Journal of King Saud University – Engineering Sciences (2011) 23, 49–66

King Saud University

Journal of King Saud University – Engineering Sciences

www.ksu.edu.sa
www.sciencedirect.com

REVIEW

Potential implementation of underbalanced

drilling technique in Egyptian oil fields
a,*
K.A. Fattah , S.M. El-Katatney b, A.A. Dahab b

a
Petroleum and Natural Gas Engineering Department, College of Engineering, King Saud University, P.O. Box 800,
Riyadh 11421, Saudi Arabia
b
Petroleum Engineering Department, Faculty of Engineering, Cairo University, Egypt

Received 20 October 2009; accepted 10 February 2010

Available online 7 December 2010

KEYWORDS Abstract The need to increase productivity and to reduce drilling damage favors the use of under-
Underbalance drilling; balanced drilling (UBD) technology. In highly depleted reservoirs, extremely low-density fluids,
Drilling fluids; such as foams or aerated mud, are used to achieve circulating densities lower than the pore pressure.
Drilling cost; In such cases, the induced modification of the in situ stresses has to be supported mainly by the
Hole problem rock, with little contribution from the drilling fluid pressure. The application of underbalanced dril-
ling depends on the mechanical stability of the drilled formation, among other factors. In general,
poorly consolidated, depleted formations are not suited for that technology.
In this paper, 23 UBD worldwide cases have been analyzed; two of which are from Egyptian
fields and the others are from Iran, Algeria, Kuwait, Oman, Texas, Mexico, Indonesia, Canada,
Libya, Middle East, Qatar, Saudi Arabia and Lithuania. From these analyses, the reasons of failure
or success have been stated. The reasons of success included depleted reservoirs and highly fractured
carbonates formation while, the reasons of failure include over pressurized shale, highly tectonic
stress areas, and downhole failures. The main attractive application of this technology was pro-
posed to be only in the reservoir section, and the target was to prevent the reservoir damage and
hence increase the productivity and recovery factor.

* Corresponding author.
E-mail address: [email protected] (K.A. Fattah).

1018-3639 ª 2010 King Saud University. Production and hosting by

Elsevier B.V. All rights reserved.

Peer review under responsibility of King Saud University.

doi:10.1016/j.jksues.2010.02.001

Production and hosting by Elsevier

50 K.A. Fattah et al.

A proposed underbalanced drilling program is developed based on these analyses to be used in

the three main regions in oil and gas producing Egyptian fields. The aerated mud was selected as
a drilling fluid to drill the reservoir section in Western Desert and Gulf of Suez region whereas
the single phase fluid was selected as a drilling fluid in the Nile Delta region.
ª 2010 King Saud University. Production and hosting by Elsevier B.V. All rights reserved.

Contents

1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2. Studied cases. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.1. Case 1: gulf of Suez area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.2. Case 2: western desert gas field area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.3. Case 3: Iranian oil field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.4. Data analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3. Proposed UBD program to be implemented in Egyptian fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.1. Gulf of Suez oil field area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.2. Western desert oil field area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.3. Nile delta oil field area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4. Conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Appendix A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

1. Introduction bit life results through the use of this medium as compared
to mud. Drilling rates as high as 90 ft/h have been attained
Drilling cost is considered one of the major components of in shales. Air drilling, however, is restricted to areas where
operating cost in the petroleum industry. Improving the pene- high volume water sands are not present ahead of the produc-
tration rate of drilling operation and reducing drilling prob- ing zone. The rate of water influx that can be handled in the
lems, such as pressure differential pipe sticking and lost case of air drilling is also not well known. Other inherent dis-
circulation, have long been considered an effective way of advantages of using air or natural gas as drilling fluids include
decreasing drilling costs. The overbalance pressure, generally possibility of downhole fires and explosions, and sloughing of
recognized as the most important among the many factors formations due to underbalance of stresses around the well-
affecting penetration rate, is often defined as the pressure dif- bore. Possibility of downhole explosions are of particular con-
ferential between the borehole pressure and formation fluid cern in air drilling operations. Small dust-like particles are
pressure (Murray and Cunningham, 1955; Eckel, 1957; Cunn- generated as a result of rock cuttings (chips) being ground
ingham and Eenink, 1959; Gamier and van Lingen, 1959; and pulverized by the drill string in the annulus, and collision
Vidrine and Benit, 1968; Bourgoyne and Young, 1974; Black of cuttings with each other, the tool joints, and the wall of the
and Green, 1978). Formation pressures lower than the static borehole due to the high velocity forces. In the presence of
pressure of a column of fresh water require the use of a lighter moisture, seal rings may form at tight places in the annulus,
fluid, such as air, injected with liquid to obtain lower overbal- which create pressure chambers. With additional influx of nat-
ance pressure to enhance penetration rate and to minimize lost ural gas from gas-bearing zones being penetrated by the bit, an
circulation and pipe sticking as well as formation damage. explosion may easily occur.
Therefore, aerated mud drilling ‘‘implies the use of air or nat- Besides having formations suitable for air drilling, the most
ural gas as the circulating medium instead of the regular mud’’ important consideration in drilling with air is the volume of air
is becoming an attractive practice in some areas. The commer- required. Air drilling often fails because of insufficient volume
cial use of aerated mud drilling began only in recent years of air necessary to clean the hole efficiently under certain con-
(Rankin et al., 1989; Claytor et al., 1991). Low-density drilling ditions, e.g., wet hole, sloughing shales, and influx of forma-
fluids used in underbalanced drilling consist of air, mist, stable tion water. A practical rule of thumb for determining
foam, and aerated mud foam with back pressure. Whereas the adequate air volume is that the volume required achieving
term ‘‘aerated mud’’ implies the simultaneous introduction of 1000 ft per minute annular velocity to clean the hole properly
air and mud together into the standpipe in order to drill special (Godwin et al., 1986; Boyun and Rajtar, 1995).
types of formations (Godwin et al., 1986; Boyun and Rajtar, Drilling with foam has some appeal due to the fact that
1995; Salah El-Din and El-Katatney, 2009). foam has some attractive qualities and properties with respect
The main advantage of air as a circulating fluid is that being to the very low hydrostatic densities, which can be generated
the lowest density fluid. It imposes minimum pressure on the with foam systems (Hooshmandkoochi et al., 2007; Moore
formation to be drilled. High penetration rates have been and Lafave, 1956; Maurer, 1998; Bentsen and Veny, 1976).
achieved in hard and dry formations with the use of air as a Foam has good rheology and excellent cutting transport prop-
circulating fluid. In addition to high penetration rate, longer erties. The fact that foam has some natural inherent viscosity
Potential implementation of underbalanced drilling technique in Egyptian oil fields 51

Table 1 Change in BHCP versus mud rate and N2 rate.

Duration (h) Mud rate (GPM) N2 rate (SCF/m) N2 (%) SPP (psi) BHCP (psi) ECD (kg/lit) Gain (bbls) MWD Signal
1.5 250 250 4.8 2250 2887 0.86 31 mud Ok
3.0 250 500 9.1 2250 2660 0.79 34 mud Ok
2.0 240 500 11.4 1800 2652 0.79 0 Ok
1.5 230 500 13.2 1600 2620 0.78 0 Ok
1.5 210 500 15.5 1450 2590 0.77 0 Ok
1.5 180 500 21.6 1120 2549 0.76 0 Ok

Figure 1 Well profile diagram for case 2: western desert gas field area.

Figure 2 Working window for case 2: western desert gas field area.
52 K.A. Fattah et al.

Figure 3 Well profile diagram for case 3: Iranian oil field area.

Figure 4 Operational envelope – native crude for case 3: Iranian oil field area.
Potential implementation of underbalanced drilling technique in Egyptian oil fields 53

Table 2 Recorded ROP in Algeria. Table 3 ROP versus pressure drop for UBD wells.
Algeria sandstone reservoir Reservoir Pressure Rate of Lithology
pressure (psi) drop (DP) (psi) penetration (ft/h)
Well number ROP overbalanced ROP underbalanced
(ft/h) (ft/h) 2900 290 45 Sandstone
3000 360 38 Sandstone
1 10.4 19.5
1350 540 16 Sandstone
2 10.4 17.6
3200 640 27 Sandstone
3 19.3 22.5
5500 990 30 Sandstone
4 19.5 22.3
5 13.5 45
6 17 26.6

Table 4 Recorded data for UBD wells.

Overbalanced Pressure ROP Production while Production after Lithology
Underbalanced drop (psi) (ft/h) drilling (%) test (%)
50
Rate of penetration ROP

290 26.6 0 1.2 Sandstone

40 320 44.7 0.8 3.9 Sandstone
350 19.45 1 2 Sandstone
30 406 22.5 1.5 1.8 Sandstone
435 17.6 2.7 3.4 Sandstone
20

10

0 Rate of penetration (ft/hr) 50

1 2 3 4 5 6 45
Well number 40
35
Figure 5 Comparison between ROP in OB and UB cases.
30
25
20
15
10
5
0
280 380 480 580 680 780 880 980 1080
Pressure drop (psi)

Figure 7 ROP versus pressure drop for UBD wells in different

reservoirs.
Rate of penetration (ft/hr)

50
40

30
20

10
Figure 6 Relationship between ROP and pressure drop. 0
280 330 380 430
Pressure drop (psi)
as well as fluid loss control properties, which may inhibit fluid
losses, makes foam a very attractive drilling medium. During Figure 8 ROP versus pressure drop for UBD wells in one
connections and trips, the foam remains stable and provides reservoir.
a more stable bottom hole pressure. It is a particularly good
drilling fluid with a high carrying capacity and a low density.
The foam normally remains stable, even when it returns to developed stable foam systems are simpler to break, and the
the surface, and this can cause problems on a rig if the foam liquid can also be refoamed so that less foaming agent is re-
cannot be broken down fast enough. In earlier foam systems, quired and a closed circulation system can be used. These sys-
the amount of defoamer had to be tested carefully so that tems, in general, rely on either a chemical method of breaking
the foam was broken down before any fluid entered the sepa- and making the foam, or the utilization of an increase and de-
rators. In closed circulation drilling systems, stable foam could crease of pH to make and break the foam. The foam quality at
cause particular problems with carry over. The recently surface used for drilling is normally between 80% and 95%.
54 K.A. Fattah et al.

The quality of foam means that the system is 80–95% gas, with the MWD can work up to 21% nitrogen. Nitrified mud (500
the remaining 5–20% being liquid. Downhole, due to the SCFM + 230 gpm diesel) was applied while close balance dril-
hydrostatic pressure of the annular column, this ratio changes ling the six in original and side-track lateral section. The six in
as the volume of gas is reduced. An average acceptable bot- hole was drilled to depth 2830 m utilizing UBDS and power-
tom-hole foam quality (FQ) is in the region of 50–60%. Fluid pack motor of 1.15 BH c/w MWD Impulse, VPWD, ADN
densities for foam range from 1.6 ppg to 6.95 ppg (0.2– tools (inclination at bit, annulus and string pressure, GR resis-
0.8 S.G.) (Godwin et al., 1986; Boyun and Rajtar, 1995). The tivity, density-neutron) with 2 · 3-1/2 in. W.FORD float val-
density ranges are adjusted with the make up of the foam by ve + motor restriction sub (nozzle 14/32 in.) for improving
adjusting the Liquid Volume Fraction (LVF) through the MWD signal. The analysis of this well results showed that,
injection of liquid and gas by adjusting the backpressure on The ROP was enhanced drastically in sand from 4 m/h while
the well. The backpressure adjusts the downhole pressure sliding to 50 m/h, and in anhydrite was 8–10 m/h (experienced
and slows down the velocities in the annulus. Experience has 2–4 m/h in normal overbalance drilling), the use of rotating
proven that foam is able to handle over 100 bbl/h of water in- head helped to control well while tripping and also in case of
flux (Godwin et al., 1986; George and Waston, 1956; Boyun separator carry over problems, and the Crew acquired UBD
and Rajtar, 1995). work experience.
So, the objective of this research work is to investigate and
analyze many worldwide applications of underbalanced dril- 2.2. Case 2: western desert gas field area
ling and state the reasons of success or failure of this applica-
tion. Based on these analyses, a proposed underbalanced The well is located at the central part of the western desert
drilling program is developed. In this proposed program, the block. The well target was to drill 3-7/8 in. · 500 m horizontal
method of selecting the appropriate technique to be applied
for these candidate areas are selected according to the geology Production while drilling
production after test
of the area and the bottom hole conditions inside the wells.

Value Compared with OB

4.5
4
2. Studied cases 3.5
3
In this section, three case studies from Egyptian fields and 2.5
other places are analyzed in detail and a summary of 20 cases 2
1.5
from other worldwide fields are given with a brief discussion
1
about their objectives, problems and results (Salah El-Din 0.5
and El-Katatney, 2009). 0
1 2 3 4 5
2.1. Case 1: gulf of Suez area Well Number

The well is located at onshore Belayim oil field. The well target Figure 10 Comparison of production while and after UBD
was sandstone of zone III (Belayim formation, Feiran mem- drilling.
ber) at a total depth of 2335 m TVD, 2854 m MD. The pres-
sure in Zone III (sandstone) was estimated to be 3000–
3500 psi (0.3917–0.4569 psi/ft). The objectives of UBD were Table 5 Drilling time and cost savings for 8-1/200 hole section
to increase rate of penetration, enhance Well control, reduce drilled underbalanced conditions.
occurrence of lost time incidents, and increase well productiv-
ity. The 20 m of the new hole at 7 in. liner shoe at 2659 m MD Well Real cost Clean cost (just drilling)
was drilled with only mud, then the MWD signal test was per- Days K$ Days K$
formed (inflow test and also to test the optimum rate combina- 8-1/200 hole – conventional
tion for better MWD signal) as shown in Table 1. Based on 1 27 1171 27 1171
this test, the formation pressure was estimated to be less than 2 25.7 1146.3 24.4 1114
2500 psi that was confirmed at 2400 psi from vacuum test and 3 30.4 2125.3 21.6 1771.9
4 19.3 1360.1 17.6 1230.8
5 31.9 2215.7 16.7 1629.3
6 23.3 1058.5 22.4 1035
500
pressure drop (psi)

7 31.4 1385.1 23 1005.6

400 8 21.6 1241.5 17.8 989.9
9 20.7 899.1 17.2 667.4
300 10 34.1 1551.6 30.3 1300.1
200 Average 26.5 1415.4 21.8 1191.5

100
8-1/200 hole – underbalanced
1 20.5 1652 14.8 1395.6
0 2 19 1458 13.7 1243.5
0 1 2 3 3 21.2 1998.6 16.5 1541.5
Production while drilling 4 17.8 1193.6 15.7 728
5 12.9 597 12.2 553.9
Figure 9 Production while drilling versus pressure drop for Average 18.3 1379.8 14.6 1092.5
UBD wells.
Potential implementation of underbalanced drilling technique in Egyptian oil fields 55

section in unit 3 of the Mesozoic Lower Safa reservoir. They It was estimated that the ROP will be between 5 and 10 m/h.
are composed of low to medium permeable (1–500 md) mica- The drilling fluid of choice was produced water. The drilling
ceous sandstones deposited in a strong tidally influenced estu- fluid could be separated from the produced hydrocarbons
ary, Fig. 1. Lower Safa formation comprises a high-energy and re-used. Due to the CO2 content of the reservoir (up to
sequence of Estuarine deposits with a total average thickness 9%) and the use of nitrogen (up to 5% O2), corrosion mitiga-
of 110 m in the area where is planned, although only 29 m of tion was required. Once the well started to produce during the
these thickness are considered productive. The objective of drilling phase, the N2 was stopped, which in turns eliminated
UBD was to prevent reservoir damage. Gasification was excessive use of corrosion inhibitors. Water and nitrogen gave
through drill pipe injection technique. the desired underbalanced margin when kicking off the well,
The well was completed as open hole. Average ROP during and water was treated with suitable chemicals for corrosion
overbalanced drilling operations on offset wells has been his- mitigation. It became apparent that the Lower Safa formation
torically 2–3 m/h in the horizontal section. Historical data was normally pressured. Hence by using just water, the BHP
for UBD wells suggested that there will be an improvement will be 260 psi underbalanced. Nitrogen was required to create
in ROP due to the elimination of the chip hold-down effect. a greater draw down than the 260 psi as it is unknown at what
draw down the matrix starts to contribute to the inflow.
As soon as the well produced, nitrogen was cut down to
zero rates. Nitrogen injection was required again every time
Table 6 Drilling time and cost savings for 6-1/200 hole section the drill string tripped through the Down-hole Deployment
drilled underbalanced conditions. Valve (DDV) to remove the water from the reservoir section.
Well Total cost Drilling cost Fig. 2 shows the working window (operating envelope) for
the well (case 2) with no reservoir inflow for, 3-7/8 in hole, 3-1/
Days K$ Days K$
2 in. · 2–7/8 in. drill pipe design, 2 · 500 m legs, and bit at TD.
6-1/200 hole – conventional Also plotted on the operating envelope, are the various con-
1 9 886.6 9 886.6
straints that must be fulfilled during underbalanced drilling
2 11.8 591.8 11.8 591.8
operations. After drilling 200 m, the drilling had been stopped
3 20.7 1186.4 18.1 1082
4 29.6 1596.7 17.8 644.7 due to failure of downhole equipment due to high temperature.
5 33.5 2074.1 20 1531.9
6 21.9 928.1 19.7 779.9 2.3. Case 3: Iranian oil field
7 19.1 995.5 17.8 938.3
8 14.1 778.5 11.8 650.6 The target reservoir for this well was Asmari formation, the
9 16.4 800.8 16.4 800.8 formation was fractured carbonated formation. The reservoir
Average 19.6 1093.2 15.8 878.5 drive mechanism was gas cap. Shale strings were not expected
6-1/200 hole – underbalanced in this formation. Expected reservoir pressure and tempera-
1 7.4 507.8 6.6 471.9 ture were 2622 psi and 141 F, respectively. Reservoir fluid
2 24 1664.6 11.9 998.9 was oil with API gravity of 25, GOR 564 SCF/STB, and
3 22.4 1804 17.2 1057.7 H2S concentration of 240 ppm. The permeability of the reser-
4 14.8 545.1 10.8 387.57 voir was 0.1–1000 md with a porosity of 9% (Hooshmandko-
5 9.5 580.6 9 560.6 ochi et al., 2007). The well was drilled from m (9-5/8 in shoe
Average 15.6 920.4 11.1 695.3
depth) to a total depth of 2938 m MD (2567 m TVD), Fig. 3.
The primary objectives of this underbalanced drilling project
were to: minimize drilling induced formation damage, elimi-
nate drilling fluid losses, and improve drilling performance.
The drilling fluid selection was one of the most critical deci-
Table 7 Gulf of Suez reservoir characteristics.
sions in planning an underbalanced well. The right fluid(s)
Parameter Belayim Kareem selection will not only lead to suitable BHCP but will also
Pressure 1500 psi 1700 psi minimize pressure transients and thus eliminating/minimizing
Temperature 180 F 190 F formation impairment. The deviated underbalanced section of
Gas–oil ratio (GOR) 15–17 SCF/STB 20 SCF/STB
this well was to be drilled with a Gachsaran field native crude
Porosity (md) 18–20% 20–22%
oil and a membrane nitrogen generation circulating system.
Permeability 200 md 500 md
API0 gravity of oil 20–23 20–30 Liquid Phase, the native crude oil, was chosen over Diesel
H2S concentration No No and other drilling fluids because it is the natural reservoir
fluid for this well. This minimized chances of formation

Table 8 Gulf of Suez formation characteristics.

Formation Lithology Top (m) Thickness (m) Pore pressure (psi)
Belayim
Hammam Faraun Shale-sand 2160 35
Ferran Shale-sand 2195 140
Sidri Mainly sand 2335 65 1500
Babaa Anhydrite 2400 15
Kareem Limestone 2415 195 1700
56 K.A. Fattah et al.

Table 9 Underbalanced drilling design parameters for Gulf of Suez area.

Rig modification  No essential modifications to be made on the rig to suite UBD operations
 The substructure has to be high enough to allow Rotating Control Head (RCH) to be installed on top
of the Hydril
Well plan  As shown in Fig. 11
Drill string design  Use a 500 DP and 500 HWDP on 6-3/400 DC
BHA  The BHA consists of 6-1/200 mud motor and MWD to drill 8-1/200 hole
 An 8-1/200 bit size of 3 · 13/3200 nozzles
Drilling fluid selection  The deviated section will be drilled using an oil bas mud and a membrane nitrogen generation circu-
lating system
A-liquid phase  Drilling fluid is native crude oil with density 7.6 ppg (0.91 S.G. or 20 API)
 Liquid flow rates were selected to achieve a drawdown from the reservoir pressure
B-gas phase  Nitrogen was selected as the injection gas
 Nitrogen will be obtained from the surrounding air and generated onsite
Operating envelope  A minimum drawdown at the bit of 100 psi is required to ensure adequate underbalanced conditions
in the well
 Using 300 gpm and more than 2400 scfm of Nitrogen will provide maximum 100 psi drawdown from
the expected reservoir pressure, as shown in Fig. 12
 In case the real reservoir pressure will result below the expected value, then the liquid injection rate
should be reduced increasing the risk for a hole cleaning issue
Hole cleaning  Minimum annular liquid velocities in deviated holes of 210 ft/min when crude oil is used as the dril-
ling fluid to ensure that the drilled cuttings are effectively removed from the wellbore
 A wiper drilling trip will help clear the problem of hole cleaning
Motor performance  The motor should be suitable for oil/nitrogen two-phase application
 A maximum Equivalent Liquid Volume through the motor of 600 gpm was used as reference
 A pressure loss of 800 psi between downhole motor and MWD was considered
 The motor should not have a bypass valve on top of it
Production sensitivity  As more reservoir fluids (oil and gas) introduced into the wellbore, the bottomhole circulating pres-
sures (BHCP) will decrease
 BHCP will therefore be controlled by increasing liquid injection and/or decreasing nitrogen injection,
based on real-time BHCP data from the MWD tool
 BHCP could also be controlled with surface backpressure
 Choking will be necessary in stabilizing the circulating system during and after drill string connections
Data acquisition  The software for the rig data acquisition has to be able to interface with the UBD equipment software
Completion  The well can be completed with barefoot completion technique, or installing a slotted liner
completions

damage in event of pressure transients and/or from fluid UBD on this well experienced some typical logistical and
imbibitions. The well was displaced with the produced fluid start up problems associated with a steep learning curve, this
after getting enough oil production. Gas Phase, nitrogen, being the first such operation in Iran. Despite all the problems
was selected as the injection gas because of its inert nature, encountered in this well, the following performance had been
economic availability and suitability for this specific achieved: drilled to 308 m of total open hole depth, no loss cir-
underbalanced drilling project. Nitrogen was obtained from culation was encountered while drilling, successfully imple-
the surrounding air and generated onsite, by nitrogen produc- mented UBD technology, and no Quality, health, safety and
tion unit (NIOC’s). The multiphase flow behavior in the well- environment (QHSE) incidents were recorded. Data for case
bore during underbalanced drilling was very complex. The 4 to case 23 are given in the Appendix A (Azeemddin, 2006;
response of the downhole conditions to changes in various Bates, 1965; Bennion et al., 1998; Dorenbos and Ranalho,
flow parameters must be characterized prior to the com- 2002; Gordon, 2005; Gray, 1957; Hongren et al., 1999; Inter-
mencement of underbalanced drilling operations in order to national Association of Drilling Contractor, 2005; Kuru,
maximize chances of success. Fig. 4 contains a plot of the bot- 1999; Louison et al., 1984; Maclovio, 1996; Meng, 2005;
tom hole circulating pressures induced by a variety of nitro- Moore et al., 2004; Nas, 2004; Negra et al., 1999; Parra
gen rates and the Gachsaran native crude oil injection rates. et al., 2003; Qutob, 2007; Qutob and Ferreira, 2005; Sunthan-
This plot was referred to as the operating envelope. Also plot- kar, 2001, Weatherford Company, 2006; Westermark, 1986;
ted on the operating envelope, are the various constraints that Whiteley and England, 1986; Zhou, 2005).
must be fulfilled during underbalanced drilling operations.
The range of flow rates that satisfy all of the constraints, de- 2.4. Data analysis
fined the acceptable operating region. A minimum drawdown
at the bit of 200 psi was required to ensure adequate under- The following analysis is carried out based on some actual
balanced conditions in the well, with a maximum drawdown wells drilled underbalanced worldwide. As mentioned before,
of 300 psi to minimize any near wellbore depletion effects. the main advantage of underbalanced drilling techniques is
The target bottom hole circulating pressure at the bit for this to increase the rate of penetration as compared with overbal-
well was 2300–2400 psi. anced drilling techniques.
Potential implementation of underbalanced drilling technique in Egyptian oil fields 57

Table 2 gives the recorded data that were collected from Table 3 gives the recorded data of ROP (ft/h) and pressure
successful underbalanced drilling cases in which the aerated drop (psi) for different reservoirs that were drilled by aerated
mud was used to drill sandstone reservoir sections (Moore fluid as an UBD drilling fluid. These reservoirs have the same
and Lafave, 1956). lithology but having different reservoir pressure.
From Fig. 5, there is an observed increase in ROP in all Table 4 gives a recorded data for different wells drilled by
cases that were drilled by underbalanced techniques. In under- aerated fluid in a reservoir that has a constant pressure and
balanced drilling, ROP was increased due to the disappearance same lithology compared to those wells drilled in overbalanced
of chip hold-down effect. So the normal trend includes that an environment (Moore and Lafave, 1956).
increase of the ROP resulted from a decrease in the hydrostatic Fig. 7 illustrates that ROP initially decreases with an
pressure of drilling fluid as compared with the pressure of the increase in pressure drop and increases with further increase
formation that drilled by UB, as shown in Fig. 6. in pressure drop. Whereas, Fig. 8 shows that ROP has no

Figure 11 Well schematic of Gulf of Suez oil field area.

Figure 12 Operating window, multiphase fluid injection of Gulf of Suez oil field area.
58 K.A. Fattah et al.

Table 10 Underbalanced drilling design criteria for western desert area.

Rig modification  No essential modifications to be made on the rig to suite UBD operations
 The substructure has to be high enough to allow Rotating Control Head (RCH) to be installed on top of the
Hydril
Well plan  As shown in Fig. 13
Drill string design  Use 500 DP, 500 HWDP and 6.500 DC
BHA  No downhole motor used
 An 8-1/200 bit size of 3 · 13/3200 nozzles size
Drilling fluid selection  Based on the pore pressure and formation depth, the reservoir formation is below the normal pressure regime
 The subnormal pressure requires the use of a multiphase (liquid + gas) drilling fluid system in order to obtain on
Underbalanced drilling condition
A-liquid phase  Drilling fluid is native crude oil with density 6.84 ppg (0.82 S.G. or 41.7 API)
 Liquid flow rates were selected to achieve a drawdown from the reservoir pressure
B-gas phase  Nitrogen was selected as the injection gas
Operating envelope  It is displayed as the area of the graph between the targets BHCP’s, bound by the maximum motor throughput,
the minimum annular liquid velocity, Fig. 11
 Using 300 gpm and more than 2200 scfm of Nitrogen will provide maximum 200 psi drawdown from the
expected reservoir pressure
Hole cleaning  Depends on several variables such as cutting size and shape; liquid properties; drill string rotation; liquid veloc-
ities; flow regime, etc.
 Minimum vertical annular liquid velocities of 180 ft/min when crude oil is used as the drilling fluid to ensure that
the drilled cuttings are effectively removed from the wellbore
Hydraulic modeling  Using a multiphase hydraulic simulator, the required underbalanced drilling parameters could be evaluated in
detail
 Graphs can be created to incorporate the limiting factors of minimum annular liquid velocity required for hole
cleaning and the desired BHCP range
Pressure while drilling  When the maximum gas volume fraction (GVF) inside the drill pipe is bellow, 20% conventional mud pulse tools
(MWD/LWD/PWD) can be used
 Otherwise, electromagnetic transition tools have to be used in order to obtain downhole data real time
Data acquisition  The software for the rig data acquisition has to be able to interface with the UBD equipment software
Completion  The well can be completed with barefoot completion technique, or installing a slotted lined

Figure 13 Well schematic of western desert oil field area.

definite relation with pressure drop if other drilling and the amount of fluid production after the well is put on pro-
parameters are ignored. However a continuous increase in duction as shown in Fig. 10.
formation fluid production while drilling was observed Table 5 highlights the savings in total rig days and cost for
with the continuous increase in pressure drop as shown in conventional versus underbalanced drilling wells in Iran (Rov-
Fig. 9. ing and Reynolds, 1994). It is clear that big savings in drilling
Fig. 10 illustrated that all wells drilled by UBD have an in- cost was realized.
creased in fluid production rate compared to those wells drilled The cost savings ranged between $90,000 and $110,000 for
in overbalanced environment. In addition, there is no clear 8-1/2 in. hole section and between $170,000 and $190,000 for
relation between the amount of fluid production while drilling the 6-1/2 in. hole size (Table 6). A total of approximately
Potential implementation of underbalanced drilling technique in Egyptian oil fields 59

3400
3200
200 gpm prod
3000
300 gpm prod
2800
400 gpm prod
2600
200 gpm
2400
300 gpm
Bottom Hole Pressure (psi)
2200
400 gpm
2000
1800
Reservoir Pressure
1600
1400
1200
1000 Minimum Vertical liquid velocity = 180 ft/min
800
600
400
200
0
0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600
Nitrogen Injection Rate (scfm)

Figure 14 Operating window, multiphase fluid injection of western desert oil field area.

Table 11 Proposed UBD program in Nile Delta area.

Rig modification  No essential modifications to be made on the rig to suite UBD operations
 The substructure has to be high enough to allow Rotating Control Head (RCH) to be installed on top of the
Hydril
Well plan  As shown in Fig. 15
Drill string design  Use a 500 DP, 500 HWDP and 6.500 DC
 An 8-1/200 bit size of 3x13/32’’ nozzles
BHA  The BHA consists of 6-1/200 PDM mud motor and MWD to drill 600 hole
 If MWD signal doesn’t observed, use electromagnetic MWD tools
Drilling fluid selection  Water based fluid (flow-drilling operation)
 Drilling fluid is water with density 8.75 ppg (1.05 S.G.)
 Liquid flow rates and surface choke backpressure were selected to achieve a drawdown from the reservoir
pressure
Operating envelope  It is recommended to pump at least 400 gpm of liquid phase to avoid any operational problem related with hole
cleaning
 The drawdown is 200 psi to prevent wellbore collapse
Motor performance  A maximum equivalent liquid volume through the motor of 600 gpm was used as reference
 A pressure loss of 800 psi between downhole motor and MWD was considered
Hole cleaning  Minimum annular liquid velocities in deviated holes of 180 ft/min to ensure that the drilled cuttings are effec-
tively removed from the wellbore
 A wiper trip will help clear the hole cleaning problem
Tripping  Some type of snubbing device can be used, or a downhole isolation valve can be installed
 Balancing the well for trips seemed the simplest and least expensive method
Data acquisition  The software for the rig data acquisition has to be able to interface with the UBD equipment software
Completion  The well can be completed with barefoot completion technique, or installing a slotted lined

$1.4MM has been saved (drilling only) and about $1MM 3.1. Gulf of Suez oil field area
(overall), for the five wells drilled.
The selected example includes drilling through the reser-
voir section, which consists of two production formations
3. Proposed UBD program to be implemented in Egyptian fields (Belayim and kareem formation from Miocene age). The
reservoir and formation characteristics are given in Tables 7
Based on the experience and the problem faced discussed in the and 8.
previous discussions, a proposed UBD program is given here- The selected reservoir can be drilled by underbalanced dril-
below. ling technique and the proposed UBD program is given in
60 K.A. Fattah et al.

Figure 15 Well schematic of Nile delta oil field area.

4000

3900
Reservoir Pressure
3800
Bottom Hole Pressure (psi)

3700

3600 100 psi BP

200 psi BP
3500
300 psi BP

400 psi BP
3400
500 psi BP

100 psi prod Max ELV = 600 gpm

3300
200 psi prod

3200 300 psi prod

400 psi prod

3100 500 psi prod Minimum Deviated wellbore liquid velocity = 210 ft/min

3000
200 250 300 350 400 450 500 550 600
Liquid flow rate (gpm)

Figure 16 Operating window, flow-drilling operation for Nile delta oil field area.

Table 9. Fig. 12 shows the operating window, multiphase fluid age. The lithology of this formation is sandstone with depleted
injection of Gulf of Suez oil field area. reservoir pressure 1600 psi, reservoir temperature 219 F, poros-
ity 19%, permeability 200 md, GOR 95 SCF/STB, 41.7 API
3.2. Western desert oil field area gravity of oil, and there is no H2S concentration. The selected
reservoir can be drilled by underbalanced drilling technique as
The selected example includes drilling through the reservoir sec- given in Table 10. Fig. 14 shows the operating window, multi-
tion, which consists of Alam El Buieb formation of Cretaceous phase fluid injection of western desert oil field area.
Potential implementation of underbalanced drilling technique in Egyptian oil fields 61

Table A.1 Summary data of case 4 to case 23.

Information Objective(s) Results
Case 4 – SE (U.S.) area
Location SE (U.S.) area Improve production rate by eliminating Production rate increased from 6 MMcfd to
formation damage 24 MMcfd
Formation Smackover & norphlet carbonates
Depth 18,300 ft TVD Reduce/eliminate fluid losses to expedite well Hostile operating environment (H2S and
clean-up 350 F BHT) safely drilled using UBS
techniques (no QHSE incidences)
Pore press 2700 psi
Well type Vertical New Drill
Hole size 6-1/2
Case 5 – Texas Panhandle area
Location Texas Panhandle Remove barium sulfate scale from liner/ Increased gas production rates from 800 Mcfd
perforations to restore production to over 5000 Mcfd
Formation Hunton limestone
Depth ±22,000 ft TVD Avoid fluid losses to formation Minimized tubular corrosion in the presence
of CO2 and H2S
Pore press 1100 psi, + 380o F
Well type Vertical cleanouts Carry metal cuttings back to surface
Hole size 3-1/16 in.
Case 6 – Texas Panhandle area
Location Texas Panhandle Mist drill 400 in. new hole to eliminate Successfully drilled target interval in fewer
formation damage days than planned
Formation Hunton limestone
Depth 19,322 ft TVD/19,700 ft MD Minimize corrosion by effective implementation Project cost $1,000,000 less than budgeted
of corrosion program
Pore press 800–1000 psi Gas production rates substantially higher
than previously drilled wells in the same field
Well type Horizontal re-entry Capture real-time surface flow and pressure
data
Hole size 4-3/4 in.
Case 7 – West Texas (Pecos County) area
Location West Texas (Pecos County) Sidetrack and drill lateral section in a severely Maintained underbalanced environment in a
depleted gas reservoir deep, 550 psi reservoir using UBS techniques
Formation Ellenburger
Depth 13,100 ft to 14,100 ft TVD Minimize fluid losses and differential sticking Encountered no lost circulation or stuck pipe,
using nitrogen mist systems
Pore press 550 psi
Well type Horizontal, ee-entries Increase rate of penetration over conventional
methods
Hole size 6-1/4 in. and 4-1/2 in.
Case 8 – NE (U.S.) area
Location NE (U.S.) Increase ROP relative to conventional Vertical deviation controlled
techniques
Formation Hard rock (surface hole)
Depth 3900 in. Minimize footprint of surface equipment to Hammer drilling increased rates of
reduce location size in an environmentally penetration from 10 ft/h to more than 50 fph
sensitive area in 28-1/2 in. hole. Realized up to 75 ft/h ROP
in 24 in. interval
Well type Vertical new drill, gas storage
Hole size 28-1/2 in. and 24 in. Minimize vertical deviation
Case 9 – Permian Basin, Texas area
Location Permian Basin, Texas Maintain an underbalanced condition in a No fluid losses recorded during
depleted sandstone reservoir while drilling 1000 underbalanced horizontal drilling operation
foot lateral
Formation Keystone field (Holt)
Depth 5634 ft TVD Reduce/eliminate formation damage due to Realized a 66% increase in rate of penetration
fluid loss compared to previous well drilled
conventionally
Well type Horizontal re-entry
Hole size 6-1/8 in.
(continued on next page)
62 K.A. Fattah et al.

Table A.1 (continued)

Information Objective(s) Results
Case 10 – Lea County, New Mexico area
Location Lea County, New Mexico Minimize formation damage due to Fluid losses reduced by 50%
fluid losses compared to wells drilled
conventionally
Formation Greyburg sandstone
Depth 4100 ft TVD Maintain underbalanced conditions Realized up to 97% increase in rate
in depleted sandstone reservoir with of penetration, with average rig time
pore pressure of 200 psi per well reduced by 22%
Well type Multiple vertical new drills & re-
entries
Hole size 4-3/4 in. re-entry deepenings; 7-7/
8 in. New Drills
Case 11- Java, Indonesia area
Location Java, Indonesia Drill 500 m lateral out of 7 in. liner Significant decrease in formation
while maintaining underbalanced damage due to maintaining BHCP
conditions using nitrified water less than pore pressure in the lateral
section
Formation Jatibarang (Volcanic)
Depth 2287 m MD Minimize formation damage due to
lost fluids and solids invasion
Well type Horizontal (New Drill) Lateral section terminated at 175 m
displacement due to limitations of
customer production facilities to
handle production during drilling
Hole size 6 in.
Case 12 – Gargzdai Field, Lithuania area
Location Gargzdai field, Lithuania Increase reservoir productivity by The IP estimated to be 3250 BOPD.
minimizing formation damage Stable production after 3 months
exceeded 2700 BOPD
Formation Cambrian sandstone + siltstone
Depth 1976 m TVD, 2426 m MD Complete well while flowing To eliminate need of snubbing unit
during completion, reservoir pressure
was balanced with 134 bbl of
formation fluid. Well started flowing
after running 21 joints of 2.875 in
tubing. Finished running tubing with
well flowing
Well type Horizontal – Type 1 New Drill
Hole size 6 in.
Case 13 – Central Alberta, Canada area
Location Central Alberta, Canada Underbalance drill the lateral section Gas rates as high as 22 MMcfd
in a severely depleted gas reservoir productions while drilling
Formation Elkton
Depth 9700 ft MD (8400 ft TVD) Increase well productivity compared Nitrified diesel drilling fluid was very
to conventional methods compatible with the formation
Well type Horizontal, coil tubing Significant production increases over
offsetting vertical and horizontal
wells drilled overbalanced
Hole size 4-3/4 in. Minimize fluid losses and differential
sticking
Case 14 – Indonesia area
Location Indonesia Underbalance drill the lateral section Oil rates as high as 400 BOPD
an under-pressured oil reservoir production while drilling
Formation Upper bata
Depth 6249 ft MD Minimize fluid losses and differential Significant (±10-fold) production
sticking increases over offsetting vertical and
horizontal wells drilled overbalanced
Pore press <650 psi Formation evaluation and real-time
fracture identification
Potential implementation of underbalanced drilling technique in Egyptian oil fields 63

Table A.1 (continued)

Information Objective(s) Results
Well type Directional, oil Increase well productivity Nitrified diesel-mist fluid was
compared to conventional very compatible with the
methods formation
Hole size 6 in.
Case 15 – OME area
Location OME Minimize fluid loss and NPT Total production of 12,757 bbls
while drilling oil while drilling
Formation Asmari
Depth 2241 m MD (2212 m TVD) Eliminate the use of drilling fluid No additives or LCM added to
additives the drilling fluid (formation oil)
while drilling
Pore press 2240 psi
Well type Deviated Minimize formation damage Saved approximately 10 days of
drilling time
Hole size 8-1/2 in
Case 16 – Libya area
Location Libya To eliminate/minimize possible First ever dual lateral to be
lost circulation drilled UB in Libya
Formation Beda C, Facha C To access the required reservoir Wells drilled with zero LTI’s
Depth 7000–8900 ft To eliminate any impairment of Successfully drilled the wells to
the reservoir formation by any- TD
non native fluid or material
Pore press 1050–3000 psi
Well type Oil wells To increase PI compared to other Positive results helped in
conventionally drilled wells promoting UBD technology in
Libya
Hole size 6 in.
No. of wells 2 To evaluate and characterise the
reservoir production and to
increase ROP
Case 17 – Eastern middle east area
Location Eastern middle east Increase production rate by 1st UBD campaign consisting of
reducing formation damage 3 wells was successfully
completed in February 2003
Formation Thebes, Risha and Dubeidib
Depth 3300 m TVD To increase ROP relative to Increased production rates &
conventional drilling Reduced formation damage
Capture real-time surface flow Excellent safety and operational
and pressure data performance led the operator to
plan for a 2nd UBD campaign
Well type Deviated All the wells delivered safely with
zero LTI’s
Hole size 5-7/8 in. ROP reached a maximum of 9 m/
h as compared to an average of
2 m/h for conventional drilling
No. of wells 6
Case 18 – Hassi Massoud oil field – Algeria area
Location Hassi Massoud oil field – Algeria To increase oil production by To date 18 wells have been drilled
minimizing formation damage using UBD technique
Formation Re Cambrian/Cretaceous
Depth Up to 4581 m MD Increase ROP compared to Significant increase in ROP
conventional overbalanced compared to offset conventional
drilling wells
Well type Deviated Successfully spread the UBD
technology in the North Africa
region
Hole size 6 in. Eliminate NPT associated with Encouraging production rates
conventional drilling problems were observed while drilling and
conducting production flow tests.
The best of 27.5 m3/h has been
observed so far while drilling the
well MDZ 550
(continued on next page)
64 K.A. Fattah et al.

Table A.1 (continued)

Information Objective(s) Results

Case 19 – Offshore – Qatar area

Location Offshore – Qatar To create moderate under An air injection rate of 750–850 scf/m
balanced conditions necessary to via the parasite string created an
achieve returns to surface while appropriate level of UB conditions to
drilling the 24 in surface hole eliminate losses in the UER
through massive loss zones formation and other zones
Formation UER, Simsima,
Fiqa, Halul, Laffan
Depth 1000–3000 ft To achieve UB conditions by To date 9 wells have been drilled
utilizing air injection via parasite using the air drilling technique
string on the 30 in conductor pipe
set at 500 ft
Pore press 600–1200 psi
Well type Gas well The low degree of UB conditions
successfully avoided massive sour
water flows from flow zones and
limited bore hole instability problems
Hole size 24 in.
No. of wells 9

Case 20 – Ghawar field – Saudi Arabia area

Location Ghawar field – To eliminate formation damage Increased Injectivity rates by more
Saudi Arabia caused by the loss of than 2 to 3-fold
conventional drilling fluid to the
formation and therefore avoids
differential sticking
Formation Arab D
Depth 11,400–11,850 ft To date 4 power water injection wells
(MD) have been drilled Underbalanced
Pore press 3520–3735 psi
Well type Horizontal Maximizing water injectivity
Hole size 6-1/8 in. To increase ‘‘on bottom’’ rate of All wells were delivered safely
penetration without LTI’s
No. of wells 3 To increase bit life
Case 21 – Greater Oman area – North East Syria
Location Greater Oman area Reduce typical drilling non- 13 wells have been drilled using the
– North East Syria productive time (NPT) by Flow Drilling technique
depleting the Shiranish Gas zone
while drilling
Formation Shiranish/Mulusa
Well type Straight & deviated Eliminate an intermediate casing Average drilling rig time of 45 days,
string from the drilling program has been reduced to an average of
21 days
Hole size 6 in. & 8.5 in.
Develop UBD technology, Intermediate casing string has been
practices and procedures for eliminated
future Syrian activity
ROP improvements and excellent bit
performance were experienced
All wells were delivered safely with
zero LTI’s
Case 22 – North East British Columbia, Canada area
Location North East British Increase well productivity PIWD as high as 4 MMscf/d/1000 psi
Columbia, Canada through
Formation Jean Marie Technical management of
bottom hole pressure
Depth 2,047 m MD Minimize fluid losses and Gas rate up to 1.5 MMscfd
differential sticking
Potential implementation of underbalanced drilling technique in Egyptian oil fields 65

Table A.1 (continued)

Information Objective(s) Results

Pore press 4560 kPa Monitor reservoir through PIWD

Well type Horizontal Evaluation while drilling
Hole size 156 mm
Case 23 – Lithuania area
Location Lithuania Increase reservoir productivity by IP estimated to be 3250 BOPD.
minimizing formation damage Stable production after 3 months
exceeded 2700 BOPD
Formation Sandstone
Depth 6480 ft. TVD; Complete well while flowing To eliminate need of snubbing unit
7960 ft. MD during completion, reservoir
pressure was balanced with 134 bbl
of formation fluid. Well started
flowing after running 21 joints of
2.875 in tubing; finished running
tubing with well flowing
Well type Horizontal new drill in-fill
Hole size 6 in.
No. of wells 3

3.3. Nile delta oil field area ments, bit type, corrosion, equipments availability, separa-
tion and fluid handling requirements especially when
The selected example includes the reservoir section, which con- dealing with hydrocarbon drilling fluid, tripping proce-
sists of one production formation (Qawasim from Miocene dures, data acquisition and completion procedures. Proper
age). It has a sandstone lithology with reservoir pressure planning and design work, addressing these parameters, is
3800 psi, reservoir temperature 185 F, GOR 1100 SCF/STB, essential to successfully conduct an underbalanced drilling
average porosity 25%, average permeability 400 md, gravity project.
of oil 50 API, and there is no H2S concentration. 4. UBD with stable foam through depleted reservoirs can be
The selected reservoir can be drilled by underbalanced dril- conducted safely and successfully in both vertical and hor-
ling technique as given in Table 11. Fig. 16 shows the operating izontal wells. Drilling with foam has some appeal because
window, multiphase fluid injection of nile delta oil field area. foam has some attractive qualities and properties with
respect to the very low hydrostatic densities, which can be
4. Conclusions generated with foam systems. Foam has good rheology
and excellent cutting transport properties.
Planned and applied correctly, underbalanced drilling technol- 5. Real time capture of production data while drilling should
ogy can address problems of formation damage, lost circula- provide information about the reservoir not otherwise
tion and poor penetration rates. The ability to investigate available.
and characterize the reservoir while drilling is another impor- 6. A proposed UBD program to be implemented in Egyptian
tant benefit of under balanced drilling. Based on the analysis fields is developed.
of the real cases studied during the research, the following con-
clusions could be cited:
Appendix A
1. Underbalanced drilling technique is a very useful technique
especially when applied in reservoir section. It prevents for- See Table A.1.
mation damage, increases ROP, increases reservoir produc-
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