IADC/SPE-170554-MS

Optimizing Well Design in Saudi Arabia: Successful Application of

Managed Pressure Drilling Enables Drilling Across Multiple Pressure
Zones and Running Liner Using Constant Bottom-Hole Pressure Technique
N.O. Pinero Zambrano, I.M. Al-Ageel, M.A. Muqeem, and A.S. Al-Mutawa, Saudi Aramco; C.M. Mazouz,
A. Hadj-Moussa, A. Zeb, and F. Al-Ghamdi, Weatherford

Copyright 2014, IADC/SPE Asia Pacific Drilling Technology Conference

This paper was prepared for presentation at the IADC/SPE Asia Pacific Drilling Technology Conference held in Bangkok, Thailand, 25–27 August 2014.

This paper was selected for presentation by an IADC/SPE program committee following review of information contained in an abstract submitted by the author(s).
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Abstract
Khurais field has seen, on an average, a 35% increase in reservoir pressure during the past three years due
to water injection for production maintenance. A workover campaign started two years ago to reenter and
workover some of the power water injection (PWI) wells. The campaign saw a dramatic increase in
non-productive time (NPT) due to differential sticking and loss of circulation as well as difficulty in
working over these wells conventionally.
Subsequently, Saudi Aramco started a campaign in late 2012 to workover these wells utilizing managed
pressure drilling (MPD). MPD has enabled personnel to workover these wells at a 20% reduced mud
weight, preventing stuck pipe and fishing related NPT.
This paper summarizes Saudi Aramco’s experience gained during the working over of a well where
drilling two formations together enabled the target hole size to be maintained as well as eliminating
running the expandable liner for pressure isolation between these two zones. It further highlights the
operational complexity and the challenges faced during the implementation of this technology while
drilling the two formations with varying pore pressures. It also elaborates on the interdisciplinary team
that was instrumental behind the safe and successful implementation of managed pressure drilling.
The paper also elaborates on the lessons learned and how they were implemented continuously with
regard to health, safety and environment (HSE) during the workover operations. The long-term goal was
to evaluate whether the application of MPD can be extended to other asset teams/areas effectively to reap
its potential benefit.

Introduction
Khurais field is located in a remote area in the central part of Saudi Arabia, approximately 200 km from
the Saudi capital, Riyadh, and 300 km from the Eastern Province port city of Dammam. The producer
wells are drilled in the middle of the field and the water injector wells are drilled close to the field
boundaries.1
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Table 1—Formation pressure, designed and actual mud weight

Saudi Aramco started a campaign to reenter and workover some power water injector wells in the
Khurais field to maintain the reservoir pressure and increase oil recovery. The wells are drilled to an
average measured depth (MD) of 14,000 ft, with an average of 6,500 ft of open hole section across the
1
reservoir. The 68 in. horizontal open hole section is particularly challenging due to heterogeneity and rapid
change in formation pressure within the same lateral resulting from water injection activities around the
area. Using conventional drilling techniques, a significant increment in the NPT due to differential
sticking and lost circulation was observed. To overcome these challenges conventionally, Saudi Aramco’s
drilling team utilized a new sliding technology to increase the rate of penetration (ROP)1. This solution
did not eliminate the risk for differential sticking but reduced the time of exposure to risk.
Previous experience at Saudi Aramco has proved the benefits of the MPD technology where the NPT
related to differential sticking, lost circulation and formation fluid influx circulation were considerably
reduced by having a more accurate control of the annular pressure profile and a more precise monitoring
of the well, which allows for a much quicker reaction.2.
MPD is basically known as a drilling process optimization tool where the main objectives are to
mitigate the drilling hazards to enhance control of the well and decrease NPT. In other words, to drill
successfully to the planned target while saving costs and improving safety conditions.3.
The objective of MPD is to navigate through narrow mud-weight windows and to avoid any fluid from
the formation coming into the wellbore; but in case that happens, the adjustment in the surface back
pressure allows for a much quicker response, minimizing the consequences of the influx, and circulating
the kick by keeping the drilling pump rate, which minimize time for kick circulation.
CHALLENGES AND PROBLEM STATEMENT
The original plan for the well KHRS-XX was to mill a window in the 7 in. liner and to drill the
Formation-A in 6 1/8 in. horizontally and then run an expandable liner to isolate it and be able to drill the
Formation-B in a 5 ½ in. hole section to avoid any problem related to differential pressure between the
two formations.
As mentioned before, the main problems encountered in the workover campaign, while using conven-
tional drilling techniques were the high occurrence of differential sticking and lost circulation events. This
was mainly due to the use of high density mud that created a condition of excessive overbalance. Table
1 summarizes the estimated formation pressures, the planned mud weight and the MPD mud weight used.
The pressure difference between the two formations is an important factor in the design of the well. The
uncertainties in these pressures as well as in the tops of the formations are a few of the causes of the
IADC/SPE-170554-MS 3

Figure 1—Original MPD Pressure Profile

Figure 2—Dynamic Pore Pressure Test at 6,370 ft MD

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Figure 3—Dynamic FIT at the Top of Formation-B

Figure 4 —Pressure profile with 168 gpm rate, with 75 pcf MW at 4,400 ft
IADC/SPE-170554-MS 5

Figure 5—Displaced Cased hole to 75 pcf mud prior to run liner with MPD

differential sticking and lost circulation problems. Another challenge observed in these operations is the
high frictional pressure losses in the annulus due to the small clearance between the walls of the wellbore
and the BHA and drillpipe. The overall overbalance is increased when the pumps are on and the frictional
pressure losses are added to the hydrostatic overbalance. In the MPD program the simulations showed a
total of 456 psi frictional pressure losses, that if added to the overbalance shown in table 1, result in a total
of 782– 687 psi for Formation-A and Formation-B, respectively.
MPD ENGINEERING
After receiving the well information and several discussions with the Aramco engineering team, an MPD
strategy was planned, which looked to minimize or eliminate the problems associated with formation
pressure in well KHRS-XX.
The approach for the design of the MPD operation was based on the Saudi Aramco Workover Program.
The initial idea was to apply the MPD technique to optimize the drilling process in a 5 ½ in. hole to drill
the Formation-B. Previously, the Formation-A would be drilled conventionally and then cased with a solid
expandable metal-skin open hole liner. This strategy was initially taken because of the Formation-B being
the one with the higher pressure and due to the pressure difference between the two formations.
Simulations were run with 75 pcf mud weight and 428 psi surface backpressure (SBP) to achieve the
target ECD of 97 pcf at the top of the window as per Figure 1.
Safety and proper engineering planning is paramount in operations where MPD is applied, and so prior
to commencement of the MPD operations on the well KHRS-XX, an MPD drilling program was prepared
taking in consideration all operational and HSE contingencies; a set of detailed operational procedures
was developed; and a Well Control Matrix and operating envelope was prepared, as well as a detailed set
of decision trees.
MPD APPLICATION
The first deviation to the original plan occurred due to unexpected high pressure encountered while
drilling the 6 1/8 in. hole through the Formation-A where the MPD equipment was called to the location
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Figure 6 —RIH liner hanger assembly to setting depth 6,420 ft

earlier. To begin the MPD operation, the RCD bearing assembly was installed two stands above the top
of the window and the MPD in-casing tests were perform to calibrate the MPD equipment. Afterward, the
well was displaced from 92 pcf to 75 pcf MW and the drilling operations resumed at 5,247 ft MD with
a pump rate of 250 gpm and 540 psi SBP, generating an ECD of 100 pcf at the top of the window.
One of the added values of using the MPD technique is the formation pressure limits evaluation by
performing dynamic pore pressure tests (DPPT) and dynamic formation integrity tests. The first DDPT
was performed by reducing the SBP gradually in steps until the choke was completely open, but no influx
was observed and so the well was balanced dynamically. The decision was made to reduce the pump rate
gradually in steps until pumps were shut down to evaluate the pore pressure. A 7.5 barrel influx (water)
in 10 minutes was observed, determining a PPT EMW of 87 pcf.
With the information of the DPPT, and to reduce the chances of lost circulation or differential sticking,
the target ECD was reduced from 100 pcf to 91 pcf at the top of the window (TOW), reducing the SBP
to 240 psi. The drilling operations continued with these parameters until 6,040 ft MD were another DPPT
and a FIT were performed, showing a PPT EMW of 87 pcf and a FIT EMW of 117 pcf.
Drilling operations were resumed, reducing the SBP from 240 to 225 psi, and so reducing the target
ECD to 90 pcf at the TOW without observing any changes in the returns of the well. Due to the pore
pressure evaluation obtained from the dynamic pore pressure tests and the dynamic formation integrity
tests, the decision was made to continue drilling through Formation-B using the same mud density and
same drilling parameters, in this case MPD was successfully used as an effective tool to reduce
uncertainty, and to directly and positively impact the design of the well.
TD was reached at 7,911 ft MD with 240 gpm, 245 psi SBP generating an ECD of 89 pcf at the top
of the window after 58.4 hours of on-bottom bit time. During the cleaning trip, the final DPPT was
performed obtaining an EMW of 83 pcf. After circulating the hole clean, the well was displaced with 95
pcf kill mud prior to the trip to surface, and losses and gains were carefully monitored at surface.
IADC/SPE-170554-MS 7

Figure 7—Displaced hole to 90 pcf brine

Figure 8 —4½ in. liner running operation with MPD

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Figure 9 —Well profile prior and after the liner run

RUNNING LINER WITH MPD

Due to the success of the MPD operation while drilling the 6 1/8 in. hole section, eliminating the events
of lost circulation and differential sticking, a program was prepared to run the liner assembly in constant
bottom-hole pressure mode with the MPD system for the first time in Saudi Arabia to reduce or eliminate
the NPT associated to these complications.
The 4 ½ in. liner assembly was planned to be run in hole conventionally down to one stand before the
7 in. window exit; then the RCD bearing assembly was installed to allow closing in the well under
pressure and diverting the returns to the MPD control system. Next, the well was displaced to 75 pcf mud
with a controlled rate taking returns through the MPD system, the pressure was all the time monitored to
ensure that it is within the safe operating window (SPP, surface back pressure, and pump rate). Hydraulic
simulation was performed to ensure that the SPP during displacement operation would not exceed the
maximum pressure for setting packer (Figure 4). The maximum pressure at the displacement operation
was 585 psi at the maximum pump rate of 168 gpm, which is less than the setting pressure for the packer
of 880 psi (Figure 5).
Once the well was displaced, the surface back pressure was applied by the MPD system by closing in
the MPD chokes to 35% against the pumped fluid from the kill line into the annulus and back up the RCD,
and into the MPD system, in a surface flow loop. Running 4½ in. liner hanger then resumed until reaching
setting depth of 6,420 ft MD, while the MPD system monitored the well conditions for any signs of losses,
gains, or differential sticking; then, if necessary, controlled it by increasing and reducing the pressure as
required. The complete cycle of RIH from 4,401 ft MD to 6,420 ft MD is shown in Figure 6.
Once the string was at setting depth, the off-bottom well was displaced back to 90 pcf kill mud weight
brine in a controlled manner (Figure 7).
Once confirmation of MW in/out at 90 pcf was made, pumps were stopped for conventional flow
check. No flow was observed. The liner was set by applying 2,500 psi stand pipe pressure and cemented.
Figure 8 shows liner running, setting, and cementing operation.
IADC/SPE-170554-MS 9

CONCLUSION
The MPD operation in KHRS-XX was executed successfully and the application of this technique
exceeded the original expectations for its benefits. It not only eliminated any differential sticking or lost
circulation incidents but it allowed for the drilling of two formations with different pore pressures with
the same mud weight, saving the cost for the original plan of running an expandable liner to isolate the
Formation-A, and the subsequent costs associated to the changes in the mud density originally required
to drill the Formation-B.
1
The 68 ft lateral hole section was drilled using 75 pcf calcium chloride WBM and average ECD at shoe
and bottom of 90 pcf and 94 pcf, respectively. Borehole conditions were successfully managed at all times
within proper limits, keeping formation fluids out of the well with no considerable fluid losses during the
operation.
No stuck pipe events were registered during drilling, wiper trip, or POOH of the open hole section from
4,401 ft MD to 7,911 ft MD. It is considered that the use of MPD technique reduced considerably the
potential NPT time that could take place if a conventional operation were carried over instead, and the
flexibility of the MPD system pressure control in real time allowed to reduce the uncertainty of actual
formation pore pressure leading to a better decision making.
The liner running operations were successfully carried out using the MPD technique to run the liner to
its target depth avoiding stuck pipe and lost circulation events. This operation has been used as a reference
for future applications in fields that present the same challenge in running liner to bottom.
After evaluating the drilling performance obtained in KHRS-XX we conclude that the use of the MPD
technique in Saudi Aramco’s water injection project in the Khurais field represents a technological
improvement that will help with achieving the company’s goals in a safer and more efficient manner.

ACKNOWLEDGMENTS
The authors wish to extend their appreciation to the management of Saudi Aramco and Weatherford
International Ltd. for their permission and the resources needed to publish this paper. The authors also
thank the many individuals within Saudi Aramco and Weatherford who have contributed to the success
of this work.

References
1. Roberto H. Tello Kragjcek, Abdullah S. Al-Dossary, Waleed G. Kotb, et al.: “Successful
Application of New Sliding Technology for Horizontal Drilling in Saudi Arabia,” SAUDI
ARAMCO JOURNAL OF TECHNOLOGY, FALL 2011.
2. Al-Thuwaini Jamal, Emad Mohamed, Iman, et al.: “Managed Pressure Drilling, the Impact of
Correctly Applying the Technology and the Results Obtained After Drilling an Exploratory Well
in a Deep Gas Reservoir of Saudi Arabia,” 131960-MS SPE Conference Paper, 2010.
3. Salar Babajan, Hani Qutob, Maurizio Arnone, et al.: “Managed Pressure Drilling Applications
Proves Successful in the Middle East and North Africa Region,” Mediterranean Offshore
Conference & Exhibition, Alexandria, Egypt 20 –22 May, 2010.