SPE 74841
Improving the Performance of Coiled Tubing Underbalanced Horizontal Drilling
Operations
R.G. Fraser R.P.T. (Eng), J. Ravensbergen P.Eng
Copyright 2002, Society of Petroleum Engineers Inc.
This paper was prepared for presentation at the SPE/IC oTA Coiled Tubing Conference and
Exhibition held in Houston, Texas, U.S.A., 9–10 April 2002.
This paper was selected for presentation by an SPE Program Committee following review of
information contained in an abstract submitted by the author(s). Contents of the paper, as
presented, have not been reviewed by the Society of Petroleum Engineers and are subject to
correction by the author(s). The material, as presented, does not necessarily reflect any
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Abstract
The paper will address the specific issues associated with
underbalance horizontal drilling using two phase flow. Firstly,
the challenges that were overcome in devising a "safe" method
of deploying a directional drilling BHA into a live well will be
presented together with a review of the deployment
performance results from over a 100 different horizontal
drilling operations.
Secondly, BHA performance issues associated with
two-phase flow will be reviewed and results presented. This
will include such issues as un-constrained vibration
(encountered when the hole is not liquid full) and such effects
as explosive decompression and the consequent reduction of
elastomer performance.
Perhaps most important will be a discussion of the
issues associated with cuttings transport in two phase flow and
the methodology devised to reduce (and in many cases
eliminate) wiper trips by varying the circulating conditions
using a circulating valve incorporated into the BHA. Data
from actual jobs will be presented to demonstrate how
effective the process has become in regular field operations.
Lost time statistics for coiled tubing underbalanced
drilling operations will be summarised and performance
improvements highlighted.
Introduction
Increasing demand for continuous underbalanced conditions
when drilling horizontal wells has allowed coiled tubing to
compete effectively with conventional drilling rigs which by
their very nature can only offer intermittent underbalanced
operations. Under the right conditions effective underbalanced
drilling allows Operators the best return for their investment
dollar by maximizing results from their drilling programs.
Important issues that have been addressed for drilling with
two-phase fluids are:
• Safety and Deployment for a true under-balanced
drilling operation.
• Benefits of using a circulating valve for improved hole
cleaning.
• Unconstrained vibration and its effect on BHA
reliability.
• Elastomer performance and the effect on performance
and costs.
• Communication on location and into the office.
Safety and BHA Deployment
The capability to safely drill in a true underbalanced
condition with coiled tubing equipment has been established
as a common practice in the Canadian Oil and Gas Sector.
This has become common practice due to the inherent ability
of the coiled tubing to deploy and run bottom hole assemblies
(BHA) in a safe and efficient manner, under flowing well
conditions.
Keeping the well in an under-balanced condition through
every operation within the drilling project is the key to a
successful operation. True underbalanced drilling dictates that
the well never be killed or over pressured during the drilling or
completion stage. Therefore it becomes necessary to retrieve
and deploy the entire BHA under live conditions. The current
tool string is approximately 20 m in length (which considers a
standard length mud motor and bit). A unique dep loyment
system was developed to safely enable this length of tool to be
deployed and retrieved from live wells.
2 R.G. FRASER R.P.T. (ENG), J. RAVENSBERGEN P.ENG SPE SPE 74841

The components of the Coiled Tubing BHA from top to The stack consists of three main components. The coiled
bottom are as follows: (Fig 1.0) tubing BOPs, the deployment/retrieval BOPs and on top of the
stack, a master valve for positive isolation.
1. CT Connector
2. Wireline Anchor and Release/Check Valve Tool The following are the general steps required for the Hands-
3. Instrumentation / Non-Magnetic / Steering Tool Free Deployment System.
4. Orienter with Circulation SUB Initially, both the valve above the casing bowl and the
5. Positive Displacement Motor (PDM) with Bend sub master valve, which is positioned on the very top of the
6. Bit (PDC or Tri-Cone) (Formation determined) BOP/Deployment stack, are closed.
The BHA is made up on the matting and is pulled into the
deployment lubricator via a wireline assembly. This wireline
assembly and grease head is integral to the lubricator (which
eliminates the need for a separate wireline unit). The
G ra ppl
e
C onne
B .O . S. S.
Tool
C a bl
e
A nc
UC
D lubricator is then picked up off the matting with a crane and
ct hor
placed over the deployment stack, secured and pressure tested.
(Fig.2.0)
UC C he c k St e e ring /I ns trume nt a t ion Too l & UC
D Va lv e s Non- Ma g’s D

Deployment
UC D C Mot ors & H y drau lic Pu mps C irc ula t i ng Orie nt in g T ool Che c k
Lubricator
D Valv e Va lv e s

Lengths from Bit

•Top of BHA =20.1m
•BOSS Release -16.6m
BHA
•Steering Tool - 13.5m
•Gamma Tool - 11.5m
Posit iv e D is pla ce me nt Mot or •Top of Motor -5.2m
B ent H ous in g PD C Bit (Estimated Lengths)

Fig. 1.0 – Schematic of Coiled Tubing Drilling BHA

Safety is of paramount concern when drilling

underbalanced. This is especially critical when drilling in a
sour gas (H2 S) environment. The main challenge when
developing this system was not to rely merely on either the
internal check valves within the BHA or pipe rams for sealing
against the wellbore. The system must operate “remotely”
with no need for human contact. The BHA remains internally
confined with two barriers between well bore pressure and the
atmostpere. In this fashion neither the field personnel nor the
Fig 2.0 – Structure with Deployment Lubricator
environment is ever exposed to the well bore fluids.
The key to being able to operate the system remotely is the
universal connect/disconnect (UCD) tool (Fig 3.0). This tool is At this time the top and bottom master valves are opened
a snap latch type connector, which joins the different modules and the BHA is run into the wellhead using the wireline and
of the BHA together. A wet connect is integral with each UCD grease head assembly. (Fig. 2.1) The appropriate rams are
and allows passage of the electrical signal. closed in the deployment stack engaging the BHA (slips and
seals), the UCD (Universal Connect Disconnect) tool is
All the modules that make up the entire BHA are
connected together via the UCD tool. There are no threaded activated and the running tool is pulled up inside the
connections to be made up during a deployment or retrieval of lubricator. The top master valve is again closed. The
deployment lubricator is disconnected and laid down with the
the drilling BHA. In this manner, the individual modules of
the assembly are never physically touched when deploying or well positively secured by the use of the top master valve.
retrieving.
SPE 74841 IMPROVING THE PERFORMANCE OF COILED TUBING UNDERBALANCED HORIZONTAL DRILLING OPERATIONS 3

wellhead. The tubing is pull tested and electric continuity

checked. The BHA is then run into the well to begin drilling.
This process is reversed when retrieving the BHA from
the well. Detail checks lists are followed, each step is
acknowledged verbally confirmed and checked before the next
step is taken to ensure a safe and efficient deployment or
retrieval.
Deployment History Data,(Fig. 2.3) shows the number of
jobs performed and an indication of well head pressures. A
minimum of one deployment and one retrieval is encountered
for each job. The majority of these deployments were on sour
gas wells.

Total Well Drilled Low High

Job Count with H2 S Pressure Pressure
(Jobs ) present (<1000 psi (>1000 psi
Wellhead) Wellhead)
238 101 156 82
Fig. 2.3 Table -Deployment History Data

Fig. 2.1 BOP/Deployment Stack with Lubricator

The portion of the structure, supporting the injector head,

is now slid over the wellhead. The coiled tubing lubricator and
injector assembly is positioned over the wellhead. Its then
made up and pressure tested. (Fig. 2.2)

Fig 3.0 (UCD with Wireline Wetconnect)

The overall time required for the Hands-Free deployment

Fig 2.2 Structure slid over and ready for Drilling
The top master valve is then opened and the coiled tubing
is run down and latched into the BHA that is waiting in the
ranges for 45 minutes for a low-pressure sweet oil well to 90
minutes for a high-pressure sour well. This time is taken from
the time the BHA arrives at surface until it is laying in the
lubricator on the matting.
In the event that there is an issue with retrieving the BHA
with the wireline/ UCD, and a specialize fishing overshot is
used on the wireline system to retrieve the BHA. To date this
as proven very effective when there is a UCD issue that does
not allow for a normal retrieval. Fishing operations have
occurred on approximately 1% of the retrievals and is very
well specific (wax buildup, excessive cuttings buildup in the
BOP, etc.).
4 R.G. FRASER R.P.T. (ENG), J. RAVENSBERGEN P.ENG SPE SPE 74841

Benefits of using a circulating valve for improved A hydraulically operated circulating valve (Fig 3.0) has
hole cleaning been incorporated into the orienting tool. The valve can be
opened or closed on demand to divert flow out of the BHA
Cuttings transport in underbalanced drilling has a major above the drilling motor.
impact on the drilling operations and the economics of the Experience and engineering analysis has shown that
complete process. Issues that arise in a conventional drilling cuttings transport is more difficult throughout the build section
system differ from the issues in an underbalanced drilling of a well bore. Increased flow rates are necessary to mobilize
environment. The ability to test and model all the phases and transport cuttings from the bottom side of the build
within the underbalanced process has greatly changed since section. The ability to by-pass the motor and increase the flow
the first wells where drilled utilizing a two -phase fluid system. rate through a circulating valve enhanced hole-cleaning
In any conventional overbalanced drilling system, attention capabilities in both the horizontal and build section of the
must be paid to the proper design of the hydraulics and the well. Furthermore during tripping for bit or BHA changes, the
effects on cutting transport. The industry has developed much circulating ports can be opened , which significantly increases
experience using annular velocities as a guide for various mud hole-cleaning efficiency.
types and hole sizes in order to ensure the drill cuttings are The circulating sub also has proven valuable in several
circulated from the well bore. This enables the drilling other circumstances. Inert gas lifting of the well bore or
engineer to specify pump sizes and pressure ratings. blowing the well dry, is now possible without circulating dry
A similar design practice has been followed for gas through the mu d motor. Also when “bit stuck”, the
underbalanced drilling but we are now adding a second phase circulating valve allows a liquid slug, chased be nitrogen, to
(inert gas) to the system. This complicates the design. The be circulated, the ensuing water hammer that occurs when the
circulation system created is referred to as a two-phase flo w. liquid slug reaches the BHA often provides sufficient jarring
However the fluid phase is still the only portion of the flow impact to free the bit.
regime relied on for cutting transport. The inert gas is added Flow testing the reservoir for production data can
for reducing the combined hydrostatic and friction pressure also be achieved without tripping the BHA. With all the test
gradient to below the reservoir pressure. data available to the production staff in real time, the decision
When designing a two-phase flow system the correct ratio to test or continue to drill ahead is just a matter of closing the
of fluid and gas is required for a bottom hole circulating circulation valve and return to the previous drilling activity.
pressure (bhcp) that will achieve an under-balanced condition. This is all performed without a trip out of the well.
The fluid phase of the two-phase flow must also meet the
minimum requirements for cutting transport. In addition, the
total volumetric flow rate equivalent of the two -phase system
must meet the flow rate requirements of the mud motor. These
are all design considerations for underbalanced drilling and
applicable regardless of the drilling equipment used.
When coiled tubing is added to the UBD process, the
design is complicated one additional step. A conventional
jointed pipe drill string can be rotated. This pipe rotation aids
in cutting transport by stirring up any cutting bed formed.
Coiled tubing can not be rotated and therefore greater attention
must be paid to the design of the two-phase flow for hole
cleaning.
One large factor, which influences the ability of the two-
phase system to transport cuttings, is the ratio of nitrogen gas
to liquid. During the job design, gas volume ratios are
optimized to ensure there is sufficient liquid in the system to
transport cuttings. Minimum ratios have been determined
through laboratory research and verified in the field. In most
typical flow scenarios the gas phase rides along the top of the
horizontal well bore (stratified flow) and the liquid phase
travels along the bottom. When a stratified flow system is Fig 3.0 Circulation Valves
combined with no pipe rotation, hole cleaning will not be
effective unless sufficient liquid is present and the liquid phase Unconstrained Vibration and the effect on BHA
velocity reaches the critical value. A second parameter that Reliability
controls efficiency is liquid viscosity, in order to minimize
gas/liquid slippage it is desirable to minimize liquid viscosity. An important performance issue during a two-phase
The consequence of reducing viscosity also m i pacts solids drilling operation, typically required to achieve under-
transport in the stratified flow stream. balanced pressures, is unconstrained vibration. To understand
SPE 74841 IMPROVING THE PERFORMANCE OF COILED TUBING UNDERBALANCED HORIZONTAL DRILLING OPERATIONS 5

how unconstrained vibration can occur, the following unconstrained vibration is eliminated. As a result there is an
paraghraphs will describe what occurs when a mud motor is increase in operational efficiencies. BHA electronics and
stalled and then pulled up off bottom. sensors are not damaged and less time is spent tripping to
The performance characteristics of mud motors are such replace failed components. Table 3.1 and chart 3.2 illustrate
that flow rate through the motor is proportional to the the improvement after the use of the circulating valve became
rotational speed of the motor (rpm) and the pressure drop common practice. A change in the average BHA down time
through the motor is proportional to the output torque of the from 52 hours per job in 1995 to 1 hour per job in 2001. (Fig
motor. Conventional drilling with a liquid i.e.: single-phase, 4.0-4.2)
couples the mud motor directly to the pump since liquid are Of the mentioned jobs performed the formations drilling
incompressible. However, in underbalanced drilling the two- using coiled tubing have varied for sandstone to carbonate
phase fluid is compressible, (depending on the volume fraction reservoirs at various true vertical depths (TVD) and varying
of the gas), and therefore the motor is decoupled from the horizontal lengths as determined by the reservoir. The
pump. following data shows percentage of wells drilled:
First, consider conventional drilling with a liquid. Further
consider, a change in the formation has occurred demanding Sandstone Sandstone Carbonates Carbonates
more torque from the motor. Since the prime mover is the Compressive Compressive Compressive Compressive
pump at surface, an increase in the pressure at the pump is Strengths Strengths Strengths Strengths
required to meet the new torque requirements, and since the <20,000psi >20,000psi <20,000psi >20,000psi
pump and motor are coupled by an incompressible medium 37 wells 42 wells 107 wells 38 wells
this occurs very quickly. Next consider, the same change in 16.5% 18.0% 47.7% 17.0%
the formation has occurred, however the motor is now Fig 4.0 -Formation Breakdown
powered by an compressible, two-phase, fluid. In this
situation it will take time for the pump to build the pressure Year Average Average Average Job
required to meet the new torque requirements. During this Drilling BHA Rig up and Count
time the motor will stop turning or stall, and the pump will Operations Down Rig Out
build pressure in the coiled tubing string. The pump will Time
continue building pressure by compressing the fluid until the 1995 29 52 19 12
required pressure to overcome the new torque load is
1996 30 51 19 39
achieved.
Second, consider the events that occur if the operator pulls 1997 35 45 20 71
the bit up, off the formation face after the motor has stalled. A 1998 43 36 21 37
large amount of energy can be stored in the drill string if 1999 69 12 19 9
considerable time has past. Further, when the drill bit is 2000 73 4 23 35
pulled up off the formation face there is a decrease in the 2001 76 1 18 21
required torque. For conventional drilling with a liquid this Fig. 4.1 -Drilling History
corresponds to a decrease in pump pressure. However during
under-balanced, two-phase drilling operations there is a slow Coiled Tubing Drilling Time Analysis
decrease in pressure drop across the motor. The stored energy DUCT (Drilling Using Coiled Tubing)
As of May 1,2001
in the compressed fluids must exhaust through the motor, Average Drilling Operations Average BHA Down Time Average Rig up and Rig Out
Job Count Linear (Average Drilling Operations) Linear (Average BHA Down Time)
expanding until the pressure drop across the motor reaches the 90
Total DUCT Wells Drilled = 224
no-load torque requirement. 80 Total Meters Drilled = 72627 m
76
Therefore with two-phase fluids it is possible to have a 71
69
73

70
Percent (%) & Job Count

mismatch between the pressure drop across the motor and the
torque loading of the motor. When the pressure drop is too 60
52 51
low to meet the torque requirements, the motor will stall. If 50
45
43
the pressure drop is too high for a given torque loading, the 39
40 36 37
35 35
motor will over speed since the hydraulic energy entering the 29 30
30
motor is more than the mechanical energy required. This 23
20 21 21
excess energy results in heat and unconstrained vibration. 20 19 19 19 18

12 12
Unconstrained vibration of the motor creates high levels of 10
9

shock and vibration in all components of the BHA. Electronic 4

1
0
components, navigational and gamma sensors are susceptible 1995 1996 1997 1998 1999 2000 2001
to damage, causing tool failures and a decrease in their life Year

span.
Fib 4.2 Chart- Drilling History
A circulating valve can prevent unconstrained vibration.
The valve bypasses the flow to the well bore before it reaches
the mud motor. Without any fluid flowing through the motor
6 R.G. FRASER R.P.T. (ENG), J. RAVENSBERGEN P.ENG SPE SPE 74841

Of the 224 wells drilled todate two (2) BHA’s have been
lost in hole, one in 1996 and one in 2001. In both cases shale
sloughing was the main cause of the BHA’s becoming stuck
and eventually lost in hole. The BOSS Tool (Ball operated
shear sub) was activated to retrieve the coiled tubing. There
have been other cased where the BOSS tool was used to
release off the BHA and retrieve the coiled tubing string (To
Improvements to motor life are illustrated in Chart (Fig
5.0). Note the trend of decreasing ROP as the motor nears the
Rate of Penatration vs. Time for PDM Life
Gulf Canada Resources 2-13-90-3w5m and 10-19-94-3w5m
12.00
10.00

Rate of Penatration (m/hr)

date-5 times). To be fished later by a service rig that utilized
fishing and jarring equipment. 8.00

Elastomers and their effect on performance
Elastomers are not impervious to gas molecules. The rate
a gaseous fluid can permeate into an elastomer depends on
pressure and temperature conditions. As a result of gas
migration into elastomers, two distinct problems occur,
elastomer swelling and explosive decompression.
Elastomer swelling creates excessive friction between the
rotor and stator of a mud motor. Friction leads to a localized
increase in temperature of the lobes of the stator, the thickest
portion of elastomer in the stator. The shear strength of an
elastomer decreases with increasing temperature. Therefore
excessive swelling will ultimately lead to chunks of rubber
shearing away from the stator, a process known as chunking.
This problem however can be managed by increasing the
clearance between the stator and the rotor to account for the
expected swelling of the stator. However, other variables such
as elastomer material and drilling fluid selection must be
considered to manage this problem.
Explosive decompression however is a problem that can
not be easily managed. Explosive decompression occurs when
a gaseous fluid permeates into an elastomer at bottom hole
pressures and temperatures, then is brought to surface and
exposed to atmospheric pressure. The gas molecules trapped
in the elastomer expand causing the elastomer to blister. The
elastomer blisters because the gas molecules do not have
enough time to flow out of the elastommer and the elastomer
does not have enough strength to contain the pressurized gas.
Therefore the thicker the elastomers will suffer greater, as the
gas molecules have a greater distance to travel in order to
escape from the elastomer. This observation is confirmed
during drilling operations, as mud motor stators blister and are
damaged to a greater extend than o’ring seals.
Careful selection of elastomers and slowly depressurizing
the elastomer slowly decreases the damage, and under certain
conditions can eliminate this damage. Field experience shows
depressurizing over minutes instead of seconds decreases the
damage to the elastomer. However as bottom holes pressures
approach or exceed the strength of the elastomer at
temperature, damage is unavoidable. The time to depressure
the elastomer may be uneconomic and even the best
elastomers may not have the mechanical properties to cope
with the stress. In addition, if chemical attack is occurring
concurrently to the elastomer, damage due to explosive
decompression is exaggerated.
6.00
4.00
2.00
0.00
0 25 50 75 100 125 150 175 200 225 250 275
Time Drilling (hours)
Ave. ROP Standard PDM (well#1) Ave.ROP Specialized PDM (well#1)
Ave.ROP Standard PDM (well#2) Ave. ROP Specialized PDM (well#2)
end of its productive life.
Fig. 5.0 Graph -ROP vs. PDM Life
Communications on location and into the office
One of the most significant differences between coiled
tubing drilling and conventional MWD drilling is “Real Time
Data”(2 second updates), this allows for very tight control of
the directional orientation of the BHA, and down hole
circulating pressures to ensure underbalanced conditions and
effective hole cleaning. All of this data is displayed and
networked throughout the wellsite location, and in addition
back to the service company’s and contractor’s offices via a
secure Internet based communication system (30 -300 second
Updates).
This Internet Data System sends a data string via a satellite
radio not a satellite phone, thus reducing the cost of near real
time data transmission 24 hours a day. (Fig 5.0 Data
transmission path). The data is then put into hands of the
experience of the complete drilling team on location and in the
office. The ability to access the data from any PC that has
Internet access makes the system very mobile, giving the
drilling team access from home and office with security and
confidence. Better and quicker decisions can be made because
of the availability of the information. The following diagram
shows the flow of the data from the field unit data acquisition
to the office. All the data is communicated via the MSAT
satellite system and a secure provider.
SPE 74841 IMPROVING THE PERFORMANCE OF COILED TUBING UNDERBALANCED HORIZONTAL DRILLING OPERATIONS 7

BJ Services Company Canada Total Successful Operations (Hours) 6900.50 68.86%

Drilling Using Coiled Tubing Total Standby/Rigup- 2209.30 22.05%
Down/Press. Test Time
From the Total BJS Down Time (Hours) 657.00 6.56%
Coiled From the Total Customer Operations (Hours) 110.00 1.10%
tubing Unit Satellite to a
to the Total Third Party Down time (Hours) 144.70 1.44%
Secure Web
Satellite via Site on your Totals (hours / percent) (Hours) 10021.50 100.00%
a Mobile desk
MSAT
Radio
Fig. 7.0 Table -BHA Drilling History

Drilling Using Coiled Tubing

Operational Time Analysis
Year ending 2001

Total Wells Drilled with time analysis = 55

Total Drilling hours =6905
Total Hours on Loacation = 10021
Total Successful
Operations
68.86%

Customers Office or Home, Total Third Party Down time

1.44%
anywhere you have Internet
Access

Total Customer Operations

1.10%
Fig 6.0 Data transmission path
Total Stanby/Rigup-
Conclusion Total BJS Down Time
Down/Press. Test Time
22.05%
6.56%

The deployment system has proven to be operationally

efficient and has enabled a safe working environment. Long
BHA's can be deployed and retrieved from a live well and not
compromise the under-balanced condition of the reservoir.
Improved hole cleaning, fewer wiper trips and operational
flexibility are the result of adding the circulating valve to the
BHA.
The use of the circulating valve can be effectively used to
control unconstrained vibration. BHA failure rates started at
52% of the operating time and have continually improved to
less than 1% in 2001.
Motor life increased three to four times as a result of
optimizing rotor stator clearances and elastomer selection.
Explosive decompression, which is a greater concern for large
elastomeric components such as motor stators, can be
managed under certain conditions, and even then only affect
performance after the elastomer has been decompressed to the
atmospheric pressure.
Communication on location and into the office empowers
the entire team; increasing job efficiency and reducing costs to
the drilling project.
The data shown next is an operational time analysis for
over 60 wells in the passed 2 years (Fig.7.0 & 7.1). It
demonstrate that the improvements to both the drilling system
and engineering the have delivered a consistent and reliable
process.
Fig. 7.1 Graph-Time Analysis for
Drilling Using Coiled Tubing
Acknowledgements
The authors would like to thank BJ Services Company
Canada for their permission and time to write this paper.
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8 R.G. FRASER R.P.T. (ENG), J. RAVENSBERGEN P.ENG SPE SPE 74841

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