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David R. Giffin, SPE, Symbol Inc., and William C. Lyons, Ph.D, NM Institute of Mining and Technology
Substitution and integration of this equation into our air Equation (2) must be integrated numerically for mist, aerated
drilling system as shown in Appendix A yields: fluid, and foam drilling because Qm is no longer equal to zero.
(2) (8)
dP dP
∫ = ∫ OH d h ∫ = ∫ OH d h
Pbh Pbh
Po 2 Po 2
Po Tav Po Tav
Qo +Qm Qo +Qm
I
t 1+ f P To It 1+ f P To
P T 2g(Dh − Dp ) π 2 2
P T 2g(Dh − Dp ) π 2 2
o av Qo +Qm (
Dh − Dp ) o av Qo +Qm ( )
Dh − Dp
4 4
P To P To
By substituting the von Karmin6 “rough-pipe” flow equation
for turbulent flow condition the friction factor equations: where
2
2
1
1 (9) f =
(3) f = 2 log Dh − D p + 1.14
2 log D + 114
.
e e
where
Computer simulations of these equations were used to model
e for pipe is 0.00015 ft. the wells described herein.
e for open hole is 0.01 ft. The minimum flowrate for all of the air and gas drilling
models can be evaluated using the minimum kinetic energy
Equation (2) can be simplified for air and gas drilling by (per unit volume) criteria. The criteria states that the
setting Qm=0 and integrated to obtain a closed-form solution minimum kinetic energy in the well (usually at its deepest and
for Pbh. The closed-form solution for Pbh is: largest annular cross-sectional area) must be equal to or
greater than the kinetic energy of sea level air with a velocity
0.5 of 50 ft/sec (Angel’s criteria).
2 2a a H
(
(4) Pbh = Po + baTav e
2
) Tav
−b T
2
a av The kinetic energy of sea level air is:
where 1 γm ix 2
(10) K E sl = v
π 2 2 g sl
S Dh (62.4 )(2.7 )K
(5) a a = + 4 Where vsl is the specific weight of air standard sea level
R Po Qo conditions (lbs/ft) and vsl is the criteria reference velocity of
To 50 ft/sec.
The kinetic energy at the deepest and largest annular
2
cross-sectional area is usually just above the collars or where
f Po Qo2 the annulus increases in size such as at a liner top. Thus, the
(6) ba =
( )
2 g Dh - D p To π
2
Dh2 - D p2 ( )
2
kinetic energy at these conditions is:
4 1 γh 2
2 (11) KEh = v
2 g h
(7) f =
1 The computer derived solutions to the equations were used to
Dh − D p model the wells listed as case histories prior to actual drilling.
2 log .
+ 114 The computer simulation contains a ratio of Equation (11) to
e Equation (10) as a non-dimensional kinetic energy index
(KEI) to check minimum volumetric gas rate as stated herein
step wise throughout the annulus of the wells. The aerated
IADC/SPE 59166 CASE HISTORIES OF DESIGN AND IMPLEMENTATION OF UNDER BALANCED WELLS 3
fluid and foam drilling models utilize a minimum cutting size Case History #3. Table I shows pressures expected versus
instead of KEI. those measured while drilling for all of the case histories.
Another technology that was used in several of these case
histories was a nitrogen membrane separation unit. These Case History No. 2
separation units were first introduced to the UBD market in The OXY USA Pirkle #2 was drilled in January of 199610.
19937. In essence, they strip oxygen from the air stream and The well was drilled into the Cretaceous Frost “A” zone of the
discharge an oxygen-depleted stream downstream to the lower Pettit limestone at 6,000 ft. TVD in the Carthage field,
booster compressor units. They have proven to be beneficial Panola County, Texas. A 1400 ft. lateral section was
in reducing down hole burn off and oxygen induced completed open hole with a bottom hole pressure of 185 psig.
corrosion8. The discharge stream is typically 50 - 60% of the A 6 ¼ inch hole was drilled out of 7 inch casing landed at
original input volume and contains 3-7% oxygen. 84.25o 6252 ft. MD just into the top of the Frost “A” pay zone.
A string of 3 ½ inch and 3 ½ inch heavy weight drill pipe was
Design Information used to drill the 6 ¼ inch lateral.
To design an underbalanced drilling fluid, the engineer must The drilling rate peaked at an instantaneous rate of 318
know the proposed well diagram, anticipated production while ft/hr with an average penetration rate of 87 ft/hr. The well was
drilling, and reservoir pressure. Next, either Angel’s Curves, drilled with 2500 SCFM and 2000 SCFM of membrane
prior UBD experience in the area, or Poettman and Berman’s generated nitrogen to 7,002 ft MD. Surface pressures were
Two Phase Flow Chart9 are used to determine a starting 600 psig and 450 psig respectively. Computer modeling
volumetric rate for the air, gas, and fluid. These starting flow showed the surface pressures to be 580 and 490 psig
rates, the well bore details, and the anticipated production respectively. From 7002 to 7625 ft. MD, the well was drilled
rates are entered into the computer solution to these equations. with mist of 12 bph, 2-4 gph of foamer, and 2000 SCFM of
Flowrates are then adjusted by trial and error to meet membrane nitrogen. Surface pressures climbed from 450 to
minimum lift criteria and volumetric rates available from 900 psig on subsequent changes of BHA. Surface pressures
compressors while checking for underbalance. The flow rate predicted by the modeling were 440 and 900 psig respectively.
at which both minimum lift criteria and underbalance amounts Bottom hole pressures predicted by the model were 147 psig
are met is the starting flow rate for UBD. Rates are then with 2500 SCFM membrane nitrogen, 119 psig with 2000
adjusted for conditions monitored at the well site. SCFM membrane nitrogen, and 147 psig with 2000 SCFM
nitrogen and 12 BPH mist. The well flared gas while drilling
Case History No. 1 with membrane nitrogen and mist at approximately 500
A 17,000 feet TVD well drilled into the Ellenburger formation MSCFD.
in Ward County, just south of Pyote, Texas. The reservoir Computer simulations of this well were later run to try to
pressure was expected to be 1200 psig. Original plans were to explain the changes in pressures, drilling rates, and gas flares
fluid drill the well to 15,900’ and then drill out with observed while drilling. When nozzle diameters were
membrane generated nitrogen. Figure 1 shows the first reduced, a decreased volumetric fluid rate through the motor
proposed casing program and resulting minimum needed flow resulted which decreased power available to the downhole
rates for adequate cleaning. The first proposed casing motor. These items are described in detail in Table II.
program was abandoned due to deviation problems and
excessive wear on existing liners plus economics of supplying TABLE 2
3400 SCFM of membrane generated nitrogen. The next Equivalent Air Volume
design involved running 5 ½ inch casing from surface to Pirkle No. 2
15,900’. Upon drilling out, cones were lost off of the bit and Stand Pipe pressure EQGPM to Motor
never recovered. The results of this are the program 450 psig 300
represented by Figure 2. 900 psig 110*
The well was eventually drilled with mist instead of
membrane generated nitrogen, because a complete dusting *change of nozzles from open to 6/32
condition was never established. It should be noted that
although there is published data for the suppression of down Eq. (12) Q (scfm) = OF x T F x D P x SP
hole fires with mist9, down hole fires have been experienced
while mist drilling, and therefore some operators opt to use
membrane generated nitrogen even while misting. Another V 1 P1 T2
Eq. (13) V2 =
phenomena seen while drilling this well was excess surface P2 T1
pressure when more than 1 gph of foamer was used. Surface
pressure increased from 1300 - 1700 psig to 2500 - 3000 psig.
This change of pressure was attributed to foam forming within V 1 P1 T2 11
Eq. (14) V2 = 0.455
the drill pipe. The pressure change will be discussed further in P2 T1
4 DAVID R. GIFFIN, WILLIAM C. LYONS IADC/SPE 59166
Case History No. 3 2350 to 2700 SCFM of membrane generated nitrogen, and 18
Four horizontal wells with a total of six laterals were drilled BPH of mist with 4 gph of foamer.
for Marathon, in Eddy County, New Mexico. These wells The first well bore design showed surface pressures of
were all whipstock exits of existing well bores drilling 4 ¾ 1150 psig on the model and 1450 psig in the field, but more
inch holes. Lateral length and direction varied, and the importantly, pressure in the annulus was 550 to 650 psig
example below uses the first well. This well had a 7,600 ft. which was above reservoir pressure. The well flared very
TVD kick off point. The curve section was drilled out of the 7 little gas while being drilled and production was well below
inch csg using fluid with a radius of 130 ft. anticipated levels. The second well bore design showed
Wells were drilled using 2-7/8 inch O.D., 10.4#, X-95 surface pressure of 900 to 1110 psig and the measured
AOH drill pipe. Flow rates while drilling ranged from 1350 to pressure was 850 to 1100 psig with membrane nitrogen. The
1450 SCFM of membrane generated nitrogen containing 3% second design with natural gas showed surface pressures of
oxygen. Misting fluid rates were 20 BPH containing 3-6 gph 550 psig and those measured were 570 psig. The expected
foamer, 3 gph corrosion inhibitor, and 2 gph of H2S scavenger. BHP were 305 and 310 psig respectively with membrane
Surface pressures measured at the booster compressor ranged nitrogen and gas. The third well bore design showed surface
from 600 to 1450 psig. This pressure of 1450 psig was 620 pressures of 510 psig as compared to 510 psig measured.
psig higher than the anticipated pressure from the computer Calculated bottom hole pressure was 217 to 290 psig. All of
simulations. A Halliburton Energy foam program was able to the wells drilled with designs two and three had sizable flares
roughly model the surface pressures seen while drilling. while drilling (estimates from 6 – 20 MMSCFD) and are good
Actual BHP monitoring showed 320 to 480 psi. This is producing wells.
compared to the 356-466 psig predicted by the model. The
reservoir pressure in the field was thought to be 1000 psig. Conclusions
Production rates while drilling closely followed rates used to 1. Updated models derived by Lyons for air and gas flow
model the wells; therefore we are confident in the accuracy of rates have been proven to be accurate. They model both
all data input into the model. On the second well drilled, a expected surface pressure and bottom hole pressure quite
large fracture was encountered, and circulation was lost. accurately.
Tripping back to vertical and unloading the hole reestablished 2. Pressure predictions for foam through small tubulars are
circulation; drilling continued 300 ft. MD past the first still not very precise. Other models available need to be
fracture with complete circulation until a second fracture was verified.
encountered and circulation was lost again. A jet sub and 3. More reliable methods of reporting real time bottom hole
increased membrane nitrogen volume was recommended to re- pressures can prove invaluable for monitoring UBD system.
establish circulation on the fourth well, but the well was TD
before this method was attempted. Nomenclature
aa= a function defined by eq. (5).
Case History No. 4 ba= a function defined by eq. (6).
Underbalanced drilling into the Pucket Field, Pecos County, Dh= hole diameter, ft [m].
Texas has produced some of the largest gas wells drilled in the Dp= pipe outside diameter, ft [m].
Permian Basin within the past 10 years. The Chevron USA e= absolute roughness of pipe, ft [m].
Robbins A-8 was reported at 30 MMSCFD CAOF and 14 f= Fanning friction factor.
MMSCFD production13. The Puckett Field has a field wide G= geothermal gradient, oF/ft [oC/m].
BHP of approximately 550 – 800 psig. The depth to the g= gravitational constant, ft/sec2 [m/sec2]
Ellenburger varies slightly but is at approximately 13,100 to h= depth below the surface to any point under
14,100 ft. The case histories focus on three different well bore consideration, ft [m].
designs. H= vertical straight hole depth, ft [m].
The first well bore design consisted of 5 ½ inch casing set K= ROP, rate of penetration, ft/hr [m/hr].
at 14,914 feet, a window cut at 13,180 feet MD, 4 ½ inch hole KE= kinetic energy.
drilled to 15,083’ MD with 1320 SCFM of membrane KEh= Kinetic energy at depth (h) in annulus eq. (12).
generated nitrogen, and 7 BPH mist through 2-7/8 inch PH-6 KESI= Kinetic energy at sea level eq. (11).
and PX-95 DP. KEI= Kinetic energy index.
The second well bore design consisted of 5 ½ inch casing P= pressure, lb/ft2 [Pa} absolute.
set at 14,870 feet, a window cut at 13,200 feet MD and used Pbh= pressure at the bottom of vertical hole, lb/ft2 [Pa]
2350 SCFM of membrane generated nitrogen or 3.0 absolute.
MMSCFD of 0.6 gravity natural gas with no mist through 2- Ph= pressure at a depth (h) of vertical hole, lb/ft2 [Pa]
3/8 inch drill pipe. absolute.
The third well bore design had 7 inch casing set at 14,100 Po= pressure at surface, lb/ft2 [Pa] absolute.
feet, 6 ¼ hole drilled to 15,600 ft. using 3 ½ inch drill pipe, Q= circulation rate, scf/min [scm/sec].
Qm= circulation rate of fluid, ft3/sec [m/sec].
IADC/SPE 59166 CASE HISTORIES OF DESIGN AND IMPLEMENTATION OF UNDER BALANCED WELLS 5
Qo= circulation rate into compressor system, ft3/sec, 9. Lyons, W. C.: “Advanced Air and Gas Drilling
[cm/sec]. Operations Short Course,” page 5-10, Presented in
R= gas constant 53.3 ft-lb/lb-oR. Midland, Texas, August 5, 1998.
S= specific gravity of gas related to air, dimensionless. 10. Lyons, W. C.: “Beginning Air and Gas Drilling
T= ambient temperature, oF [oC]. Operations Short Course,” page 2-16, Presented in
Tav= average temperature in well bore, oF [oC]. Midland, Texas, August 4, 1998.
To= temperature at sea level, oF [oC]. 11. Elord, J. P.: “Horizontal air drilling increases gas
V= velocity, ft/sec [m/sec]. recovery in depleted zone,” Oil & Gas Journal, Vol. 95
I g= weight flow rate of gas or air into well, lbs/sec No. 26, June 30, 1997, pg 49-63.
[Kg/sec]. 12. “Blackmax Downhole Motor Field Manual,” Black Max
I m= weight flow rate of fluid into well, lbs/sec [Kg/sec]. Inc., pg 42, 1995.
13. “Chevron USA – Robbins A-8 completion report,”
I s= weight flow rate of solids drilled, lbs/sec [Kg/sec]. Midland Reporter Telegram, Oil & Gas Report, February
I t= total weight flow rate in annulus, lbs/sec [Kg/sec]. 1999.
γ = specific gravity of item related to water,
dimensionless Appendix A
γ m = specific gravity of fluid related to water, The differential pressure change, dp (lbs/ft2, abs) over an
dimensionless incremental distance, dh (ft), for the downward flow of a
three phase fluid in the annulus is given by the expression:
γ m ix = specific gravity of mix related to water,
dimensionless
γ o = specific gravity of air or other gas to compressor fv 2
d P = γ mix 1 + 2
intake, dimensionless
2 g Dh − D p
2
dh
( ) .... (A-1)
γ h = specific gravity of mix at depth (h) in well bore,
dimensionless
Where γ m ix is the specific weight of the mixture of air (or
Acknowledgments: gas), incompressible fluid (mud), and rock cuttings (lbs/ft3), f
We thank Symbol Inc., New Mexico Institute of Mining and is the fanning friction factor, v is the average velocity in the
Technology, Chevron USA, Marathon Oil Company and annulus (ft/sec), Dh is the diameter of the borehole (ft), Dp is
Patterson Energy for allowing us to include information from the outside diameter of the drill pipe (ft), g is the acceleration
their companies for this paper. of gravity (32.2 ft/sec2).
Note that the above is composed of two parts. The first
References: term on the right side of Equation (A-1) describes the static
1. Martin, D. J.: “Use of Air or Gas as a Circulating Fluid in pressure head of the mixed air (or gas), liquid (water, mud, or
Rotary Drilling – Volumetric Requirements,” Huges crude oil), and rock cuttings. The second term on the right
Engr. Bull No. 23, November 28, 1952. side describes the pressure head due to friction loss.
2. Angel, R. R.: “Volume Requirements for Air or Gas The derivation will be carried out assuming a surface
Drilling,” Petr. Trans. AIME (1957), Vol. 210, pp 325- location at standard sea level conditions(i.e., API, to = 60oF,
330. and po = 14.696 psia). The general form of the ideal gas law
3. Weymouth, T.R.: “Problems in Natural Gas is:
Engineering,” Trans, ASME (1912), Vol. 34, 184.
4. Nikuradge, J.: Forschungshelf, p. 301, 1933. P RT
= ................................................................. (A-2)
5. Guo B., Miska, S. K., Lee, R.: “Volume Requirements for γ S
Directional Air Drilling,” IADC/SPE 27510 presented at
the IADC/SPE Drilling Conference held in Dallas, TX,
15-18 February 1994. Where R is the gas constant (53.3 ft-lbs/lb- oR), S is the
6. Daugherty, R. L., Frazini, J. B.: “Fluid Mechanics with specific gravity of the gas (S = 1.0 for air at standard
Engineering Applications,” McGrow Hill 7th edition conditions), T is temperature (oR).
1977, Egn 8.36 pg 212. Using Equation (A-2) the specific weight of the
7. Allan, P. D.: “Nitrogen Drilling System for Gas Drilling atmospheric air or other gas going into the intake of the
Applications,” SPE 28320 presented at the SPE Technical compressor system can be written as:
Conference in New Orleans, LA, 25-28 Sept. 1994. Po S
8. Chitty, G. H.: “Corrosion Issues with Under Balanced
γo = ................................................................... (A-3)
R To
Drilling in H2S Reservoirs,” SPE 46039 presented at the
Coiled Tubing Roundtable held in Houston, TX 15-16
April 1998.
6 DAVID R. GIFFIN, WILLIAM C. LYONS IADC/SPE 59166
Thus the weight rate of flow of the air (or gas) into the well, Solving the above for Q yields:
wg (lbs/sec), can be written as:
P Tav
I g = γ o Qo ............................................................(A-4) Q= o Qo ......................................... (A-11)
P To
Where Qo is the volumetric flowrate of air (or gas) into the
compressor system (ft3/sec). Therefore, γ m ix can be defined as:
The weight rate of flow or drilling mud (or other
incompressible fluid) into the well, wm (lbs/sec), can be It
written as: γ mix = ........................... (A-12)
Po Tav
Qo + Qm
I m = γ m Qm ..........................................................(A-5) P To
Where Qm is the volumetric flowrate of mud into the well. The velocity of the mixture at any position in the annulus can
The quantities wg and wm enter the well through the inside be written as:
of the drill pipe at the top of the string and flow to the bottom
of well through the inside of the string. They exit the inside
Q + Qm
of the string through the bit nozzles and entrain the drill bit v= .............................................. (A-13)
π 2
cuttings and then the three phases (gas, incompressible fluid,
and solids) flow to the surface in the annulus. The entrained 4
(Dh − D p2 )
weight rate of flow of solids, ws (lbs/sec), is:
Substituting Equations (A-11) into the above gives:
π
I s = Dh2 (62.4)(2.7 )k ....................................(A-6)
4 Po Tav
+ Qm
P To
Where k is the rate of penetration 9ft/sec). The quantity v= ..................................... (A-14)
(62.4)(2.7) is the average sedimentary rock specific weight.
The total weight rate of flow, wt (lbs/sec), in the annulus
π 2
4 h
D − Dp (2
)
from the bottom of the wells to the surface is:
Substituting Equations (A-12) and (A-14) into Equation (A-1)
I t = I g + I m + I s ...........................................(A-7) gives:
2
The specific weight of the gas at any position in the annulus Po Tav
Q + Qm
can be written as: o
d P=
It 1 + f P To d h
P T 2 g (Dh − D p ) π 2
o av Qo + Qm
(Dh − D;2 )
PS P To
4
γ = .............................................................(A-8)
R Tav ............................................................................. (A-15)
Where Tav is the average temperature of the well between at Separating variables in Equations (A-15) and integrating form
that position in the well annulus (over the length being the surface to the bottom of the well (in a uniform cross-
considered). Therefore, the wg term can be written as : section annulus) yields:
I g = γ o Qo = γ Q ...............................................(A-9) dP
∫ = ∫ OH d h
Pbh
Po 2
Po Tav
Where Q is the volumetric flowrate at any position in the Qo +Qm
annulus (ft3/sec). Substituting Equations (A-3) and (A-8) into It 1+ f P To
P T 2g(Dh − Dp ) π 2 2
the two terms on the right side of Equation (A-9) yields:
o av Qo +Qm Dh − Dp ( )
4
P To
Po S PS
Qo = Q ......................................... (A-10) (A-16)
R To R Tav
IADC/SPE 59166 CASE HISTORIES OF DESIGN AND IMPLEMENTATION OF UNDER BALANCED WELLS 7
TABLE 1
FLOW RATE Cir BHP-Calc
Case TVD GAS SCFM LIQUID FOAMER FORMATION PREDICTED MEASURED PSIG ECD MEASURED
History BPH GPH INFLUX BPD SURFACE SURFACE (PPG) Circ. BHP
PRESSURE PSIG PRESSURE PSIG
1A 16610 3000 12 1 0 1675 1300-1800 968 0.48 -
1B 16610 3000 12 2 0 1675 2500-3000 968 0.48 -
1C 16610 2300 0 0 0 1245 1000-1300 576 0.29 -