OTC 22654

Case Study: A High Throughput Mud-Gas Separator for Underbalanced

Drilling
Chris LeBlanc, Marco Amorim, and Roberto Piacentini - National Instruments

Copyright 2011, Offshore Technology Conference

This paper was prepared for presentation at the Offshore Technology Conference Brasil held in Rio de Janeiro, Brazil, 4–6 October 2011.

This paper was selected for presentation by an OTC program committee following review of information contained in an abstract submitted by the author(s). Contents of the paper have not been
reviewed by the Offshore Technology Conference and are subject to correction by the author(s). The material does not necessarily reflect any position of the Offshore Technology Conference, its
officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written consent of the Offshore Technology Conference is prohibited. Permission to
reproduce in print is restricted to an abstract of not more than 300 words; illustrations may not be copied. The abstract must contain conspicuous acknowledgment of OTC copyright.

Abstract
Underbalanced drilling (UBD) is a drilling technique in which hydrodynamic pressure, exerted by the drilling mud and
circulating fluids in the well bore, is below the pressure of the well formation. In UBD applications the surface pressure is
lower than the well pressure, resulting in the flow of hydrocarbons to the surface at a controlled rate. This drilling technique
requires specialized surface equipment for continuous separation of the drilling mud and hydrocarbon components for
recirculation, sampling, storage, flaring, and disposal. Underbalanced Drilling technology provides significant technical and
economical value and reduces damage to the well formation. This paper highlights how custom-off-the-shelf technology
provided a cost-effective solution where Petrobras was able to reduce the time required to reach full production and eliminate
or reduce, the fracturing required after a well is completed.
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Index Terms — Computer-based instruments, Energy,

Graphical Programming, Real-Rime System Deseign,
Underbalanced Drilling

I. INTRODUCTION
In order to keep up with world consumption needs for
oil derivatives and the growing number of depleted
reservoirs around the world, oil companies must
constantly research new sources of petroleum, as well as
improve the efficiency of traditional drilling technologies.
One of the technologies increasingly being used
worldwide is known as underbalanced drilling.
Drilling operations are classified by the pressure Figure 2: Underbalanced or managed pressure drilling technique [4]

differential between drilling fluid and reservoir. In

conventional or “overbalanced” method, the drilling fluid ,
which is responsible for cooling the drill bit and carrying
rock cuttings away from the drill bit[1], is pumped into the
well shaft at pressures that are higher than the reservoir
being drilled (Fig 1).
Figure 1: Conventional or Overbalanced drilling technique [2]
Excessive overbalance can dramatically slow the
drilling process by effectively strengthening the near-
wellbore rock and limiting removal of drilled cuttings
under the bit. In addition, high overbalance pressures
coupled with poor mud properties can cause differential
sticking problems [3]. Another challenge in over balanced
drilling application is to keep the fluid pressure at within
appropriate levels as reservoir pressures vary from one
formation to another. If too much pressure is applied,
drilling fluid and mud is forced into the formation (process
called invasion), which could cause damages to the
formation as well as decrease flow rates.
In underbalanced drilling (UBD), or managed pressure
drilling, drilling fluid is pumped into the well shaft at
lower or equal pressures than the reservoir being drilling
(Fig. 2).
Chris LeBlanc is with National Instruments, 148 S. Dowlen PMB
#604, Beaumont, TX 77707 USA (e-mail: chris.leblanc@ni.com).
Marco Amorim is with National Instruments Brasil, Av. Paulista,
509, Sao Paulo, SP 013911 BRASIL (e-mail:
Hmarco.amorim@ni.comH)
Roberto Piacentini is with National Instruments, 11500 N. Mopac
Expwy, Austin, TX 78759 USA (e-mail: roberto.piacentini@ni.com).
By utilizing a light-weight drilling fluid that applies
less pressure than formation pressure, flow from the
reservoir is driven into the wellbore during underbalanced
drilling, rather than away from it (overbalanced drilling).
This prevents damage to the reservoir rock and allows oil
and gas to flow freely, resulting in increasing production.
Although more costly to set up, underbalance drilling
reduces common conventional, or overbalanced drilling
problems, such as lost circulation, differential sticking,
minimal drilling rates, as well as extending the life of the
drill bit because the drilling gases cool the bit while
quickly removing cuttings [5]. These added benefits; helps
offset the initial added cost to underbalanced drilling.
In UBD, flow control instead of primary well control
(drilling fluid pressure is higher than formation pressure
but less than fracture gradient while drilling) becomes the
dominant control methodology [6]. In the flow control
methodology, the influx of formation fluids must be
controlled and maintained between two pressure
boundaries: the lower limit being the borehole stability or
the flow rate or pressure capacity of the surface
equipment, and the higher limit being the formation
pressure.
Besides the controlling the flow and keeping the
drilling fluid pressure within the underbalanced pressure
window, another challenge of underbalanced drilling is
related to the fact that drilling fluid that returns to the
surface will contain other elements besides drilling fluid
such as hydrocarbon fluid, and rock cuttings. All of this
material will need to be controlled and separated at the
surface by a separation unit. This separation unit is
specialized equipment that separates the material
components, meters the return material (oil and gas to
production systems), drilling fluid for return to the system,
and rock cuttings are disposed.
Petrobras has deployed UBD technology in the field to
reduce the time required to reach full production and
eliminate, or at least reduce, the fracturing required after a
well is completed. This paper is intended to describe how
Petrobras developed a high-throughput Mud-Gas
Separator for Underbalanced Drilling, in record time
saving between US$500K and US$2M depending on the
OTC 22654 3

size of the well and the cost of a fracturing job.

II. THE USES OF UNDERBALANCED DRILLING

While underbalanced drilling techniques are not new, it
was however, considered a niche application and only
utilized in certain areas of the world. During the mid-
1980s, horizontal drilling became fairly common and
helped to spur resurgence in underbalanced drilling
operations. In addition to horizontal drilling, other factors
leading to increased underbalanced drilling include: closed
systems, high-pressure rotating control devices,
electromagnetic MWD systems, better rock and reservoir
analysis, and the ability to re-circulate fluids. While these Figure 3. The effect on drilling rate of reduced mud weight or reduced differential pressure [8].

factors have contributed to the increased use of

underbalanced drilling techniques, we will also describe
the performance and technical considerations for these
applications. As mentioned earlier, underbalanced drilling
requires more equipment and attention to the drilling
process than conventional overbalanced drilling. Given
the additional cost, major economic advantages must exist
for UBD. Specifically, from a geological perspective
there must be a high probability of success. Additionally,
the drilling program must be planned to maximize the
advantages of UBD and minimize other drilling and
completion problems. The proper uses of UBD must
consider the proper geologic and hole conditions, and the
drilling program for UBD. The best uses of UBD are to
increase the drilling rate, avoid or limit lost circulation,
reduce completion, avoid differential sticking, find
potential reservoirs. Examples that fulfill these conditions
include: horizontal drilling, geothermal drilling, depleted
reservoirs, and old or poorly logged hydrocarbon
producing sections. In the next section we’ll look at the
drilling rate.
IV. MEASUREMENT AND CONTROL OF THE SURFACE
SEPARATION UNIT
The mud-gas separation system, or surface separation
unit, for UBD continuously separates a multiphase fluid
consisting of gas, liquid, cuttings, and drilling mud before
recycling the drilling mud into the well bore. It is required
that the surface separation unit be a rugged system capable
of withstanding the harsh environment of the well site. As
part of its function the system will have to control and
measure at high enough rates so as to keep up with the
returning fluid flow. Accuracy is key to such a system due
to its critical measurement nature and speed of the system.
As part of this surface separation equipment, a high speed
measurement and control platform is required to deliver
the necessary sampling rates and measurement accuracy
all within a rugged platform capable of surviving field
conditions [7].

III. INCREASED DRILLING RATE

Critical to understanding UBD, operators need to
understand the relationship ratios of mud weight and
drilling rate. For instance, when the mud weight
decreases, the drilling rate increases. This critical point
for the drilling rate is approximately 500-psi overbalance.
As overbalance pressure decreases to less than 500-psi, the
drilling rate continually increases. The drilling rate
increase continues into the underbalanced range until a Figure 4: Probe SC-95 operating UBD in Estreito field,
state of Rio Grande do Norte, BR
point is reached where operators need more bit energy
(weight and speed) is needed, or where the bit begins to
flounder. Bit flounder occurs when the cuttings are not Petrobras UBD system requirements include: (A)
cleaned out from under the bit fast enough and the bit Compact design that can handle high flow rates of gas and
redrills the cuttings. Figure 3 illustrates the differential liquid, (B) Dynamic response to injected or produced
pressure when the drilling rate starts and increases to Bit variations in gas flow rates and pressures, and (C) Support
Flounder. for nonstandard flow phenomena when drilling with
compressible fluids.
Next we will explore the key technologies required
for high speed and high accuracy measurement and control
systems that meet Petrobras system requirements
described earlier.
4 OTC 22654
V. TECHNOLOGIES FOR MEASUREMENT AND CONTROL
Underbalanced drilling requires hardware and
software technologies that respond in real-time to
variations in the pressure or flow rates from injected or
produced variations in the dynamic systems - thus
performing high-speed measurements [7]. Also, it is
necessary to be flexible enough to be configured to
communicate with drilling control programmable logic
controller (PLC) and connectivity to remote systems.
The challenges engineers and scientists face in
developing real-time systems include (1) programming
applications that employ precise timing and absolute
reliability, (2) sharing data efficiently without affecting
determinism among multiple processes, or logical nodes
that are either directly connected on a single PCB or box
or remotely connected on a network, (3) coordinating all
nodes as a single system, including the timing and
synchronization between nodes, (4) integrating different
types of I/O such as high-speed digital, and analog
waveforms, (5) incorporating additional services to the
data shared between nodes, such as logging, alarming,
remote viewing, and integration with enterprise SCADA
systems.
The following sub-sections discuss key technologies
and approaches to mitigate the new challenges introduced
by distributed intelligence applications.
A. Graphical Programming Languages
These advanced concepts are commonplace not only
in oil and gas but also in other demanding industries such
as military/aero and automotive. With the introduction of
graphical programming languages, such as National
Instruments LabVIEW that leverage the data flow
paradigm, the complexity of such concepts can be
abstracted at a higher level facilitating application and
system development. In the data flow paradigm, a program
node executes when it receives all required inputs. When a
node executes, it produces output data and passes the data
to the next node in the dataflow path. The movement of
data through the nodes determines the execution order of
the VIs and functions on the block diagram. Visual Basic,
C++, JAVA, and most other text-based programming
languages follow a control flow model of program
execution [8]. In control flow, the sequential order of
program elements determines the execution order of a
program. For a dataflow programming example, consider a
block diagram that adds two numbers and then subtracts
50.00 from the result of the addition, as shown in Figure
4. In this case, the block diagram executes from left to
right, not because the objects are placed in that order, but
because the Subtract function cannot execute until the Add
function finishes executing and passes the data to the
Subtract function. Remember that a node executes only
when data are available at all of its input terminals and
supplies data to the output terminals only when the node
finishes execution.
Figure 5: Dataflow Programming Example
The graphical programming approach addresses those
programming challenges by providing the tools to program
real-time applications using an intuitive block diagram
methodology that is familiar to engineers and scientists.
This approach to developing applications significantly
reduces the learning curve because graphical
representations are more intuitive design notations than
text-based code. You can access the tools and functions
through interactive palettes, dialogs, menus, and hundreds
of function blocks, known as VIs (virtual instruments).
You can drag and drop these VIs onto a diagram to define
the behavior of your real-time applications. This point-
and-click approach shortens the time it takes to get from
initial setup to a final solution. Additionally, the ability to
leverage a high-level diagram offering a clear system
functionality view dramatically reduces the complexity
and increases the efficiency of real-time application
development.
B. Communication and Data Transfer
Real-time application development also requires
various forms of communication and data sharing.
Addressing communication needs between often
functionally different system nodes is challenging. While
various standards and protocols exist for communication –
such as Modbus, DNP3, 60870, RS232, RS 422, RS 485,
TCP/IP – one protocol cannot usually meet all of an
engineer’s needs, and each protocol has a different API.
This forces engineers designing real-time systems to use
multiple communication protocols to complete the entire
system. For deterministic data transfer between nodes,
engineers are often forced to use complex and sometimes
expensive solutions based on technologies such as
reflective memory, EtherCAT, and Modbus. In addition,
any communication protocol or system an engineer uses
also must integrate with existing enterprise SCADA
systems. One way to address these often competing needs
is to abstract the specific transport layer and protocol. By
doing this, engineers can use multiple protocols under the
hood, unify the code development, and dramatically save
development time. Once more graphical programming
languages addresses these challenges with flexible, open
communication interfaces that provides data sharing
among multiple device nodes (for example, downhole
pressure measurement system, drill bit positioning system
and flow-control system) and integrates with SCADA
systems.
One technology that offers much needed abstraction
mechanism for communication protocols is the Object
Linked and Embedded for Process Control (OPC). OPC is
OTC 22654 5

the original name for a standard developed in 1996 by an NI LabVIEW also provides connectivity to the drilling
industrial automation industry task force. The standard control PLC through an RS-232 serial drive and
specified the communication of real-time plant data connectivity to a remote system [7].
between control devices from different manufacturers. The
standard is now maintained by the OPC Foundation and
has been renamed the OPC Data Access standard [9].
It is an open standard that permits a consistent
method of accessing field data from plant floor devices.
This method remains the same regardless of the type and
source of data. Traditionally, any time a software package
needed access data from a device, a custom interface, or
driver, had to be written. The purpose of OPC is to define
a common interface that is written once and then reused by
company, SCADA, HMI, or custom software packages
[9].

Figure 7. ALEPH system interface for end-user

In addition to enabling the integration of all data

Figure 6. OPC is designed to improve enterprise system connectivity
By levering graphical programming languages and
high-speed data acquisition devices, Petrobras designed a
vertical-pressure operating helical separator, equipped
with an automatic supervisory and control system for land
and offshore operations. The next section details the
acquisition and control system for land operations.
acquisition and management functions in a single
environment, it was developed with a specific driver for
LabVIEW to communicate with the controller SMAR
CD600. The playback mode is a special feature for the
purpose of training and analysis of field operations: the
recorded data can be read and played on the screen as in
the operation (playback) [11].
The control system is divided into two loops: one
control loop for level measurement and another control
loop for pressure measurement. The control mesh is made
by one SMAR CD600 controller and management by the
software allows changing of set points and manual control
of the electro-pneumatic control valves [11]. Figures 8 and
9 respectively shows a high-level functional diagram of
the server and client sides modes of operation.

VI. REAL-TIME MUD-GAS SEPARATION TECHNOLOGY FOR

LAND OPERATIONS
The mud-gas separation system uses an HMI/SCADA
application, ALEPH, which was designed using National
Instruments LabVIEW, graphical programming language;
a microcomputer that runs the NI LabVIEW application;
drivers for integration with other programmable logic
controllers (PLCs); and screens for operator control of the
UBD operation.
ALEPH and NI LabVIEW provide process diagram
visualization, separator measurements, and real-time
control loops for the continuous separation. The data
acquisition system measures:
• Drill bit position through an electromagnetic
measurement while drilling (EM MWD);
• Gas and liquid flow rates;
• Liquid height and pressure within the Figure 8. High-level functional diagram of server side operation mode

separator;
• Downhole pressure measurements and
control valve positions through intrinsically
safe sensors and transmitters capable of 4-20
mA;
6 OTC 22654
Figure 9. High-level functional diagram of client side operation mode
VII. CONCLUSION
NI LabVIEW system exceeded Petrobras' design
requirements, providing real-time measurements and
trending to equip operators with better data for decision
making and improved safety along the drilling operations
[7].
The strongest results from this separating system
consist of making available in one place all data
acquisition needed to execute the operation of
underbalanced drilling and the flow control output that
reduces the oscillation amplitude of pressure at the bottom
of the well.
The equipment onshore wells has been tested and
approved via real scale tests in the municipality of Taquipe
- Bahia, and also in the drilling of four wells in Campo de
Estreito - Rio Grande, where interpretations of events in
real time allowed safer decisions during the operation [7].
In sum, the system met all design requirements describe
earlier including:
• Safety – intrinsically safe sensors and a
separate UBD control PLC
• Flexibility – flexible software and modular
hardware for additional I/O
• Integration – open protocols and LabVIEW
software with a wide range of connectivity
• Ease-of-use – LabVIEW graphical
development environment
VIII. ACKNOWLEDGMENTS
The authors gratefully acknowledge the contributions
of Theresa Woodiel for her work on reviewing this
document, and Manoel Feliciano da Silva Jr & José Luiz
Arias Vidal from PETROBRAS – Petróleo Brasileiro S.A.
IX. REFERENCES
Technical Reports:
[1] Standard Handbook of Petroleum & Natural Gas
Engineering, William C. Lyons and Gary J. Plisga, Second
Edition
[2] Airdrilling Associates,
http://www.airdrilling.com/images/s-conventional-
drilling.jpg
[3] Schlumberger, Overbalance definition,
http://www.glossary.oilfield.slb.com/Display.cfm?Term=o
verbalance
[4] Airdrilling Associates,
http://www.airdrilling.com/images/underbalanced-
drilling.jpg
[5] Rigzone, How underbalanced drilling work,
http://www.rigzone.com/training/insight.asp?insight_id=3
12&c_id=1
[6] Bourgoyne, A.T. Jr.: “Well Control Considerations for
Underbalanced Drilling”, paper 38584 presented at the
SPE Annual Technical Conference and Exhibition held in
San Antonio, Texas. 5-8 Oct. 1997.
[7] Petrobras Uses NI LabVIEW to Develop a High
Throughput Mud-Gas Separator for Underbalanced
Drilling http://sine.ni.com/cs/app/doc/p/id/cs-784
[8] Graphical Programming:
http://zone.ni.com/devzone/cda/tut/p/id/12255
[9] Connect LabVIEW to Any Industrial Network and PLC
http://zone.ni.com/devzone/cda/tut/p/id/5407
[10] Graphical programming saves Petrobras up to $2 million:
http://www.instrumentation.co.za/news.aspx?pklnewsid=2
6275
[11] Sistema de Instrumentação e Controle para Separadores
Multifásicos Aplicados a Perfuração Sub-Balanceada de
Poços de Petróleo http://sine.ni.com/cs/app/doc/p/id/cs-
12393
[12] A Petrobrás utiliza tecnologia NI LabVIEW para melhorar
a Exploração de Petróleo e Gás
http://digital.ni.com/worldwide/portugal.nsf/web/all/3DA4
E248A64B0663802573D20057CDBA
OTC 22654 7

X. BIOGRAPHIES

Chris LeBlanc manages National

Instruments North American customer and
partner projects for oil and gas and utilities
sectors. As part of his role, his
responsibility includes senior-level
leadership for delivering customer solutions
and planning while also acting as the
communication conduit to clients and
National Instruments. He is a member of
SPE, and IEEE. LeBlanc received his
electrical engineering degree from Lamar
University and his expertise includes: real-time, embedded, and
industrial monitoring and control systems. He is based in Houston,
Texas.

Marco Amorim was born in Itumbiara,

GO, Brazil on December 10, 1976. He
graduated with a Bachelor of Science
degree in Electrical Engineering from the
School of Engineering at Federal University
of Uberlandia (UFU) in 2000, and currently
pursuing a masters’ degree in Business
Administration from The Business School
Sao Paulo (BSP). He joined National
Instruments in 2003 as an applications and
software engineer with increasing levels of
responsibility including Sales Manager for Electronics Workbench, now
a National Instruments Company, Business Development Manager for
Academic Teaching&Research, and recently Business Development
Manager for Energy, Oil&Gas. He is based at National Instruments
Branch Office in Sao Paulo, SP, Brazil

Roberto Piacentini was born in São Paulo,

Brazil on October 6, 1973. He graduated
with a bachelor of science degree in
Electrical Engineering and Computer
Science from the São Paulo. Polytechnic
School at the University of São Paulo in
1999, and with a masters’ degree in
Business Administration from The
University of Texas Red McCombs School
of Business. Throughout his career he
managed large, complex customer
technology programs for energy, utilities,
and oil and gas customers worldwide. His
responsibilities include senior-level leadership for structuring customer
technology solutions and program planning and administration. He also
acts as a communications liaison to client and executive sponsors and
ensures the schedule, budget, and quality of customer deployments..
Piacentini is a member of the Brazilian Professional Engineering Society
(CREA-SP) and IEEE Power & Energy Society, and he actively
participates in the Center for the Commercialization of Electric
Technologies (CCET) and the North American SynchroPhasor
Association (NASPI). He joined National Instruments in 2000 as a senior
applications and software engineer with increasing levels of
responsibility including R&D Group Manager for Embedded Real-Time
Control software. He is based at National Instruments headquarters in
Austin, Texas.