IADC/SPE 106367
Well-Control Aspects of Underbalanced Drilling Operations
Ramalho, John, and Davidson, Ian A., Shell E&P Intl. Ltd.
Copyright 2006, IADC/SPE Asia Pacific Drilling Technology Conference and Exhibition
This paper was prepared for presentation at the IADC/SPE Asia Pacific Drilling Technology
Conference and Exhibition held in Bangkok, Thailand, 13–15 November 2006.
This paper was selected for presentation by an IADC/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 International Association of Drilling
Contractors or the Society of Petroleum Engineers and are subject to correction by the
author(s). The material, as presented, does not necessarily reflect any position of the
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Abstract
Underbalanced drilling is not a new technology. All wells
drilled up until the introduction of the rotary drilling rig
were drilled underbalanced. However, knowledge of
subsurface conditions was limited, well control risks
were not managed and well control incidents, when wells
struck over-pressured zones, were common. The
introduction of the rotary rig, resulted in mud circulation
systems. As wells were drilled deeper into over-
pressured formations blowout preventers (BOPs) that
enabled better well control were introduced.
Overbalance (conventional) drilling replaced
“underbalance” cable tool drilling and became the
normal practice.
In conventional drilling, the hydrostatic pressure created
by the mud column provides primary well control and
BOPs provide secondary well control.
Underbalance drilling has emerged in the past 15 years,
and, just as there have been improvements and
refinements in conventional well control equipment and
procedures overtime, the same holds true for
underbalanced drilling technology. In underbalanced
drilling, the primary well control function of the mud
column is replaced by a combination of flow and
pressure control, while secondary well control
functionality is provided by the BOPs. The complete
UBD closed-loop flow control system comprises of the
drill pipe (DP) circulating system, a UBD control device
(UBD-CD), which provides the sealing mechanism
around the drill string at surface, a UBD choke manifold
(not the rig’s well control choke manifold), a UBD
separator and flare system. In addition, non-return
valves (NRVs) are installed in the bottom hole assembly
(BHA) and drill string to prevent flow up the DP.
This paper provides an overview of underbalanced
operations primary well control. It briefly describes the
equipment and techniques used and the critical issues to
consider during project planning to ensure the safety of
staff, the rig, the well and to ensure that the life cycle
objectives of UBD wells are addressed.
Introduction
Underbalanced drilling is not a new technology. Wells
drilled in the early days of the oil and gas industry were
drilled underbalanced with cable rigs. Cable rigs make
hole by repeatedly dropping a heavy tool string onto the
rock-cutting bit. The process stops every few feet and
the bottom of the hole is cleaned with a bailing bucket.
This technique, which is still in use today for drilling
domestic water wells in rural areas, is safe, but hole
stability and water influx results in some pretty slow rates
of penetration.
Borehole stability was a challenge for the early cable tool
“underbalanced” oil-well drillers, as it is for today’s. Also,
well control, although not considered much of a problem
in shallower horizons was a problem as they ventured
into deeper pressured formations. With the introduction
of the rotary drilling rig into the Oil Patch, a mud
circulating system was introduced where mud is
circulated through the bit and returns are brought back to
surface. With the mud column thus created, overbalance
drilling became the normal “safe” practice drilling for
hydrocarbons, and the concept of primary well control
utilizing the mud column became the norm1. The
introduction of the rotary drilling rig enabled drilling into
pressured formations that would typically collapse and/or
flow uncontrolled when drilled with cable tools. In
conventional rotary drilling, hole stability and well control
risk have been mitigated by the development and
improvements of wellheads, blow-out-preventers, casing
string design and metallurgy, cementation and drilling
fluids technology. However, nothing comes without a
price and the downside of overbalanced drilling
observed over time, is poor rate of penetration in some
formations, potential for lost circulation and differential
sticking of the drill string under certain conditions and the
requirement for stimulation treatments to mitigate
2 IADC/SPE 106367

formation damage, due to mud filtrate invasion in some positive impact on well control incidents over
hydrocarbon bearing production reservoirs. conventional drilling well control and it includes
Air Drilling overbalanced and underbalanced techniques in the
The introduction of air drilling considered by many to be tool kit as illustrated.
the modern rebirth of underbalanced drilling2, was driven One study of
conventional drilling
MPD
by the need to address some of these “conventional
operations in the Gulf of An Adaptive Process
drilling" drawbacks and improve drilling performance.
The Gas Research Institute’s Underbalanced Drilling Mexico and North Sea
Manual3 provides a good description of the air drilling regions, found that 63% Closed Systems
process as follows. “Compressors are used to pump air of all blowouts
via the swivel or top drive connected to the top of the drill Overbalanced
occurred during
string, down the drill string, through the bit and back up Development and Tool Kit

Top Hole
the annulus. A rotating control device provides a seal
Exploration drilling 4. Dual Gradient
around the drill pipe at surface to divert return flow away
This percentage Mud Cap
from the rig floor. The diverted cuttings-laden-air-flow is
taken down a blooie line and discharged a safe distance increases to 80% if Constant BHP
away from the rig in a pit. A flare is maintained at the workovers are included. DAPC
end of the blooie line to burn any hydrocarbon gas in the These stats are related CCS
return flow”. Mist drilling, foam drilling, flow drilling and to what are considered CCV
gasified fluids drilling were all refinements of conventional activities in Air Drilling
underbalanced drilling techniques designed to overcome mature basins. As the Mist Drilling

drilling challenges generally, but not restricted to, the
overburden.
The introduction of horizontal drilling in the reservoir was
the catalyst for further improvements of underbalanced
drilling equipment and procedures especially in rotating
control devices, surface separation equipment and drill
string non-return valves. In the past 15 years
underbalanced drilling technology has developed and
progressed especially in the area of well control, with the
introduction of the closed-loop system, to enable its use
in more challenging environments.
Managed Pressure Drilling
Today, a new term has crept into the vocabulary of the
unconventional driller, “Managed Pressure Drilling”
(MPD). MPD enables drillers to safely drill within a
tighter pressure range relative to reservoir or pore
pressure, thus eliminating many of the negative impacts
of weighted conventional mud systems.
The International Association of Drilling Contractors
(IADC) defines Managed Pressure Drilling as “an
adaptive drilling process used to precisely control the
annular pressure profile throughout the well bore. The
objectives are to establish the down-hole pressure
environment limits and to manage the annular hydraulic
pressure profile accordingly”. Managed pressure drilling
has also been described as “a basket of drilling
techniques that can be adapted to solve drilling related
problems, reduce formation damage and or dynamically
characterize production reservoirs (while drilling) to
enable improved reservoir management” 2.
Shell views MPD as an adaptive process that
enables safely drilling top-hole and reservoir sections
as efficiently and effectively as possible. It generally
uses a closed circulating system, which can have a
Reservoir
industry steps up Foam Drilling
drilling operations in Gasified Liquids
areas with tight drilling Flow Drilling
margins (the difference
between pore pressure Underbalanced
and fracture initiation
pressure) (Figure 1), it is expected that managed
pressure drilling will reduce the potential for
escalation of on-bottom well control incidents into
surface or subsurface blowouts.
To discover what is driving this expectation let us
appraise a conventional overbalanced drilling
operation from a well control perspective.
In a conventional drilling system, the static annular
hydrostatic pressure is designed to be greater than
the formation pressure. The hydrostatic pressure
created by the mud column provides primary well
control. The level of the fluid in the well-bore is
monitored both under static and dynamic conditions
and provided the well, respectively does not flow, or
does not gain volume, the well is considered to be
“under control”. To detect a kick there are systems in
place to monitor parameters that may indicate the
presence of abnormal pressures. A pit volume
totalizer (PVT), a Flo-show meter installed in the
return flow line combined with a competent mud
logging engineer and vigilant rig crews are key to
early kick detection. An observed well flow with the
pumps off is a definitive indicator of a kick. However,
as Schubert pointed out in a recent presentation5, a
Flo-show meter measures a percent flow ranging
from zero to 100% flow with questionable accuracy.
Also the sheer size of the pit volume and ballooning
effects of drilling in certain formations also affects
IADC/SPE 106367
the accuracy of the PVT system. The result is a time
delay in the detection of the kick in conventional
drilling operations. After a kick is taken the system is
closed with the BOPs and the kick is then circulated
out through a choke with backpressure at surface.
An MPD operation utilizing a closed system, (a
rotating control device (RCD) and a drilling choke at
surface) and including a Pressure While Drilling
(PWD) Tool in the BHA, has the potential for
improved well control due to more sensitive kick
detection capability. Shubert used the following
equation to demonstrate
that for a constant area,
or choke opening, an
increase in flow rate
results in an exponential increase in pressure. He
concluded, this makes the choke pressure much
more sensitive to an increase in flow than the Flo-
show meter. Since in an MPD operation the system
is already closed, faster kick detection will result in
reduced influx rate and volume and a faster killing
operation, which potentially should reduce the risk of
on-bottom-well-control incidents escalating into
surface or subsurface blowouts hence a safer
operation for rig personnel, reduced potential impact
for area residents and the environment.
To establish if this is a reasonable expectation, let us
now look at the experience of the underbalanced
drillers from a well control perspective.
Underbalanced Drilling Well Control
Underbalanced drilling is different, but is not considered
unsafe when compared to conventional drilling.
During underbalanced drilling the hydrostatic pressure in
the circulating down-hole fluid system is intentionally
kept below the pressure of the formation being drilled.
The well is designed such that the annular pressure
(both static and dynamic) is deliberately maintained at a
value less than the formation pressure. If formations
having permeability and porosity are encountered, the
system is designed to allow flow from the formation into
the well-bore. The primary well control function of the
mud column, is replaced by a combination of flow and
pressure control. Bottom-hole pressure and return well
flow are continuously measured and controlled by
means of respectively, pressure while drilling
measurements and volume measurement within the
closed-loop system. Figure 2 is a schematic
representation of the UBD closed-loop circulating
system. The complete UBD system comprises of the drill
pipe circulating system, a rotating control device, a UBD
choke manifold (not the rig’s well control choke
manifold), a separator and a flare stack or flare pit.
Milligan et al provides an excellent description of the
surface separation system and its functionality6. In
addition, non-return valves (NRV’s) are installed in the
BHA and drill string to prevent back-flow up the DP. As
3
in conventional overbalanced drilling operations, the rig’s
BOP’s are still considered as secondary well control
equipment.
Underbalanced Drilling Well Control Incidents
Kicks are classically defined as “unexpected flow” from
the well. Any flow from a conventionally drilled well is
unplanned therefore is treated as a kick. On the other
hand, the primary objective of underbalanced well
control is to prevent the well going overbalanced
therefore flow is planned. In a UBD planned well, we
define the system’s kick tolerance and have the unique
ability to manage kicks by proper sizing and rating of
surface equipment. During normal UBD operations,
drilling with the bit on bottom, well control is readily
managed by the 4UBD system that is designed to
handle both normal and abnormal flow. If a kick
(“unexpected flow”) is taken, which implies flow
parameters of pressure, rates and or temperatures are
outside of the normal UBD design envelope, both
procedures and capability are in place to bring the flow
parameters back within the design envelope.
Underbalanced kicks can be caused by a number of
conditions; reservoir permeability higher than expected,
reservoir pressure higher than expected and or poor
control of choke or injection parameters7.
High temperatures encountered in some UBD wells
require particular attention, similar to that given to HTHP
well equipment. Surface temperatures can be very high
on UBD wells having high flow rates and bottom hole
temperatures and measures are required to safeguard
elastomers in the BOP and surface flow control systems
and may require alternative seal designs.
Whatever the cause, the primary indicator of a kick in an
underbalanced drilling operation is increased flow rate7.
• Higher permeability than expected will result in a
higher flow rate.
• Higher reservoir pressure than expected leads to a
higher differential pressure (drawdown) relative to
the target bottom hole drilling pressure, which
results in a higher flow rate and
• Similarly, poor choke control can result in lower than
planned target bottom hole drilling pressure, which
leads to a higher drawdown pressure, which in turn
results in a higher flow rate.
Secondary kick indicators in an underbalanced drilling
operation are:
• Increased choke pressure with no choke setting
change,
• Change in the bottom hole pressure with no change
in surface controls and
• Higher rates of penetration.
4 IADC/SPE 106367
The consequence of a well control incident during
underbalanced drilling operations can range from critical
to a non-event. Pressure and or temperature rating of
surface equipment can be exceeded, flow capacity of
surface equipment can be exceeded and there is an
increased risk of erosion failure at surface if conditions
outside the design envelope remain undetected for any
length of time. However, it should be stressed that in
UBD operations a continuous monitoring process is in
place and well control is readily re-established by closing
in the well, similar to conventional practice.
This emphasises why in the planning and design stages
of an underbalanced drilling project, both static and
dynamic multi-phase flow modelling is required and why
the reservoir parameters used in the models need to be
as accurate as possible. Multi-phase transient flow
modelling of the proposed close loop circulating system
during the planning and design phase will also ensure
the appropriate UBD system design. If the well has an
appraisal nature then suitable margins of error will need
to be incorporated into the design.
Proper design, safety factors and correct procedures
reduce the risk of exceeding the design envelope (the
kick tolerance so to speak) of the underbalanced drilling
equipment even when unexpected features such as
fracture permeability or drilling into a fault block with
virgin pressure, occur during the underbalanced
operation. Over the years Shell has developed UBD well
control processes and procedures in the course of
drilling over 400 wells both onshore and offshore. Some
of these have become standard accepted industry
practices. The UBD well control matrix illustrated in
Figure 3 is an example of one such process. It is a risk-
based approach relative to the basis of design for a
specific UBD project based on:
• Maximum temperature rating and flow capacity of
the surface system
• Pressure rating on the flow control equipment (up to
and incl. choke manifold)
• Erosion rates of the surface equipment (max drilling
gas rate)
• Maximization of the service interval for the RCD
• Casing design limits
It should be noted this matrix only applies while on-
bottom-drilling. During round trips different well control
factors need to be addressed and some of these are
discussed below.
Understanding the Hazards and Threats During UBD
In low-energy wells, unplanned events can be easily
controlled using conventional means and procedures
such as adjustment of liquid or gas injection rates to
reduce surface pressure or by shutting in the emergency
shutdown (ESD) valve or BOP’s in an emergency. In
high-energy wells, extreme care is needed to ensure
conditions are known, or sufficient margins of safety are
included, so that during the execution of operations the
design envelope is not exceeded and that controls are in
place to mitigate the consequences of uncertainty.
Therefore, it is critically important to understand the type
of well to be drilled before operations begin and then
plan accordingly.
To assist with understanding the risk potential of all wells
drilled using underbalanced techniques, the IADC has
adopted a classification system. Details of the
classification system, as well as well as examples of its
use are available on the IADC UBO Committee website8
and are not repeated here. A brief excerpt from the
website is however provided as an introduction to the
system. “The purpose of the IADC Well Classification
System is to describe the overall risk application
category and fluid system used in underbalanced
operations (UBO) and managed pressure drilling (MPD).
Wells are classified according to:
• Risk Level (0 to 5)
• Application Category (A, B or C)
• Fluid System (1 to 5).
The classification system provides a framework for
defining minimum equipment requirements, specialized
procedures, and safety management practices”.
During the planning of an underbalanced drilling
operation, hazard identification and operability exercises
are recommended. During these exercises many
hazards will be identified and it is very important that
each and every one receive adequate consideration to
ensure effective control during the execution phase.
Many of the hazards identified will be common to other
activities of an exploration and production (E&P)
Company and or the Drilling contractor and should
already be identified and addressed in the appropriate
hazard registers. However, a few new hazards are
introduced in a UBD operation. These generally relate to
the change in primary well control barrier philosophy,
which results in drilling with pressure at surface, the use
of drilling fluids such as condensate, low flash point
crude etc. and flowing while drilling and tripping, in
combination with other simultaneous operations.
Depending on the nature and classification of the
operation, other safety and training related issues
9
described in the IADC UBO HSE Planning Guidelines
and other papers on the subject 1, 10
will emerge and have
to be addressed.
Underbalanced Operations
As indicated before, underbalanced drilling is different,
but not unsafe. Anyone can drill underbalance, but it
takes good planning, engineering and attention to details
to safely drill underbalanced. Figure 4 illustrates some of
the key areas that need to be addressed depending on
the specifics of the project.
IADC/SPE 106367
Well Control Barriers
In most of the areas where oil and gas E&P activities
occur, company policy, legislation or regulations
stipulate well control barriers required. These are
generally of the form:
• “All planned well operations shall normally be
executed under the protection of two independent
barriers between reservoir and environment, in order
to prevent an unintentional flow from the well.
Should one barrier be lost then the focus of
operations shall divert to regaining two-barrier
status”.
It is good practice to develop barrier matrices or
diagrams for safety critical underbalanced drilling,
tripping, completions and work-over operations. Figure 5
is an example of a barrier matrix used by Shell1. Another
good example is the approach required by NORSOK11
and illustrated in Figure 6.
The primary well control barriers introduced to enable
underbalanced drilling are the rotating control device and
the drilling non-return valve.
Rotating Control Device
The RCD is defined as a drill through device with a
rotating seal that contacts and seals against the drill
string (drill pipe, casing, kelly etc.) for the purpose of
controlling the pressure or fluid flow to surface. There
are three types of RCD systems; passive systems,
active systems and Hybrid systems12. The passive
system depends on a friction fit between the drill pipe
and the rotating pack-off and well bore pressure to affect
a seal. The active system RCD uses hydraulically
actuated packing elements to seal around the drill pipe.
The hydraulic closing pressure can be varied
automatically as the well-bore pressure varies. The
hybrid system combines a passive element and with an
active element and hydraulic closing system.
Catastrophic RCD failure can result in an uncontrolled
release of hydrocarbon fluids to surface. To ensure this
does not occur proper sizing and selection of the
equipment, appropriate to the well classification, is
critical. In addition, recognition that the RCD packing
element is a consumable product, operational
constraints suggested in the UBD well control matrix
illustrated in Figure 3 and good operational practices
specifically related to the RCD will ensure a proper
maintenance schedule is followed and elements are
replaced well before a catastrophic failure occurs. An
example of a good practice is the preparation of an
operating envelope for the RCD, which addresses:
• Stripping including pressure, speed, and the
maximum allowable amount of pipe to be stripped.
• Rotating pressure and the maximum allowable
rotating hours.
5
Non-return Valve
The drilling NRV is a type of back pressure valve
installed in the drill string that provides positive and
instantaneous shutoff against high or low differential
pressure from below thus ensuring continuous control of
fluid flow from the drill string during underbalanced
drilling or conventional drilling operations13. There are
different types of NRVs used in UBD operations; flapper
design, dart design, a ball design and a pre-charged
pressure actuated piston design. Selection of the NRV
type is project specific, but in general the flapper design
and the dart design are most used. There are also wire-
line set and retrieve, NRVs available.
Failure of the NRV in the drill string, a leak or a drill
string failure, above the NRV can also potentially result
in an uncontrolled release of hydrocarbon fluids to
surface. However, proper design, including back-up in
the drill pipe, string positioning, QA/QC inspection
procedures, specific operating and maintenance
procedures for critical tools and equipment used in
underbalanced operations have been shown to mitigate
the risk of failure1. Likewise, having written procedures
or decision trees that leads to problem identification and
appropriate problem resolution will mitigate the risk of
lost drill string integrity escalating into an uncontrolled
release of hydrocarbon fluids to surface.
Multi-Lateral UBD Wells
It cannot be stressed enough that in order to safely
conduct an underbalanced drilling operation the well
design for the drilling phase is critical. For example UBD
is primarily targeted at horizontal wells, but multilateral
underbalanced wells are also drilled. While at first glance
this may not appear relevant to well control it can have
significant impact and for this reason it is briefly touched
on here.
Multilateral underbalanced wells present their own
challenges compared to single underbalanced laterals,
especially on gas wells. Understanding and planning for
near-well-bore-depletion will enable the 2nd leg to be
drilled without negatively impacting the operation from a
well control perspective and or the objectives of drilling
underbalanced.
To reduce the risk of losses occurring in Lateral #1 while
the 2nd lateral is drilled considerations for plugging the
top of Lateral #1 should be included in the planning and
design of the well. In addition to the potential for losses
in leg #1, to drill underbalance in leg 2 with leg 1 open
may require higher drawdown capability in the circulating
system design. This can lead to significant hydrocarbon
flows at surface, potentially exceeding the design
envelope of the equipment. This can potentially impact
not only the equipment design, but in an offshore well it
may impact the rig’s safety case and ultimately could
lead to an early TD of the well and a negative impact on
the well objectives.
6 IADC/SPE 106367
Finally, in the event of an emergency kill operation,
experience has shown that having multiple legs open
can complicate the kill operation. Procedures for killing
gas filled multilaterals need to be carefully thought out
and modelled during the planning phase to ensure safe
execution if and when required during the execution
phase.
Round Trips
During round tripping the same control systems are in
place as in on-bottom UBD operations, but the potential
for an uncontrolled release of hydrocarbon fluids does
not disappear. In addition to failure of RCD and the NRV,
the following activities could potentially release the
hazard and lead to an incident or event
• BHA recovery when the “closed loop” cannot be
maintained.
• Ineffective (inadequate) barriers in place to enable
safe removal and or installation of the wellhead and
or BOP
• The primary and/or secondary well control
equipment is rendered dysfunctional due to the
complexities of the completion string being run or
pulled.
Whether tripping pipe with the well flowing or shut in,
there is a point in wells under pressure, where a “pipe
light” situation will exist. This occurs when the force
inside the well-bore acting to push the string out, is
greater than the force acting to keep it in the well bore (a
combination of the weight of the drill string and friction at
the RCD). This will be the case, for instance, on non-
depleted gas wells and oil wells. The following options
are available to manage pipe light conditions while
tripping:
1. Reduce surface pressure by flowing the well
while tripping – if pipe light is not possible or is
not a concern.
2. Utilize a push-pull machine, a, snubbing unit or a
down-hole isolation valve (DIV).
Retrieval of the BHA presents the next challenge
requiring proper pre-planning. In addition to the pipe light
scenario, previously discussed, the BHA must be
retrieved above the rotary table while the integrity of the
closed loop system is maintained.
The options to deal with this situation are:
1. Push-pull machine or snubbing unit for pipe light
situation.
2. Downhole Isolation Valve (DIV) for pipe light
situations and closed system retrieval of the
BHA, or if a DIV is not available
3. Lubricate the BHA above the blind rams.
Pre-perforated liners and sand screens can also be
deployed in a UBD well; the use of a DIV or an inflatable
bridge plug, have enabled this to be safely accomplished
on a number of wells.
On depleted oil wells, pipe light while tripping is readily
addressed, and is usually not a concern.
Concentric Casing
Commonly used in low energy reservoirs for gas
injection, concentric casing (CC) string wells require
some attention since it may not be possible to maintain
closed-loop system integrity due to the complexity of the
string design. In this case a bridge plug, plugged packer
assembly or a packer and Formation Isolation Valve
(FIV) assembly will need to be run and set below the
concentric string to isolate the reservoir prior to tripping
the CC string out of the hole. Figure 7 illustrates an
example of the well design considerations for retrieval of
the concentric casing string without having to kill the
well.
Workover - Wellhead and BOP Removal etc.
Apart from drilling and round tripping, it can be expected
that during the life of a well, interventions will be required
to sustain or optimize production rates. Therefore, it is
important to recognize the hazards inherent in wellhead
and BOP removal, installation and subsequent handling
of completion equipment and accessories. This may
require additional barriers to be put in place. To lock in
the value of underbalanced drilling it is necessary to
consider the completion and future work-over in the
upfront planning and well design to mitigate killing the
well or exposing the formation to non reservoir fluids.
Figure 8 illustrates some of the complexity of the
completion that must be considered.
Formation isolation systems are available that will allow
future work-over to be conducted without exposing the
formation to potentially damaging work-over fluids1.
These tools have a common theme; a sump packer run
below the completion but above the reservoir. They
automatically prevent back-flow to the reservoir as soon
as flow from the reservoir ceases. They are retrievable
either as an assembly utilizing underbalanced tripping
procedures or with the completion string in an
overbalanced condition, but without exposing the
formation to potentially damaging work-over fluids.
UBO Well Control Training
IADC WellCAP® UBO Well-control Certification is
available from a number of accredited schools. This
training programme emphasizes flow control utilizing
different equipment and procedures from conventional
drilling operations. Underbalanced Operations
WellCAP®, is aimed at training the well-site supervisors
to ensure that conventional well control thinking and
procedures do not compromise UBD well objectives9.
Information on accredited schools can be obtained from
the IADC.
Conclusions
• With proper planning and execution, well control in
underbalanced drilling operations can be readily
managed.
IADC/SPE 106367
• Tripping the drill pipe and the BHA from a “live well”
does present some special problems, but specialized
equipment, procedures and training have been
successfully developed and used to manage the risk
to an as low as reasonably possible (ALARP) level.
• Recovering a concentric injection string, running and
retrieving completion equipment and the removal
and installation of BOPs and wellhead equipment
without loading the well with potentially damaging
fluids all present additional challenges, but
specialized completion equipment is available to
overcome these challenges.
• Designing the well for a full underbalanced
(reservoir) well life cycle increase the value of the
asset.
• Underbalanced Drilling Well Control Training
available to the industry, includes certification to an
industry acceptable Standard.
Many safety-related studies and research projects
relative to UBD have been conducted. The depth of
investigation and the quality of work present in these
studies and reports, indicate that safe and cost effective
management of UBD in high-pressure oil/gas reservoirs,
whether onshore or offshore is possible. UBD operations
involve more equipment, more people and significantly
different operations from conventional drilling, which
translates into potentially higher risk9. However,
enhanced safety is a result of proper planning, hazard
assessment and risk mitigation combined with the closed
circulation system employed as confirmed by UBD’s
excellent HSE record to date.
Therefore from an equipment point of view, it is a
reasonable expectation for other MPD techniques
utilizing a closed system, that faster kick detection
will result in reduced influx rate and volume and a
faster killing operation, which potentially should
reduce the risk of on-bottom-well-control incidents
escalating into surface or subsurface blowouts.
However, unlike UBD in the reservoir where
hydrocarbon flow is expected and is generally not an
issue for well control, much work remains to identify
the new hazards introduced, to understand and
quantify the associated risk and to develop and test
safe work practices and procedures.
Nomenclature
BHP = Bottom Hole Pressure
DAPC = Dynamic Annular Pressure Control
CCS = Continuous Circulation System
CCV = Continuous Circulation Valve
Acknowledgements
The authors would like to thank Shell E&P International
for permission to publish this paper and to acknowledge
the work of the Shell UBD Team in EP Europe, the Shell
7
UBD Global Implementation Team and the many
industry partner companies, who together have been
instrumental in developing many of the processes and
procedures referred to in this document. The authors
would also like to acknowledge the efforts of the IADC
UBO Committee and the many volunteers involved, for
their commitment to promoting the safe and efficient
execution of underbalanced operations worldwide and
sharing the vision that “all wells should be drilled
underbalanced unless there are substantiated reasons
for not doing so.”
References
1. Ramalho, John, Shell E&P Limited, UBD Global
Implementation Team, Davidson, Ian A., Shell E&P
Limited, UBD Global Implementation Team: “Well
Control in Underbalanced Drilling Operations - Life
Cycle Philosophy”, This paper was presented at the
IADC World Drilling 2004 Conference held 1-2 July,
2004 in Dubrovnik, Croatia.
2. Ramalho, John Shell E&P Limited, UBD Global
Implementation Team: “Underbalanced Drilling In The
Reservoir, An Integrated Technology Approach”,
paper SPE-103576 was prepared for presentation at
the 2006 SPE Russian Oil and Gas Technical
Conference and Exhibition held in Moscow, Russia,
3–6 October 2006.
3. Underbalanced Drilling Manual, Published by the Gas
Research Institute, Reference No. GRI-97/0236
4. SINTEF Offshore Blowout Database,
http://www.sintef.no/content/page14649.aspx
5. Schubert, Jerome J., Texas A&M University, Well
Control Perspectives of MPD and UBO, 2006
IADC/SPE MPD-UBO Conference, 28-29 March,
Galveston Texas, USA
6. Milligan, M.R., SPE, et al.: "Coiled-Tubing Drilling of
Horizontal Sidetrack in House Mountain Field,
Alberta", paper SPE 35127, first presented at the
1996 IADC/SPE Drilling Conference held in New
Orleans, 12-15 March.
7. Blade Energy Partners “Underbalanced Drilling Well
Design Course”
8. http://www.iadc.org/committees/underbalanced/index.
html
9. IADC UBO Committee: “Underbalanced Drilling
Operation – HSE Planning Guidelines,” IADC
Publishing 2003
10. Jansen, Sjors et al: “Safety Critical Learnings in
Underbalanced Well Operations”, paper SPE/IADC
67688 was prepared for presentation at the
SPE/IADC Drilling Conference held in Amsterdam,
The Netherlands, 27 February-1 March 2001.
11. NORSOK (Norsk Solkels Konkuranseposisjon)
Standards are developed by the Norwegian
Petroleum Industry.
12. Specification for Drill Through Equipment – Rotating
Control Devices, API Specification 16RCD, First
Edition February 2005
13. Specification for Drill String Non Return Valves, API
Specification 7NRV, First Edition July 2006
8 IADC/SPE 106367

Figure 1 - Graphical Illustration of the "Drilling Window"

2
Depth (thousands feet TVD)

Pore Press ure

Frac
G radien t
Gradient
4

Drilling Window

9 ppg 10 11 12 13 14
10
0 1 2 3 4 5 6 7
Pressure (thousands psi)

Figure 2 - UBD Closed-loop Circulating System

Flow
4-Phase Separation Unit

Drill
Oil Fluid Solids
Solids
Flare System
UBD Geological
Sample Manifold

UBD Flow Control

Manifold

Oil Storage
and Shipping
Rotating Control
Device
Flow Spool
ESD and Gate
Annular Preventer
N2 Storage Valves
Pipe Ram
Blind / Shear Ram
Kill Spool

N2 Pumpers
Non Return Valves
Rig Well Control
Manifold
Drill Fluid Storage
By-Pass
Liquid Pumps
Re to Flare
se
rvo
ir F
or
ma
tio
n
IADC/SPE 106367
Figure 3 – Underbalanced Drilling Well Control Matrix
Range 1 (Min1 - Max1)
SURFACE FLOW RATES (unit/day)
Range 1
Optimum
(0 - Max1)
Adjust system to increase BHP:
Range 2 · Increase liquid injection rate
(Max1 - Max2) · Decrease the gas injection rate
· Increase the surface back-pressure
Stop drilling, pick-up off bottom:
Range 3 · Increase liquid injection rate and
(Max2 - Max3) · Decrease the gas injection rate
· Increase the surface back-pressure
> Max3 Shut-in well with BOP's
Figure 4 – Well Design Drilling Phase
Wellhead Flowing Pressure (unit)
Range 2 (Max1 - Max2)
Adjust system to decrease WHP:
· Increase liquid injection rate or
· Decrease the gas injection rate
Stop drilling, pick-up off bottom:
· Circulate and work drill string
· Increase liquid injection rate and
· Decrease the gas injection rate
Stop drilling, pick-up off bottom:
· Circulate and work drill string and
· Increase the surface back-pressure
· Monitor well parameters until stabilized
Shut-in well with BOP's
9
Range 3 (Max2 - Max3) > Max3
Pick-up off bottom, stop rotation:
· Circulate with increasing liquid rate Shut-in well
· Decrease the gas injection rate and with BOP's
· Monitor well parameters until stabilized
Pick-up off bottom, stop rotation:
· Increase liquid injection rate and Shut-in well
· Decrease the gas injection rate with BOP's
· Increase the surface back-pressure
Pick-up off bottom, stop rotation:
· Circulate with higher density mud Shut-in well
and adjust the gas injection rate with BOP's
· Monitor well parameters until stabilized
Shut-in well
Shut-in well with BOP's
with BOP's
10 IADC/SPE 106367

Figure 5 – Underbalanced Operations Barrier Matrix

Figure 6 – Example of Norsok Well Barrier Diagram

IADC/SPE 106367 11

Figure 7 – Preparation for Retrieval of Concentric String

Figure 8– Well Design Considerations Production Phase