SPE 171966Number

Successful Integration of Innovative Technologies Enabled Operator to Drill

and Complete First Horizontal Well in Depleted Shale Inter-bedded
Limestone Reservoir in Pakistan - A Milestone Achieved.
Dr. F.I. Siddiqui, PPL, M.O. Naseem, PPL, F.B. Khan, PPL, M. Asrar, Weatherford

Copyright 2014, Society of Petroleum Engineers

This paper was prepared for presentation at the Abu Dhabi International Petroleum Exhibition and Conference held in Abu Dhabi, UAE, 10–13 November 2014.

This paper was selected for presentation by an SPE 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 Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessarily reflect any position of the Society of Petroleum Engineers, its
officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written consent of the Society of Petroleum Engineers 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 SPE copyright.

Abstract
The name “Sui” has become synonymous with natural gas in Pakistan on discovery of the first well in 1952. Sui is Pakistan
Petroleum Limited’s (PPL) flagship gas field and is one of the major contributors in meeting the energy demands of the
country since its inception. Two major reservoirs of this field are the Sui Main Limestone (SML) and Sui Upper Limestone
(SUL); both of which have become highly depleted over time.

Pakistan is striving to meet its growing energy needs and is making all possible efforts to enhance production. Operator
successfully drilled one horizontal well in the Sui Main Limestone in underbalanced conditions and planned to drill the FIRST
HORIZONTAL WELL in the SUL reservoir to enhance production of the field. Drilling a horizontal well in this formation
with conventional drilling techniques was a high risk task due to depleted reservoir with shale interbedding, complete loss of
circulation, hole instability and reservoir damage issues which altogether made it almost impossible to complete the well.

The operator took this challenge to implement innovative technologies to mitigate all hazards and meet objectives. First of all;
drilling and reservoir related problems were identified in detail. A comprehensive Geo-Mechanics Study was conducted to
define the safe drilling window of the SUL Reservoir. To maintain bottom hole pressure within the defined drilling window,
further integration of Multiphase Fluid Drilling (Membrane Nitrogen & Water Based Mud) and Electromagnetic Measurement
While Drilling tools along with real time ECD (Equivalent Circulating Density) and Gamma Ray monitoring Sensors were
selected. A major challenge for the operator was to complete the well in the same reservoir conditions; this happened by
applying Downhole Deployment Valve Technology with 9-5/8” casing.

This paper will elaborate the details of the planning and execution phase to meet this challenging task to complete the project.
The application of all these innovative technologies represents a step change in improving Operator’s ability to exploit mature
reservoirs, especially those that are severely depleted like the Sui Gas Field and also for the Oil & Gas Sector in Pakistan.

Overview of Application
Sui Upper Limestone is secondary reservoir in Sui Gas Field of Pakistan. It is depleted reservoir having pressure range of 774
- 970 psi (3.65 ppg – 4.58 ppg EMW). Operator planned horizontal well targeting Sui Upper Limestone reservoir from 1208m
(TVD) to 1261m (TVD) in this field. This was very first horizontal well planned and drilled in this reservoir.

Drilling horizontal well in this depleted formation was very difficult with conventional overbalanced drilling methods. This
could jeopardize achieving the well objectives. Drilling hazards like complete loss of circulation, differential pipe stuck, low
drilling performance and severe formation damage were identified as potential risks. These could lead to substantial NPT and
associated cost. Operator had faced all such problems while drilling offset vertical wells in SUL Formation in same field.

The formation also has interbedded shale strings of 3-4 m thickness. This could consequence wellbore stability concerns while
drilling horizontal well in subjected formation. This was identified as secondary potential risk.
Operator addressed drilling challenges and defined use of innovative technologies to mitigate them. Geo-Mechanics study
addressed the wellbore stability possibilities, uncertainties and minimum mud weight ranges were identified to safely drill the
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horizontal well. Closed loop nearbalanced drilling technology used to achieve defined mud weight ranges in multiphase
drilling fluid form. Electromagnetic MWD technology adopted to control and monitor wellbore trajectory and downhole
pressure profiles. Performing post drilling operations in same nearbalanced environment was addressed by use of Downhole
Deployment Valve.

Application Objectives Placed

After detailed review of challenges and possible solutions, well planning team defined following well objectives.
 Perform detailed Geo-Mechanics study; define critical mud weight window and mechanical earth model (MEM) for
field.
 Drill 6″ horizontal hole +/- 400 m (MD) in reservoir with Nitrified Drilling Fluid (Water base mud & membrane
nitrogen) in closed loop nearbalanced environment targeting ECD in range of critical mud weights defined in Geo-
Mechanics study.
 Maintain the wellbore stability mechanically and chemically. Using the shale inhibitors and the near-balanced conditions
to not allow the shale strings to cave in.
 Eliminate mud losses and associated NPT events.
 Avoid Reservoir damage and hence increase well productivity and life.
 Increase drilling performance.
o Allow for potentially faster ROP and reducing the total drilling days by avoiding drilling problems.
 Perform all the drilling and post drilling operations in nearbalanced drilling condition.

Geo-Mechanics Study
3-D Geomechanical Models are the basis for assessing and mitigating geomechanical risks on a field scale and to make
optimal decisions through the life of the field such as completion strategies. The upscaled geomechanical (physical and
mechanical) properties can be used to conduct field scale stress analysis and predict “sweet spots” based on estimated strain
maps for each horizon which will help in informed well placement for new wellbores to be drilled.
The assessment of the planned wellbores will include wellbore stability and optimization of mud weight. The typical workflow
for the generation of 3-D Geomechanical Model (MEM) applying geomodelling software is presented in Figure-1. The
different geomechanical properties such as stresses pore pressure and formation mechanical properties are integrated into a
geomodel based on the 1D data interpretations for different well locations.
A wellbore stability study was conducted for the SUL Formation with focus on the drilling of subjected horizontal well. Past
experiences of this formation showed severe mud losses, but the presence of shale beds was also a big concern for hole
stability. The main objectives of conducting Geo-Mechanics study were defined as follows:
 Construction of Geo-mechanical model for overburden and reservoir.
 Evaluation of wellbore instability risk in the overburden and the reservoir.
 Quantitative Risk Analysis with respect to wellbore collapse.
 Defining minimum mud weight range for closed loop nearbalanced drilling.
The main results were as follows:
 Drilling may be conducted in the depleted reservoir limestone with risk of breakout formation at about 20% of the
hole circumference if drilling with mud weight equal to the reservoir pressure. For lower mud weight values larger
caving may start to occur.
 Penetration of interbedding shale that might be overpressure relative to the SUL reservoir may represent a significant
wellbore instability risk even at low degree of overpressure. The risk of penetrating shale sections appears less at the
lower half of the SUL reservoir.
 Drilling the reservoir with mud weight in the region 0.24 – 0.43 s.g. will prevent mud losses at the price of
instabilities in shale stingers and at the upper part of the SUL and to a less degree in limited zones in the lower half of
SUL. Mud weight close and/or above the pore pressure gradient (0.43 s.g.) is recommended. Mud weight higher than
pore pressure will impart less instabilities and safe mud weight is near the fracture gradient, which will impart severe
mud losses eventually.
 Critical mud weight limits do not seem to vary greatly with well azimuth in the reservoir section.
The detailed deliverability of this study is shown in Figure-2. Recommendations of Geo-Mechanics study were further used to
plan this horizontal well and closed loop nearbalanced drilling program.
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Closed Loop Nearbalanced Drilling

Nearbalanced drilling technology is defined as drilling with the mud weight which results in bottom hole pressure just above
the reservoir pressure. In this technology ECD is maintained just above the reservoir pressure to minimize the losses and
formation damage. The application of nearbalanced drilling technology benefits the wellbore stability issues by drilling with
the least possible mud weight.

Why Drill Nearbalanced?

There are many reasons which proved the application of nearbalanced technology. The main reasons are described below:
1. No Fluid Losses
In general, a reduction of the hydrostatic pressure in the annulus reduces the fluid losses into a reservoir formation. In NBD,
the bottom hole pressure is always kept near the reservoir pressure, so no fluid losses will be there while drilling near-
balanced.
2. Reduced Formation Damage
NBD results in minimum invasion of solids or mud filtrate into the reservoir formation and hence reduce formation damage.
3. Better Reservoir Management
Due to the minimum formation damage because of near-balanced drilling; the reservoir characteristics are improved. The
minimum formation damage will result in enhanced production and life of the reservoir. The minimum Skin will reduce the
cost of wellbore acid cleaning and acidizing.
4. Less Differential Sticking
The presence of a minimum overburden on the formation in Near-balanced drilling along with the minimum filter cake serves
to prevent the drill string from becoming differentially stuck. The minimized losses in case of NBD also reduce the chances of
pipe sticking.
5. Minimize Wellbore Stability Issues
The wellbore stability issues which significantly affect the drilling operation specially in case of underbalanced drilling are
mitigated with the increase of mud weight. In near-balanced drilling as the ECD is maintained just near the reservoir pressure
so the wellbore stability issue is minimized.
6. Improved Penetration Rate
The lowering of the overbalance over the formation pressure has a significant effect on penetration rate. The reduction in the
so-called chip hold down effect also has a positive impact on bit life. The increased penetration rate combined with the
effective cuttings removal from the face of the bit leads to a significant increase in bit life.
7. Reduction of ECD in extended reach wells
The drilling of long horizontal or near horizontal sections creates more and more frictional pressure in the annulus. This
friction pressure acts on the bottom of the well and slowly increases the overpressure over the formation interval. This results
in a reduction of ROP and increases the potential for losses. In Near-balanced drilling such pressures are minimized because of
using the lowest possible mud weights.
Drilling Fluid System and Flow Modeling
Correct selection of the drilling fluid in NBD is the key for successful application. Figure-3 will illustrate the drilling fluids
densities and those are selected based on reservoir that is going to be drilled nearbalanced.
Based upon reservoir pressure and formation characteristics, inhibited mud (treated with PH controller, shale and corrosion
inhibitor) and membrane generated nitrogen was selected to drill target hole section. Drill pipe injection technique was
utilized. Mud was being pumped at a specified calculated rate from the mud pumps into the standpipe manifold. The gaseous
nitrogen was also pumped at a calculated rate into the standpipe manifold. Flow returns were diverted from RCD to close loop
circulation system.
Drilling Fluid Flow Modeling
NBD multiphase flow simulations were performed in the planning phase as well as during drilling phase of the project to
achieve the following set objectives:
1. Maintaining nearbalanced conditions at all times while drilling the reservoir.
2. Achieving good hole cleaning.
Initial simulations also examined the effect of different bottom hole pressures on the nearbalanced condition using different
gas and liquid injection rates. Operating window is the plot that includes bottom hole circulating pressure induced by variety
of Nitrogen and Liquid injection rates. Various constraints that must be fulfilled during nearbalanced drilling operations were
plotted on this envelope. These constraints include: the range in which the well remain in nearbalanced condition; the optimum
rates which are selected for the well and the minimum liquid velocity in the annulus to provide adequate hole cleaning. Figure-
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4 can be referred to see operating window and simulations developed in planning and drilling phase. The design parameters
used for NBD Modeling are as under:
Nitrogen Injection Rates = 400 – 600 scfm
Liquid Injection Rates = 150 - 200 gpm
Reservoir pressure = 774 - 970 psi
Minimum Annular Velocity = 180 ft/min
Target ECD Range = 5.0 – 6.0 ppg

Closed Loop Nearbalanced Drilling Equipment Layout

Full NBD Equipment along with 4-Phase Separation System was utilized in addition to Compression and Nitrogen Pumping
equipment. The RCD being the surface diversion system is the vital point of the system. Equipment layout used is shown in
Figur-5.

Downhole Deployment Valve

The majority of well control incidents occur during tripping operations after drilling to the depth of interest. The Downhole
Deployment Valve (DDV) tool creates efficiencies in drilling operations by allowing for safe, timesaving installation and
retrieval of tubular and BHAs under pressure. The DDV tool was ran an integral part of the 9-5/8” casing string, at a
predetermined depth below the point where pipe light condition will occur. With the valve closed and pressure isolated below
it, the string can be run at conventional tripping speed.
The DDV system consists of a flapper valve casing deployed downhole tool that is controlled from surface through a Control
Line which was run inside of the annular space between casing strings. The typical DDV running sequence is shown in Figure-
6.
In Near-balanced drilling operation the well is being drilled with the bottom hole pressure slightly above the reservoir
pressure. During drilling operation because of being in overbalanced conditions the operation goes smooth. In depleted
reservoirs in order to achieve the nearbalanced condition the drilling fluid system was nitrified drilling fluid. In such
operations when the circulation remained suspended for long period of time the well need to be killed. Killing the well
damages the reservoir and diminishes the benefits of nearbalanced operation.
In order to avoid the killing operation, it was required to isolate the reservoir. The DDV was the only option in the industry
right now. In this well all the post drilling operations were benefited because of DDV. The well was drilled till the desired
depth in nearbalanced mode of drilling with nitrified drilling mud. After reaching target depth the well was not killed in order
to intact the reservoir conditions. The drill string was pulled out till the DDV depth. The DDV was closed and the string was
pulled out of hole to surface. The DDV was opened and closed many times during different post drilling operations.

Post Drilling Operations in Nearbalanced Mode

In industry, many wells were drilled underbalanced or nearbalanced but all the benefit of these operations may be
compromised during the post drilling operations. Killing the well before the post drilling operations damages the reservoir.

After reaching target depth, a wiper trip was performed, then pulled the drill string to surface but the well was not killed as the
DDV was closed / opened to perform following operations in nearbalanced mode in close loop system.
 Perforated liner running and setting
 Formation evaluation / wireline logging
 Completion running and setting

Electromagnetic Measurement while Drilling (EM-MWD) Technology

Electromagnetic measurement-while-drilling (EM-MWD) system allows operators to drill and survey wells independent of rig
hydraulics. Bit pressure drop, flow rates, and drilling fluid and formation loss are irrelevant to EM technology, creating
substantial savings in drilling time and project costs. EM MWD saves an average of two to five days per well due to faster
survey times and fewer limitations on hydraulics, compared to mud pulse MWD and steering tools.
Maintaining the bottom hole pressure was the most important and critical aspect of the closed loop nearbalanced operation in
the subjected well. Due to selection of multiphase drilling fluid and presence of higher volume of gaseous phase in drilling
fluid, conventional mud pulse MWD tools were not feasible for application. This problem was solved by using EM-MWD
tools and technology. In such operations the need of the downhole pressure sensor becomes significant. By use of Pressure
While Drilling (PWD) tool, ECD can be precisely monitored.

The application of EM-MWD with Gamma Ray and PWD sensors helped to achieve precise control of downhole pressures
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and flow rates. EM Transmission sequence is shown in Figure-7.

Operational Overview
Operational performance was closely monitored by multi-disciplinary team. Final well profile is shown in Figur-9. Detailed
operational overview defined in following parameters.

Drilling Rate
One of the major benefits of such operations was the increased rate of penetration. During this operation about 68 hours were
spent on the drilling. The average ROP during the drilling was about 7 m/hr. It was quite high as compared to the rate that was
observed in the offset wells while drilling with the conventional techniques. The ROP vs time graph of this well is shown
below in Figure-10.

Bit Performance
To drill the 384 m horizontally into the SUL formation two bits were used. The first bit drilled about 212 m and the second bit
drilled about 172 m. Both the bits gave almost the same average ROP of 7 m/hr.

Hole Cleaning and Wellbore Stability

The hole cleaning depends upon the cutting transport ratio of the drilling medium. During the planning and simulation phase
this was one of the major selecting parameters. Throughout the drilling operation, the circulating rates were selected very
accurately and the hole cleaning was never compromised.

Drilling Curve
6” hole section drilling curve is shown in Figure-11. Substantial time and associated cost was saved.

Application Objectives Achieved

The following objectives were successfully achieved:
 Successfully drilled in nearbalanced condition to Target Depth.
 Wellbore remained stable with no major caving observed during the drilling operation.
 Achieved substantial increase in Drilling Performance (Rate of Penetration).
 Minimized formation damage while drilling.
 Eliminated all fluid losses, differential sticking and associated NPT.
 Established an initial set of parameters by which future NBD wells can be drilled more effectively. The well was not
killed and the DDV was effectively used to isolate the reservoir from the well.
 All the post drilling operations were performed in nearbalanced conditions.
Conclusions and Recommendations
Drilling the nearbalanced horizontal well in Sui Upper Limestone formation was very successful merger of the innovative
drilling technologies. This well was challenging for the operator; but the successful integration of right technologies, detailed
planning and operational excellence helped operator to achieve all objectives.
All tools involved in this application played their individual vital role and proved to be essential for the success of such
operations. The Geo-mechanical study made very clear picture which helped in correct planning of this well. Closed loop
nearbalanced drilling was major show performer. The application of E-MWD tools helped in accurate execution of this
operation. Last but not the least DDV made it possible to complete the well as desired. Such applications opened new horizons
in the oil & gas industry of the country to drill such challenging wells.
Acknowledgement
The authors would like to thank the management of Pakistan Petroleum Limited (PPL) and Weatherford Oil Tools M.E.
Limited Pakistan for permission to submit the paper for conference. In addition we also extend our deepest gratitude to the
TEAM who worked to see this project succeed.
Nomenclatures
EMW Equivalent Mud Weight
NPT Non-Productive-Time
SUL Sui Upper Limestone
NBD Nearbalanced Drilling
POOH Pull out of hole
DDV Down hole Deployment Valve
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PWD Pressure While Drilling

ECD Equivalent Circulating Density
CTR Cuttings Transport Ratio
BHCP Bottom Hole Circulation Pressure
DAQ Data Acquisition
BHT Bottom hole Temperature
BHP Bottom hole Pressure
GPM Gallons per Minute
SCFM Standard Cubic Feet per Minute
RCD Rotating Control Device

References
[1] Diederik Zwager, Kennedy, Tony Diemert, Prapseno Danusubroto, John Wasson. 2002. The application of
underbalanced drilling and completion techniques on exploitation well in south Sumatra, Indonesia. Paper IADC/SPE 77238
presented at the IADC/SPE Asia Pacific Drilling Technology held in Jakarta, Indonesia, 9-11 September.
[2] Hussein Safar, et al. 2007. Dual lateral horizontal well drilled underbalanced in a depleted reservoir in Libya-Case Study.
Paper SPE/IADC 107307 presented at the SPE/IADC Middle East drilling technology conference & Exhibition held in Cairo,
Egypt, 22-24 October.
[3] Muhammad A. Muqeem, Clark M. Jarrett, and Hassan J. Abdul.2008. Underbalanced drilling of Oil wells in Saudi Arabia:
Case history and lesson learned. Paper SPE/IADC 114258 presented at the SPE/IADC Managed pressure drilling and
underbalanced operations conference and Exhibition held in Abu Dhabi, UAE, 28-29 January.
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Figure 1: Graphical workflow for building a 3-D Geomechanical model

Figure 2: Geo-Mechanics Study Poster Deliverability

Figure 3: Drilling Fluid Densities

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Figure 4: Drilling Fluid Flow Modeling

Figure 5: Electromagnetic Transmission

Figure 6: DDV Open and Close Position

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• Run and set • Open Deployment

Deployment Valve Valve and run in
at predetermined hole.
depth with casing • Drill out plug and
string. drill into formation.
• Once open,
Deployment Valve
provides full bore
passage for bottom
hole assembly.

• Isolate formation • When in open

downhole to safely
and quickly deploy
drilling or completion
assemblies of any
length.
position, DDV allows
for full bore passage
of standard bottom
hole assemblies
through tool.

Figure 7: Typical DDV Running Procedure

Figure 8: Electromagnetic Transmission

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Figure 9: Well Profile

Figure 10: ROP Graph

Figure 11: 6” Hole Section Drilling Curve