Lesson 10 Flow Mudcap Snub Closed Systems1

PETE 689 Underbalanced Drilling (UBD) Lesson 10
Flow Drilling Mudcap Drilling Snub Drilling Closed Systems Read: UDM Chapter 2.8-2.11 Pages 2.180-2.219
Harold Vance Department of Petroleum Engineering
Flow Drilling
Flow drilling refers to drilling operations in which the well is allowed to flow to surface while drilling. All UBD operations are really flow drilling operations, but the term is usually applied to drilling with a single phase mud, and no gas is injected except by the formation.
Flow Drilling
Clear drill brine density less than or equal to 1.02 g/cm3
Oil, Gas, and Brine
9.5 ppg Brine
Pressure higher in HEEL of well causing lost returns
Pressure lower in TOE of well causes influx

Pore Pressure =3030 psi at 6234 ft
Flowdrilling a naturally fractured horizontal well (courtesy of Signa Engineering Corporation)

Drilling Fluid Selection

Density is determined by: Maximum pressure to formation pressure. Minimum pressure dictated by wellbore stability. Pressure limitations of diverter and BOP equipment.
Surface Equipment
MUD PITS
STACK
CHEMICAL INJECTION
GAS/FLUID SEPARATION SYSTEM
UNDERBALANCE DRILLING MANIFOLD
Schematic of surface equipment required for flowdrilling (courtesy of Signa Engineering Corporation)
Surface Equipment
12 in. Flare 6 in. Flare 4 in. Flare
4-6 in.
Gas boot (open on bottom) Water to rig Grade
Gas Separator
Choke Manifold
Gas Separator ROP Annular Preventer Pipe Rams Blind Rams Pipe Rams
Skimmer tanks
Oil tank
Oil to treatment off location
Atmospheric surface system for flowdrilling (courtesy of Signa Engineering Corporation)

Surface Equipment
RBOP
Choke Line
Typical flowdrilling BOP stack (courtesy of Signa Engineering Corporation)

Surface Equipment
Rotating blowout preventer (RBOP).

Surface Equipment
Kelly Packer
Hydraulic Fluid
RBOP sealing elements

Nitrile
Surface Equipment
Hydraulic Choke
Manual Choke
A typical flowdrilling choke manifold (courtesy of Signa Engineering Corporation)

Sizing Flare Line

Weymouths equation can be used to predict the pressure drop for a gas, in steadystate, adiabatic, flow along the pipe:
Sizing Flare Line

Q = 433.5 To Po d16/3(P21-P22) STLZa
2.73 Where: Q gas flow rate (scf/D) d inside diameter of the pipe (the gas flare line in this case) (inches) To standard temperature (520 oF) Po standard pressure (14.7 psia) S gas gravity (air = 1) T pressure above the bit (psfa) L bottomhole pressure below the bit (psia) Za average compressibility factor (Weymouth used Za = 1) P1,P2 the inlet and outlet pressures (psia)
Sizing Flare Line

Weymouth's Equation 2.73 incorporates a friction factor, f = 0.032/d1/3
Sizing Flare Line

Assuming a gas gravity of 0.6, and substituting for standard temperature and pressure, Equation (2.73) becomes:
Q = 19,754 d16/3(P21-P22) TL
2.74
Sizing Flare Line

Converting length, L, from miles to feet, and flow rate, Q, from scf/D to MMscf/D, the inlet pressure, P1, is:
Q2TL 2.06d16/3
P1 =
+ P22
2.75
Sizing Flare Line

The pressure differential exerted by the U-tube head can be expressed as: P1 P2 = 0.433h Where: specific gravity of the fluid in the U-tube or separator. h height from the top of the gas boot to the bottom of the U-tube (feet).
2.76
Sizing Flare Line

Equations (2.75) and (2.76) can be combined to solve for the U-tube height, in terms of the gas flow rate, temperature, outlet (atmospheric) pressure, and flare line diameter:
Q2TL h= 2.06d16/3 0.433
+ P22 - P2
2.77
Surface Pits
Primary oil separation pit. Secondary oil separation pit. Skimmer system safety. Drilling fluid pit. Oil transfer tank.
Operating Procedures
Mechanical objectives flow drilling are: during
To control the well. Minimize differential sticking problems. Minimize drilling fluids losses.
Maximum tolerable surfaces pressures should be established before drilling starts.

Mudcap Drilling
Utilized with uncontrollable loss of circulation during flowdrilling operations. Higher pressures than can be safely handled with the rotating head or RBOP. It is not strictly an underbalanced drilling technique.
Mudcap Drilling
Driller loads the annulus with a relatively high density high viscosity mud and closes the choke with surface pressure maintained.
Drilling is then continued blind by pumping a clear non-damaging fluid down the drillstring through the bit and into the thief zone.
Mudcap Drilling
Applications:
Sustained surface pressures in excess of 2,000 psi. Sour oil and gas production. Small diameter wellbores.
Mudcap Drilling
Viscous Fluid Mudcap
Mudcap Interface (Formation Fluid / Drillwater)
Water replacement in formation fractures
An example of mudcap drilling (courtesy of Signa Engineering Corporation)

Mudcap Drilling
GAS BUSTER RIG FLOOR To flare pit
MUD PITS
MUD PUMPS
HCR Valve (Closed)
CHOKE (closed)
Chemical Injection
DIVERTER
Schematic of equipment required for mudcap drilling (courtesy of Signa Engineering Corporation)
Determining Pore Pressure

Pressure, psi
9,200 11.8 9,400 9,600 9,800
Depth (TVD)/ 1,000, ft.
12.0 12.2
12.4 12.6 12.8
Pore Pressure Bore Hole Pressure PP Datum Determining the Reservoir Pressure Along the Wellbore
Static Standpipe Pressures

PSPPstatic= 0.052 (EMWpore pressure - MWinjection fluid)TVD
Where: PSPPstatic EMWpore pressure MWinjection fluid TVD
static standpipe pressure, psi.

equivalent mud weight of formation pore pressure, ppg. density of the injection fluid, ppg. true vertical depth of the top of reservoir, ft.
Given: Reservoir described in Figure 3-1-2. Injection fluid is fresh water with no additives. A lateral is planned to intersect the formation top at 12,750 MD (12,000 TVD) and encounter the formation bottom at TD of 17,000 MD (12,500 TVD). Fractures exist at both the top and the bottom of the formation. Find: Maximum static standpipe pressure when the bit is at the top and at the bottom of the formation.
Formation To Formation Bottom
Example
EMWpore pressure 15 ppg MWinjection fluid 8.34 ppg TVD 12,000 ft PSPPstatic 0.052*(15-8.34)*12,000
= 4,156 psi
14.7 ppg 8.34 ppg 12,500 ft

0.052*(15-8.34)*12,000 4,129 psi
Dynamic Standpipe Pressures

PSPINJECTION = PSPPstatic+PDP+P
Drill collars+PMWD+P Motor+P Bit+P frac
Where:
PSPINJECTION PSPPstatic PDP P Drill collars PMWD P Motor P Bit P frac
standpipe pressure while circulating or injecting down drillpipe.. static standpipe pressure, psi. frictional pressure drop of fluid flowing down drillpipe. frictional pressure drop of fluid flowing down drill collars. pressure drop across the measurement-while drilling tool. pressure loss to power motor. pressure drop across bit nozzles. frictional pressure drop of fluid flowing through fractures.
Example
Given: The reservoir described above. A directional hole is to be drilled with a 4-in. mud motor that requires a flow rate of 240 gpm resulting in a 400-psi on-bottom pressure differential. MWD pressure drop is equal to 150 psi. The MWD and Motor together have a total length of 60 ft. The drillpipe to be used is 3-in. 13.3 lb/ft. No Drill Collars are in the string. Nozzles are (3) 17s (32nd of an inch). Assume the pressure drop through the fractures is 100 psi and average injection water viscosity is 0.5 cp. Find: The circulating standpipe pressure at the top and bottom of the formation.
Example
Formation Top
PSPPstatic PDP PDC PMWD PMotor PBit Pfrac
PSPINJECTION
Formation Bottom 4,129 psi 948 psi 0 psi 150 psi 400 psi 100 psi 100 psi
4,156 psi 710 psi 0 psi 150 psi 400 psi 100 psi 100 psi
Formation Top: 4,156+713+0+150+400+100+100=5,616 psi Formation Bottom: 4,129+948+0+150+400+100+100=5,827psi

PSPINJECTION
Example
If the circulating system is limited to only 5,000 psi in the example above, the injection fluid density can be increased to lower the required injection pressure. If the injection fluid is changed to 10.0 ppg (average viscosity of 0.8 cp), then the standpipe pressures will be as follows: Formation Top Formation Bottom
PSPPstatic PDP PDC PMWD PMotor PBit Pfrac = = = = = = =
3,120 psi 915 psi 0 psi 150 psi 400 psi 120 psi 100 psi
3,050 psi 1,222 psi 0 psi 150 psi 400 psi 120 psi 100 psi
PSPINJECTION PSPINJECTION
Formation Top: 3,120+915+0+150+400+120+100= 4,805psi

Formation Bottom:
3,050+1,222+0+150+400+120+100=5,042psi
Fluid Volume Requirements

The drillpipe injection rate during Mudcap operations can be expressed simply as:
QDP = 0.0408 (IDHole2 - ODDrillpipe2)/AV

Where: QDP IDHole ODDrillpipe AV injection rate down the drillpipe, gpm hole or casing inside diameter, in. drillpipe outside diameter, in. annular velocity across drillpipe-casing annulus, ft/min.

The cumulative daily drillpipe injection volume consumed may be expressed as:
QDP DailyCum = (18/24)QDP(60)(24/42)

This assumes 18 hrs of circulation/injection over a 24-hour period.
Where: QDP DailyCum

QDP
daily cumulative injection volume down the drillpipe, bbls defined by equation above

Given: MCD is planned for a 6 1/8-in. hole using 3in., 13.3 lb/ft drillpipe and 4-in. mud motor. Assume desired minimum AV = 100 ft/min Find: Minimum injection rate and minimum daily consumption of injection fluid.
QDP = 0.0408 (6.125 2 3.5 2)/100 = 103 gpm QDP DailyCum = 25.7*103 = 2,649 bbls/day

Annular volumes will depend upon whether the operator desires continuous or periodic injection of annular fluids or whether a floating mudcap is to be used.

The amount of fluid to inject into the annulus periodically can be estimated by:
QAnn = (SF)VHMTPI(IDHole2 -DDrillpipe2)/1,029

Where: QAnn SF VHM T PI IDHole ODDrillpipe periodic annular injection volume, bbls. safety factor hydrocarbon migration rate, ft/min. time period between injection volumes, min. hole or casing inside diameter, inc. drillpipe outside diameter, inc.

An estimate of the cumulative volume injected into the annulus daily can be determined with:
QAnn Daily Cum = 24*60*QAnn/TPI

Where: QAnn Daily Cum QAnn
T PI
annular daily cumulative injection volume, bbls/day. periodic annular injection volume, bbls. time period between injection volumes, min.
Given: MCD is planned for a sour gas well in a fractured reservoir. Use a gas migration rate of 15 ft/min. A 6 1/8-in. hole is planned to be drilled using 3in., 13.3 lb/ft drillpipe. Use the periodic injection method with time between injection periods equal to 30 minutes. Assume a safety factor of 2. Find: The minimum daily annular fluid or mudcap volume requirement.
Example
QAnn = 2*15*30*(6.125 2 -3.5 2)/1,029 = 22 bbls. QAnn Daily Cum = 24*60*22/30 = 1,060 bbls/day
Snub Drilling
UBD operation utilizing a snubbing unit or coiled tubing unit. Expense is justifiable if very high formation pressures are anticipated, and uncontrollable loss of circulation is expected.
SNUBBING CABLES COUNTER BALANCE WEIGHTS SNATCH BLOCK PIPE GUIDE TRAVELING SLIP ASSEMBLY OPERATORS SLIP CONSOLE OPERATORS BOP CONSOLE WORK BASKET
UPPER CABLE GUIDE
STAND GUIDE
STATIONARY SLIP ASSEMBLY
SHEAVES SWIVEL BASE ASSEMBLY
DUAL SHEAVE DROWN SWIWEL STARTING VALVE TONG ARM

POWER TONG PIPE ELEVATOR
QIN POLE TRAVELING SLIPS ROTARY TABLE KELLY HOSE CONTROL CONSOLE WORK BASKET DUAL WINCH STATIONARY SLIPS STAND PIPE
STRIPPER
BOP RISER SPOOLS PIPE RACKS
HYDRAULIC EQUALIZING VALVES POWER PACK FUEL TANK TOOL BOX
PUMP MANIFOLD HOSE BASKET
7 26# @ 8128
Pilot hole dressed off to 8285
Top of productive interval @ 8157
KOP @ 8302 60 deg 6-1/8 Hole to 8550 4-3/4 Hole FORMATION DIP 6-80 N 820E
SHALE Target Center (Primary Target) (Secondary Target) SHALE 8558 8578 8594 8618
Pilot Hole
Top of SHALE 8821
Drilling Spool 7-1/16, 10M x 7-1/16,5M
RIG FLOOR
Cameron single 7-1/6, 10M Annular Preventer Cameron 7-1/16, 10M Cameron U double 7-1/16, 10M Install companion flange w/2 WECO 1502 thread Drilling Spool 7-1/16, 15M x 10M Cameron U double 7-1/16, 15M DSA 7-1/16, 10M x 7-1/16, 15M Frac Valve 7-1/16, 10M TUBING HEAD 11, 5M x 7-1/16, 10M Outlet with (2) 1-13/16 10M Gate Valve SOW CASING HEAD 11, 5M x 9-5/8,
BOP stack ( courtesy of Signa Engineering Corporation)

FLARE PIT 6 GAS
6 GAS
Gas LIQUID Buster
SKIMMER
LIQUID
Gas Buster
4 GAS
MUD PIT ADJUSTABLE MANUAL CHOKE DRILLING FLUID RETURN

SAND SEPARATER
ALL GAS
DRILLING FLUID RETURN HYD.L CHOKE
MANUAL CHOKE
GAS + LIQUID
Prevailing Wind Direction
WELLHEAD
Snub drilling choke system ( courtesy of Signa Engineering Corporation)

Closed Systems
Refers to UBD operations with a specific surface system. A pressurized, four phase separator and a fully closed surface system, is used to handle the returned fluids.
Ignitor
Flere Stack Sample Catcher
Production Tank
Pressure Vessel
Choke Manifold
Stack N2 Pumpers
Mix Drilling Fluid Tank Rig Pump Vaporizor
A typical closed surface system (modified after Lunan, 19942).

Rotating Blow out Rotating Blow out Preventer/Diverter Preventer/Diverter RBOP Height 1700 mm
RBOP
To Shala Shaker ESD Northland Manifold 6 Gate Valve 4 Globe Valves Wills Choke Choke Line Connected to Northland Separator Manifold Separator 200 psi Vessel Flare Stack Sample Catchers
Annular Returns to Choke Manifold and Separator Annular Preventer 127mm (5) Pipe Rams Kill Line
Shear/Blind Rams 127mm (5) Pipe Rams Kill Line Tubing Spool Casing Spool Choke Line Connected to Rig Manifold HCR
Choke
Rig Manifold
Water Returned to Rig Tanks
Oil Storage/ Transport
Choke
Flare Pit
Surface Casing 300-400m, 508.0mm Intermediate Casing

1300-1450m, 339.7mm
Production Casing
1890m, 244.5mm
Flow control arrangement (after Saponja, 19957).

Valve #2 Sample Catcher #1
Flow Direction Output Data Header Sample Catcher #2
Full Bore Valve #2
Valve #3
Full Bore Valve #1 Valve #1
Choke Bypass Well Effluents Flow Direction
Input Data Header
Valve #4
Integrated flow control and sample catcher manifold (after Lunan and Boote, 199412).
Adjustable Partition Plates
Well Effluents In
Gas Out
Gas
Gas
Velocity Reducer
Continuous Pressurized Solids Transfer Pump
A typical, horizontal, four-phase separator, for underbalance drilling (after Lunan and Boote, 199412).
Other Surface Equipment

Cuttings filter. Heater. Degasser. Flare stack/pit. Production tank. Water tank. Solids tank. Instrumentation.

Lesson 10 Flow Mudcap Snub Closed Systems1

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PETE 689 Underbalanced Drilling (UBD) Lesson 10

Oil, Gas, and Brine

9.5 ppg Brine

Pressure higher in HEEL of well causing lost returns

Pressure lower in TOE of well causes influx

Flowdrilling a naturally fractured horizontal well (courtesy of Signa Engineering Corporation)

Drilling Fluid Selection

GAS/FLUID SEPARATION SYSTEM

UNDERBALANCE DRILLING MANIFOLD

Gas boot (open on bottom) Water to rig Grade

Oil to treatment off location

Atmospheric surface system for flowdrilling (courtesy of Signa Engineering Corporation)

Typical flowdrilling BOP stack (courtesy of Signa Engineering Corporation)

Rotating blowout preventer (RBOP).

RBOP sealing elements

A typical flowdrilling choke manifold (courtesy of Signa Engineering Corporation)

Sizing Flare Line

Sizing Flare Line

Sizing Flare Line

Harold Vance Department of Petroleum Engineering

Sizing Flare Line

Harold Vance Department of Petroleum Engineering

Sizing Flare Line

Harold Vance Department of Petroleum Engineering

Sizing Flare Line

Sizing Flare Line

Q2TL h= 2.06d16/3 0.433

Harold Vance Department of Petroleum Engineering

Harold Vance Department of Petroleum Engineering

Maximum tolerable surfaces pressures should be established before drilling starts.

Harold Vance Department of Petroleum Engineering

Viscous Fluid Mudcap

Mudcap Interface (Formation Fluid / Drillwater)

Water replacement in formation fractures

An example of mudcap drilling (courtesy of Signa Engineering Corporation)

HCR Valve (Closed)

Determining Pore Pressure

Depth (TVD)/ 1,000, ft.

12.4 12.6 12.8

Static Standpipe Pressures

static standpipe pressure, psi.

14.7 ppg 8.34 ppg 12,500 ft

Harold Vance Department of Petroleum Engineering

Dynamic Standpipe Pressures

Formation Top: 4,156+713+0+150+400+100+100=5,616 psi Formation Bottom: 4,129+948+0+150+400+100+100=5,827psi

Formation Top: 3,120+915+0+150+400+120+100= 4,805psi

Fluid Volume Requirements

QDP = 0.0408 (IDHole2 - ODDrillpipe2)/AV

Fluid Volume Requirements

QDP DailyCum = (18/24)QDP(60)(24/42)

Where: QDP DailyCum

Fluid Volume Requirements

Fluid Volume Requirements

Fluid Volume Requirements

QAnn = (SF)VHMTPI(IDHole2 -DDrillpipe2)/1,029

Fluid Volume Requirements

QAnn Daily Cum = 24*60*QAnn/TPI

UPPER CABLE GUIDE

STATIONARY SLIP ASSEMBLY

SHEAVES SWIVEL BASE ASSEMBLY

Harold Vance Department of Petroleum Engineering

DUAL SHEAVE DROWN SWIWEL STARTING VALVE TONG ARM

BOP RISER SPOOLS PIPE RACKS

QAnn Daily Cum = 2460QAnn/TPI