SPE 105536

First Application of Underbalanced Drilling in Fractured Carbonate Formations of

Iranian Oilfields Leads to Operational Success and Cost Savings
A. Hooshmandkoochi, M. Zaferanieh & A. Malekzadeh, National Iranian Oil Company

Copyright 2007, Society of Petroleum Engineers

This paper was prepared for presentation at the 15th SPE Middle East Oil & Gas Show and
Conference held in Bahrain International Exhibition Centre, Kingdom of Bahrain, 1114 March
2007.
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Abstract
Underbalanced drilling techniques (UBD) are evolving at a
fast pace as oil companies learn how to use the technology to
maximize well production and lower finding costs.
Although there was some air drilling through surface drilling
activities in Iran for the past decade, the full package of UBD
equipment and other UBD techniques were not introduced
until National Iranian Oil Company (NIOC) supplied the
package for a pilot project in southern Iran. The first well
selected to be drilled UBD was GS 333, the reason for
selecting that particular well was because the Gachsaran field
is depleted and sever mud losses is experienced while
conventional drilling, also, the UBD technique is expected to
increase productivity of the well by decreasing formation
damage resulted from drilling fluid losses.
The drill pipe injection technique was proposed to be utilized
in this well because of its suitability for the well conditions
where it is not expected to drill through the gas cap and the
well will be completed in 8 open hole.
This paper discusses the well design, UBD design parameters,
Underbalanced modeling considerations and the lessons
learned from this job which all led to the success of this
project. It is also describe the process used to address HSE
issues of the project in the face of the potential presence of
H2S while drilling. The drilling and production results that
were achieved were significant to the future operational
potential and viability of this mature field. Of equal
importance was the success of the operation from a health,
safety and environmental (HSE) perspective in an
environment in which the industry has been traditionally
reluctant to use UBD techniques.
Introduction
NIOC GS 333 was the 1st well of the NIOC UBD campaign.
The well was drilled from 2,630 m (9 5/8 shoe depth) to a

total depth of 2,938 m MD (2567m TVD). The underbalanced

section of this well was drilled in approximately 99 hrs.
The key performance indicators included:
1. To drill the deviated reservoir section from 2,630 m MD
to 2,938 m TD eliminating/minimizing lost circulation
such that no drilling time is lost curing losses or
associated with drilling problems.
2. To eliminate, as far as realistically possible, formation
damage caused by the loss of conventional drilling fluid
to the formation while drilling overbalanced.
3. To eliminate, as far as realistically possible, impairment
of the reservoir formation by damaging fluid or material.
4. To evaluate and characterize the reservoir production
rates along the well path.
To
achieve
these
key
performance
indicators,
NIOC/Weatherford UBS was enlisted to provide
underbalanced drilling services along with RIG 78,
Schlumberger (MWD, motor and directional services). GS333 was drilled using a nitrified Diesel circulating system
employing the drill string injection UBD technique.
Procedures were put in place for the maintenance of constant
bottomhole pressures and reduction of pressure transients.
UBD on this well experienced some typical logistical and start
up problems associated with a steep learning curve, this being
the first such operation in Iran. Despite all the problems
encountered the well GS-333, was:
Drilled to 308 m of total open hole depth.
No loss circulation was encountered while drilling.
Successfully implemented UBD technology.
No QHSE incidents were recorded.
Objective
The primary objectives of this underbalanced drilling project
are to:
Minimize drilling induced formation damage
Eliminate drilling fluid losses
Improve drilling performance
Well plan
GS 333 is a new drill, underbalanced deviated well. The well
plan is as outlined in Figure 1 [2].
Geological and Reservoir Description
The target reservoir for the GS 333 is Asmari formation, the
formation is fractured carbonated formation. The reservoir

drive mechanism is Gas Cap. Shale strings are not expected in

this formation.
Expected reservoir pressure and temperature are 2622 psi and
141 F, respectively. Reservoir fluid is oil with API gravity of
25, GOR 564 SCF/STB, H2S concentration of 240 ppm. The
permeability of the reservoir is 0.1 1000 md with a porosity
of 9% [2].
Underbalanced Drilling Design Parameters
Casing Design- 9 5/8 casing design was checked for
underbalanced drilling operations and the result shows there is
no need for any casing modifications.
Rig Modification- There are no essential modifications to be
made on the rig to suite UBD operations. The substructure has
to be high enough to allow RCH to be installed on top of the
Hydril.
BHA and Drill String Design- The plan is to use a 5 DP and
5 HWDP on 6 BHA. The BHA consists of 6 Mud
Motor and MWD to drill 8 hole.
Drilling Fluid Selection- The drilling fluid selection is one of
the most critical decisions in planning an underbalanced well.
The right fluid(s) selection will not only lead to suitable BHCP
but will also minimize pressure transients and thus
eliminating/minimizing formation impairment. The deviated
underbalanced section of GS 333 is to be drilled with a
Gachsaran field native crude oil and a membrane nitrogen
generation circulating system.
Liquid Phase- The native crude oil was chosen over Diesel
and other drilling fluids because it is the natural reservoir fluid
for this well. This will minimize chances of formation
damage in event of pressure transients and/or from fluid
imbibitions. If the reservoir fluid available on location is too
heavy to achieve UBD conditions with the available nitrogen
rate, the use of diesel will be recommended to initiate UBD
condition with nitrogen. The well will be displaced with the
produced fluid after getting enough oil production.
Gas Phase- Nitrogen was selected as the injection gas because
of its inert nature, economic availability and suitability for this
specific underbalanced drilling project. Nitrogen will be
obtained from the surrounding air and generated onsite, by
NIOCs nitrogen production unit.
Operating Envelope and Optimum Rate- The multiphase
flow behavior in the wellbore during underbalanced drilling is
very complex. The response of the downhole conditions to
changes in various flow parameters must be characterized
prior to the commencement of underbalanced drilling
operations in order to maximize chances of success.
Figure 2 contains a plot of the bottom hole circulating
pressures induced by a variety of nitrogen rates and the
Gachsaran native crude oil injection rates. This plot is
referred to as the operating envelope. Also plotted on the
operating envelope are the various constraints that must be
fulfilled during underbalanced drilling operations. The range
of flow rates that satisfy all of the constraints, defines the
acceptable operating region. A minimum drawdown at the bit
of 200 psi is required to ensure adequate underbalanced
conditions in the well, with a maximum drawdown of 300 psi
to minimize any near wellbore depletion effects.
The target bottom hole circulating pressure at the bit for this
well is 2300 - 2400 psi. The downhole conditions are also

SPE 105536

constrained by the ability of the circulating system to

effectively achieve an underbalanced state, provide adequate
hole cleaning, power the BHA and provide well control. The
maximum nitrogen generation capacity of the underbalanced
drilling package, under local conditions, is also factored in.
Typically, the flow rates are also constrained by the maximum
and minimum downhole positive displacement motor
equivalent flow rates [2].
Drilling Fluid: Nitrogen and Native Crude Oil (0.9 SG).
Injection Rates = 600 - 1400 scfm N2 & 240 - 360 gpm
Crude Oil.
Optimum Rate = 1400 scfm Nitrogen and 320 gpm
Crude Oil
Induced BHCP = 2300 psi (no production); Wellhead
Pressure = 50 psi
Reservoir Pressure = 2622 psi
Min Motor flow = 300 gpm; Max Motor flow = 550 gpm
Min Vertical Velocity = 165 ft/min
H2S
Hydrogen sulfide (H2S) is a major concern in hydrocarbon
production. Operating problems caused by H2S can include:
severe corrosion and fouling, injection well plugging with iron
sulfide and QHSE problems associated with H2S gases. Trace
amounts of H2S are anticipated. A thorough monitoring
system will be put in place before the underbalanced drilling
phase in preparation for any emergencies. The advice of
Weatherford QHSE department will be fully enlisted. H2S
scavenger is to be supplied by NIOC and to be added to the
Native Crude if needed while drilling reservoir section of this
well underbalanced.
Operations
The 8.5-inch directional wellbore was drilled with a nitrified
Diesel to a total depth of 2,938 m MD (2,567 m TVD) with
one motor and two bits. The directional bottom hole assembly
(BHA) consisted of a 8.5-inch tri-cone bit, a 6-7/8 inch
positive displacement motor (PDM having a 1.5o bent
housing) with a drillstring consisting of 5-inch drill pipe and
heavyweight drill pipe. A MWD tool was incorporated in the
BHA for survey telemetry.
The Top hole of GS-333 directional well was drilled
conventionally and cased with a 9 5/8 casing to 2,630 m MD.
The Shoe track was drilled out to 2630 m with fresh Water,
prior to arrival of UBD equipment and crew. A new BHA with
directional tools were made up and run into the hole.
The hole was initially displaced to Diesel and circulated for
two complete circulations. A two-phase flow commenced with
400 gpm of Diesel and 800 scfm of N2. The BHCP before
drilling operations commenced was calculated at 2275 psi. A
total of 307 m of directional wellbore was drilled at 10% to
20% drawdown. Average liquid injection rate was 400 gpm,
and average N2 injection rate was 900 scfm [3].
Production/Losses While Drilling
During the underbalanced section of this well, no losses were
encountered. Also no oil and gas production were recorded
while drilling the underbalanced drilling section [3].

SPE 105536

Lessons Learned
Hydrocarbon based fluids are particularly susceptible to
the increase of density due to natural solids accumulation.
This warranted accurate monitoring of the diesel to make sure
that the re-injected diesel would not exceed 1 % of solids
content. It is important to ensure that minimal drilling fines
are re-circulated back into the wellbore.
High fines
concentrations will increase slugging and the likelihood of
BHCP spikes.
It is crucial to minimize the time with the pumps off
during a connection. The rig crew should be on the rig floor
with the tongs ready to break off the Kelly as soon as it is bled
off. Every effort must be made to start the pumps as soon as
possible after a connection has been made. Any time saved
during the pumps-off period will also reduce the amount of
time required to regain circulation prior to drilling ahead and
also reduce pressure transients.
During underbalanced drilling operations, mud weight
often increases as a result of the milling action of the drill bit
on the formation. This was present while drilling on GS-333.
For the 307 m drilled, the density of the diesel changed from
52.5 pcf to 54.5 pcf. Although increasing nitrogen injection
rate compensated this increase in density, it is highly
recommended to reduce the solids in the surface system by
continuous dilution with fresh diesel. Deployment of
centrifuge also may aid to reduce percentage of solid particles
in the active liquid system.
The Data Acquisition System will provide more value to
the UBD Engineering and separation team with the integration
of more data points from the rig and MWD provider. Digital
stroke counters can be added to the rig pumps and taken
directly into the Data Acquisition to provide real-time injected
fluid rates.
Conclusions and Recommendations:
1. The NIOC GS-333 well was successfully drilled to the
target total depth.
2. No loss circulations were encountered while drilling UBD
section.
3. During Underbalanced drilling, base liquid weight often
increases due to the penetration of new hole, on the
formation. This natural solids accumulation will no doubt
result in increased effective bottomhole circulating
pressures and may make maintenance of underbalanced
conditions difficult. Therefore accurate monitoring of
the base liquid weight on a continuous basis is essential
for the proper evaluation and monitoring of
underbalanced states.
4. As this was the first directional underbalanced drilling
project, in this Field, a steep learning curve was the case
for everyone involved at various stages of the GS-333
well.
5. Good communication and following the well program is
important for successful underbalanced drilling
operations.
6. Planned and applied correctly, underbalanced drilling
technology can address problems of formation damage,
lost circulation and poor penetration rates. The ability to

investigate and characterize the reservoir while drilling is

another important benefit of underbalanced drilling.
7. As gas percentage in the drillstring has a significant effect
on conventional MWD survey tool performance.
Alternative survey tools such as EM-MWD or concentric
gas injection needs to be considered for future UBD
wells.
8. The effect of long connection periods could be greatly
reduced by proper operating practices, which include
among others, the use of trained rig crews capable of
making connections in a rapid and yet safe fashion.
9. The ability to obtain real time bottom pressure would be
an additional benefit to UBD engineering during the
operation. It is highly recommended the use of PWD
measuring tool for the future UBD wells to accurately
measure and analyze bottom hole parameters.
Acknowledgement
The authors wish to thank NIOC for permission to publish this
paper, and to the many whose efforts on the wellsite
contributed to the success of the completion.

References
1. Mc Lennan John., et al Underbalanced Drilling Manual
Published by Gas Research Institute Chicago, Illinois, 1997, GRI
Reference No.GRI-97/0236.
2. NIOC, South Drilling Engineering Division, Underbalanced
Drilling Program for well GS 333. December 2004.
3. NIOC, South Drilling Department, Underbalanced End of Well
Report, Well GS 333, Gachsaran Field, 2005.

SPE 105536

Figure 1. Well Profile Diagram

Figure 2. Operational Envelope Native Crude

BHCP vs Oil and Nitrogen Injection Rates

NIOC, GS 333
Gachsaran Field, Iran
3000

Static Reservoir Pressure 2,622 psi

2800
240gpm
2600
BHCP (psi)

360gpm
320gpm

Min. Liquid Velocity

2400

Max. Motor Flow Rate

100gpm
Operating Area

2200

60gpm

80gpm

280gpm
2000
Min. Motor Flow Rate
1800
400

600

800

1000
N2 Injection rate (scfm)

1200

1400

1600