
2.5 Fluid loss and solid loss in overbalanced /underbalanced operations……………………..11
2.6 Snubbing system…………………………………………………………………………..18
2.7 Various flow regimes in horizontal wells during gasified (aerated) fluid operation……...23
2.8 Compression of the fluid at different depths in a wellbore decreases hydrostatic pressure
disproportionately…………………………………………………………………………24
2.9 Gasified mud injection reduces BHP……………………………………………………..25
2.10 Formation damage reduction in gasified systems………………………………………...25
2.11 Differential sticking results from higher pressure exerted by mud than the formation
fluids……………………………………………………………………………………...26
2.12 ROP decreases as BHP increases…………………………………………………………27
2.13 Inconsistent pressure in UBO…………………………………………………………….27
2.14 BHP remains much more constant with gas circulation before connections……………..28
2.15 Parasite tubing string……………………………………………………………………...29
x
2.16 Concentric casing string…………………………………………………………………..30
2.17 Foam is made of bubbles that are surrounded by a liquid film…………………………...31
2.18 Large cutting cleaning in foam drilling operations……………………………………….32
2.19 Difference in phases between foam and a mist system…………………………………...33
2.20 Foams reduces BHP, avoiding lost circulation…………………………………………...34
2.21 Foams minimize reservoir damage because flow is from the reservoir to the wellbore….34
2.22 In UB Operations with foam, reservoir pressure is higher than wellbore pressure,
differential sticking can not occur………………………………………………………...35
2.23 Mist formed by water drops in suspension………………………………………………..36
2.24 Shales destabilized by water invasion cause formation of mud rings, which clog
the hole…………………………………………………………………………………….40
2.25 Mud ring formation and downhole fire……………………………………………………41
2.26 Oxygen partial pressure in distilled water………………………………………………...42
2.27 Angel’s Curves for air drilling…………………………………………………………….43
2.28 Relative permeability curves ……………………………………………………………..50
2.29 Jointed pipe system for well control………………………………………………………56
2.30 Coiled tubing system for well control……………………………………………………..57
4.1 Hollow glass spheres Vs specific gravity, Fluid formulation table A1…………………...78
4.2 Hollow glass spheres Vs specific gravity; Fluid formulation table A2…………………...78
4.2 Hollow glass spheres Vs specific gravity; Fluid formulation table A3…………………...79
4.3 Hollow glass spheres Vs specific gravity; Fluid formulation table A4…………………...79
xi
ABBREVIATIONS
UBO Underbalanced operations
UBD Underbalanced drilling
ROP Rate of penetration
BHP Bottom hole pressure
FD Formation damage
IADC International association of drilling contractors
mD Mille darcy
PI Productivity index
PBR Polished bore receptacle
TCP Tubing conveyed perforation
BOP Blow out preventer
Pu Minimum required underbalanced
SEM Scanning electron microscope
PPM Parts per million
NPT Non productive time
BHA Bottom hole assembly
SOL The percentage of solids in drilling fluid
EMW Effective mud weight in the annulus
DIA Hole diameter
ERCB Energy resources conservation board
RBOP Rotating blowout preventer
ESD Emergency shutdown
HGS Hollow glass spheres
TVDSS Total vertical depth subsea
AHD Australian height datum
xii
NOMENCLEATURE
K Permeability (mD)
Kh Formation flow capacity (m3)
h Thickness of reservoir (m)
µ Viscosity of reservoir fluid (cP)
Bo Oil formation volume factor (rb/stb of oil)
re Radius of drainage (m)
rw Radius of well (m)
L Length (m)
S Skin factor (dimensionless)
Q Flow rate (m3/s)
∆Ps Pressure drawdown (psi)
IFr Fracture index
ILC Lost circulation index
IV Vugs index
CC Cuttings concentration (%)
AV Apparent viscosity (cP)
PV Plastic viscosity (cP)
YP Yield point (lb/100ft2)
Gel0 Initial gel strength (lb/100ft2)
Gel10 Gel strength after ten minutes (lb/100ft2)
1
Chapter 1: Introduction of Underbalanced Operations
1.1 What is Underbalanced Operations?
Underbalanced operations (UB operations) have been defined as a condition generated any time
the effective circulating downhole pressure of a drilling, completion, stimulation or workover
fluid (the pressure exerted by the hydrostatic weight of the fluid column and the associated
frictional pressure drop) is less than the effective pore pressure in the formation adjacent to the
sand face [Medley G.H.et al., 1998]. It implies the use of particular equipment and techniques to
handle formation fluids entering the well and going up to the surface [Rehm B., 2002].
Underbalanced operations are used increasingly in oil field operations as well as in extraction of
coal bed methane as an alternative technique to conventional overbalanced operations to reduce
invasion near wellbore formation damage problems in producing formations. If underbalanced
operations are properly designed and executed, it can eliminate or significantly reduce formation
damage due to mud or drilled solids invasion, lost circulation, fluid entrainment and potential
adverse reaction of invaded drilling or completion fluids with the reservoir matrix or in-situ
reservoir fluids.
Underbalanced operations are not a panacea, but when properly applied, the time, productivity
and economic results can be significant. Application of a poorly planned and designed
underbalanced operations can often results in additional cost, greater formation damage, and
reduced production compared with a well-designed conventional overbalanced program.
Several studies have been focused in underbalanced operations which provide its definition,
advantages, disadvantages, case studies, fluid hydraulics and equipments used in the operations.
It is stated that underbalanced operations is a very complex process which should not be
designed and implemented on a gut feel basis, or because it appears to be the trendy approach to
a difficult problem. Underbalanced operations provide a new technological approach to resolve
2
complex reservoir management problems and results the economic completion as well as
exploitation of reserves unobtainable by any other type of currently available technology [Qutob
H. et al., 2005]. The implementation of this technology for Indian Sub-hydrostatic reservoirs will
be beneficial.
The success of UB operations is described in many case studies which results in less completion
time of the operations compared to overbalanced techniques. [R.A. Joseph, 1995]The author
describes the planning, procedures and well design to alleviate formation damage from the mud
and tool failures from high temperature in the Austin Chalk play which is one of the first fields
where underbalanced technology started gaining more acceptances in the U.S. after the great
success achieved in this field. Then, the author addressed the complications during the operation
and the equipment used. The operating parameters and results experienced for dual-lateral
horizontal wells in depleted reservoirs of Libya obtained during the UBO is discussed by the
author [Hussein S. et al., 2007]. Another study [C.P. Labat et al., 2000] shows how
underbalanced operations along the Gulf of Mexico coast brought new life to an old oil field, it
reviews how detailed safety hazard analysis and proper planning resulted in a safe and successful
operation even under the most extreme design and regulatory requirements.
[D.M. Hannegan, 2001] Hannegan provides a discussion of underbalanced operations future in
offshore applications, the author mentions that UBO is expected to revolutionalize deepwater
drilling because it is estimated that approximately 20-30% of the known world’s offshore oil and
gas resources cannot be economically developed with current drilling methods, due to the
depletion aspect as well as the deepwater limitations. The author describes about the key
situations that are typically encountered during drilling offshore and make comparisons between
conventional methods and underbalanced technology. The latest technology was reviewed to
illustrate how underbalanced drilling at offshore can be safe and sufficient to achieve a
“successful” well from multiple perspectives.
[Vieira P. et al., 2007] This study presents an expert system that can screen rock parameters
required to design an effective underbalanced operation. Once it is concluded that a particular
reservoir presents a good candidate for underbalanced technology, the system goes through
3
another screening procedure to select optimal UBO fluid. These screening procedures assess
formation damage potential, lost circulation possibilities, and assure wellbore stability. After
determining the optimal UBO fluid, the system will determine the optimal circulation rate that
assures an effective underbalanced operation.
1.2 History of Underbalanced Operations
A number of wells drilled initially in eighteenth century were drilled underbalanced. These wells
were operated with fluid column pressure in the annulus compared to the adjacent formation, but
these wells were collapsed when well flows through a permeable zones. Being an uncontrolled
flow this resulted in lost reserves. The earliest underbalanced operation patent can be traced back
to the mid-1800s.The patent was issued for using compressed air to clean out cuttings from the
bottom of a hole. Advances in the UBO continued in the exploration of hydrocarbon throughout
the mid-1900s. Then after use of mist and multiphase fluids to control downhole fires in air/gas
fluid operations started and provide a higher tolerance to water influxes. Algorithms and
equations were developed to predict the amount of gas required to clean holes and the bottom-
hole pressure resulting from circulating mixtures of fluid and gas. Advances were made in
understanding and modeling of air and multiphase systems. This technology enhancement
continued into the early nineteenth century with the first application of multiphase fluids
occurring in the 1930s.
The use of multiphase fluids, air and natural gases mixed with water or oil, became used in oil
well operations in the 1930s. Mist fluid system in underbalanced operations was first introduced
in late 1930s. Drilling underbalanced with pure air or natural gas also increased at this time.
Closed systems were started in use to capture produced fluids and improve safety. Foam came
into underbalanced operation fluid system in the 1960s because of its characteristics of better
hole-cleaning capability as compared with air and multiphase systems. UB technology was used
in limited applications before 1970s. Limitations were due to environmental problems,
particularly in gas fluid systems, where large amounts of dust were released into the atmosphere.
In single-circulation foam systems, the waste generated was a serious concern. Most wells drilled
4
underbalanced prior to 1985 were low-pressure applications. The primary aim of many of these
applications was to increase the rate of penetration (ROP) in non-productive zones.
New technologies developed in the late 1980s and through the 1990s have seen a reemergence
of UBO, with improvements in multiphase modeling capabilities and the development of higher
pressure rotating control heads. Rotating heads have been available for decades in drilling
operation industry but innovation since 1987 has brought about the development of rotating
control devices capable of withstanding up to 3,000 psi while drilling. Thus this pressure rating
of RCD has greatly expanded the applicability of underbalanced operations.
Underbalanced operations have since proven to be an effective technology in minimizing the
damage during operations in horizontal wells. The technology is being attempted throughout
South America, the Middle East, and Southeast Asia. Several UBO projects have also been
completed in Africa, Australia, and Europe. Underbalanced operations were introduced to the
offshore environment by Shell in the late 1990s.
5
Chapter 2: Literature Survey
2.1 Underbalanced Operations
The following underbalanced operations are widely in practice worldwide and they provide
the significant advantages as well.
2.1.1 Underbalanced Drilling
Underbalanced operation has the following benefits. Each of these benefits is discussed in
detail.
Fig 2.1 Conventional Overbalanced Vs Underbalanced Operations [Babajan S. et al., 2009].
Increased rate of penetration: While drilling conventionally in an overbalanced state, the
hydrostatic pressure of the drilling fluid exerts a force against the rock that is being penetrated,
6
thus requiring more energy to remove the rock. At the same time, a filter cake is deposited due to
spurt loss of drilling fluid. The bit cutters must remove this deposit along the formation being
penetrated thus the type of drill solids and total content of solids in fluid system impact
penetration rate. The sub-micron particles are the biggest culprit, not the larger particles.
Conventional drilling is a process of grinding where re-circulated drill solids that are not
removed by the solids control equipment are re-introduced into the wellbore and subjected to
regrinding. Reducing the micron size of the drilling fluid constituents into colloidal.
In UBD operation, there is no pressure on the rock to hold the solids in place and cause the
deposition of filter cake. Since the UBD fluid is free of solids, they cannot be reintroduced into
the circulation system for re-grinding. Furthermore, since the formation pressure is greater than
the wellbore pressure, less energy is expended in breaking the rock, and results in extraordinarily
high rates of penetration. Increases of penetration by a factor of ten with respect to conventional
drilling are not uncommon while drilling underbalanced as compared with conventional drilling.
A UBD Project done by The Exxon/Mobil PASE showed an average increase in penetration rate
from 6 feet per hour, when drilled conventionally, to 27 feet per hour, when drilled
underbalanced through the fractured basement production zone. Underbalanced drilling has
produced marked improvement in improvements in both ROP and overall drilling time in the
Hassi Messaoud field [Moore D.D. et al., 2004].
Improved formation evaluation: Another significant advantage of UB Operation is that it
allows continuous reservoir evaluation and characterization. While production characteristics,
such as fluid types, flow rates, and pressures can be identified, reservoir parameters such as static
pressures can also be estimated while drilling underbalanced. Further, formation fractures and
the resulting flow/pressures may be identified during UBO. Underbalanced conditions allow
formation fluids to flow into the wellbore under a negative pressure differential, and therefore
allow detection at the surface that would otherwise be masked by an overbalanced state. A
marked increase in flow rate from the well detects the presence of a formation. When
conventional fluids are used, there are several factors that need to be considered to ensure that
subsurface geological information can be properly evaluated, such as; salinity of the mud, filtrate
7
invasion depth, pressure-induced fractures caused by the fluid and type-base fluid (chemistry) of
the system.
The rock cuttings during drilling operation or geological specimen are subjected to mechanical
fluid agitation during its travel up the wellbore. This action, in conjunction with the chemical
effects of the drilling fluid results in sample deterioration. Because overbalanced conditions
prevent inflow from the formation, a possible zone of consideration could be overlooked. During
underbalanced drilling, all of the above drilling fluid characteristics disappear.
Increased productivity/ reduced formation damage: Increased productivity from a reservoir is
perhaps the most important advantage of UB Operations. Conventional techniques that employ
weighted muds can create a large overbalance pressure between the wellbore and reservoir. This
overbalance can result in the invasion of contaminants like drilled solids and foreign fluids into
the formation. Subsequently, this overbalance causes significant reservoir impairment, and
reduced productivity, thus requiring further costly stimulation jobs. By the definition of
underbalanced operations, these problems are prevented if the operation stays in an
underbalanced state. If the drilling fluid causes no damage, as is usually the case with
underbalanced drilling, the probability of stimulation is reduced or eleminated.
The remediation of formation damage requires costly well stimulation techniques such as
acidizing and fracturing. Formation damage is of particular concern when drilling high-angle and
horizontal wells where reservoirs are exposed to an overbalance of drilling fluids and solids for a
considerable length of time. By employing underbalanced drilling operation techniques, fluid or
solid invasion can be minimized, or in some cases eliminated, thereby reducing formation
damage and maximizing well productivity. The extent of formation damage is measured through
skin factor.
The productivity index for a vertical well is:
Eq. (2.1)
8
The productivity index for a horizontal well is:
Eq. (2.2)
The relation between PI and drawdown is:
Eq. (2.3)
During underbalanced operation generally filter cake does not buildup, due to negligible drill
solid accumulation. Therefore, depth of fluid penetration may be deeper if overbalanced
conditions occur during underbalanced operation. If the formation is sensitive to damage from
the liquid phase, damage can be more severe than that caused by conventional procedure.
Therefore, careful planning is necessary while operating underbalanced.
Fluid compatibility as well as proper modeling of down hole pressure before underbalanced
operation is important to prevent production hindrance. If modeling is not conducted, there is a
strong possibility for occurrence overbalanced conditions in the reservoir. Figure 2.2 illustrates
pseudo-steady-state depletion condition near well bore region during underbalanced operation.
Figure 2.3 shows the invasion mechanism during reduced underbalanced/overbalanced
condition. The gravity induced invasion in underbalanced drilling operations through macro
fractures in horizontal well operations is depicted in Figure 2.4.
9
Fig. 2.2 Pseudo-steady-state depletion condition near well bore region during underbalanced
drilling condition
Fig 2.3 Invasion during an overbalanced/reduced underbalanced condition phase in the near
wellbore depletion region
10
Fig 2.4.Source: The JCPT September 98, volume 37, page 48.
Minimized loss of circulation: Loss of circulation is defined as the loss of mud in quantity to
the formation during any oil field operation. This loss occurs when the hydrostatic pressure of
the drilling fluid exceeds the fracture gradient of the formation. The openings in the formation
are about three times as large as the largest particles in the fluid used for operations. Due to the
nature of conventional fluids, loss of circulation is a constant risk. As long as an underbalanced
state is maintained, there is no loss in circulation. However, it may happen in special cases, such
as water flows, due to the formation of mud rings and subsequent packing off or due to poor hole
cleaning of the formation.
11
Fig 2.5 Fluid loss and solid loss in overbalanced/underbalanced operations [Bennion D.B., 2002]
In severely depleted reservoirs with high permeability and deepwater marine risers, loss of
circulation is a serious problem with overbalanced systems. In these cases, the ability to remove
12
cutting solids from the wellbore is lost. If pore spaces are not large enough to take the cutting
solids, solid buildup takes place and finally results in the mechanical sticking of the drill string.
For this reason, severely depleted fields or under-pressured reservoirs cannot be operated with
conventional fluids. The Exxon/Mobil ARUN field is an example of how to drill a severely
depleted formation underbalanced. This field could not have been drilled conventionally.
Elimination of differential sticking: During the oil field operations when the drill string is in
the center within a wellbore, the hydrostatic pressure exerted on the drill string is equal in all
directions. But when the drill string comes in contact with the wall cake opposite a permeable
formation zone of lesser pore pressure, the drill string can get stuck to the wall cake against the
wall of the hole due to pressure difference. The hydraulic force then acts across the isolated
portion of the drill string squeezing of wall cake occurs, holding the string in place. For every
square inch isolated by the cake, there is a confining force of hydrostatic differential pressure
known as the mechanism of differential sticking. In conventional operation, all the necessary
ingredients are always present, and always a possibility of differential sticking. With
underbalanced drilling operation, there is no hydrostatic pressure differential to the formation
and no filter cake. It is impossible to get differentially stuck while drilling underbalanced.
Increased bit life: Due to the friction at the bit a considerable amount of heat is generated
between the drill strings and wellbore. The circulating drilling fluid transports heat away from
these frictional regimes through convection. It should be noted that the solids in the drilling fluid
contribute to additional frictional heat generated at the bit; the higher the inert solid content, the
more heat that is generated. Transportation of heat away from the bit is more efficient in
underbalanced operations because there is no additional force holding the formation in place
(less frictional force), the bit does less work to cut the formation. By using UBD operation, the
fraction of retained solids is maintained at a minimum value, depending if a one-way process is
used or a closed-loop system is employed. UBD also requires less weight on the bit to obtain
optimum ROP. In this way underbalanced operations improves bit life.
13
Reduction of expensive drilling fluid: Conventional drilling fluids are having many costly
additives that are added to control fluid properties such as viscosity and fluid loss. As in the case
of loss circulation zones, additional chemicals and sized particles are added to control losses.
These fluid systems may be very costly. Simple fluids such as, KCl water or produced oil are
typically used in UBO, costly drilling fluid programs can be eliminated for the hole section
drilled in an underbalanced state. Significant expenditure savings may be realized by not losing
expensive drilling fluids to the formation. During conventional operation, the well is designed
such that reservoir fluids do not enter the wellbore during drilling operations. If reservoir fluids
enter the wellbore, the system relies on personnel to recognize the inflow and control the well
pressures correctly to remove the formation fluids from the system. Most blowouts occur, not
because of poor engineering or planning, but due to failure of personnel to correctly recognize an
inflow and properly handle it.
Improved safety and reduced environmental impact: Conventional oil field operational fluids
are heterogeneous mixtures of organic, inorganic, and inert substances. The composition is
variable that dictates the level of toxicity of the fluid. The efficiency of the solids removal
equipment is necessary to continue the dilution to maintain a usable fluid. As an example, for
every incorporated barrel of drilled solids a nineteen-barrel dilution is required to maintain a
five-percent total active drill solid content that is considered to be the upper limit in a water-
based drilling fluid. While UBO requires naturally occurring fluids such as gas and water, when
gas, mist, and gasified fluid systems are applied. In some cases a corrosion inhibitor is required
or it may be coated on the drill-string or in both forms. Drilling with foam fluid system requires
the addition of surfactants and defoamers. The chemical concentration of the additives are very
low (ppm) and normally of a non-toxic nature. The majority of surfactants used for foaming
agents are biodegradable so that having less impact on environment. As gas is the larger
component, very little waste is generated as compared to conventional oil field operational
fluids. Therefore disposal problems are minimized when considering volume and toxicity. A
properly designed UBO system is less reliant on personnel recognizing an accidental event. The
system is designed to safely handle a continuous inflow from the formation. Underbalanced
14
operation systems also give a continuous positive BHP reading throughout the operation leads in
to improved safety.
At present Petroleum Development Oman a joint venture of Shell is carrying on underbalanced
drilling programs for more complex UBD multi-lateral in south Omani fields. In the first or pilot
phase, PDO drilled 14 wells underbalanced in the Nimr field in Southern Oman.
Future of Underbalanced Operations is a young progressing game-changing technology
developed in response to the oil & gas industry needs to control project cost while enhancing
productivity. Underbalanced operation challenges the tradition-bound operating procedures the
industry had used for more than half a century. Even though, underbalanced operations (UBO) is
getting more and more popular in the world. The main reason is that its advantages can meet
requirements of current world petroleum exploration and production situation. The world Oil &
Gas industry quickly saw the advantages of underbalanced drilling, and the technology is now
employed where the geology and reservoir are suitable. Soon, UB operations will become the
standard field development technique, both onshore and offshore [Babajan S. et al., 2009].
2.1.2 Underbalanced perforation
Every cased well must be perforated so that fluids can flow from subsurface zones or be injected
down hole. Optimizing production or injection requires careful design, pre-job planning and field
implementation to obtain clean conductive perforation that extend beyond formation damage into
unaltered reservoir rock. During, explosive perforating it pulverizes formation rock grains, which
causes a low permeability crushed zone in the formation and creating the strength for migration
of fine particles. This process also leaves some detonation debris inside the perforated pathway.
Underbalanced pressure is the most widely accepted technique for optimizing perforated
completions. In this method wellbore pressure before perforating is less than the adjacent
formation pressure before perforating. The study suggests that surge flow from a reduction in
near-wellbore pore pressure mitigates crushed –zone damage and sweeps some or all of the
debris from the perforated tunnels.
15
In 1970s, completion engineers recognized the potential of underbalanced pressure for improving
perforated completions. During the 1980s and 1990s researches confirmed that a high static
pressure differential between wellbore and formation often yielded more effective perforations.
The study concluded that rapid fluid influx was responsible for perforation cleanup and
recommended for general underbalanced perforating criteria [Johnson A.A. et al., 2003].
Schlumberger scientists analyzed transient perforating pressure during laboratory tests and found
that static underbalance alone does not ensure clean perforations. Results indicate that previously
neglected fluctuations in wellbore pressure immediately after shaped charges detonate, not the
initial pressure differential, actually govern perforation cleanup. This improved understanding of
dynamic wellbore pressure to develop the patented PURE Perforating for Ultimate Reservoir
Exploitation process [Brooks J.E. et al., 2003]. In 1989, researchers calculated underbalanced
pressures in gas wells based on sand- production potential determined from sonic logs [Crawford
H.R., 1989]. The author combined new data with data from the prior Amoco project to develop
equations for the minimum underbalance required to eliminate the need for acid stimulation
[Tariq S.M., 1990]. Another study indicates that flow and surging after perforating are less
critical in damage removal, but might sweep debris and fines into the wellbore [Hsia T.Y. et al.,
1991].
Dynamic underbalanced perforating is applied by Anadarko Petroleum Corporation in the Brady
gas field of Wyoming. In addition to high concentrations of hydrogen sulfide, the weber
formation comprises about 600ft (183m) of inter-bedded sand, shale and dolomite stringers.
Permeability ranges from 0.5 to 1.5 mD with a current reservoir pressure of less than 2800 psi
(19.3 MPa) at 14000ft (4267m).The 18 existing well completions in this field used wireline-
conveyed guns and static overbalanced perforating techniques, which resulted in minimal flow.
Anadarko performed perforation- wash treatments using hydrochloric-hydrofluoric acid to make
a commercial production. After acidizing, these wells typically flowed 1to5 MMcf/D (28640 to
143200 cubic meter/day). Three of the wells required fracture stimulations. Anadarko chose the
PURE perforating technique to recomplete the Brady 38 W well in an upper section of the Weber
formation [Stutz H.L. et al., 2004].
16
Dynamic underbalanced perforating provides a successful completion without additional
stimulation. A pre job NODAL production system analysis for the same indicated that the well
should produce about 3.85MMcf/D (110,260 cubic meter/day) without any formation damage.
However, completion skin enhanced 20 after perforating overbalanced and before acidizing. The
PURE technique achieved a sustained flow rate of 5.2MMcf/D (148,930 cubic meter/day) just
hours after perforating with an initial 3250-psi (22.4-MPa) overbalance .The estimated
perforation skin was negative 1.17, or slightly stimulated. Later in 2002, Anadarko drilled the
56W well after the success of the Brady 38W recompletion convinced Anadarko to use the
PURE technique again. Both wells used permanent TCP completions. An innovative completion
method has been used to complete two oil fields in the central and northern areas of the North
Sea. The Skua field was a single well development high-pressure/high temperature (HP/HT) with
a reservoir pressure of 9350 psi and reservoir temperature of 307°F. The Penguin field is a 4-well
development with an average reservoir pressure of 8000 psi and reservoir temperature of 265°F.
Each sub-sea well required a long horizontal section to maximize production from the tight,
highly compartmentalized reservoirs [Martin B. et al., 2002].
A new gun deployment system based on production packer technology is chosen because it
appears to meet all the well requirements. The polished bore receptacle (PBR) and hydraulic set
permanent packer has been designed with the guns hung off the seal assembly of the PBR. The
system also allows the tubing conveyed perforating (TCP) guns to recover if they failed to fire or
malfunction. The Skua and Penguin wells are completed with a fully cemented liner. By using
this completion method and TCP guns, the wells are successfully completed and perforated
underbalanced in a single trip. A slickline plug is set in the nipple below packer, and the tubing
pressure is tested to 5000 psi to set the packer. After the retrieving the plug, the packer is tested
from above and below. Tubing hanger plugs is set, and the blowout preventer (BOP) stack is
retrieved. The Xmas tree is run and tested, and the tubing-hanger plug is retrieved. The TCP gun
firing head is deployed on slickline, and the well is perforated at 500-psi underbalance with time-
delay initiation [Martin B. et al., 2002].
17
The Etive/Rannoch reservoirs are located at a depth of approximately 11,400 to 11,500 ft
TVDSS, 14150 to 20300 ft AHD and are accessed with a 1200 to 4600 ft horizontal section. The
average reservoir pressure is 8000 psi and reservoir temperature is 265° F. The wells are shut in
until all four wells are completed. The production is by natural depletion drive via a flow line to
the platform. Optimum perforating performance is achieved by subjecting the entire interval to
an underbalance. The impact for one of the wells has been modeled for 5 mD and 10mD for 20-
in. penetration. The result shows the benefits of the underbalance, when the permeability is low,
the optimum underbalance of approximately 2000 psi. is achieved [Martin B. et al., 2002].
The following underbalanced pressure differential has been recommended by [Crawford H.R.,
1989] to achieve “clean” perforations in oil wells:
Eq. 2.4 2.1.3 Underbalanced Workover
If a well is drilled underbalanced then killed and completed overbalanced .the original purpose of
drilling underbalance is defeated .Ideally ,the well must be completed underbalance to prevent
/minimize formation damage , thereby maximizing productivity .
Snubbing system: If tripping is to be conducted underbalanced; a snubbing system will be
installed on top of the rotating control head system. The current systems used for offshore
workover operations are so called rig assist snubbing systems. A jack with a 10ft stroke is used
to push pipe into the hole or to trip pipe out of the hole. Once the weight of the string exceeds the
upward force of the well, the snubbing system is switched to standby and the pipe is tripped in
the hole using the drawworks. The ability to install a snubbing system below the rig floor allows
the rig floor to be used in the conventional drilling way. The snubbing system is so called rig
assist unit. This unit needs the rig drawworks to pull and run pipe. It is designed to deal only
with light pipe situations.
18
Fig. 2.6 Snubbing System (Source: www.istockphoto.com/file_closeup/industry/heavy-
industry/4434253)
Following are the method adopted for completions:
Open hole completion: It is a commonplace practice, presently to have underbalanced
completions in the form of simple openhole / barefoot completions, where producing interval is
left uncased openhole completions offer advantages of simplicity, low cost and less maintenance.
However, the openhole completion method is limited to well consolidated formations.
These disadvantages are as long term borehole stability is questionable and the well may get
impaired by the production of unwanted fluids (gas or water). The final completion string is
lowered in the openhole by one of the following methods:
a) After balancing the reservoir pressure with a compatible, clean solids free completion fluid or
with formation fluids which is allowed to flow into wellbore.
b) Snubbing unit can be deployed to run in jointed completion string, under pressure without
subducing the well.
19
c) Well can be completed with coiled tubing as final completion string, using coiled tubing unit.
Cased hole completion: In most cases liner / casing is lowered after subduing the well with
clean fluids. Alternatively, the following techniques can be adapted to lower liner/casing,
underbalanced conditions:
a) Snubbing unit can be used to lower liner /casing in under pressure, with out killing the well.
However main disadvantage compared to conventional drilling rig, is slower tripping speed.
b) Downhole lubricator: This technique involves the use of inflatable bridge plug as a temporary
barrier to prevent flow. After drilling open hole section of the well underbalanced , an inflatable
bridge plug is the run (on electric or coiled tubing) and set in the intermediate casing at a depth
that will allow accommodating the complete liner string above it. The intermediate casing now
acts as a subsurface lubricator; the liner is then run into the hole with a standard type J-overshot
attached to the bottom. After liner string is run in, the rotating BOP is closed around the running
string .When the liner comes in contact with the inflatable bridge plug, the inflatable bridge plug
is engaged and released by the overshot. After packing elements have relaxed, the liner is run to
the depth. The inflatable bridge plug and the overshot are left in hole. In the above two cases, if
casing /liner is required to be cemented, the well would need to be subdued, thereby sacrificing
underbalanced conditions. Foam cementation technique may be adopted to minimize formation
damage.
20
2.2 Underbalanced Fluid System and Techniques
2.2.1 Selection of an underbalance operations fluid
Selection of an underbalanced fluid operation is performed on the basis of Reservoir
characteristics like formation type (such as sand, limestone, and clay), pore pressure,
characteristics of reservoir fluids, reservoir permeability, rock matrix porosity, well geometry
includes directional characteristics and hole size, environmental issues are also taken care during
the selection of UB fluids for cuttings disposal and disposal of fluids because the early
production during the operation, well test data, production history & drilling reports of the offset
wells are also taken in to knowledge prior for selecting the fluid
2.2.2 Underbalanced operational fluid design aspects
The primary concern for underbalanced operational fluid design includes as like the fluid design
for conventionally operated wells, which are for bringing the cuttings to surface, cooling and
lubrication of the bottom hole assembly and to control the bottom hole pressure. UBO fluid
system design is one of the most overlooked parts of underbalanced projects. While designing an
underbalanced fluid system the impact on the desired equivalent circulating density must be
considered. The equivalent circulation density is a combination of annular fluid density,
frictional pressure loss in the annulus, and surface chock pressure. The design must result in a
pressure that is below the formation pressure without creating any wellbore stability or excess
production during the operation. Compatibility between the components of the fluid system to
the rock matrix components of the formation, the fluid system compatibility with produced fluids
incompatibility will lead into entire objective of underbalanced operations.
Hole cleaning is a very critical factor in designing the fluid for any underbalanced wells. Most
underbalanced fluid systems prefer the velocity of the fluids to the viscosity for cleaning the
hole. Cuttings carrying capacity is better in foam fluids compared to the pure gaseous fluids.
21
Temperature stability of fluid constituents must also be considered in designing an
underbalanced fluid system. Many of the chemicals like surfactants and viscofying agents may
break down with high temperatures or its effectiveness is negligible. It will also affect the density
of the fluids used in designing the system. With increase of Temperature density of used
chemicals falls down.
Corrosion factor is also plays significant role while designing a fluid for underbalanced
operations. The injected fluids should contain the anti corrosive chemicals or the equipment and
other down hole assemblies should contain the protective film layer during gaseous operations.
Due to the production during operations the H2S and other gases improves the corrosion rate
which leads to the sulfide stress cracking of down hole equipment’s materials. The efficiency of
the downhole equipment should not be decrease when using the multiphase fluids. The fluid with
elastomers can affect the functionality and longevity of the mud motors and downhole measuring
devices. Downhole tools (such as tools with no elastomers) should be selected that will not be
effected by the fluid. The fluid selected should be able to transmit data from downhole. Gas is a
compressible fluid; if gas is used in the fluid system, it may dampen or eliminate any signal
transmitted downhole.
Health, safety and environmental must be considered in selecting an underbalanced fluid system.
The points in consideration are handling of fluid at surface and disposal of return fluids,
produced fluids and solids. The return fluid may contain various toxic contaminants.
22
2.2.3 Fluid system selection
Underbalanced fluid systems have been categorized by the IADC by the following system:
Table 1- IADC fluid classification
Fluid System Specific Gravity Equivalent Mud Weight (ppg)
Classification Level
Gas Drilling 0-0.02 0-0.02 1 Mist Drilling 0.02-0.07 0.2-0.6 2 Foam Drilling 0.07-0.6 0.6-5 3 Gasified Liquid drilling
0.55-0.9 4.5-7.5 4
Liquid drilling 0.8 and >0.8 6.9 and >6.9 5
The fluid system selected for a particular project is dependent on the desired BHP, tolerance to
water influx, hole cleaning, cost and environmental consideration. Fluid system used in
underbalanced operations mentioned in Table 1 will be discussed in details in the next section.
2.2.3.1 Gasified (aerated) fluid operations
In this type of fluid operations gas and liquid phases have been intentionally mixed to decrease
the density of the fluid. The gas (mostly air or nitrogen) is introduced into the fluid at the surface
before it enters the drill pipe or it is introduced downhole into the liquid at the annulus. For
safety concern natural gas (primarily methane) has also been used to gasify fluids in place of air
or nitrogen. As per the well fluid design as well as feasibility aspects any liquid (oil, water/salty
water etc.) may be used for the operation.
In general., the selected fluid system is easily separated into its constituent phases the system
reaches the surface once. Various flow regimes is shown below for a horizontal well operation.
23
Fig.2.7 Various flow regimes in horizontal wells during gasified (aerated) fluid operation
[Ghalambor A. et al., 2004].
Gasified fluids are optimized to clean the hole and maintain the BHP below the pore pressure
and above the wellbore-stability pressure. Proper hole cleaning, pressure maintenance as well as
keeping the entire fluid system together are mandatory requirement for successful underbalanced
operation. Viscosities, gel strength, velocity act and other forces act in the annulus to maintain
fluid stability with gasified fluids. In UB operations, the pressure will make the greatest impact
on the gas properties. Because of the compressibility of the gas phase, the gas content of the
fluid, as measured by volume, changes with temperature and pressure.
One fact is that if the gas/liquid mixture reaches about 5,000 ft of vertical depth (it may vary
with other pressure and downhole conditions), no significant compression takes place. This depth
is called “depth of effective compression” and is particular for each gas. The introduction of gas
24
to a system below the depth of effective compression does not help in the UB operation. Gas
may be injected through other ways like parasite string, concentric string or by drill pipe.
Fig.2.8 Compression of the fluid at different depths in a wellbore decreases hydrostatic pressure
disproportionately, after [Medley G.H.et al., 1998]
The amount of gas in the fluid at any point, measured by volume, can be expressed as foam
quality or as fluid ratio. Ratio R (% by volume of gas) is the ratio of gas to liquid unit under
existing conditions of pressure and temperature. A good rule of thumb for a gasified fluid is to
try to maintain the ratio through the system at 5:1 to 40:1 (i.e., 80 %< foam quality < 97.5 %).
Merits of Gasified System: The gasified system has various merits which include avoiding lost
circulation, to reduce formation damage, to avoid differential sticking and, to increase the rate of
penetration. Lost circulation is the main reason for using gasified fluids (Fig.2.9). The
introduction of gas into the system makes the fluid column lighter by replacing some of the mud
with gas. In such case the flow is from lost circulation zones to within the well bore.
25
Fig. 2.9 Gasified mud injection reduces BHP, after [Rehm B., 2002].
If the hydrostatic pressure of mud in the wellbore is greater than formation pressure, the mud
invades in to the reservoir pores reduces the permeability of reservoir rock near the wellbore
(Fig. 2.10).Underbalanced operations allow fluids from the reservoir to flow into the borehole.
Gasified systems prevent filter cake and filtrates from entering the formation.
Fig.2.10 Formation damage reduction in gasified systems (a) Hydrostatic overbalance leads to
formation damage. (b) Reduction in pressure by gas injection prevents formation damage, after
[Rehm B., 2002].
26
When the fluid column exerts more pressure than the formation fluid then due to the differential
pressure sticking can occur. Due to the higher pressure the pipe tends to move towards the
formation rather than being it in the center of well bore and finally got stuck up. (Fig.2.11). If the
well is operated underbalanced, flow is from the formation into the wellbore. Thus it does not
build up filter cake so that eliminates the possibility of differential sticking.
Fig.2.11 Differential sticking results from higher pressure exerted by mud than the formation
fluids, after [Rehm B., 2002].
Increased rate of penetration is also a merit of gasified fluid operation. ROP depends on many
factors like bit weight, rotary speed, jet impact, hydraulic horsepower, rock strength, and chip
hold-down force. When fluid column pressure is greater than the pore pressure in the rock, the
overbalance holds the rock chip cut by the bit in the wellbore. With gasified fluid column during
UBO, the pore pressure is greater than mud-column pressure. This lighter column allows the
formation cuttings to flow up the system. This leads in to easy and quick removal of cuttings and
results in higher rate of penetration.
27
Fig 2.12 ROP decreases as BHP increases, after [Rehm B., 2002].
Barriers in the gasified system: The biggest problem with a gasified system is the
discontinuous nature of the operations. Whenever any tripping or any problem within the
wellbore happens due to some technical reasons, the gasified fluid begins to separate, mainly in
the annulus. Once the circulation is re-established, the resultant slugs of liquid without any gas
can exert higher hydrostatic pressure downhole in the formation that may exceed the reservoir
pore pressure (Fig.2.13).
Fig 2.13: Inconsistent pressure in UBO, after [Medley G.H.et al., 1998].
28
Several techniques are used to overcome this problem due to the slug effect, creating gas slugs to
counteract them. The formation will initially feel the effects of only the gas-phase hydrostatic
pressure when circulation is restarted (Fig.2.14).
Fig.2.14 BHP remains much more constant with gas circulation before connections, after
[Medley G.H.et al., 1998]
Special equipment has been designed to carry a gasified fluid in the annulus or in a portion of the
drillstring and part of the annulus, rather than circulating the gas phase all the way from the
surface to total depth and back again [Medley G.H.et al., 1998].
29
Parasite strings: It is a permanent or temporary tubular string connected to one of the casing
strings near the bottom (but above the float collar) in the wellbore. A parasite string will allow
for the introduction of gas into the annulus between the two (Fig. 2.15). Gas is injected into the
tubing string at the surface and enters in the fluid system near the bottom of the surface pipe at a
depth 2500ft -3000ft.
Fig.2.15 Parasite tubing string, after [Medley G.H.et al., 1998]
Concentric string: It is like as a casing string which is run into a wellbore and temporary hung
off in a special wellhead, it is concentric to the casing (Fig.2.16).Gas is injected into the annulus
between the two strings, gas comes out from the bottom part of the concentric string. The point is
termed as injection point.
30
Fig. 2.16 Concentric casing string, after [Rehm B., 2002].
2.2.3.2 Foam fluid operations
Foam systems are created when water and gas are mixed with a surfactant. The structure of foam
is made up of bubbles of gas surrounded by a liquid film. A surfactant or foaming agent, in the
liquid phase stabilizes the films that form the bubble walls, which allow the foam structure to
persist. Foam has normally composition of about 97% gas and only about 3% liquid at surface
conditions (Fig.2.17).
31
Fig. 2.17 Foam is made of bubbles that are surrounded by a liquid film, after [Rehm B., 2002].
Two basic types of foam are used in UB operations [Rehm B., 2002 and Medley G.H.et
al.,1998]. Stable foam is made off a surfactant as a binder and stiff foam. Stiff foam is built by
using surfactant, bentonite, polymers and using any gas. Air is most frequently used in foam
fluid operations. Other gases, such as nitrogen, natural gas, or carbon dioxide, can be also used
instead of air. Occurrence of hydrogen sulfide or any other low Ph acid gases makes counter
effect on the foam stability. The most common used fluid is fresh water. Freshwater-based foam
will be feasible. The only way freshwater will cause foam to deteriorate is when the foam quality
is very low. Brine can also be used to generate foam with specific surfactants. Oil is seldom used
as the base liquid for foam fluid. The hydrocarbon contaminants decrease the effectiveness of
foam.
Cutting carrying capacity as well as hole cleaning is better with foam fluids compared to the
other fluid system. The high effective viscosity of foam provides the good transportation mode to
the cuttings from down hole to the surface. Any size cutting generated at the bit can be brought
out of the hole with foam. Even when circulation stops, the foam will continue to expand for a
while and carry on lifting the cuttings.
Bubbles
Liquid films
32
Fig. 2.18 Large cutting cleaning in foam drilling operations, after [Medley G.H.et al., 1998].
Foam Quality:
Quality of foam is defined by the ratio of gas to liquid. Quality of foam is the percentage of gas
in the foam at a specific depth or pressure. For example, 70% quality foam contains 70% gas by
volume, while 85% quality foam contains 85% gas by volume. Foam with a quality of 65%
means it is 65% gas and 35 % water. The same foam deeper in the hole might have a quality of
only 60% because increased pressure compresses the gas. Therefore, foam quality varies with
hole depth.
As the quality of the foam (ratio of gas to liquid) increases, the carrying capacity of foam also
increases. Good foam has foam quality between 55% and 96%. This keeps the foam stable. If the
foam quality exceeds about 97%, the fluid undergoes a two-phase fluid having gas as the
continuous phase. This is called a mist fluid (Fig.2.19).
Large cuttings
33
Fig.2.19 Difference in phases between foam and a mist system, after [Medley G.H.et al., 1998].
Foam composition: Foam is usually made up locally because what works in a particular well in
one area may not work in another. Once the optimum ratios of gas and liquid have been decided
on, the elements that must be mixed together to form the liquid phase should be determined. The
other constituents are caustic soda, soda ash, foaming agent and corrosion inhibitor.
Advantages of foam fluid operation: The advantages with the foam fluid operations are generally
the primary benefits with the underbalanced operations. Foam systems are among the best
underbalanced lost-circulation fluids. As being a light fluid, foam has a major advantage in
avoiding lost circulation (Fig.2.20). As the flow is from the formation to the wellbore due to less
BHP. The small bubbles of the foam system that enter in to the lost circulation zone, slightly
expand, and plug the zone. Reduction of lost circulation is enhanced without creating any
damage to the reservoir as there is not any solid plugging
Foam fluid operation avoids the reservoir damage. Almost every conventional fluid system
damages the reservoir near the wellbore. The best way of performing the operation is when flow
comes from the reservoir into the borehole and does not push filter cake solids and filtrate into
the formation. For reservoir protection the casing may set up at the upper part and then drill the
reservoir UB with a clear, non-damaging fluid or non-invasive foam.
34
Fig.2.20 Foams reduces BHP, avoiding lost circulation, after [Rehm B., 2002].
Fig. 2.21 Foams minimize reservoir damage because flow is from the reservoir to the wellbore,
after [Rehm B., 2002].
Foam fluid system avoids differential sticking. Differential sticking occurs when the drill pipe or
drill collars lie against the side of the hole and pressure in the hole is higher than pressure in the
35
formation. The possibility of sticking in deviated holes is more. If the pipe becomes stationary
for any reason, it can become stuck. Forces required for removal of sticking depends on the
contact area of the pipe with the filter cake. The solutions to differential sticking include the use
of oil mud. The best solution is not to allow differential sticking conditions to exist. If the well is
operated underbalanced, flow is from the formation into the wellbore and filter cake and filtrate
do not exist. Foam contains very less constituents. The constituents have not any such properties
which cause any stuck pipe phenomenon (Fig.2.22).
Fig.2.22 In UB Operations with foam, reservoir pressure is higher than wellbore pressure. Thus,
differential pressure sticking cannot occur, after [Rehm B., 2002].
Foam fluid operation increases drilling rate. Generally, the drilling rate increases as hydrostatic
pressure decreases. The foams can provide faster overall penetration rates. Cuttings and fluid
removal will be more efficient, allowing higher ROP. A major effect on drilling rate is cuttings
removal, which is determined by chip hold-down force. In UBO pore pressure is greater than
36
fluid column pressure. The lighter mud column pressure allows the bit cuttings to explode under
the bit, and the lifting characteristic of the foam quickly sweeps the bit cuttings away.
Hole-cleaning problems are minimized by using the foam fluid system. The system has excellant
cuttings transportation property. Foam lifts the cuttings and carries them with very little slip.
Foam can clean a hole with small liquid volumes and low annular velocities. The foam system
also holds cuttings in suspension when circulation is stopped.
Foam fluid system has its own merits which have been described earlier. The system has also
few limitations which are hindrances in making it successful operations among all the fluid
systems.
Corrosion may be controlled is rather than being a permanent limitation to foam fluid operations.
A corrosion inhibitor is used to the injected liquid to control the corrosion rate; slow corrosion of
downhole equipment is permissible until its function should not be affected by any formation
fluid inflows that might occur. Corrosion problems with foam increase with increasing depth
with increase in temperature.
Wellbore instability is another limitation with foam fluid operations. The instability may be
cause by mechanical or chemical reasons. To overcome this limitation foam should have a lower
tendency to erode the borehole wall. Erosion is due to reduction in shear stress of the well bore
boundary naturally fractured formations. This occurs because foams are efficient at cuttings
transport at low annular velocities. Foam used for the operation should have high viscosity at low
shear rate. The foam fluids are having higher bore hole pressure in comparison to created by gas
or mist fluids. This will decrease the difference between circumferential stress and borehole
pressure without providing the support to wellbore so this will lead to mechanical instability in
weak rock. During the foam fluid operation formation fluid and formation water influx happens.
They alter the foam composition and leads to chemical instability of the system.
Downhole fires occurrence with this system are also a limitation. The limitation is due to the
separation of air and foam in horizontal or deviated wells. As low annular velocities are used in
37
foam fluid operations, gravity induced separation may occur forming air as a continuous phase at
the upper part of the hole. Which increases the possibility of down hole fire in such conditions.
Foam disposal is also a major concern with using foam fluid operations. The cost of handling
and disposing the foams is an extra addition with this fluid system. There are several developed
methods of defoaming systems. Even if the foam, water, and chemicals are not reused, these
defoaming methods are termed recyclable foam systems.
2.2.3.3 Mist fluid operations
Mist Fluid System Operations refers to those operations where the drilling fluid is a combination
of gas with a small ratio of water. For a mist system, the gas is the continuous fluid with liquid
bubbles dispersed in the gas. Mist is formed if the liquid volume fraction is less than 2.5% water
at the current pressure and temperature (Fig.2.23).
Fig.2.23 Mist formed by water drops in suspension.
The mist fluid operation is performed by creating the mist which consists; a small quantity of
water treated with a foaming agent is injected into the compressed air flow. Any produced water
should also disperse in to mist. Mist fluid move at approximately the same velocity as the gas. If
an important water inflow is encountered, the liquid volume fraction downhole can increase to a
38
level where foam is formed. During mist operations hydraulics is important for cleaning the hole.
High velocities of gas is required for proper hole cleaning because in mist flow gas have the
continuous phase which is less efficient for lifting cuttings compared to liquid as continuous
phase. For fluids to lift cuttings have some viscosity compared to lesser viscosity. For better hole
cleaning the volume rate of gas circulated through a wellbore is generally based upon three hole-
cleaning criteria.
Minimum energy criteria depicts that a certain minimum kinetic energy is required to lift a
cutting of a given size [Ghalambor A. et al., 2004]. The same minimum kinetic energy must be
maintained throughout the wellbore to lift the cuttings out of the hole. This is simple among all
methods implemented for lifting the cuttings. Terminal velocity criteria explains that the
minimum velocity of gas has to be greater than the terminal velocity (or slip velocity) of the
cuttings to bring them out [Ghalambor A. et al., 2004]. This method describes only the minimum
rate of gas required to lift the cuttings. Minimum BHP criteria explain that the maximum hole
cleaning and the maximum penetration rate can be achieved when the BHP is minimum
[Ghalambor A. et al., 2004].
Although mist fluid operations have various advantages yet it has its own particular limitations.
These limitations are like air compression requirement. Mist fluid operation requires air injection
rates 30% higher than as required for dry-air operations at the same depth and penetration rate.
The higher air requirement leads in more work for compressors so that high fuel consumption for
the additional work by compressor. Waste water and other additives disposal give additional cost
to the whole operation.
In mist fluid operations the gas flow rate tends to be higher and the density of the circulation
fluid is greater than it is for dry-air drilling. These factors increase the potential for wellbore
erosion if weak or poorly consolidated formations are penetrated. Chemical instability of
wellbore is another limitation with the mist fluid operation. Instability occurs when water-
sensitive shales are encountered during the aqueous phase in the mist fluid. Hydration and
swelling of shales creates irregular cutting and create hindrance in the operations. Swelling may
39
be reduced by the addition of salts, such as potassium chloride (KCl), to the injected water
[Economides M. J. et al., 2000].
There is a significant possibility of corrosion to downhole equipment during mist fluid
operations. The high oxygen concentration present in the aqueous phase promotes corrosion of
exposed steel of downhole equipment. An appropriate corrosion inhibitor is added to the injected
water to prevent the corrosion possibility.
2.2.3.4 Air/Gas fluid operations
Air or gas was the first fluid used for underbalanced operations. Air, nitrogen, or natural gas
(preferably methane) is used in UBD. Underbalanced drilling operation with air injection is
common while there is always possibility of significant corrosion and downhole fires. To avoid
these problems nitrogen has become the gas of choice for UBO.
Advantages to Air/Gas fluid operations: Air/gas fluid operations have advantages similar to
several other UBO [Medley G.H.et al., 1998 and R.A. Joseph, 1995]. Advantages are
i. Increase ROP
ii. Increased bit life
iii. Minimal formation damage.
iv. No hidden productive zones
v. Early production
vi. Better production from openhole completions
vii. Reduction of lost circulation and elimination of pipe sticking possibility.
Air/gas fluid operations has three main limitations which are water inflows, wellbore instability,
and downhole fires. The flow of water from the formation to within the wellbore during
operation is termed as the water influx. Water invasion causes the cuttings to ball up the bit and
form mud rings on the wall of the hole (Fig.2.24). These decrease the life of bit and mud rings
limit hole cleaning. For water influx shutoff specific size material is injected into the water-
producing formation, where it sets to form a barrier to water flow. Other fluid system may be
used to overcome this problem.
40
Fig. 2.24 Shales destabilized by water invasion due to formation of mud rings, which clog the
hole, after [Rehm B., 2002].
The possibility of downhole fires is a potential limitation on the use of dry air operation due to
various factors like improper cooling of the downhole system and formation of mud rings above
the drill collar. The presence of liquid hydrocarbons increases the chances of down hole fires. As
soon as the mixture of liquid hydrocarbon and dry air reach its ignition temperature the
downhole fires start. Three stages of development of downhole fires is explained below
(Fig.2.25):
a. The top of drill collars where the cuttings accumulate due to low velocity region in the
annulus.
b. Mud ring formation in presence of liquid influx as the cuttings pack off around the
drillstring in regions of low velocity.
c. During Air circulation if liquid hydrocarbon comes out through influx, there is an isolated
chamber is generated below the pack off region which leads the fire ignition.
41
Fig.2.25 Mud ring formation and downhole fire, after [Medley G.H.et al., 1998].
Wellbore Instability is the serious concern during this fluid system. This air or gas fluid system
provides the lowest wellbore pressures of any other method. These low wellbore pressures can
cause collapsing of wellbore especially in weak formations. Water influx also creates the well
bore stability problem.
The oxygen level in water is a major factor in corrosion during air/gas fluid operations.
Increasing hydrostatic pressure in the fluid causes additional oxygen to be dissolved from a gas
source, which makes more corrosive environment. In distilled water at ambient temperature and
pressure, the critical concentration of oxygen is 12 ppm. This would be the oxygen level in water
that would cause the most corrosion [Ghalambor A. et al., 2004]. The dissolved oxygen in water
trend can be seen in Fig. 2.26. Nitrogen can be used in place of oxygen to reduce the corrosion.
42
Fig. 2.26 Oxygen partial pressure in distilled water [Medley G.H.et al., 1998].
Specific volume of gas is required for the successful operation. Angel’s method presents an
equation to determine the volume or circulation rate at particular depth with a specific hole size.
The figures in Angel's tables are about 30% low for deep wells but are adequate for shallow
wells. Fig.2.27 is a graph that plots circulation rate versus hole depth. As an example, Angel's
graph shows that in a 15,000-ft hole that is 8¾ in. in diameter, drilling at 60 ft/hr, the circulation
rate should be about 2,000 ft3/min.
43
Fig.2.27 Angel’s Curves for air drilling, from [Medley G.H.et al., 1998].
2.3 Candidate Screening and Selection
2.3.1 Drivers to consideration of underbalanced operations
The process of UBO candidate screening begins with the answer to the question, “What are the
reasons for considering UBO in this well or field?” The reason the question is framed in this way
at present is that UBO has often been implemented in order to overcome problems or obstacles
associated with conventional operations. It means that the primary choice is conventional
techniques and UBO is only considered if conventional operations are either facing many
problems or impossible.
44
In general, at the current state of the technology, the key drivers for the selection of UBO have
been:
i. Severe lost circulation or differential sticking problems
ii. Highly depleted reservoirs, which typically present the various problems
iii. Hard rock formations that result in very low rates of penetration and poor bit life during
conventional operations.
iv. Formation damage resulting in wells with productivity much below it’s potential.
v. Early production
2.3.2 Reservoir aspects of underbalanced operations
Feasibility study is necessary before undergoing any underbalanced operations. A proper study is
mandatory about the reservoir for a successful operation. Damage mechanism in the reservoir
must be studied which will not only ensure that we should go for underbalanced operations but
also gives the idea which method is suitable for the reservoir and the other benefits. Few
reservoirs are good candidates for underbalanced operations and result in an enhanced recovery.
Other formations or fields may not be suited to underbalanced operations for a variety of other
reasons. A summary of indicators that help to determine whether a particular reservoir will be a
good or bad candidate for UBO is pointed below.
2.3.2.1 Good candidate indicators for UB operations
• Hard rock formations are usually consolidated and good for underbalanced operations
because of well stability as well as good candidates because of the higher ROP and bit
life from underbalanced operations.
• Mature field or depleted reservoirs exhibit lost circulation and differential sticking
problems. If formation is consolidated, makes an excellent candidate for UBO.
• Naturally fractured and vugular formations usually exhibit huge losses, which can
exacerbate well control problems or lead to differential or mechanical sticking, making
them good candidates for underbalanced operations.
• Highly permeable formations with less pore pressure are also good candidates for UBO.
45
• Formation that usually suffer major formation damage by the invasion of fluids during
drilling or completion operations. Wells with a skin factor of 5 or higher is a good
candidate.
• High production reservoirs with low-medium permeability.
• Formations with rock-fluid or fluid-fluid sensitivities.
Underbalanced operations are not a technology that should be utilized for all situations. Utilizing
the technology in the wrong application may create an unsafe situation, increase formation
damage, increase the probability of well failure or increase well cost without any probability of
economic gain.
2.3.2.2 Bad candidate indicators for UB operations
• Formations where knowledge of reservoir pressure is poor.
• Poor quality reservoirs. If there is nothing in reservoir UBO will not do any thing.
• Swelling shale and unconsolidated formation. Wellbore stability problems during
underbalanced operations underbalanced.
• High pore pressure coupled with highly permeable formations will require costly
equipment and extra accessories for UBO.
• Formation susceptible to spontaneous imbibitions.
• Wells which require frequent trips could create excessive oscillation between
underbalanced and overbalanced conditions, causing damage, and eliminating the
advantages of UBO.
• Candidates requiring UBO for long intervals..
• Wells with high H2S. High levels of H2S will complicate the system design and
associated risk with safety.
• Hole sections with variations of pressure. Sometimes it may be feasible to reduce the
wellbore sufficiently so that all zones produce into the well.
46
The IADC underbalanced operations committee worked to promote the safe and efficient
application of underbalanced operations worldwide. The following standard classification
system for UBO and a set of standard nomenclature is given by the committee, which are
listed in Tables 2:
Table 2 -IADC UBO Committee classification system for UBD wells
.
Level Description
0 Performance enhancement only; no hydrocarbon containing zones.
1 Well incapable of natural flow to surface, inherently stable and a low-level
risk from a well point of view
2 Well capable of natural flow to surface but enabling conventional well
control methods and has limited consequences in the case of catastrophic
equipment failure.
3 Geothermal and non-hydrocarbon production. Maximum shut in pressures are
less than UBD equipment operating pressure rating. Catastrophic failure has
immediate serious consequences.
4 Hydrocarbon production. Maximum shut-in pressures are less than UBD
equipment operating pressure rating. Catastrophic failure has serious
consequences.
5 Maximum projected surface pressure exceeds UBO operating pressure rating
but are below BOP stack rating. Catastrophic failure has immediate serious
consequences
2.3.3 Assessing rock potential for formation damage
Formation damage assessment is necessary before selecting a candidate for underbalanced
operation. Formation damage may be through the various reasons. Various damage mechanisms
are explained below. If possibility of formation damage is making significant reduction in
47
permeability and ultimately reducing the expected production with the conventional techniques
then we will go for the UB operation.
Formation damage with fines migration occurs due to the loosely bonded matters within the rock
matrix. This may be induced due to the filtrate invasion near the well bore region. Filtrate
invades into the formation by the high hydrostatic pressure of the fluid column where it makes
loosely bond or preexisting particulate matters to move. The particles then become a barrier in
the natural permeability of the rock. Depth of formation damage depends of the exceeding
hydrostatic pressure. It may be vary from few inches to feet of radius around the well bore.
Migrating fines can be a any type of formation materials depend upon the mineralogy of the
formation which includes clays (a typical size less than 4 µm) and silts (sizes ranging from 4 to
64 µm). Table 3 presents particle mineralogy and its constituents.
Table 3.Main components of various clay and fine particles, from [Economides M. J.et al., 2000]
Particle Mineralogy Major Components
Quartz Si, O
Kaolinite Al., Si, O, H
Chlorite Mg, Fe, Al., Si, O,H
Illite K, Al., Si, O, H
Smectite (montmorillonite) Na, Mg, Ca, Al., Si, O, H
The damage with fines migration can be minimized. When the wetting phase of the reservoir is
in motion at that time fines migration tends to be most significant. Velocity of the fluids flowing
in the pore space, pore-size distribution and size of fines control the severity of problems. In high
underbalanced case the high rate early production initiates the fines mobilization. This
mobilization can be from early drilling stage to the production phase of oil well operations.
The formation damage may be due to the reactive clays in the sandstone formations. Certain
clays like smectite are susceptible to hydration by fresh-or low-salinity water contact.
Deflocculation or dispersion in kaolinite caused by abrupt salinity transitions or caustic pH
48
[Vitthal S. et al., 1989]. Several authors [Economides M. J. et al., 2000; Azari M. et al., 1988 and
Sharma M.M. et al., 1985] have dealt with clay swelling in sandstones, showing factors that
cause clay dispersion. Smectite and smectite mixtures are most common swelling clays. Swelling
can increase its volume up to 600%, significantly reducing permeability. Smectite occupies the
larger pores and especially the pore throats.
The formation damage may be due to clay deflocculation. Clay deflocculation is caused by a
disruption of the electrostatic forces holding the surfaces of individual clay units that are
attracted to each other as well as the walls of the pore system. A rapid salinity change from high
to low ion concentration, or rapid transitions in pH can create deflocculation. By using
underbalanced operation the above problems can be eliminated/minimized as there is very less
chances of filtrate invasion in the formation.
The permeability impairment caused by clays has been worked out by researchers. It has been
widely known that a variety of clays are sensitive to changes in the fluid pH and to the
concentration of certain ions. To determine the potential permeability impairment caused by clay
swelling and fines migration, the author [Vitthal S. et al., 1989] established two damage indices,
which is particularly used to estimate the potential reduction to rock permeability as a result of
clay swelling (swelling index) and fines migration (fine-migration index). To calculate the
overall damage potential of the rock, each clay index is multiplied by its corresponding weight
coefficient and its volume fraction. The overall damage potential is the sum of these products.
The overall swelling index is calculated as below:
Eq. 2.5
The swelling potential (in percent) is given by
Eq. 2.6
The overall fines-migration index is given by
Eq. 2.7
49
Here Vi is the volume fraction of the particular clay. The fines-migration potential (in percent) is
given by
Eq.2.8
The percentage values of indices are equivalent to probability values for the occurrence of fines
migration and clay swelling events. Tables 3 show the swelling index and fine migration index
for clay components and Table 4 provides a summary of the damage indices for various clay
types and their distribution correction factors, respectively.
Table 4. Damage indices for pure clays [Vitthal S. et al., 1989]
Table 5 - Distribution correction factors [Vitthal S. et al., 1989]
Phase trapping refers to the permanent increase in trapped fluid saturation in a porous space of
rock matrix. The losses of mud filtrate to the formation in the near-wellbore region caused by
50
leak off during conventional overbalanced operations. This can result in permanent entrapment
of a portion or all of the invading fluid. The blockage of the invaded fluid causes a reduction in
the relative permeability to oil or gas near the wellbore boundary.
Fig. 2.28 Relative permeability curves illustrating water block caused by extraneous water
introduced drilling, coring, or workover fluids [Economides M. J. et al., 2000].
In figure 2.28, increasing the water saturation from 20% to 35% decreases the relative oil
permeability from 90% to 30%, respectively.
Phase trapping may occur due to invasion of water-based fluids/filtrates into regions of low
water saturation, invasion of oil-based fluids/filtrates into zones of low or zero oil saturation.
Phase trapping is caused by production condensate type gases below the dew point pressure
which results in the accumulation of condensate type gases near-wellbore region. Another
Water saturation (% Pore space)
R
elat
ive
P
erm
eabi
lity
51
condition of phase trapping is the production of liquid hydrocarbons below the bubble point
resulting in the release of gas from solution and the formation of trapped critical-gas saturation.
The formation damage caused by bacteria is termed as bacterial damage. This type of damage is
associated with the introduction of viable bacteria to the formation. Bacteria grow in the
formation either in aerobic or anaerobic environment. During any water added operation in the
well leads to the bacterial damage problem. The problem occurs in certain bacteria favorable
environment. Bacteria can grow in many different environments and conditions: temperatures
ranging from 12°F to greater than 250°F, pH values ranging from 1 to 11, salinities to 30% and
pressures to 25,000 psi [Economides M. J. et al., 2000]. Damage mechanism attached with
bacterial damage are like plugging of pore spaces, some sulfate reducing bacteria creates toxic
environment, some bacteria creates corrosive environment which leads to the failure of down
hole equipments. The other formation damage are formation fluid/extraneous fluid
incompatibility and rock/fluid incompatibility.
The proper use of underbalanced technology prevents the continuing losses of potential water-
based fluids which may contain viable bacteria colonies into the formation. Therefore during the
water based fluid operations bacterial treatment is necessary. Generally it is treated by oxidants,
or by biocides. Table 6 presents a summary of the formation type vs. damage mechanism which
has been given by [Bennion D.B., 2002]. This matrix of formation damage mechanisms provides
the damage mechanism possibility & probability with formation type under various conditions.
The matrix will help to predict the possible formation damage for a particular well. The
candidate then is selected either it should be operated underbalanced or not.
52
Table 6 - Damage mechanism vs. formation type matrix, after [Bennion D.B., 2002]
53
2.3.4 Assessment of lost circulation potential
The phenomenon of losing drilling, completion fluids partially or in totality in to the formation
are termed as lost circulation. These losses can occur in naturally fractured formations,
unconsolidated and highly permeable formations. The losses are due to high hydrostatic pressure
of mud column exceeding the formation pore pressure and the losses are through the large pore
openings of naturally fractured or in induced fracture regions. To determine the lost circulation
potential is determined by the following procedure.
i. Estimate of both permeability (k) and porosity (ɸ).
ii. A qualitative description of the reservoir. The presence of natural or induced fractures
and the presence of vugs.
iii. The presence of fractures is assigned an index (IFr) that takes the value of 10 for highly
fractured formations, and the value of one for un-fractured formations.
iv. The presence of vugs is assigned an index (IV) that takes the value of 10 for vuggy rocks,
and the value of one for rocks that do not display any vugs.
v. A number between 1 and 10 for both indices may be selected based on experience.
vi. Lost circulation index (ILC) is the product of all the above variable factors as being the
independent events.
The lost circulation index can be formulated as follow:
Eq.2.9
Lost circulation index calculated from the above formula can be compared from the below
relations to know the lost circulation potential.
ILC ≥ 5% Severe lost circulation problem
ILC < 0.1% No lost circulation
ILC 5% ≥ ILC ≥ 0.1% Some losses
54
2.3.5 Assessing pipe sticking possibility
Pipe sticking possibility assessment is important during the candidate selection. During the
conventional operation, the problem of sticking pipe increases the non productive time.
Sometimes problem is severe upto such extent that the organization lose it’s all down hole
assemblies below the stuck up region. Pipe sticking occurs because of the filter cake formation
build up at wall. The differential pressure between the fluid column and the formation leads to
sticking of pipe. Once the pipe stuck the pressure differential acts as the force which holds the
pipe against the wall of well bore. The holding force is determined by multiplying the differential
pressure by the cross sectional area of the pipe imbedded in the wall cake.
The stuck pipe problems are studied and analyzed by [Sharif Q., 1997]. The author analyzed
from the history and data of various offshore located well and prepare a model to predict the
probability of getting differentially stuck. The model can be used for determining the pipe
sticking possibility for a selected candidate. The probability function developed by [Sharif Q.,
1997] is given by:
SDSI = - 4.4 + 0.5 × CC + 0.075 × SOL × EMW + 0.0045 × DIA × ROP Eq. 2.10
Eq. 2.11
Where SDSI is “Sharif’s” Differential sticking index.
.
UB operations eliminate both the filter cake and the differential pressure. As most multiphase
fluids do not have solids that produce the filter cake, one will not be generated. In underbalanced
operations differential pressure acts from the reservoir to the annulus. If designed properly, it is
impossible to have positive differential pressure in underbalanced operations.
55
2.4 Well Control Aspects in Underbalanced Operations
Well control in underbalanced operations is very critical because the formation fluids are
allowed in to the wellbore during drilling and flow to the surface under controlled conditions.
ERCB (Energy Resources Conservation Board), Calgary, Canada has laid down guidelines for
executive underbalanced operations safely. Well control involves the surface BOP system and
subsurface system.
2.4.1 Blowout prevention system
BOP stack shall consist of diverter preventer, annular preventer, diverter line, kill line, pipe ram,
blind ram, emergency bleed off, for a convention rotary rig . BOP stack for coiled tubing drilling.
The accumulator system used to control the diverter preventer shall be independent of the rig’s
standard accumulator system. No primary well control equipment (blowout preventer other than
the diverter preventer) shall be used for stripping, snubbing or drilling except in emergency
situations. The diverter preventer may be a rotating blowout preventer or a rotating head.
Rotating head is a low pressure diverter designed for rotation with drill pipe or kelly stem.
Rotating head provide a rotating seal that allows drilling to proceed under pressure. In the past
rotating head was typically limited to just few 100 psi (upto 500 psi).Rotating blow out
preventer is an annular preventer designed to rotate with pipe rotation and capable of providing a
seal on both smooth pipe or kelly stem. The rotating blowout preventer (RBOP) is used to
maintain surface pressure upto 1500 psi.
2.4.2 Sub-surface control system
At least two non ported devices (floats) should be installed near the bottom of the drill string to
prevent back flow from the well during underbalanced drilling. One of these devices can be a
profile nipple designed to accommodate a pump down back- flow device. When planning to use
air fluid system for underbalanced operations, precaution shall be taken to ensure explosive
mixtures are not generated at any point of operation. Fire floats/ fir stops are used near the
bottom of the drill pipe to shut off air flow automatically if a down hole fire is initiated.
56
2.4.3 Well control equipment
Jointed pipe systems: The conventional BOP stacked used for drilling is not compromised during
underbalanced drilling operations. The conventional BOP stack is not used for routine operations
and will not be used to control the well except in case of emergency. A rotating control head
system and primary flow line with ESD valves is installed on top of the conventional BOP. If
required a single blind ram, operated by a special koomey unit is installed under the BOP stack
to allow the drilling BHA to be run under pressure.
Fig. 2.29 Jointed pipe system for well control (Courtesy: Zueitina Oil Company, Libya)
57
Coiled tubing system: Well control when drilling with reeled systems is much simpler. A
lubricator can be used to stage in the main components of the BHA or if a suitable downhole
safety valve can be used then a surface lubricator is not required and the injector head can be
placed directly on top of the wellhead system. Reeled systems can be tripped much faster and the
rig up is much simpler. One consideration that must be made with reeled systems is the cutting
strength of the shear rams. It must be verified that the shear rams will cut the tubing and any
wireline or control line systems inside the coil. For a stand-alone operation on a completed well
an example stack up is shown in figure 2.30.
Fig.2.30 Coiled tubing system for well control (Courtesy: Zueitina Oil Company, Libya)
58
2.5 Problem Identified
• A stable low gravity fluid formulation is desirable, as foam stability is major concern
during the underbalanced operation. Gasified fluid operation does not maintain the
continuous underbalanced condition thus requires the injection of compressed gases
through annulus which is not effective at higher depths and typically deviated wells.
• Due to poor hole cleaning in horizontal well, underbalanced condition is lost which leads
to the unwanted formation damage.
• In horizontal wells the fluid invasion will be through the gravity when underbalanced
condition is lost.
59
Chapter 3: Methodology & Experimental work
The methodology adopted for absolving the problems identified during literature survey is as
follows:
i. To study and identify the feasible low gravity solids which can reduce the density of fluid
column during underbalanced operation and can provide a stable low specific gravity
fluid formulation for sub-hydrostatic underbalanced workover operation.
ii. To study the Non invasive mechanisms and to develop the non invasive fluid formulation
for sub-hydrostatic underbalanced workover operation.
3.1 Development and Evaluation of Low gravity, Non invasive Water based Fluids for
sub-hydrostatic Underbalanced Workover Operations
Before involving in the development of Non invasive, low gravity workover fluids for sub-
hydrostatic / depleted reservoirs, it is very important to undergo about the entire geological
aspects of the specific field as well as fluid components selection with couple of factors
capability and economic feasibility. The followings are very brief introduction about the fluid
components which are used in laboratory experiments for development of low gravity and Non
invasive desired fluids.
Organic polymers
During the formulation of drilling, completion and workover fluids the organic polymer plays
very vital role. They are used in fluids to reduce filtration, stabilize clays, flocculate drilled solids
and increase carrying capacity. They also serve as emulsifiers and lubricants. They are composed
of a number of repeating or similar units. The groups of atoms, called monomers are consisting
primarily of compounds of carbon. The term organic polymer is applied to the several varied and
60
versatile substances which are composed of a number of repeating or similar units, or groups of
atoms (called monomers) consisting primarily of compounds of carbon. Organic colloidal
materials are used in drilling fluids to reduce filtration, stabilize clays, flocculate drilled solids,
increase carrying capacity, and (incidentally) to serve as emulsifiers and lubricants. They have
versatile characteristics so it is used for multipurpose requirements. Polymers like starch and
guar gum is naturally available. Other semi-synthetic polymers like sodium
carboxymethylcellulose are also used as a component of fluid. The derivative of starch and
gums are also used as organic polymer. These are used after few processing. Polyacrylates and
ethylene oxide polymers are purely synthetic. They are the derivatives of petrochemicals. The
organic polymers develop highly swollen gels even in very low concentrations.
XC polymer
Xanthan gum production method was developed at the Northern Regional Research Center,
Agricultural Research Service, U.S. Department of Agriculture, Peoria, Illinois, in 1961.
Xanthan is a water-soluble polysaccharide produced by bacterial action (genus Xanthomonas) on
carbohydrates. It was introduced as a drilling fluids component in the mid 1960s under the name
"XC polymer," The polymer builds viscosity in water or salt solutions. Xanthan gum solutions
show exceptional shear-thinning property. Cross-linking of XC polymer with chromic ion
increases viscosity. The increase in pH has very little effect on it’s viscosity. XC polymer does
not show degradation upto 1200C. It is used in the fluids as a thickener or a suspending
agent. It has exceptional suspending ability at low concentrations. Xanthan gum is not a
filtration-control agent. Xanthan gum is used in very low concentrations of 0.2 to 2 lb/bbl (0.6-6
kg/m3) [H.C.H. Darley and G.R. Gray, 1988].
Sodium carboxymethylcellulose
It is generally abbreviated as CMC. Cellulose comprises the greater part of the cell walls of
plants. Sodium carboxymethylcellulose is a water-dispersible, colorless, odorless, nontoxic
powder. It is preferred to starch for applications in other than high-pH and salt-saturated muds.
CMC costs more than starch but quantity needed to reduce filtration rate is less compared to
starch.
61
Polyanionic cellulosic polymer
It is generally abbreviated as PAC. PAC thickens salt solutions. When PAC is used with
diammonium phosphate, it provides an environmentally acceptable polymer-electrolyte, shale-
inhibitive composition. The polymer solution alone has exceptional inhibitive qualities. The
concentration range of PAC is from 0.2 to 5 lb/bbl (0.6 to 14 kg/m3 [H.C.H. Darley and G.R.
Gray, 1988].
Hydroxy ethyl cellulose
It is generally abbreviated as HEC. HEC is nonionic. HEC is effective in reducing filtration and
in thickening salt solutions. Although HEC can be used in drilling muds, more commonly it is
used in completion fluids. HEC is used in concentrations of 0.2 to 2 lb/bbl (0.6 to 6 kg/m3).
Inorganic Chemicals
Magnesium oxide (MgO)
It’s common name is magnesia. It found as white powder, very slightly soluble in water. MgO is
produced by calcining the hydroxide, carbonate, or chloride. It is used as a buffer, or stabilizer,
in acid-soluble completion fluids in conjunction with polymers. It is generally used in a
concentration of 0.5 to 2 lb/bbl (1to 6 kg/m3) [H.C.H. Darley and G.R. Gray, 1988]. .
Potassium chloride (KCl)
It’s common name is potash. It appears colorless or white crystals. It is mined and then; purified
by re-crystallization. It is generally used in a concentration 2 to 60 lb/bbl (6 to 170 kg/m3).
Potassium hydroxide (KOH)
It is generally called as caustic potash. It can be found as white lumps, pellets or flakes. It is
prepared by electrolysis of potassium chloride. It is toxic by ingestion and inhalation. It used to
increase pH of potassium-treated muds and to solubilize lignite. It is generally used in
concentration 0.5 to 3 lb/bbl (1 to 8 kg/m3).
Sodium chloride (NaCl)
It appears as white crystals. It is produced by evaporation of brines and by dry mining. It is used
to prepare brine in completion and workover operations to saturate water before drilling rock
62
salt. It is used to lower freezing point of mud, raise the density (as a suspended solid) and act as a
bridging agent in saturated solutions. It is generally used in Concentration 10 to 25 lb/bbl (30 to
360 kg/m3).
Sodium hydroxide (NaOH)
It is generally called caustic soda. It is found in shape of beads, pellets, flakes. It is produced by
electrolysis of sodium chloride. It is used in water muds to raise pH, to solubilize lignite,
lignosulfonate and tannin substances. It is also used to counteract corrosion, and to neutralize
hydrogen sulfide. It is generally used in concentration 0.2 to 4 lb/bbl (0.6 to 11kg/m3).
Surfactants
The term surfactant is basically the phrase surface-active agent. It is the substance which acts at
an interface between two phases. Surfactants are used for several purposes. They serve as
emulsifiers, foamers, defoamers, wetting agents, detergents, lubricants, and corrosion inhibitors.
Hollow glass spheres (HGS)
The hollow glass spheres are unicellular, made from soda lime borosilicate glass, chemically
inert other than in the presence of HF, and having high water resistance along with high
temperature and pressure resistance. The concept of adding HGS is to decrease the density of the
base fluid and create a light weight yet incompressible fluid was seen as a potential solution to
the design of workover fluids for sub-hydrostatic wells. HGS are engineered fillers and have
been used in many industries aerospace and automotive, where weight reduction while
maintaining strength is beneficial. Also because of their high strength to weight ratio, HGS find
utilization in buoyancy modules for subsea risers.
Precedent existed for the use of spheres [Medley, George H. et al., 1995], although not hollow
glass as well as near sphere shaped particles have already been used drilling and cementing
application as well. Under relatively challenging conditions of temperature and hydrostatic
pressure demands, an inert additive with high tolerance for iso-static pressure environment is
desirable .The HGS selected for evaluation had a good combination of physical properties. There
are many attractive features of HGS none as dominant as the simplicity of the approach. HGS
63
can be added to virtually any type of existing fluid system in order to reduce its density. HGS
basically extends the density window of a single phase liquid into a density range which is
normally only achievable by the injection of a gas to liquid.
Density of HGS based workover fluids
Addition of HGS to any fluid reduces its density. The density reduction is proportional to the
concentration of HGS in the fluid, so increasing HGS concentration decreases the fluid weight.
There are practical limitations as to how much weight reduction can be accomplished for a given
HGS grade. The upper limits of HGS addition are controlled by viscosity and will vary
somewhat for different bases [Medley, George H. et al., 1995].
Field handling of HGS
HGS material properties dictate their handling. Understanding handling principles for materials
with diameter less than 100 microns and with low bulk density is important in implementing
successful field usage. HGS are slightly more challenging than free flowing coarse granules or
pellets. Their sizes, shape, density, and pore size distribution can create a nuisance dusty
environment if improperly handled, especially indoors at a fluid plant. At a rig site, they can be
unloaded from their boxes or bags either manually, by gravity feeding into a compounding
hopper or mechanically or by using pneumatic conveying system. The unloading personal should
wear safety goggles before unloading by either method [Medley, George H. et al., 1997].
HGS Suspension
The density ratio of hollow glass spheres of SG=0.38 to water is approximately the inverse of the
density ratio between low density solids, representative of formation cuttings and water .Based
on the similarity of these ratios, it would be expected that the segregation velocity for both type
of particles would be the case for hollow glass spheres which being less dense than water would
float. As a result it is expected that a properly formulated underbalanced workover fluid,
designed to suspend and transport, would also do fairly well suspending HGS. In fact
experimental observations have confirmed that hollow glass spheres are maintained in
suspension for extended time periods in fluids, especially when fluids are non-Newtonian. For a
64
non-Newtonian fluid, the settling speed is thought to be linked more with rheology rather than
density differential between the particle and the medium.
Formation damage tests (Permeability Return) The result of formation damage tests have been reported by the author with Berea cores using the
formation testing apparatus. These tests showed that HGS help from a tight filter cake and
caused less formation damage than the corresponding fluids without HGS. The filter cake can be
removed by back flooding and the original permeability was completely restored [Arco M. J. et
al., 2000].
Lubricity and Casing Wear
Solid plastic spheres are routinely used as friction reducers in highly deviated wells. Medley
tested the potential reduction of friction and casing wear in conventional water-based fluids
which contained HGS.A significant reduction in drill string and casing wear was noted.
Non Invasive Fluids: It’s a new class of ultra low solids drilling fluids which are technically
advanced and are the successor to the low solids non dispersed fluids .These are capable of
replacing the use of oil. These consist of an optimum blend of soluble synthetic polymers and
partially soluble and insoluble non ionic polymers with varying hydrophobic liophilic balance
(HLB) ratio. During overbalanced conditions in the well bore, they form an impermeable film on
the wall of well bore and therefore do not allow the fluid to invade the formation beyond few
inches. It greatly helps in stabilizing the well bore .In the pay zone , when pressure is removed
and well is flowed , the film is removed thereby permeability is restored.
Mechanism of invasion and its control: Two invasion mechanisms are relevant. Static filtration
occurs when fluid pumping is interrupted and filtration occurs due to the hydrostatic pressure in
the well and reservoir pressure .Under static conditions, the cake thickness increases as a
function of time and the filtrate volume proportionally increases with the square root of time.
The filtration rates are controlled by the continuously increasing the thickness of filter cake in
conventional overbalanced operations. Dynamic or cross filtration occurs when the fluid is
65
pumped through well. In this process the cake thickness results from the dynamic equilibrium
between the solid particles deposition rate and erosion rate due the shear stresses generated by
the fluid flow through the wellbore. Under dynamic filtration, the cake thickness and
permeability are constant with the time and the filtrate volume proportionally increases with
time.
Two mechanisms of invasion control is identified for minimizing/eliminating the invasion
possibility. One through the plugging solids that promote the external and internal cake
formation and other through the liquid phase resistance to flow in the porous medium.
Factors governing invasion:
i. Rock permeability and porosity
ii. Wellbore –reservoir pressure differentials
iii. Native fluids properties
iv. Nature of fluid flowing through porous medium
v. The adsorption level of polymers used. There are different parameters responsible for it
like polymer structure, charges, molecular weight etc. The adsorption value of starch only
gives global information since this polymer may not be completely soluble. The
adsorption levels are ranked as: starch > xanthan ≥ PAC etc.
vi. Temperature and pressure affects behavior and interactions of water or oil, clay, polymers
and solids in mud. The effect of increasing the temperature of a liquid is to reduce the
cohesive forces while simultaneously increasing the rate of molecular interchange. The
former causes a decrease of shear stress while the latter causes it to increase. The net
result is that liquids show a reduction in viscosity with increasing temperature. The effect
of increased pressure on oil based mud is to increase the cohesive forces, which leads to
increase the viscosity.
vii. Extensional viscosity
viii. Trouton ratio: It is (a relation between extensional and shear viscosity at similar
shear/extensional rates) the major rheological parameter governing fluid invasion
mechanism.
66
Methodology for the Formulation of Non Invasive Fluids
The solids free non invasive fluid consists on identifying polymeric solutions that generate
extremely high pressure drop when flowing through porous media without showing excessive
viscosity in the well. Thus without limiting the pumping capacity of the system its rheological
behavior prevents the invasion into the rock.
FLC 2000
FLC 2000 is the main additive in the fluid formulated to control the invasion of fluid into the
formation. Extensive testing using a range of different mud weights in a water base mud system
shows that FLC 2000 is capable of working effectively in everything from a low density solids
free fluid to 16 ppg mud. It is unaffected by contamination, in fact here is often a small
improvement in the low invasion properties when OCMA clay is added.
By using magnesium oxide as a pH buffer in the water based mud formulations, the excellent
sealing properties of FLC 2000 are better preserved after hot rolling at (2500F & 300 psi for 18
hours). Then if potassium hydroxide or sodium hydroxide is used, it appears that combination of
FLC 2000 and MgO also helps in stabilizing the other polymeric additives such as XC Polymer
during heat aging. MgO alone without FLC 2000 is not effective. The most common way to
reduce invasion is to load the fluid with sized calcium carbonate because of the lack of solids in a
brine system as it has always been very difficult to prevent formation invasion with this brine
system. FLC 2000 (unique blend of polymers and sized, surface modified particles) easily
transforms a range of brine systems into a very good ULIF (Ultra low invasion fluid) without
bridging agents such as calcium carbonate. Even with the high concentration of calcium ions
present, FLC 2000 performs very well. It is suitable for use in oil based mud and synthetic based
fluids as well as water based mud. Both oil and synthetic based fluids are generally considered to
be a low invasion fluid, but when compares to the fluid system with FLC 2000, it is apparent that
this product will lower invasion even further by adding as little as 2ppb FLC 2000 to some
fluids.
67
FLC 2000 and its role
FLC 2000 additive is a blend of soluble synthetic polymer, and partially soluble & insoluble non-
ionic polymers with varying hydrophobic liophilic balance (HLB) ratios. It is a synergistic blend
of modified low molecular weight polymers, surface functionalized organic solids and other
additives.
Properties of FLC 2000
i. Appearance : Dry tan colored, free flowing powder,50-500 mesh size
ii. Specific Gravity: <1
iii. Bulk Density: 30-40 lb/cu ft
iv. Broad particle size distribution for optimum sealing of wide range of pore and fracture
openings.
v. Biodegradable
vi. pH: Near neutral at 3% concentration in water.
Functions of FLC 2000
FLC 2000 is responsible for providing non invasive property in non invasive fluid system. It is
used in drilling, workover and completion fluids to form ultra low invasion fluid. The products
forms a compressible, extremely low permeability filter cake which minimizes fluid invasion and
the transmission of bore hole pressure to the formation despite high pressure differential (200 psi
or more) for a considerable time. The very low permeability barrier formed by the FLC 2000
additive is much more effective at preventing fluid invasion than conventional fluid additives
and as such greatly reducing formation damage, reducing the risk of differential sticking and
prevents wellbore instability. The barrier also effectively increases the fracture gradient and so
widened the safe drilling window by allowing the wellbore fluid density to be raised without
inducing losses.
The results of various experiments performed by using non invasive fluids additive FLC 2000 as
an effective non-invasive composition in the sand bed of very high permeability and are highly
68
encouraging. This shows that the impermeable film formed by non invasive fluid additive has a
high strength to withstand the pressure rigors of borehole.
Wellbore strengthening
Wellbore stability is the prime consideration in underbalanced operations, for avoiding
unpredictable borehole problems and to reduce non productive time during drilling. FLC 2000
form an ultra low permeability barrier very quickly across matrix permeability or micro-fracture
openings. This can restrict pressure and fluid invasion enough to give an appreciable measure of
wellbore strengthening. The effectiveness of FLC 2000 in giving wellbore strengthening in
permeable formations is undoubtedly due to the very low permeability of the filter cake formed.
It is too soft a material and is present in too low a concentration to work by stress cage
mechanism. While it is feasible that the product can form a very low permeability seal that is
completely enough (and formed quickly enough) to prevent the initial pressure penetration into a
permeable formation (and hence stop a fracture initiating), it is more likely that the additive
mainly functions by plugging a fracture with a very low permeability membrane once it starts to
grow – the formation of this seal will stop the invasion of wellbore fluids in to the formation.
Advantages with FLC 2000:
i. It can be applied in any water-based, oil-based and synthetic-based drilling completion
and workover fluid.
ii. The blend is designed for ease of mixing in all systems with minimal increase in
viscosity.
iii. The low permeability cake is easily removed by flow back or by simple wash fluids.
iv. It provides invasion control that exceeds that seen with sized solids and other
conventional systems.
v. Imparts wellbore stability to micro-fractured/ bedded shales and brittle coal seams.
vi. Reduces formation damage and differential sticking.
vii. Increases the fracture gradient to reduce induced losses during drilling, completion and
workover operations.
69
Working principle of FLC 2000 FLC 2000 is a blend of modified cellulosic polymers and surface functionalized organic solids.
The molecular weights of the polymer components are low, which allows easy mixing and does
not significantly contribute to fluid viscosity. The high grade polymers and organic solids in FLC
2000 are modified to exhibit a range of water and oil solubility as well as wettability. When FLC
2000 is added to a water based fluid certain components partially miscible because of their oil-
loving characteristics. These components assemble into small deformable aggregates that give an
FLC 2000 fluid its ultra low invasion and non-damaging characteristics. The similar mechanism
operates in oil based fluids except that here it is the more water loving components now produce
the aggregates. The aggregates are present in the fluid in a very wide range of sizes (from a few
microns to several hundred microns in diameter) provides the excellent invasion control. As well
bore fluid tries to enter rock pores or micro-fractures because of the overbalance pressure; an
ultra low permeability layer of aggregates quickly forms and greatly reduces any further invasion
of solids or fluid. The aggregate making up the layer are deformable so as the pressure is raised,
they are increasingly compressed and the barrier even further. FLC 2000 makes a virtual caging
called stress caging and provides strength to formation. It also works as sealant, thus prevent
fluids as well as pressure transmission into the formation.
Micronized calcium carbonate (MCC)
Calcium carbonate is recommended as a weighing material because the filter cake that form on
the productive formation can be removed by the treatment of hydrochloric acid. Calcium
carbonate is readily available as ground limestone or oyster shell. Calcium carbonate is dispersed
in oil muds more readily due to its low specific gravity (2.6-2.8) .The maximum density of the
mud is about 12 lbs/gal (1.4 gm/cc). High filtration slurries carrying graded marble or limestone
particles in suspension have been found effective in overcoming loss of circulation.
Micronized calcium carbonate abbreviated as MCC is one of the most important components of
non damaging fluid systems, which acts as bridging material. Bridging is required at the pore
throat of the reservoir and to initiate filter cake formation. The filter cake itself will then control
70
further losses of filtrate to the formation and migration of fines. Calcium carbonate has been used
as one of the main bridging agent s as it is readily available in desirable particle size distribution.
By designing the ideal particle size distribution of MCC (i.e. bridging material) in fluid system,
for a given pore size distribution in the core, it is possible to minimize
i. Formation damage caused by solid invasion and filtrate invasion
ii. Depth of the formation damage.
Some researchers suggest that the depth of damage due to the solid should be less than 2.5 cm (1
inch) if the drilling fluid is suitably design. Several studies, however have reported that solid
invasion exceeds 7.5 cm (3 inches) and invasion upto depth of 30 cm (12 inches). In order to
prevent solid invasion in to the large pores, the fluid system should contain a wide range of
particles to obtain a thin and low permeability filter cake. How quick the internal mud cake
forms depends on the compatibility of particle size of the mud solids and the pore size of the
formation. Particles larger than pore openings can not enter the pores and are therefore
continuously re-entrained in the annular fluid stream. Solely large particles can not be used, even
though they would not invade the pores, because the fluid loss rate would be uncontrollable and
filter cake thickness will continue to grow.
Also the particles, those are considerably smaller than the pore openings will enter the pores and
migrate freely into the formations. In order to plug and form a stable bridge at the pore openings,
the average diameter of mud solid particles should be around one third of that the largest pore
opening. Once a stable bridge is established at the pore opening and pore constriction in near
wellbore region, smaller particles will trapped in between the larger particles to form an initial
internal mud cake .This internal mud cake forms is governed by hydrodynamic forces prevailing
in mud stream which tends to deposit particles on the cake surface and the shear stress due to
mud circulation which tends to sweep particles off the cake surface. The growth of the cake
thickness will cease once the action of the two forces are in balance. The higher the annular fluid
circulation velocity and the smaller the size of the particles deposited. The thickness of filter
cake will be less and will have better properties i.e. low porosity and low permeability.
Obviously the availability of proper particle size in the mud for bridging the pore openings and
71
pore constrictions is critical in determining the quantity of spurt loss at the initial stage of initial
cake formation.
There are some rules of thumb for choosing the particle size distribution, firstly the 1/3rd rule and
secondly d1/2 relationship; Basic summary of the 1/3rd rule is that the mean particle size of the
bridging material should be greater than one third of the median pore size of the formation. The
1/3rd rule also suggests that the effectiveness of a bridging material in reducing mud solids
invasion is a function of both its concentration and particle size, as well as the pore size
distribution of the rock [Smith P.S. et al., 1996] . A median particle size of the bridging additive
equal to or slightly greater than one third of the median pore size of the formation [Suri A. et al.,
2001]. The d1/2 relationship suggests that for ideal bridging, the cumulative weight percentage of
the bridging materials should be directly proportional to the square root of their particle size
[Smith P.S. et al., 1996]. The concentration of the bridging agents must be at least 5% by volume
of the solids in the final mud mix. The D90 (90 % particles by weight are larger than this size) of
the particle size distribution of the bridging agents should be equal to the pore size of rock [Suri
A. et al., 2001].
Selection of bridging particles: Calcium carbonate is recommended as a bridging material for
fluid formulations due to the following reasons:
i. CaCO3 can be chemically removed by the acids or chelating age.
ii. Calcium carbonate is commercially available in a broad range of particle sizes. This
facilitate the selection of a blend that will efficiently bridge formation pore throats and
form a totally extra ultra low permeability filter cake on the surface of the exposed pay
zone. This adds in reducing the fluid loss rate and prevents solid invasion into the
formation when underbalanced condition is lost.
iii. The minimum concentration required of calcium carbonate is fixed 5-7% (w/v), which is
sufficient to bridge formation pore and ensure a thin high quality filter cake.
iv. The blend of Calcium carbonate products such as medium, fine and micronized grades
can be used to fit the purpose with respect to the pore size distribution of the reservoir
rock.
72
FLC 2000 versus CaCO3:
o The broad size distribution and compressibility of the aggregates means that the one
grade additive can seal a wide range of pore sizes and micro-fractures. Hence there is no
need to change the size distribution of the FLC 2000 as operation moves from formations
of one permeability to another as required in the case with CaCO3.
o Effective concentrations of FLC 2000 in drilling, completion or workover fluid range
between 3 and 8 ppb is much lower than sized calcium carbonates (30 to 40 ppb). The
optimum FLC 2000 concentration depends on the base fluid properties.
o The very low permeability barrier formed by the FLC2000 additive is much more
effective at preventing fluid invasion than conventional mud additives including sized
CaCO3.
Workover Fluid design:
Before embarking on laboratory experimental work it is essential to design sub-hydrostatic
workover fluids with low density additive so that the workover fluid density may be lowered
upto 0.65 with good rheology and to incorporate such additives in the design which shall ensure
the good rheological and filtration properties of the sub-hydrostatic underbalanced work over
fluids.
Selection of design parameters:
The designed parameters are effective mud weight should be less than 8 ppg. The fluid should
have a good rheology and filtration properties at room temperature as well as at bottom hole
temperature of 900C (selection of bottom hole temperature is according to the field X).
Selection of workover fluid type:
The design of sub-hydrostatic workover fluids for the specific field (X) has led to the selection of
three types of workover fluids. The first type fluid is based upon emulsification of non-toxic
73
oil/mineral oil in water thus reducing the specific gravity of based fluid itself. The fluid is then
incorporated with low density additive to further its specific gravity to desired level. The second
type of sub-hydrostatic workover fluid selected is a water based system incorporating low
density material for weight reduction. The rheological properties were managed by using XC
polymer, and the filtration properties were controlled by using pre-gelatinized starch (PGS). The
selection of both these additives is based upon their relative non-damaging characteristics to the
reservoir. The third type of sub-hydrostatic workover fluid is also a water based system
incorporating light weight material for density reduction, and hydroxyl ethyl cellulose (HEC)
based fluid loss controlling agent.
Selection of Additives:
This is an important step before the designed workover fluid can actually be formulated in the
laboratory. The selection of additives is based on the demanding requirement of low specific
gravity upto 0.65. Ideally the low gravity material should be chemically inert to the water and
reservoir fluids. It should be compatible with the fluid systems to which it shall be exposed
without any rheological and filtration control problems. The material should be user friendly and
should be non-damaging to the formation. One such material that has been identified is hollow
glass spheres (HGS). Since workover fluid should also have good rheological and filtration
properties suitable additives like XC Polymer for imparting viscosity to the fluid and pre-
gelatinized starch (PGS) or hydroxyl ethyl cellulose (HEC) for control of filtration properties
were incorporated into the designed sub-hydrostatic workover fluids. The selection of these
additives is based on their non-damaging characteristics for the payzone.
Workover fluid preparation:
The base fluid selected is fresh water and to this different additives are added. In one of the
compositions non-toxic oil / mineral oil has been used as a component of the based fluid. The
dosage of the additives is generally used by considering the final volume of workover fluid
including the low density material hollow glass spheres (HGS).
74
Polymer selection:
For this fluid system different polymers used are XCP, PGS, PAC (R), PAC (LV), FLC2000 and
Polyol.
Methods of evaluation of non-invasive fluids:
The following two methods have been used to evaluate the non-invasive behavior of these fluids:
Injection syringe method: A 60 ml capacity injection syringe is taken and properly packed
with 20-40 mesh quartz sand up to the mark of 30ml. Sand standardized by WSS for operations
is used in the tests. Sands of the other mesh size as per the field requirement according to the
candidate. Based on the average pore throat size of the formation can also be used. Even the
shale powder formations needing borehole stability may be used for the test. Once the syringe is
properly packed, the desired fluid is filled upto the top on the sand bed and piston is pressed
against the filled fluid. The pressure applied is manual i.e. by hand. The fluid invades the bed
and starts flowing through the pores downward .In case the normal fluid, the fluid quickly passes
through the bed and starts flowing the nozzle/opening at the bottom. But when Non-Invasive
fluid system is used, initially some invasion takes place but quickly an impermeable film on the
bed is formed and further invasion stopped completely. The distance traveled by the fluid
through the bed in a specific time is noted and comparison is made for different fluids.
Sand bed invasion test cell: A glass cell volume 630ml (approx.) with steam opening is taken.
A 60 mesh sieve is placed at bottom and properly packed with 20-40 mesh quartz sand up to the
mark of 6”. Sand standardized by WSS for operations is used in the test. However, sand of the
other mesh sizes as per the field requirement based on the average pore throat size of the
formations can also be used. Once the cell is properly packed with the sand bed, the fluid under
test is filled upto the top and a constant pressure of 100 psi pressure is applied. The fluid invades
the sand bed and start flowing downwards. In case of normal fluid (not treated with FLC 2000),
the fluid quickly passes through the bed and starts flowing the nozzle/opening at the bottom , and
entire fluid comes down even at 5 to 10 psi pressure almost immediately. However when the
fluid treated with FLC 2000 is implemented some invasion takes place but quickly an
impermeable film on the sand bed is formed and further invasion is either completely stopped or
75
its rate becomes very slow. The distance travelled by the fluid in 30 minutes at the same 100 psi
pressure is measured and a comparison is made with other fluid. For every test fresh sand is used
and sand bed is prepared.
Apparatus used: For formulation and evaluation of underbalanced workover fluid during the
project the following apparatus are used (Courtesy: IDT-Chemistry division, R&D Lab-II).
1) Electronic weighing machine
2) Hamilton beach
3) Fann VG- Viscometer with 6-speeds
4) Glass electrode pH-meter
5) API Filtration loss apparatus
6) Roller oven
7) Sand bed invasion test cell
76
Chapter 4: Results and Interpretations
. Results:
Refer table A-1, A-2, A-3 and A-4 in appendix for fluid components and their rheological properties
1) The sub-hydrostatic workover fluids for underbalanced operations, can be designed and
formulated using oil in water emulsion as the base fluid and hollow glass spheres as the
low density material (Refer table A-1). The fluid so designed is formulated with XC
Polymer and pre-gelatinized starch to impart stable rheological and filtration control
properties to the fluid. The oil used in the base fluid is non-toxic oil and provided a stable
emulsion even after hot rolling at 900C.
2) The oil in water emulsion based the sub-hydrostatic workover fluids for UBO is
formulated in four specific gravity ranges i.e. 0.84,0.78,0.72, and 0.65 depending upon
the quantity of specific gravity material i.e. hollow glass spheres added . The fluid is
found to be stable at room temperature and after hot rolling at 900C for 24 hours, it shows
good and stable rheological as well as filtration properties.
3) The second type (Refer table A-2) of oil and water emulsion based sub-hydrostatic
workover fluids (mineral oil based) for UBO is also formulated and evaluated for four
specific gravity values i.e. 0.84, 0.79, 0.73 and 0.65. The fluid is found to be stable at
room temperature and after hot rolling at 900 C for 24 hrs. and shows good, stable
rheological and filtration properties.
4) The sub-hydrostatic workover fluids for UBO are also formulated with the water as the
base fluid (Refer table A-3) using XC Polymer and Pre-gelatinized starch as suitable
formation friendly viscosifiers and filtration controlling agent respectively. The density
reduction is achieved by using low density material hollow glass spheres. Four such sub-
hydrostatic underbalanced workover fluids are formulated with specific gravity ranges
0.84, 0.78, 0.72 and 0.65 using different concentrations of HGS. The fluid is found to be
77
stable rheological properties. But these formulations do not have the desired filtration
properties as evaluated after their hot rolling at 900C for 24 hours.
5) The sub-hydrostatic workover fluids for UBO are also formulated using hydroxy ethyl
cellulose (Tylose) as the primary filtration control additive (Refer table A-4). Four sub-
hydrostatic underbalanced workover fluids are formulated having the specific gravity
0.84, 0.77, 0.70 and 0.65. The fluid is stable at room temperature and shows good
rheological and filtration properties even after hot rolling at 900C for 24 hours.
Please refer to table no.A-5 for detailed rheological properties of the non invasive fluid
formulation developed.
o The filtration loss is observed as due to unwanted overbalanced condition during the
underbalanced operations. Sl.No.1 composition of fluid provides very much filtration loss
more than 200 ml. Sl. No. 2 provides less fluid loss.
o Sl.No.3, this composition gives even though very less fluid loss.
o During the sand bed invasion test on 20/40 frac. Fluid formulation in table A-5- Sl.no.3,
with 5% micronized calcium carbonate give the invasion of 2.34 cm (100 psi) and 1.90
cm (50 psi) before this Sl.No.1 fluid composition is tested which results complete fluid
discharge from the lower nozzle.
Interpretations:
1. By adding sufficient HGS to a base fluid, one is able to lower the density of the base
fluid.
2. HGS-based fluids are homogeneous, single-phased, non-compressible, stable and have
useful rheological as well as filtration properties for use in high permeability, low
pressure producing zones.
3. Conventional solids control equipment can be used with HGS-based fluids. Field mixing
of HGS is readily accomplished.
4. HGS based fluids can help avoiding problems like differential sticking in case of when
underbalanced condition is lost.
5. FLC 2000 and MCC based non-invasive fluids can be used in underbalanced operations.
78
Fig 4.1 Sub-hydrostatic workover fluid, oil in water emulsion (Non- toxic oil)
(Refer table A-1 from appendix)
Fig 4.2 Sub-hydrostatic workover mineral oil based fluid formulation
(Refer table A-2 from appendix)
79
Fig 4.3: sub-hydrostatic workover fluids water based fluid formulation
(Refer table A-3 from appendix)
Fig 4.4: sub-hydrostatic workover fluids water based fluid formulation
(Refer table A-4 from appendix)
80
Chapter 5: Conclusion & Recommendations 5.1 Conclusion
Almost every operation of well intervention whether it is initial Completion, Recompletion
including Perforation & Stimulation. They cause irreparable damage to the reservoir resulting in
reduced productivity. It happens because of extraneous fluid invasion into the reservoir in an
overbalanced design to address operator’s genuine concern to keep the well under control.
Development of a safe technique to implement underbalanced design therefore goes well with
the proverb “Prevention is better than the Cure”. The study/reports bring out wide applicability
of underbalanced operations in the following areas:
1. Underbalanced Drilling
2. Underbalanced Workover
3. Underbalanced Perforation.
Although this technology is used to avoid the potential formation damage in the pay zone but
several times underbalanced condition is lost for keeping the well under control or other
associated down hole problems which defeats the aims and objectives of underbalanced
operations.
5.1 Recommendations
The following recommendations are made for underbalanced operations;
5.1.1 Recommendations for underbalanced drilling
Underbalanced drilling is recommended for the selected candidates where the possibility of
formation damage is significant in conventional drilling. Underbalanced drilling is recommended
to employ in severely depleted / mature fields. The sub-hydrostatic fields should be drilled
underbalanced. Non productive time is very critical factor as per the economics of any oil field
operation. The formation where the lost circulation problem and sticking pipe possibility is very
81
much, the NPT increases. Sometimes the problems are severe upto extent of deviating the
wellplan and significant increment in operating cost can be observed. The underbalanced drilling
is recommended for such type of problematic fields as per the economic consideration.
Fluid system selected for the underbalanced drilling are air/gas drilling, mist drilling, foam
drilling. The considerations during the selection of fluid system are wellbore stability as well as
air/gas volume requirement for the cuttings cleaning in air/gas drilling. The formations where the
wellbore stability is limitation to the air/gas drilling are recommended to use water based fluid or
oil in water emulsion based fluid with polymers XCP, PAC (LV), PAC(R). Polymers are used
for better rheological properties. The specific gravity should be reduced by the hollow glass
spheres upto 0.65 as according to the formulation developed (Refer tables A-1-A-4 from
appendix). The specific gravity can be minimized upto 0.65 by adding 40% (w/v) hollow glass
spheres in water. For minimizing or eliminating the possibility of formation damage when
underbalanced condition is lost, the fluid system with FLC2000, POLYOL and Micronized
Calcium Carbonate is recommended.
Safety of human being, environment and costly assets should be taken into consideration before
implementing the operation. The technology should not be implemented on a gut feel basis.
Proper handling of hollow glass spheres is recommended and when planning to use air fluid
system for operation then precaution shall be taken to ensure that explosive mixtures are not
generated at any point of operation. Jointed pipe system or coiled tubing system is
recommended to use as well control equipment. Each element of BOP should be individually
pressure tested to a high and low pressure as determined by the drilling condition anticipated.
Choke, kill line valves and the choke manifold should also be tested during this test sequence.
The accumulator performance should also be examined. The fluid volumes, pre-charge pressure
and pressure regulators are recommended to check out and adjusted prior to the spudding of each
well. After testing of BOP stack the accumulator should also be tested for minimum pressures.
Examination of accumulator and adjusting of operating parameters should be done prior to
function testing the BOP stack.
82
5.1.2 Recommendations for underbalanced workover
The underbalanced workover operation is recommended to exploit the formation to full of its
potential and to protect the reservoir from subsequent damage during each intervention.
Fluid system recommended for underbalanced workover is as like in underbalanced drilling only
the quantity of the polymer added in the low gravity fluid is adjusted as per the desired fluid
rheology.
In order to ensure safety during the workover operations; the Conventional Rig is to be replaced
by Snubbing Unit.
5.1.3 Recommendations for underbalanced perforation
After drilling a well depth upto the desired payzone, the underbalanced perforation is
recommended to achieve maximum benefits from the operation. Although this underbalanced
perforation also leave some detonation debris inside the perforating pathway but some surge
flow from reduction in near wellbore pore pressure mitigates crushed-zone damage and sweeps
some or all of the debris from perforated tunnels. High static pressure differential between
wellbore and formations provide more effective perforations. The rapid fluid influx is
responsible for perforation clean up thus it is recommended for general underbalanced
perforation.
The minimum underbalanced pressure differential is recommended to achieve ‘clean’ perforation
is
Fluid system recommended a very low gravity fluid to achieve maximum underbalanced within
the well bore stability criteria.
83
Because most of the hazards happen immediately after the perforation; Tubing conveyed
perforation (TCP) in underbalanced condition (partly emptying the well using compressor)
should invariably be used. Deep penetrating charges can be used to provide effective and deep
penetration in to the hydrocarbon bearing zones. In fact this should be made an industry standard
for depleted/ sub-hydrostatic reservoirs.
APPENDIX
Table A-1: Composition and properties of sub-hydrostatic workover fluid for underbalanced operation, oil in water emulsion (Non- toxic oil)
S/No.
Composition of
workover fluids
Temp0C Sp.Gr. pH Rheology Remark
AV PV YP Gel0 Gel10 API
F/L
1.
60% Water + 40%
Non-Toxic oil +
1% Emulsifier
At room
temperature
0.9 8.61 4.5 4 1 1 2 - A stable
workover fluid
is formulated
2. Fluid at
Sl.No.1+0.1%
XCP+ 1% PGS+
5% HGS
At room
temperature
0.84 9.15 35 30 10 3 8 - -do-
After hot
rolling at
900C for 24
hours
0.84 9.13 33 29 08 3 7 10.5
ml
-do-
3. Fluid at Sl.No.2+
5% HGS i.e.
(Total 10% HGS)
At room
temperature
0.78 9.25 40 32 16 3 8 - -do-
After Hot roll
at 900C for
24 hours
0.78 9.21 38 31 14 3 7 8.2
ml
-do-
4. Fluid at Sl.No.3+
5% HGS i.e.
(Total 15% HGS)
At room
temperature
0.72 9.35 52.5 42 21 3 8 - -do-
After Hot roll
at 900C for
24 hours
0.72 9.32 50 40 20 3 7 6.5
ml
-do-
5. Fluid at Sl.No.4+
5% HGS i.e.
(Total 20% HGS)
At room
temperature
0.65 9.35 72.5 58 29 5 9 - -do-
After Hot roll
at 900C for
24 hours
0.65 9.31 69 56 25 4 8 5
ml
-do-
Table A-2: Composition and properties of sub-hydrostatic workover fluids for
underbalanced operation, mineral oil based formulation
Sl.
No.
Composition of
workover fluids
Temp0 C Sp.Gr. pH Rheology Remark
AV PV YP Gel0 Gel10 API
F/L
1.
Mineral oil + 0.1% XCP
+1% PGS +10% HGS
At room
temperature
0.85 8.63 10.5 7 7 3 4 - -
2. Fluid at Sl.No.1+ 10%
HGS i.e. (Total 20%
HGS)
At room
temperature
0.75 8.9 20 15 10 2 4 - ---
3. Fluid at Sl .No. 2 + 5%
HGS i.e.( Total 25%
HGS)
At room
temperature
0.72 9.1 29 23 12 3 5 -
--
4. Fluid at Sl. No. 3 + 5%
HGS i.e. (Total 30 %
HGS)
At room
temperature
0.68 9.2 45 36 18 4 6 - ---
5. Fluid at Sl. No. 4 + 5%
HGS i.e. (Total 35 %
HGS)
At room
temperature
0.65 9.33 89 68 37 5 9 - ---
After hot
rolling at
900C for 24
hours
0.65 9.35 87.5 69 37 5 9 50 ml --
Sl.
No.
Composition of workover
fluids
TempoC Sp.Gr. pH Rheology Remark
AV PV YP Gel0 Gel10 API
F/L
1.
Water + 0.1% XCP + 1%
PGS +10% HGS
At room
temperature
0.87 8.95 19 11 16 3 5 -
After hot
rolling at
900C for
24hours
0.86 8.75 12.5 9 7 2 4 150 ml Very high
filtration loss
2.
Water + 0.1% XCP + 1%
PGS +20% HGS
At room
temperature
0.79 9.3 30 22 16 3 6 -
After hot
rolling at
900C for
24hours
0.77 9.1 23 17 12 2 5 165 ml Very high
filtration loss
3.
Water + 0.1% XCP + 1%
PGS +30% HGS
At room
temperature
0.72 9.5 51.5 39 25 5 9 -
After Hot
roll at 900C
for 24 hours
0.72 9.2 42.5 34 17 3 5 170ml Very high
filtration loss
4.
Water + 0.1% XCP + 1%
PGS + 40% HGS
At room
temperature
0.65 9.35 86 65 42 7 12 -
After Hot
roll at 900C
for 24 hours
0.65 9.34 66 64 14 4 7 165 ml Very high
filtration loss
Table A 3: Composition and properties of sub-hydrostatic workover fluids for underbalanced operation, water based formulation
Table A-4: Composition and properties of sub-hydrostatic workover fluids for
underbalanced operations, water based formulation
Sl.
No.
Composition of
workover fluids
Temp oC Sp.Gr. pH Rheology Remark
AV PV YP Gel0 Gel10 API
F/L
1.
Water + 0.5%
Tylose + 10 %
HGS
At room
temperature
0.86 9.30 21.5 14 15 2 4 - -
After hot
rolling at
900C for 24
hours
0.86 9.30 37.5 20 35 3 6 20 ml
2. Water + 0.5%
Tylose + 20% HGS
At room
temperature
0.77 9.20 31 21 20 3 5 -
After hot
rolling at
900C for 24
hours
0.77 9.10 52.5 25 55 4 8 15.0ml
3.
Water + 0.25%
Tylose + 30% HGS
At room
temperature
0.70 9.28 53 30 46 3 6 -
After Hot
roll at 900C
for 24 hours
0.70 9.25 55 42 26 2 6 7 ml
4. Water +0 .25%
Tylose + 40% HGS
At room
temperature
0.65 9.49 55 50 10 2 5 -
After Hot
roll at 900C
for 24 hours
0.65 9.42 60 52 16 3 5 5ml
Sl.
No.
Composition of workover
fluids
Temp0 C Sp.Gr. pH Rheology Remark
AV PV YP Gel0 Gel10 API
F/L
1.
60% Water + 40% Non-
Toxic oil + 1%
Emulsifier+0.1%
XCP+0.7% PAC
(LV)+0.1% PAC (R)+
NaOH
At room
temperature
0.93 9.32 50.5 37 27 7 9 Very
much
Filtration
loss was
very much
2. 50% Water +50% LTMO +
emulsifier(1%) + 0.4%
XCP + 0.7% PAC (LV)+
0.2% PAC(R) + 1.2% FLC
2000 + 0.1% MgO + KOH
At room
temperature
0.92 9.30 52.5 43 19 6 8 14ml Sub-
hydrostatic
workover
fluid
3. Water +3% KCl +
0.45%XCP +1.2% PAC
(LV) + 0.3% PAC(R) +
1.2% FLC 2000 +
3% Polyol + 5 % MCC
+0.1% MgO+
KOH
At room
temperature
0.75 9.25 59 28 62 15 11 -
After Hot
roll @
1000C for
18 hours
0.72(with
foam)
1.02
(without
foam)
9.18 50 28 44 9 8 8ml
Table A-5: Water and oil based Non damaging / Non Invasive fluid formulation for underbalanced workover operation
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