4.

0 Gaseous Liquids

4.1 Types
4.2 Gas Behavior
4.3 Fluid Selection
4.4 IADC, Equipment Guide
4.5 Separation Systems
4.6 Pipe Light
4.7 Practices

Section 4 - Page 1
Liquid Phase

 Generally do not contain surfactants

 Liquid phase is cleaned at surface and re-pumped downhole
 Base liquid is normally water, or oil and is gasified with
nitrogen
 Horizontal wells are often UBD w/gasified liquids
 Usual underbalance desired is from 250 psi to 500 psi

Section 4 - Page 2
Gas Phase
 Gases commonly considered
are air, nitrogen, and natural gas
 Air increases corrosion severity
and downhole combustion
 From mud ring development
with gas present
 Air/diesel and pressure gives
the same effect as a diesel
engine
 Air commonly used if liquid
phase is continuous H2O
 Nitrogen eliminates risk of
downhole fires
 Gas phase has minimal effect on
hole cleaning

Section 4 - Page 3
Multi-Phase Flow

 2 phase flow (injection

gas and drilling fluid)
down drill string
 Lightens DP x Casing
annulus from bit to
surface
 BHP depends on effective
Drilling fluid
density of annular fluid Injection gas
Formation influx

?
Section 4 - Page 4
Hydrostatic and Friction Dominated BHP

Initially, BHP decreases as the gas

injection rate is increased. The reduction of
the hydrostatic pressure is greater than the

Bottomhole Pressure (psi)

increase in annular friction pressure. But, Hydrostatic Friction
as gas rate continues to increase, the Dominated Dominated
annular friction pressure becomes more Region Region
significant and eventually increases BHP.
There is a critical gas rate for which the
BHP is a minimum.
Gas inflows can cause the BHP to
decrease or increase. The rate of gas
inflow is added to the gas being injected
Critical Gas Injection Rate
and may alter a hydrostatically dominated
flow regime to a friction dominated flow.
A liquid inflow will always increase BHP. Gas (Air) Injection Rate (scf / bbl)

Section 4 - Page 5
Bottom-hole Pressure and ECD
Conventional Drilling Underbalanced Drilling
Bottom-hole pressure when
circulating is the sum of the Surface Back
hydrostatic pressure of the RCH Pressure
fluids in the well and the
annular friction pressure.
In underbalanced drilling, the
back pressure is used to
maintain the BHP at an
equivalent value.
APL - Annular APL - Annular
Pressure Loss Pressure Loss

APL
ECD = MW + APL + Back Pressure
0.052 x TVD ECD = MW +
0.052 x TVD
Section 4 - Page 6
Gasification Techniques
Drillstring Injection Annulus Injection
Parasite String

Annulus Injection
Parasite Casing Annulus Injection
Through Completion

Section 4 - Page 7
Disadvantages to Drillstring Injection

 BHP is difficult to Gas Liquid

maintain when making
connections and when
tripping
 Two phase system
 Gas compressibility
blocks MWD signals
 Mud motor efficiency
reduced
 Increased corrosion
rates possible

Section 4 - Page 8
Passage of 1 SCF N2 through Diesel System

Surf. Temp 600 F

Gas temp 1000 F
Injection pressure 1000
Casing pressure 200 psi
psi 3
1
1 Volume N2 = 0.0147 cff

2 Volume N2 = 0.0055 cff

2 BHT 2400 F
3 Volume N2 = 0.079 cf
Formation Pressure
3600psi

Section 4 - Page 9
Gas Chart – Motor Throughput (example)
Equivalent motor throughput

5-1/2" Vectordrill HS
400.0

350.0

Maximum
300.0
Motor Throughput gpm

250.0

200.0

150.0
Minimum

100.0 200 gpm

250 gpm
300 gpm
50.0
Minimum Motor
Maximum Motor
0.0
0 200 400 600 800 1000 1200 1400
Gas injection rate

Section 4 - Page 10
Gas Chart – Equivalent BHP (example)
Bottom Hole pressure vs Gas rate

7000

6000

5000
Bottom hole pressure (psi)

4000

3000

2000
200 gpm

250 gpm
1000
300 gpm
Reservoir pressure
0
0 250 500 750 1000 1250 1500
Gas injection rate (scft/min)

Section 4 - Page 11
Initiating UBD (N2/Diesel Case Study)

 Used to remove undesirable Booster Cap. – 1000 psi

diesel volume from the well Typical Circulating
after setting and cementing Pressure – 250 psi
@ 2 – 3 bpm 6.5 ppg Diesel
casing (or after the well has
been killed) so that N2
injection for UB operations 5”, 19.5 lb/ft DP
can begin
 Can be done with medium
capacity booster (1000 psi)
 Saves time compared to Reservoir Pressure

“staging-in” operations 3870 psi @ 12000 ft

9 5/8”, 47 lb/ft Casing
@ 12000 ft TVD/MD

What is the necessary injection rate of N2 to reduce

the hydrostatic pressure by 450 psi?

Section 4 – Page 12
Example Calculations (N2/Diesel Case Study)
Step 1 – Volumes What is the estimated injection rate of N2 to
reduce the hydrostatic pressure by 450 psi?
DP volume = 0.0177 x 12000 = 212 bbls

Annular volume = 0.048 x 12000 = 576 bbls Surface Temp – 800 F (5400 R)

Step 2 – Average Hole Conditions

Booster Cap. – 1000 psi
Bottomhole Temp = 0.014 x 12000 + 80 = 2480 F (7080 R) Typical Circulating
Pressure – 250 psi
540 + 708
Average Temperature = = 6240 R @ 2 – 3 bpm 6.5 ppg Diesel
2
Hydrostatic Pressure = 0.052 x 6.5 x 12000 = 4056 psi
5”, 19.5lb/ft DP
Surface Injection Pressure = 900 psi Cap – 0.0177 bpf
Annular
4056 + 900 Capacity – 0.048 bpf Disp – 0.0076 bpf
Average Pressure = = 2478 psi
2
Step 3 – Volume 1 scf of N2 at Average Conditions
9 5/8”, 47lb/ft Casing
V1 x T 2 x P 1 Reservoir Pressure
1 x 624 x 14.7 @ 12000 ft TVD/MD
V2 = = = 0.0071 ft3 3870 psi @ 12000 ft
T 1 x P2 520 x 2478 Cap – 0.0732 bpf

Temp Grad (F) = 0.0140 / ft + Surface

Section 4 – Page 13
Example Calculations (N2/Diesel Case Study cont.)
Step 4 – Equivalent Gas Weight at Average Conditions Nitrogen
Density of N2 at standard conditions = 0.0724 # / ft3 Surface Temp – 800 F (5400 R)
0.0724
EGWa = = 10.20 # / ft3 = 1.36 ppg
0.0071 Diesel

Step 5 – Required EMW for Desired Underbalance

Desired BHP = (0.052 x 6.5 x 12000) - 450= 4056 – 450 = 3606 psi 6.5 ppg Diesel
3606
EMW for Underbalance = = 5.78 ppg
.052 x 12000

Step 6 – N2 Injection Rate for Desired Underbalance

Mass balance formula w/ 3 bpm diesel circulating rate

5.78 x (3 + N2) = 6.5 x 3 + 1.36 x N2

( Diesel Wt. – EMW ) ( 6.5 – 5.78 ) Reservoir Pressure

N2 Injection Rate = Q x =3x
( EMW - EGWa ) ( 5.78 – 1.36 ) 3870 psi @ 12000 ft

N2 Injection Rate = 0.49 bpm = 2.75 ft3 / min

2.75 Temp Grad (F) = 0.0140 / ft + Surface
N2 Injection Rate (scfm) = = 387.3 scfm
0.0071
Section 4 – Page 14
 Initiating UBD (N2/Diesel Case Study)
Pumps Off 732 scf N2 N2 in Annulus Begins 732 scf N2 Steady-state
Prior to N2 Injection Unload Process Conditions
3 bpm Diesel 3 bpm Diesel

String
Valve
N2

Diesel

BHP decreasing Estimated !

BHP = 4056 psi And Fluctuating BHP = 3606 psi

Section 4 – Page 15
System Units of Measurements

Fluids & Flow In

N2 – scfs / minute Nitrogen System Gas Rate –MM scf / day
Diesel – gpm Choke Vent

KO
Manifold
PWD – psi
ROP – ft / hour
Echometer – ft
Vent

Liquid System
Fluids & Flow Out Cuttings
Gas – MM cf / day Return
Oil Return
Diesel – gpm
Cuttings – lbs / hour
Oil – bbls / day

Section 4 - Page 16
IADC Recommended Equipment Guide
IADC Classification Level 0
“UBD used for performance enhancement only; no hydrocarbon containing zones present.”

Rotating diverter The IADC UBD Classification System

Blooie Line w/auto igniter
Mist pump
Non-return drillstring valves
Closed system – for H2S work
should be referenced whenever planning
for UBD. A sound drilling practice is to
use the next highest well classification
whenever selecting equipment needs.
That way, the equipment should be
sufficient to handle any severe well
conditions that may exist.
Additional considerations must be given
to the type of UBD drilling fluid designed
for the operation. Consideration should
also be given as to whether H2S will be
encountered and brought to the surface.

Section 4 – Page 17
Recommended Equipment Guide
IADC Classification Level 1
Well incapable of natural flow to the surface. Well in “inherently stable” and is low level risk
from a well control point of view.

Flame arrestor Feed compressor

Atmospheric separator (recommended Booster compressor
for closed system)
Mist pump
Low pressure choke manifold
Non-return drillstring valves
BOP (rams and annulars)
Rotating diverter
Blooie Line w/auto igniter
Flare stack

Section 4 - Page 18
Recommended Equipment Guide
IADC Classification Level 2
“Well capable of natural flow to the surface but enabling conventional well kill methods and
limited consequences in case of catastrophic equipment failure.”

Flame arrestor Feed compressor

Atmospheric separator (recommended Booster compressor
for closed system)
Mist pump
Low pressure choke manifold
Non-return drillstring valves
BOP (rams and annulars)
ESD or emergency procedures
Rotating diverter
Fluid cushion maintained in the vessel
Blooie Line w/auto igniter
Flare stack

Section 4 - Page 19
Recommended Equipment Guide
IADC Classification Level 3
“Geothermal and non-hydrocarbon production. Maximum shut-in pressures less than UBD
equipment operating pressure rating. Catastrophic failure has immediate serious
consequences.”

Closed system Feed compressor

Two phase separator Booster compressor
Triplex liquid pump Mist pump
Choke manifold Non-return drillstring valves (minimum of two)
BOP (rams and annulars) ESD or emergency procedures
Rotating diverter Fluid cushion maintained in the vessel
Blooie Line w/auto igniter
Flare stack
Flood pump (deluge) on annulus

Section 4 - Page 20
Recommended Equipment Guide
IADC Classification Level 4
“Hydrocarbon production. Maximum shut-in pressures less than UBD equipment operating
pressure rating. Catastrophic failure has immediate serious consequences.”

Closed system
Feed compressor
Two phase separator
Booster compressor
Triplex liquid pump
Mist pump
Redundant choke / flow manifolds
Non-return drillstring valves (minimum of
BOP (rams and annulars)
two)
Rotating diverter
ESD or emergency procedures
Blooie Line w/auto igniter
Fluid cushion maintained in the vessel
Flare stack
Flood pump (deluge) on annulus

Section 4 - Page 21
Recommended Equipment Guide
IADC Classification Level 5
“Maximum projected surface pressures exceed UB equipment operating pressure rating but
are below BOP stack rating. Catastrophic failure has immediate serious consequences.”

Closed pressurized separation system

Feed compressor
Triplex liquid pump
Booster compressor
Redundant choke / flow manifolds
Non-return drillstring valves (three minimum)
BOP (rams and annulars)
ESD or emergency procedures
Rotating diverter
Fluid cushion maintained in the vessel
Blooie Line w/auto igniter
Flare stack
Flood pump (deluge) on annulus

Section 4 - Page 22
Rotating Control Heads

Section 4 - Page 23
Williams Rotating Control Head
Model RCH 7100

 Dual Rotating Stripper Rubbers Kelly Driver

 Water Cooled Seals
 Positive Oil Lubrication Top Rubber

 Hydraulic Operated Clamp

 Rotating Working Pressure: 2,500 psi Bearing
Assembly
 Static Pressure: 5,000 psi
 Shell (Housing) capable: 10,000 psi
 Maximum Operating: 100 rpm Bottom
Rubber
 Operating Temperature:
 - 28 + 121 C
 -20 + 250 F
 Fluid Rating: H2S Service Bowl

Section 4 - Page 24
Williams Rotating Control Head
Models RCH 8000 & 9000

Specifications
 Universal quick change bearing assembly.
 Bottom flange sized 7 1/16” through 30”
 Model 8000 – 8 ¼” bore / Model 9000 – 9” bore
 Operating pressure – 500 psi
 Static tests to – 1000 psi
 Maximum rotary rate – 100 rpm
 tripping speed: +/- 45 sec per stand
 Rotating hours: +/- 400 hrs

Rotating heads can be tested against

the annular after replacement.

Section 4 - Page 25
Shaffer Rotating BOP - PCWD
The Shaffer rotating BOP is very similar to
the standard Shaffer Spherical BOP except
that radial and thrust bearings added to the
Thrust Bearing
upper and lower inner housings create an
entire assembly that can seal on the Dynamic
drillstring and rotate with the drillstring. A Seals Rubber Element
separate cooling circuit is required to
remove heat generated by the bearings and
rotary seals. Upper Housing

PCWD Specifications
Lower Housing
• Tested to 10,000 psi Radial
Bearings
• Working pressure (static) – 5,000 psi Piston
• Working pressure (rotating) – 3,000 psi
• Maximum rotation speed – 200 rpm
• Standard Spherical packer Pressure Control While Drilling (PCWD)
• Full 11” bore ( 13 5/8” available soon)
• Weight 12,500 lbs
• Dedicated hydraulic control unit

Section 4 - Page 26
N2 / Diesel Closed System (4.B.4)

 Feed Air and Booster Compressors

 N2 Filter System
 BOPS and Rotating Head
 Choke Manifold and ESD
 5 K Separator, Knock Out Pods, and PSC Valve
 Drilled Solids Removal Cyclones
 1440 Separator

Section 4 - Page 27
Membrane Nitrogen Production Unit

Drilling Feed Air

Rig Booster Membrane System Compressor

Section 4 - Page 28
Feed Air Compressor
Compressor Nitrogen
Filters

Nitrogen System

Fluid System

Feed air is fed to the N2 filter

Types: membranes by the feed air
compressors.
Reciprocating Rotating
Single Acting Positive Displacement Dynamic
Double Acting Lobe, vane, & screw Radial & axial

Section 4 – Page 29
Membrane Nitrogen Modules and
Control Panel

Section 4 – Page 30
Individual Hollow Polymeric Gas
Separation Fiber

 95% nitrogen, 5%
oxygen
 Corrosion
considerations
 Combustion
considerations
 Mob/demob costs

Section 4 - Page 31
N2 Generating Unit (a bundle of fibers )

Nitrogen
Enriched Gas
Hollow Fiber
Membrane

Individual Hollow Oxygen

Polymeric Enriched Air
Gas Separation Fiber

Feed Air

Section 4 - Page 32
Booster Unit

Booster Unit

Nitrogen System

Fluid System

The booster unit “boosts” the N2 produced by the filter membranes to the required
injection pressure. The injection pressure is determined by fluid quality, well depth, and
desired flow rates for hole cleaning.

Section 4 – Page 33
Nitrogen Manifold

Booster Unit Nitrogen

Manifold

Nitrogen System

Note:
Fluid System Safety Slings

The nitrogen manifold allows for isolating either of the high pressure discharges of the
booster compressors. The N2 manifold is then routed to the standpipe or “injection manifold”.

Section 4 - Page 34
String Float Valves

Flapper-type
Float

Dart-type
Float

Valve Opening Tool

Several float valves are run in the string and are used as check valves to reduce the time required for the string to
bleed down prior to breaking a tool joint for a connection. The N2 is bled from the string and vented to the
atmosphere. The valve opening tool should always be used to check for pressure beneath a float valve whenever a
valve is pulled through the rotary on a trip OOH.
Two tandem float subs are run below the PWD / EM tool. One is a flapper type and the other a spring type.
Note: String floats are generally wireline retrievable.

Section 4 – Page 35
Floats in an Underbalance Operation
• In conventional and underbalanced drilling the primary role of a float is to
stop backflow of fluids into the drillstring.
• In conventional drilling the imbalance between the bottomhole pressure
and the hydrostatic in the drillpipe results from the additional hydrostatic
exerted by the cuttings load in the annulus causing flow up the pipe on
connections if no float is present.
• In an underbalanced operation the imbalance is caused by the hydrostatic
in the pipe being less than the formation pressure.
• The consequence of float failure in an underbalance operation can be
catastrophic, whereas in overbalance it could only be a plugged bit and
resulting round trip.
• The float can then be categorised as a primary well control barrier.

Section 4 - Page 36
Float Numbers
• Using the accepted well control concepts on redundancy a minimum of two
floats should be run close to the bit (on some jobs this number has been
increased to four).
• In addition to the role of a primary well control barrier, floats are used to
speed up the drilling process by reducing the time it takes to bleed off any
pressure trapped in the drillstring. This is done by placing a float in the
string at surface prior to the start of actual drilling (a string float). This
allows the pressure to be bled off above the float reducing the volume
therefore the time.
• Where possible string floats should be wire line retrievable or the flapper
type with the closing spring disabled.

Section 4 - Page 37
Float Testing
• As a primary barrier the pressure integrity of the float must be assured
before use.
• Most floats are run in specific subs, which are incorporated into the string
as a unit.
• This allows the testing of the installed float on surface prior to the sub being
installed.

Testing Frequency and Pressures Recommendations:

A. Prior to each bit run.

B. Pressure equivalent to the rating of the stack.

Section 4 - Page 38
BOP Arrangement

S8 S7 Rotating Head
S9
B1 B2 SDV1 B9 FLOW LINE

Annular
Preventer
Upper
Blind/Shear
B3 B4 Ram

Upper
CV2 B5 B6 Pipe Ram
P1 P2 CHOKE LINE

Lower
LOWER KILL LINE Pipe Ram
Lower
The BOP equipment is required to The rotating head allows for
provide for well control whenever
B7 B8 Blind Ram
a back pressure to be held
uncontrolled flow from the well occurs. on the wellbore while
rotating the drillstring.

Section 4 - Page 39
Accumulator Systems

Section 4 - Page 40
Accumulator Systems
Accumulator Volumes
Accumulator bottles store hydraulic fluid under pressure for use in closing the selected BOP. UBD
eliminates the barrier of hydrostatic pressure making the role of the accumulator more important than
when conventional drilling. The volume of stored hydraulic fluid is dependent on operating parameters
such as N2 pre-charge and operating pressures.
The volume of hydraulic fluid stored at a pressure of 1200 psi and above is often referred to as the usable
fluid volume and should be at a minimum of 1 ½ times the volume required to close (and hold closed) all
BOP stack functions. This applies to snubbing stacks, drilling stacks, and coiled tubing stacks.

Pre-charge pressure Pre-charge pressure

Volume Delivered = Bottle Volume x ( Final pressure System pressure
)
Hydraulic Fluid Reservoir
The fluid reservoir should have a volume of at least two times the volume of all accumulator bottles.
Pressure Regulators
Pressure regulators control system pressures to proper operating values. Rigs typically set the
accumulator system pressure to 3000 psi but regulate this value to 1500 psi for the manifold which
contains the 4-way valves. The annular preventer has it’s own regulator so that the closing pressure
can be varied for stripping operations and prolonged element life.

Section 4 - Page 41
Accumulator Systems
Special Considerations
The closing system should be capable of closing each ram preventer within 30 seconds. Closing time should not
exceed 30 seconds for annular preventers smaller than 20 inches and 45 seconds for annular preventers 20 inches
and larger. Consideration should be given for back-up power supply. Nitrogen bottles should be on hand in addition to
the triplex electric pump and the air operated pump for emergency use.
Closing Unit Location and Remote Control Requirements
The main pump unit should be located in a safe place which is easily accessible to rig personnel in an emergency.
Each installation should be equipped with a sufficient number of control panels such that the operation of each BOP
and control valve can be controlled from a position readily accessible to the driller. To perform UBD work safely it is
prudent to have regularly scheduled maintenance of the accumulator unit as standard practice.

Pre-charge Maintenance Check

Accumulator Maintenance
• Check all equipment for leaks and wear
• Clean and lubricate all fluid pumps (air and
electric)
• Check all pump packing
• Lubricate all 4-way valve controls
• Check and adjust all regulators for proper values
• Check hydraulic fluid level in reservoir
• Check and lubricate all controls on remote panel
Section 4 - Page 42
1. Turn off pumps (air and electric)
2. Close the accumulator bottles (shut off valves)
3. Open hydraulic bleeder valve
4. Bleed fluid to low pressure reservoir
5. Close hydraulic bleeder valve
6. Install charging and gauging assembly and check
pre-charge
7. Remove charging assembly and open shut-off valve
8. Turn on pumps (air and electric)
 Electro Magnetic Data Transmission
Transmitter- Earth
Normal mud signals will not Receiver Antenna
transmit through fluids with a
quality greater than 15-20%.
Electro magnetic (EM) helps to
overcome this however, certain
formations can block
transmissions, therefore antenna
cables are run insider the string to
permit signals. EM will also give Bi-directional
signals when tripping. Transmission

Length of antenna
dependent upon depth
of any high resistivity
Zones (eg anhydrite). Emitting Injected
Antenna Drill Bit Current

Section 4 - Page 43
ESD Valve

Emergency
Shutdown Valve

Nitrogen System

Fluid System

The ESD or emergency shutdown valve is used to close in the well during emergency conditions. It
can be closed by the driller and is closed automatically whenever high level alarm conditions exist.

Section 4 - Page 44
Choke Manifold

Choke
Manifold

Nitrogen System

Fluid System

The choke manifold is an assembly of high pressure valves, piping, and manual and hydraulic
controlled choke valves. Its purpose is to control and route the flow of high pressure fluid and
gas discharge from the wellbore.

Section 4 - Page 45
Closed (Pressured) Systems

The distinguishing feature of the closed system is the use of a pressurized, four-phase
separator and a fully closed surface system to handle the returning fluids. These UBD
operations are sometimes called “production drilling” since the closed nature of the
system (when so designed) allows for continuous measurement of a wells productivity.
Closed systems are becoming more and more popular around the world. The system
originated in Canada but additional applications are being found in Colombia,
Argentina, Libya, Oman, UK-North Sea, and Oman. With closed systems, all fluids are
contained within pressured flow-lines and vessels. The closed system can handle H2S
safely and prevents hydrocarbon vaporization from open pits.

Section 4 - Page 46
Closed System
High Pressure 5000 psi

Flare L.C.V. B.P.V. Standard separator Liquid storage tank

Standard heater
B.P.V.

B.P.V.

E.S.D. Standard Surge tank

Tranfer pump
Rig fluid system

Section 4 - Page 47
Closed System Flow Control Arrangement
To Shale Shakers Separator
ESD
Manifold Sample
RBOP To Separator Manifold Catcher

Annular
Pipe Rams Manual
Kill Line
Choke

Blind/Shear Choke Flare

Rams Stack
Pipe Rams
Pressured Separator

Kill Line Water to Oil Storage

Rig Tanks
Choke
To Flare Pit Cuttings
Rig Choke Manifold
The closed system flow arrangement offers redundant choke line outlets and choke manifolds. An
Emergency Shutdown Valve (ESD) should also be installed to automatically shut-in the well should
downstream separators or flow lines fail. The separator manifold allows for placement of a sample
catcher to extract cuttings and fluids by isolating the flow process. The pressured separator is the
distinguishing feature of the system. It routes the gas phase to flares and returns hydrocarbon liquids
and drilling fluids to storage and / or suction pits.

Section 4 - Page 48
Closed System Considerations
 Drilling fluids
– Majority of applications have been with nitrified liquids.
– Avoid fluids that could cause a potentially explosive mixture (air,
natural gas, mist, or air foams).
– Avoid viscous fluids
– Separation of gas from liquid will be more difficult (particularly true
when H2S is present).
 Operations
– Monitor and record periodically the liquid and solid levels in the
separator (can be compared to injection rates for productivity
analysis.)
– Use gas “back-pressure” to increase separator and system
efficiency

Section 4 - Page 49
Closed Systems Limitations

 High surface pressures

– Properly designed systems can handle up to 35MMsch/D gas rates.
– Plugging of separator or flare line could cause excessive back
pressures on surface equipment.
 Equipment and personnel
– Personnel must be trained as to the application, testing, and
maintenance of these systems.
 Costs
– Closed systems are quite expensive when compared to more
typical UBD techniques, however, the advantages of these systems
when the application merits use make them attractive.

Section 4 - Page 50