Underbalanced Drilling and Its Advancements: An Overview: September 2014
Underbalanced Drilling and Its Advancements: An Overview: September 2014
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Abstract
Ever increasing global energy demand associated with depletion of conventional
hydrocarbon resources drives exploration and production (E&P) industry to invent
advanced new technologies in frontier areas of drilling, production and reservoir
engineering to enhance hydrocarbon production from unconventional resources or
depleted reservoirs. Demand to produce from a low pressure marginal reservoir and the
discoveries of naturally fractured reservoirs lead to the development of new drilling
techniques like underbalanced drilling along with other technological advances.
Underbalanced drilling (UBD) technology can overcome a number of problems
encountered during drilling, which is otherwise impossible with conventional
overbalanced drilling. However, in-depth understanding of the characteristic behavior of
different components during operation is an essential criteria for efficient application of
this technology. In drilling operation, drilling fluid plays a very important role in
controlling the entire operation efficiently without any interruption or damage to the
reservoir. Foam-based drilling fluid, one of the most favored techniques of UBD needs a
thorough study for its applicability and smooth functioning under bottom hole condition.
Foam fluid is very much unpredictable for its very sensitive rheological behavior,
specifically for small variation in pressure, temperature, and composition along with
other parameters during drilling. Hence, utmost care should be taken for proper
designing of foam-based fluid, failing of which may negatively affect the process. Present
paper deals with the developments of foam fluid as an efficient drilling fluid since its
inception, composition and rheology, merits and demerits, comparison with conventional
fluids which will help the researchers working in the field to get the intensive information
without consulting a large literature.
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Underbalanced Drilling Overview Saxena et al.
underbalanced. Ill effects caused by conven- The main cause for its lesser success is the
tional drilling fluid may be overcome by using difficulty in maintaining the underbalanced
specially designed fluids which are capable of conditions. Also, its stability under bottom
efficiently performing necessary drilling hole condition is susceptible to increased
operations without causing formation damage temperature and column weight. Moreover,
[10]. Air, aerated water, foam fluids is foam-based drilling is the only technique in
frequently used to mitigate the problems the domain of underbalanced drilling, which
related to formation damage, pipe sticking or can handle large water influxes and has a
lost circulation with the added advantage of maximum cutting carrying capability as
the high rate of penetration. Foam fluids can compared to any other underbalanced drilling
provide the maximum efficiency as it can also fluid. This review work enables a better
prevent fire and explosion in addition to other understanding of the underbalanced drilling
advantages of underbalanced drilling fluid [11, techniques and its applications in various
12]. When the condition arises that the domains of exploration and production (E&P)
formations under consideration are highly industry.
fractured and cannot be drilled using
conventional drilling fluid, use of CLASSIFICATION OF DRILLING
underbalanced drilling technique becomes TECHNIQUES
inevitable. Subnormal pressured formation or The drilling industry has evolved over the
mature reservoir is being encountered and the years with the development of new techniques
reservoir has depleted from its original to drill the more complex formations even up
condition then it becomes impossible to use to a few miles which were thought to be
over balanced drilling technique. In this impossible in the recent past. The intricacies
situation foam developed by inclusion of are overcome by utilization of innovative
noncondensable gases such as nitrogen, CO2, technologies and applied chemistry involved
etc. in an aqueous surfactant media can be in the process. Scientists have made
used as the best candidate for drilling the well revolutionary contributions to drilling fluid by
underbalanced [13]. Foam drilling prevents continuous development of fluids which can
formation damage that can be induced by efficiently drill in more and more complex
conventional techniques and applies less environments.
pressure than the formation pressure [14]. The
reduced pressure differential between the A drilling fluid is considered to be an efficient
reservoir and the wellbore during foam drilling one if it performs its functions.
encourages production of formation fluids and (i) Carrying and suspend the cuttings.
gases [15]. (ii) Lubrication and cooling of bit.
(iii) Stabilizing the well bore.
In foam drilling, flow from the reservoir is (iv) Forming cake to prevent fluid invasion to
driven into the wellbore during production, formation and other jobs in an efficient
rather than away from it as in the case of manner [17, 18].
conventional drilling. Although initially more
costly, underbalanced drilling reduces Thus, there is no existence of any universal
common conventional drilling problems such fluid which can efficiently drill every
as loss of circulating fluid, differential formation. Each category of formations
sticking, reduced formation damage, etc. demands for very specialized drilling fluid.
Additionally, underbalanced drilling extends Thus, it is obvious that highly fractured and
the life of the drill bit because the foam cools tight formations cannot be drilled with the
the bit while quickly removing cuttings [1]. same fluid. Conventionally used drilling fluids
An important factor in successful have high density and they may cause severe
underbalanced drilling is maintaining the problems such as lost circulation, formation
underbalanced condition throughout the damage, and differential sticking during the
drilling operation. To accomplish this, drilling operation of highly fractured
preplanning and onsite engineering are critical reservoirs. So the need for an alternate drilling
to the success of underbalanced drilling fluid becomes inevitable to conserve and
procedures [16]. economically exploit the fast depleting energy
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resource [19, 20].The different conventional It only exploits the most productive zone
and unconventional drilling fluids are and less productive zones are left
described below: unattended but economic feasibility of the
process overshadowed the negative
Conventional/Overbalanced Drilling prospects of this and eventually
Conventional drilling, the oldest method used production suffers.
for drilling well now has landed in the most Formation damage up to a certain limit
sophisticated technology. Overbalanced cannot be avoided. Solid and fluid
drilling is defined as the process in which the invasion into the formation generally
hydrostatic head of the drilling fluid column results in skin damage and can greatly
exceeds the pressure exerted by the formation affect the production.
being drilled [21]. In the initial stages of E&P Lost circulation, it occurs when the
industry when the formations were drilled injected fluid moves into the fractures and
underbalanced due to insufficient is not retrieved on the surface to
technological advancements there were unbalanced pressure conditions, thus
frequent instances of accidents due to lack of overshooting the drilling cost.
availability of effective wellbore control Drilling rate (rate of penetration) is
techniques. But the technoeconomic comparatively slow and the drill string
development has ignited the development of wears out at a rapid rate.
fluid that could serve the purpose; and thus the Unexpected blowouts can take place if
over balanced drilling came into existence high pressure zones are encountered.
[11]. Over balanced drilled wells provide a Differential sticking is a common
mechanism for primary well control. phenomenon which results in loss of
drilling time and cost [21–25].
Characteristics of conventional drilling fluids
for stable and controlled operations may be Underbalanced Drilling
recognized for Underbalanced drilling is defined as the
1. Maintenance of hydrostatic pressure in the process in which the hydrostatic head of a
wellbore due to the high density of the drilling fluid is intentionally designed to be
fluid used (mud) and the density lower than the pressure of the formation being
contribution of any drilled cuttings. drilled [26].The reservoirs whose production
2. Dynamic pressure from the fluid have reached its peak and started to decline are
movement due to friction of the circulating referred as matured reservoirs. The decline in
fluid used and the relative fluid motion hydrocarbon production rate makes the drilling
caused by surge/swab of the drill pipe. of such formations an expensive affair. It is
3. Imposed pressure, which occurs due to the found that formations above and below
pipe being sealed at surface resulting in an matured reservoirs have high pore pressure
area with pressure differential (e.g., a and needs to be balanced with high density
rotating head or stripper element). drilling fluid. This high density fluid exploits
the depleted zones and problems of formation
For conventional drilling the bottom hole damage and lost circulation are encountered.
pressure can vary with hundreds of psi from The solution to this is drilling underbalanced
dynamic to static conditions. Hence drilling in which the density of drilling fluid has been
the formations with a narrow drilling pressure just enough to balance the lowest pore
window is considered unsafe and impractical pressure in the reservoir [7, 27]. If fractured
using conventional drilling techniques [22]. reservoirs are drilled using the conventional
This technique was reliable and safe. technique they could get damaged and
However, some disadvantages associated with production is hampered along with problems
it could be detrimental to the well bore of lost circulation and differential sticking.
production in the long term and may not be Underbalanced drilling technology is the
economically feasible [15, 20]. A few utilization of compressed air or other gases as
drawbacks associated with overbalanced the rotary circulating fluid to carry the rock
drilling are: cuttings to the surface that are generated at the
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Underbalanced Drilling Overview Saxena et al.
bottom hole during the advancement of drill conditions [31, 32]. Application of
bit along the course of well bore. The underbalanced drilling is growing at a rapid
compressed air can also be injected into the rate because of its properties to reduce
well along with the incompressible fluids such invasive formation damage and drilling
as water, drilling mud, etc. Aerated drilling problems associated with many horizontal
fluids are being used in drilling technology wells in challenging reservoir conditions [33].
since the mid of 1930s, though the first Application of underbalanced drilling is
engineering discussions on an aerated drilling becoming more popular and economical
mud was published in 1953 [4].Currently specifically to the depleted, marginal and
underbalanced drilling contributes to 20%– complex reservoirs [34]. The severity of the
30% of the total drilling operations [28]. The problems caused by conventional drilling fluid
hydrostatic head of the drilling fluid may be depends on mud rheology, time period through
naturally less than the formation pressure or it which it is exposed to the mud, pressure
can be created artificially. The artificial state exerted by the mud, the permeability of the
may be created by adding air, nitrogen, or rock and reservoir rock’s mineralogical
natural gas, to the liquid phase of the drilling composition. The “skin effect” comes into
fluid. Whether induced or natural, this can account because of solid and mud invasion
result in an influx of formation fluids to the which can be attributed to different damage
wellbore which must be circulated from the mechanism and can significantly alter the
well and controlled at the surface to prevent production and/or injection rates. Thus the use
accident [29]. of underbalanced drilling becomes inevitable
[25, 34].
Typical underbalanced drilling system/process
is shown in Figure 1 in which a high pressure If water influx is encountered while drilling
gas in injected down the bore hole which than drilling underbalanced using foam as a
carries the cuttings along its course to the drilling fluid if the most feasible option
surface. This cutting carrying stream is passed because of its high cutting carrying capability
through a cutting separator and cuttings are along with its water handling capacity.
separated. In this assembly the foam is being Furthermore shale’s are also found pressurized
produced by injection of nitrogen into a stream along with the sands. This requires
of base fluid (surfactant + polymer). The simultaneous pressure stabilization. Drilling
produced foam passes through the drill pipe to these formations safely with conventional
the bit from where it carries the cutting to the technique is a tedious job [35, 36]. The drilling
surface along with the formation fluid through fluid for highly fractured wells such as coal-
the annulus. The stream is fed into the UDB bed methane is selected after analyzing the
flow control manifold. Under balanced geological settings of the coal. Minimal use of
drilling is used in many locations in the world surfactant and polymer produced foam greatly
where sufficient reservoir depletion exists or reduces lost circulation and avoid damage of
the reservoirs are highly fractured which coal seams. More over foam can control the
damages the formation and prohibits the increased volume of methane gas liberated
economic production of hydrocarbon [30]. during multilateral horizontal drilling of coal
Success rate with the underbalanced drilling seams [37].
has not been up to the mark; the prime reason
is the improper application of this technology FIELD APPLICATIONS
and inability to maintain the underbalanced Underbalanced Drilling has been used in
condition all the time. Nonexistence of filter largest Algerian oil field Hassi Messaoud
cake results in a net outflow of fluid from which was discovered in 1956. The production
formation. Hence, slightest imbalance in the was from a hard sandstone reservoir [38].
pressure condition and relatively small rise in Sonatrach introduced the underbalanced
overbalance condition can cause huge invasion drilling in this field in March 2002 to
of solid and fluid into the formation leading to eliminate the problems associated with
severe damage. Sometimes it is more than the conventional drilling fluid. The encouraging
damage caused by overbalanced drilling using results were obtained in terms of increased
a good drilling fluid under the same reservoir drilling rates up to five times but reduced bit
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life. Eventually the total drilling time was southern Mexico along with northern and
reduced from the original. Also, the southern Gulf of Mexico offshore blocks. The
production rates were increased above field revamping of these fields enhanced the growth
average. In 2004, UBD was introduced into a of the associated companies attributed to the
carbonate field in northern Oman to avail increased production rates and minimal
increased production and enhanced drilling damage.
rates [39]. Up to 2006, 16 wells were
successfully drilled in this field using UBD The Quinn #3H a highly fractured high
and are today producing at double the initial temperature well is located in Brooke land
production rate. Field in Tyler County near Spurger, Teaxs.
Over the years it has witnessed six failed
In 1995 Mexican oil companies started using drilling attempts following a blowout. In 2009
UBD with intent to exploit depleted reservoirs. Signa Engineering successfully drilled this
But soon it was being implemented in fields well using managed pressure drilling [41]. It is
experiencing formation damage to enhance the evident from the available literature that UBD
productivity and reduce formation damage and is in the phase of development all around the
other associated problems [40]. In early 2000s globe serving the demand for increased
UBD was employed from the Burgos basin in production and minimal damage.
Northern Mexico to the rich classic fields of
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Underbalanced Drilling Overview Saxena et al.
Compressed air or gas is injected into the employed [54]. The field results gave a boost
borehole along with an incompressible fluid to the users of this technique. Foam was used
such as water or oil in this technique. The in different parts of the world where mature,
addition of liquid into the gas stream leads to depleted or highly fractured reservoirs are
formation of mist/unstable foam making it encountered. Comparative results showed
unstable foam drilling technique. This liquid is increased productivity, early oil production,
added to saturate the cuttings and preventing it enhanced ultimate recovery, reduced drilling
from choking the top of drill collar and time, and safer operations [21]. Stable foam
prevent pipe sticking. It also can reduce the consists of water, surfactant or foaming agent,
risk of mud ring formation. It is widely used gas or air. The water and surfactant form a
for formations such as CBM, etc. where water continuum of foam. The incompressible fluid
is present because of its higher efficiency to (with surfactant) and compressible air (gas) are
lift liquid to the surface compared to air. simultaneously injected from the top of the
Cutting removal is governed by annular drill string. These fluid streams get mixed
velocities. However, it requires a higher along the course and pass through the nozzles
volume of air (30%–40 % more than dry air of drill bit. The stable foam is generated at the
drilling) and pressures exceeds normal air bottom of the annulus. Produce foam entrains
drilling operations. Incorrect air/gas liquid the cutting to the surface [30].
ratio can lead to an abrupt increase in pressure.
The foam quality is defined as the volume
Characteristics of mist-drilling: fraction of gas phase of foam. It has been
Similar to air drilling, but with addition of studied that foam qualities in the range of
liquid. 70%–95% are best suitable for being used as
Cutting removal rate is governed by drilling fluid. The specific gravity of the foam
annular velocities of fluids. can vary in the range of 0.2–0.7. When gas
Reduces formation of mud rings. fractions in the foam exceed 95% it forms
High volumes required (30%–40% more unstable foam or mist which is unsuitable for
than dry air drilling). being used as a drilling fluid as it cannot hold
Pressures generally higher than dry air the cuttings in their matrix [55, 56]. The large
drilling. viscosity of these systems is attributed to
Incorrect air/gas-liquid ratio can lead to an increased surface areas. The viscosity of these
abrupt increase in pressure [53]. foams is improved by adding vicosifiers in the
base solution [57]. Under given reservoir
Stable Foam Drilling condition and given liquid and gas flow rates
They are being used as circulation fluids in foam quality is a function of pressure.
drilling and work over operations from 1960s. Backpressure is often required to keep the
The use of preformed foam as a drilling fluid foam stable along its course to the surface.
gained importance in the 1970s when the When the gas phase fraction falls below 60%
problems of lost circulations were the foam structure collapse and phase
encountered. Lost circulation is undesirable separation occurs. This makes the foam
because it requires additional drilling fluid to unsuitable to be used as a drilling fluid [52].
make up for the loss, thereby adding a
significant cost to the drilling operation. Lost With the growth in use of underbalanced
circulation also damages the productivity drilling techniques, the use of foam as a
zone, which can lead to well blowout with drilling fluid has increased drastically. The
serious safety and environmental flow and behavior properties of foam are more
consequences. Earlier, air was used to drill complicated as compared to other drilling
underbalanced but the foam’s ability to carry fluid. Its properties change along its course
large amount of cutting along with its ability within the well bore. So the study of its
to inhibit down-hole fire and explosion made it rheology and variation with varying reservoir
a worthy competitor. The advent of foam as a condition is inevitable. Proper estimation of its
drilling fluid saved thousands of dollars and rheological properties helps in modeling of its
reduced other associated problems which were hydrological behavior [58]. The selection of
not even thought of when it was being underbalanced drilling pressure window can
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Volume 4, Issue 2
ISSN: 2231-1785 (online), ISSN: 2321-5178 (print)
be explained easily using the line diagram in operations are discontinued for work over
Figure 2. The blue line demarcates the jobs or making connections.
reservoir pressure at a particular depth. The Stable foam possesses very high carrying
light red line above it denotes the pressure that capacity. Improved cuttings transport
will be exerted if conventional drilling results in reduced pump.
technique is employed in drilling the Stable foam increases the production rate.
formation. This pressure is almost 200–1000 The breaking down of the foam at surface
psi greater than the formation pressure at that needs to be addressed at the design stage
particular depth. While the red line below it [52].
denoted the pressure which will be employed
when underbalanced drilling technique is More sophisticated surface equipments are
employed. It can be seen the UBD pressure is required to carry out underbalanced drilling
slightly lower than the formation pressure, but operation [60]. A comparative study of
is really very advantageous when compared to different underbalanced techniques is shown in
conventional drilling methods [59]. It can Table 1. Surfactants reduce the interfacial
eliminated most of the problems associated tension between the liquid films thereby,
with conventional drilling technique. Figure 2 providing the stability of the liquid film. With
clearly gives us the operating window for changing requirements in drilling industry the
pressure that is needed during the modification in production techniques of foam
underbalanced drilling operation. is taking place. Some polymers or stabilizer
such as hydroxyethyl cellulose (HEC), Guar
Characteristics of foam-based drilling can be gum, Xanthan Gum, Carboxymethylcellulose
described as (CMC), PHPA, PAA, etc. are added to
This technique helps in eliminating the use enhance the stability and mechanical strength
of additional down hole equipment. of the bubbles. These surfactants and polymer
Since the major portion of the annulus is get adsorbed on the surface of the films and
occupied by the foam, the variety of provide interfacial elasticity to the lamella of
bottom hole pressures can be achieved. the bubbles, thereby enhancing its stability and
The stable foam matrix has a high yield foamabilty [61]. Polymers used to enhance the
point. This can keep the small rock properties are selected on the basis of stability
cuttings suspended when the drilling they provide, bio-degradability, cost etc.
[9, 62].
Depth (ft)
Fig. 2: Schematic Diagram for Selection of Pressure Window for Drilling with Height.
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Volume 4, Issue 2
ISSN: 2231-1785 (online), ISSN: 2321-5178 (print)
This can lead to pipe sticking. Moreover the tremendous cutting carrying capability of foam
cost of disposal of excessive water is a major can outclass all other methods of
concern. The other favorable component is the underbalanced drilling amongst all the classes.
hydrocarbon production. But too high It can handle enormous amounts of water
production rate, which is beyond the handling influx making it a strong candidate for drilling
capacity of the surface equipment can lead to while drill underbalanced.
blow out. Hence this needs to be converted to
overbalance [68–71]. A detailed investigation of hydrodynamics
properties and rheological behavior of
Problems in Directional Drilling underbalanced drilling fluid is needed to be
Conventional directional drilling tools are carried out before implementing it into a
designed to drill overbalanced. Most of these million dollar project. The study is important
tools cannot be used with compressible because of the compressible nature of the
drilling fluids. Mud pulse telemetry drilling fluids used in UBD which influences
measurement while drilling tool cannot be the behavior of drilling fluid drastically during
used as the pulse does not propagate through reservoir bottom hole conditions.
compressible fluids which are used in
underbalanced drilling. Hence, specialized This study will be helpful in understanding the
electromagnetic measurement while drilling basic theories and advancements in the field of
tool are needed to carry out the operation. The underbalanced drilling along with its future
performance of motors is greatly reduced prospects in the E&P industry. Also, it will
whey they are used on compressible fluid [52, provide thoughtful information in the selection
71–72]. of the best technique for drilling a particular
formation by assessing the pros and cons of
Problems in Safety different techniques available.
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JoPET (2014) 37-51 © STM Journals 2014. All Rights Reserved Page 50
Journal of Petroleum Engineering & Technology
Volume 4, Issue 2
ISSN: 2231-1785 (online), ISSN: 2321-5178 (print)
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