SPE/IADC 168946

Planning Managed Pressure Drilling With Two-Phase Fluid in a Depleted

Reservoir
Martyn Parker, Jelle Wielenga, and Vladimir Bochkarev, TAQA; Isabel Poletzky, SPE, Mark Juskiw, and Saad
Saeed, Halliburton

Copyright 2014, SPE/IADC Managed Pressure Drilling and Underbalanced Operations Conference and Exhibition

This paper was prepared for presentation at the SPE/IADC Managed Pressure Drilling and Underbalanced Operations Conference and Exhibition held in Madrid, Spain, 8-9 April 2014.

This paper was selected for presentation by an SPE/IADC program committee following review of information contained in an abstract submitted by the author(s). Contents of the paper have not been reviewed
by the Society of Petroleum Engineers or the International Association of Drilling Contractors and are subject to correction by the author(s). The material does not necessarily reflect any position of the Society of
Petroleum Engineers or the International Association of Drilling Contractors, its officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written consent of the
Society of Petroleum Engineers or the International Association of Drilling Contractors is prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300 words; illustrations may not
be copied. The abstract must contain conspicuous acknowledgment of SPE/IADC copyright.

Abstract
The Bergermeer Rotliegend sandstone reservoir has been depleted by production. This has substantially reduced reservoir
pore pressure and well deliverability. Pressure depletion has been accompanied by an expected decrease in minimum in-situ
stress, resulting in a substantially sub-hydrostatic drilling fluid density being required to enable drilling. As a result, Managed
Pressure Drilling (MPD) using two-phase fluid has been chosen as the enabling technology for drilling and completing initial
wells for the Gas Storage Bergermeer Project.
MPD for the Bergermeer wells is defined as the use of two-phase flow of drilling fluid including nitrogen injection via a
tieback casing to maintain bottom hole pressure (BHP) below the anticipated reservoir minimum in-situ stress at a long hole
depth. Application of MPD technology in the Gas Storage Bergermeer Project will allow drilling the planned boreholes
without exceeding minimum in-situ stress, minimizing the risks of differential sticking and drilling fluid losses if natural
fractures are present.
Reservoir pressure in the Rotliegendes reservoir was originally 238 bar (3451 psi) at 2100 m (6890 ft) subsea. By mid-
2009, gas reinjection was started to bring the reservoir up to an operating pressure of 133 bar for gas storage operations. By
May 2013, the time of drilling the 1st of the new gas storage wells into the Bergermeer reservoir, the formation pressure had
been brought up to 81 bar in block 1 and 35 bar in the adjacent block 2.
Due to permitting restrictions, it was not possible to drill a test/pilot well before drilling the first gas injection/production
wells to physically determine formation rock strength. Therefore a decision was made to drill into the 81 bar reservoir with a
target BHP of 117 to 127 bar; this equated to an equivalent circulating density (ECD) of 0.57 to 0.63 SG. Two wells were
drilled during MayJune 2013, one S-shaped vertical well in block 1 and one horizontal well into block 2. This was achieved
maintaining a constant BHP within the predetermined window using MPD with gasified fluid; in reality it was possible to
drill the wells with a very stable BHP with a 0.6 SG ECD. Dynamic formation integrity tests (FIT) were performed to
determine the formation rock strength in a controlled manner using two-phase MPD techniques at predetermined depths in
the reservoir; results indicated that rock strength was adequate for using conventional drilling techniques. Despite the
successful implementation of MPD, future wells will be drilled conventionally although MPD could deliver the wells should
the formations turned out to be weak, and it remains as an important contingency in case formation strength turns out to be
weak in future wells.
For the Gas Storage Bergermeer project, significant planning into the overall system design, equipment selection,
techniques, procedures and training lead to an operation where precise control of the annular pressure profile was achieved
and maintained throughout the operation. This paper documents the key planning considerations required to drill and
complete a highly depleted reservoir using two-phase MPD techniques.

Introduction
The Rotliegendes reservoir is Permian, and consists of well-sorted, fine-grained Aeolian sandstones. The average thickness of
the reservoir is approximately 200 m. Porosity is generally high, ranging from 15 to 30%, and averaging 23%. Vertically, the
best porosities occur in the middle part of the reservoir, with generally lower porosity in the upper portion in the
Weissliegendes facies. Horizontal and vertical permeability is generally high, with 300 and 200 MD, respectively. A number
of thin low-porosity streaks occur throughout the reservoir. The upper and side reservoir seals are provided by Zechstein
evaporites.
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The Weissliegend, the upper formation of the reservoir, is better cemented but is less permeable than the Rotliegend,
which attributes to greater rock strength. The formation permeability also favors the horizontal plane over the vertical. There
are two sections of the reservoir that slant, therefore the water cut level is below both formations in the 1st section but
traverses up into the bottom formation Rotliegend in the 2nd section. With these factors in mind, the 1st section wells are
planned to be S-shaped and the wells in the 2nd section will be horizontal in the stronger Weissliegend.
The Bergermeer Rotliegend sandstone reservoir has been depleted by production. This has substantially reduced reservoir
pore pressure and well deliverability. Independent studies into the field depletion indicated that there was a high potential for
a decline in the minimum in-situ (fracture closure) stress in the Rotliegendes reservoir, requiring sub-hydrostatic ECD fluids
to be used to avoid drilling fluid losses to the formation.
Uncontrollable mud losses resulting from a mud with a density such that it cannot adapt to MPD techniques could result
in consequences ranging from compromising sand face completions, to complete loss of an expensive wellbore. FITs were
performed, to prove or disprove the possibility of reservoir stress rebound, and plans for drilling future wells can be made
accordingly.
The location of the wells was in a semi-urban setting between the towns of Bergen and Alkmaar requiring extra
precautions with regards noise and light to accommodate the proximity to the local population and limit disruption to the
environment (Fig. 1).

Fig. 1Geographic Location (Source: Google Maps).

Background
The MPD objectives were to drill into the depleted Bergermeer formations (2100 m to 2200 m TVD) with a sub-hydrostatic
ECD fluid and to maintain a desired bottom-hole pressure (BHP) between 117 to 127 bar (the fracture reopening pressure).
This required a two-phase mud system, nitrogen and oil-based mud system, which yielded an ECD of 0.54 to 0.63 SG.
It is worth noting that an ultra-low density mud system using hollow glass spheres had been evaluated for this project,
however field trials in nearby wells found that a 0.90 SG OBM system could be reduced to a 0.78 SG density. However, as a
dynamic system, the achievable ECD was 0.90 SG as proven by a field trial in similar nearby well.
Regarding the drilling fluids selected for drilling the reservoir sections, the drilling mud that appeared likely to offer the
best overall performance was synthetic oil-based mud (SOBM). It appeared to have the least impact on formation damage,
and minimized the risk of foaming in a nitrified mud system.
Formation evaluation was critical for the project, and historically, two-phase flow has been detrimental to conventional
Measurement While Drilling (MWD). To maintain a viable MWD system, a parasitic injection string was designed so that no
nitrogen would be pumped down the drill pipe string. This design also allowed the use of a Pressure While Drilling (PWD)
tool, which aided in providing early detection of fluid losses.
To achieve stable BHP conditions in a two-phase MPD system, it was clear that the overall system would benefit
significantly from uninterrupted injection of both nitrogen and drilling mud. Thus, a continuous circulation system was used
making it possible to maintain continuous mud pump rates for the drilling operations from start of reservoir to TD. The
continuous circulating system also allowed for trips while pumping back into the shoe with nitrogen injection.

Defining the MPD Parameters

Normally, MPD is thought of as a single-phase system and many would argue that the introduction of nitrogen, a
compressible gas, to the system reduces the level of control. Past operations similar to this have been termed as Low-Head
Drilling operations.
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However for the Gas Storage Bergermeer project, significant planning into the overall system design, equipment
selection, techniques, procedures and training lead to an operation where precise control of the annular pressure profile was
achieved and maintained through out the operation. This paper details this planning process in the following sections.
While MPD drilling the 8-1/2 in. reservoir sections in Block 1, or the 6-1/8 in. reservoir laterals in Block 2, nitrogen was
added primarily by tieback annulus injection. Addition of nitrogen resulted in fluid density reduction such that BHP did not
exceed reservoir minimum in-situ stress. Mud pump rate, nitrogen injection and the geometry of the bottom hole assembly
(BHA), drill string and A annulus (drill string x liner-tieback annulus or the drill string x production casing annulus),
determined BHP and hole cleaning parameters.To determine whether it was possible to use a single-phase fluid, it was
necessary to quantify the change in reservoir stress. This was most useful if there were natural fractures in the reservoirif
no fractures existed, test pressures were not high enough to initiate fracturing.
Repressurization will bring the reservoir pressure into the recommended BHP operational envelope towards the end of the
current drilling schedule. Multiphase simulation runs were made to determine flow combinations of drilling fluids (both
SOBM and water-based mud (WBM)) and nitrogen gas, in the various possible hole sizes, with a variety of drill strings, but
all aimed at achieving a maximum BHP of 127.6 bar (1850 psi).
Fluid levels were carefully managed during tripping, since they were substantially below surface. Briefly, it was proposed
to use a 97 to 131 bar (1400-1900 psi) BHP operational envelope, as periodic unloading of the A annulus was required on
trips in the hole. This 97-131 bar BHP operational window was also the target for sand face completion operations. Note
initial assumption was formation pressure of 81bar (1175 psi). It was conventional practice to include a 13.8 bar (200 psi) trip
margin. In order to drill and trip as recommended, the designed MPD operations cannot proceed past the point where
reservoir pressure rises to 103.4 bar (1500 psi).
Performing FITs was recommended to determine whether reservoir stresses were changing. With significant
improvement, determinations could be made as to when use of a single-phase SOBM would be appropriate. If there is no
rebound, planning should commence for consideration of stress cage or other drilling fluids, which contain additives to seal
porosity and fractures, which may allow drilling and other operations at higher bottom hole pressures.

Basis for MPD Well Design Optimization

MPD design for Bergermeer was based primarily on the requirement for a maximum of 127.6 bar (1850 psi) bottomhole
circulating pressure and adequate bottomhole hole cleaning to remove drilled cuttings from the wellbore.
Initial multiphase simulator runs aimed at simply achieving the target maximum BHP of 127.6 bar (1850 psi). Once a
combination of mud pump rate and nitrogen injection arrived at a satisfactory BHP solution, annular liquid velocity was next
considered. Minimum acceptable annular liquid velocities of 45.7 m/min (150 ft/min) in vertical and low-inclination holes,
and 54.9 m/min (180 ft/min) in high-angle and horizontal wellbores are used.
Injecting additional nitrogen had a minor effect on liquid velocity. Nitrogens main influence was in reducing the
effective density of the drilling fluid. With the low BHP, these wells could not accommodate higher liquid rates without
exceeding the design pressure limit.
For a constant mud pump rate, annular BHP at the bit initially decreased as nitrogen gas was introduced into the system.
This hydrostatic pressure reduction was gradually offset by increasing fluid flow friction and decreasing liquid fraction in the
fluid. This portion of the curve is referred to as being hydrostatically dominated, and is prone to slug flow.
Computer modelling for Bergermeer indicated slug flow was going to prevail in most situations, with (typically) discrete
flows of liquid with lower wellhead pressures, followed by discrete gas flow and higher wellhead pressures. The MPD
manifold had a programmable choke, which assisted in maintaining a stabilized wellhead pressure.
Liquid pumping rate was an important factor in the control and magnitude of the two-phase BHP. Small changes in pump
rate resulted in significant changes in BHP specifically for the 6.125 hole section in the horizontal wells. It was also found
that the 8.5 in. sections had a greater tolerance to change of the mud flow rates. The effect of a single phase flow on the BHP
clearly demonstrated the importance of using a continuous circulation system.
Other factors that were considered with respect to the annular BHP of a circulating system using tieback nitrogen
injection were the drill string connections. Normal connections involve stopping circulation, which interrupts the steady state
flow of a two-phase system and cause significant pressure transients or pressure spikes. If conventional connections were
made, nitrogen and the liquid drilling fluid would phase-separate in the A annulus, and a period of circulation would be
required to re-stabilize flows and BHPs prior to resuming drilling. To avoid this issue and its associated non-productive time,
use of in-string continuous circulation subs were included into the plan.
Use of continuous circulation subs maintained circulation during connections, keeping BHP constant. They also avoided
pressure variations associated with re-establishing two-phase circulation. This also assisted in not worsening any hole
instability which could have developed.
Two-phase Hydraulics Flow Modeling
Two-phase circulation for MPD is complex with no linear relationships, due to the compressive nature of the injected
nitrogen in the circulation fluid. To account for this complexity, a computer simulator must be used. For Bergermeer, two-
phase hydraulics modelling simulations were run using steady state software and the results were then verified using a
transient two-phase hydraulics simulator. To validate results of the modelling, data was collected from two-phase flow during
a familiarization period, and this data was analyzed and used to calibrate the computer modelling.
4 SPE/IADC 168946

The steady state multiphase simulator predicts flow conditions for extended flows at the nominated rates and the
described geometric and fluid situations. It can predict changes which may occur in a wellbore if circulation conditions are
changed, but could not predict the dynamic changes between one circulation condition and another.
A transient wellbore hydraulics simulator that has been extensively used for Underbalanced Drilling (UBD) operations
was used, since it is also a valuable tool when used for MPD operations when gas injection is required. The physical and
mathematical basis of the transient simulator enables the user to investigate a wide variety of problems (both static and
dynamic) related to UBD operations.
In summary, the two-phase hydraulics modelling simulations indicated that it would be possible to reduce the hydrostatic
of the fluid system by introducing nitrogen to achieve the desired operating window. There was an initial slug related to the
start of gas injection in all the different hole sections for both wells but the effect on BHP was minimal. While the simulator
took into account this initial start-up condition, the actual drilling program included a staged pumping schedule to minimize
slugging and pressure spikes at start up.

Dynamic Simulation of Different Drilling Events

The modeling performed with the transient simulator for the 8-1/2 in. hole sections verifies the operating envelope of the
modeling performed with the steady state software. Again the main difference between the static modelling and the more
comprehensive dynamic flow modeling is that effects on flow parameters and pressures can be seen vs. time rather than just
as a snap shot at a given flow period as per the steady state. These results were interesting as the slug flow condition can be
reviewed in more detail. These results showed that after the initial two-phase MPD start up, the dynamic conditions stabilized
in a short time, thus having the ability to maintain both nitrogen and mud returns as separate discreet flow regimes led to a
very stable two-phase system where the effects of slug flow conditions could be minimized.
Transient wellbore hydraulics software was used to simulate the entire drilling process, especially the main events that
could result in a BHP being outside the required operating window. Fig. 2 shows some of the transient simulation results for
one of the two wells, where events such as start of nitrogen injection, simulated connections with different times for pump
offs to get the surface survey, and dynamic FIT can be observed.

Fig. 2 Results from the Transient Simulator.

Concentric Nitrogen Injection

The decision was made early in the planning phase to use concentric nitrogen injection (injection of nitrogen between the
outer casing and a preinstalled drilling liner) in favor of drill string nitrogen injection. Drill string nitrogen injection is
SPE/IADC 168946 5

considerably more efficient than injection of nitrogen higher up the well via concentric casing and although this technique
would have required less nitrogen there are simply too many disadvantages for using drill string nitrogen injection.
Due to the Bergermeer wells being designed as large bore with 9-5/8 in. completions for the high flow rate gas wells with
the need for injection and production capability, the Bergermeer wells required the use of a drilling liner to achieve suitable
hole cleaning velocities regardless of nitrogen injection location.
The disadvantages for drill string injection can be summarized as follows:
Injection of nitrogen via the drill string would have led to the requirement for specialized MWD tools, EM-
MWD (electromagnetic measurement whilst drilling).
Nitrogen injection via the drill string would have complicated the use of continuous circulating subs.
Nitrogen injection comingled down the drill string with drilling mud would have led to high velocities in the drill
string with the potential for localized erosion of drill string/BHA components.
Nitrogen injection would have required a change out of the rotary drilling hose to a nitrogen compatible one.

The use of concentric nitrogen injection had the following additional benefits:
Provided a suitable conduit to inject nitrogen on a continuous uninterrupted basis.
Allowed for the installation of a purpose-built nitrogen injection downhole choke assembly to ensure that the
nitrogen injection point was always maintained at a suitable differential pressure to prevent U-tubing from the
drilling annulus to the concentric casing annulus during MPD operations.
Allowed for installation of a surface read out real-time downhole pressure gauge to control BHP.
Ensured that the two fluid streams where separated thus allowing for use of the continuous circulation subs.
The nitrogen injection requirements and availability were a critical factor in defining the two-phase MPD requirements.
As a part of an overall system, it was found from the hydraulics modelling that rates up to 4000 to 5000 scf/min would be
required for concentric nitrogen injection.

Measurement Whilst Drilling (MWD) BHA Configuration

As previously stated, the MWD section of the BHA was not subjected to nitrogen flow either from the inside or the outside of
the tools as the MWD tools were always below the nitrogen injection point whilst drilling. The main considerations therefore
for MWD/BHA selection essentially centered on the following points:
MWD tool selection for reduced mud flow rates.
MWD tool selection/configuration for minimal drilling pump rate changes for communication and downlinks.
MWD tool porting/restricted orifice to achieve suitable standpipe pressure and minimize the effects of U-tubing
drill pipe to drilling annulus.

Suitably Applied Surface Back Pressure

To have a suitable degree of control on the BHP, it was necessary to manipulate the annular pressure profile (operating
window) and this could only be achieved with a suitably applied surface back pressure (ASBP).
All adjustable choking devices have a control range which is referred to as the Cv range (flow coefficient or flow capacity
range). For the two-phase MPD planning on Bergermeer, the flow capacity of the choking devices was a critical issue that
had to be reviewed using specialized process engineering software. Simply put, the combined flow of comingled drilling mud
and nitrogen returns had to be controlled by the MPD automated choke manifolds at very low pressures of 4 to 14 bar (60 to
200 psi):
Drilling mud rates required for suitable hole cleaning and the BHA 950 to 1000 lpm (250 to 260gpm)
Nitrogen rates required 4000 to 5000scf/min
Drilling mud density of 0.9 SG
Two-phase hydraulics modelling indicated that the desired ASBP range required would be 4 to 14bar (60 to
200psi).
A typical 3 MPD drilling choke has a Cv max. range of 120
The above combination is the worst possible situation: relatively high comingled flow rate with a relatively low operating
pressure to be controlled by a proportionally small Cv operating window.
The specialized process engineering software identified that to control the ASBP with the required MPD parameters then
the throughput of the system had to be designed so as not to create surface flowline restriction that would create a very high
surface pressure, yet allow the required ASBP to achieve the desired MPD BHP drilling window of 117 to 127 bar.
The process engineering software also identified that the surface flowlines upstream of the MPD choke manifolds would
have to be 8 flow lines, and that to use standard 3 MPD chokes, at least 3 X 3 MPD chokes in parallel would be needed to
drill 8-1/2 hole section with an ASBP of 4 bar (60 psi); above 7 bar (100 psi), 2 X 3 MPD chokes would be required.
The large ID flow lines also remained important to the separation system to be able to run the MPD 1st stage separator at
a minimum operating pressure of 2 bar (30 psi), required to ship drilling mud the distance from the separation package to the
rigs header box at an elevation of 4.5 m.
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With the contractual requirement for 100% system redundancy in the MPD chokes this meant that two full automated
MPD choke systems were required.

Description and Application of Equipment and Processes

In principle, the theory is simple enough. The drilling hydrostatic is reduced by introducing nitrogen into the drilling annulus,
the volume of drilling mud removed by the nitrogen is then controlled by application of ASBP (choking the return flow from
the drilling annulus), to precisely control the annular pressure profile. A full underbalanced separation system downstream of
the MPD choke manifolds was used to remove and safely vent the nitrogen from the drilling mud. The drilling mud with all
nitrogen removed from solution was then returned back to the rigs header box for processing as normal i.e., over the shakers,
centrifuges, and then back to the active mud pits. Fig. 3 shows a simplified MPD two-phase equipment overview, and Fig. 4
shows the rig location.
Some of the main considerations during the up front planning and engineering were:
Since MPD drilling procedures deviate significantly from conventional methods, it was required to perform
detailed equipment design reviews, Hazard Identification (HAZID), and Hazard and Operability (HAZOP) to
develop MPD procedures specific to the MPD equipment being supplied and the MPD operating window
available for the Bergermeer project. These procedures required activities in addition to conventional procedures
to properly manage a dynamic two-phase circulation system.
Development of MPD training courses to familiarize the operator, drilling contractor, mud loggers, and
MWD/DD personnel was performed in the months leading up to the 1st MPD operation.
Additionally there was an equipment commissioning, familiarization, and calibration process scheduled prior to
entering the reservoir to allow function testing of MPD equipment, including a surface control and separation
package, the Rotating Control Device (RCD), and nitrogen generation unit, to establish baseline monitoring
trends and to train crews.
An auditable process (NORSOK Z-MC-007) was used to check the MPD piping, electrical, and instrumentation
of the RCD, RCD, separator, nitrogen, and continuous circulation subs. Each item had an individual Mechanical
Completion Certificate (MCC) used to ensure the equipment was rigged up, installed, and functioned correctly.
All MPD equipment was signed off as per the MCCs and included all relevant pressure tests.
The process return lines from the RCD to the MPD manifold were exposed to flow of a mixed gas-liquid system
containing drilled solids. To monitor for erosion, it was recommended to use an Ultrasonic Thickness (UT)
meter to survey the flow lines periodically. A baseline UT survey was conducted once the equipment was rigged
in, and additional surveys were performed periodically to monitor for changes in the system.

Fig. 3Two-phase MPD System Overview.

SPE/IADC 168946 7

Fig. 4Rig Location.

MPD Equipment
The MPD equipment rigged up for the wells included (see Fig. 5):
Cryogenic Nitrogen Pumping Package
RCD
Emergency Shut Down (ESD) valve skids for primary and secondary flowlines
2 x MPD choke manifolds run in parallel
1st stage separator c/w pump and piping skid and spare pump
2nd stage pressurized knockout vessel
Coriolis metering skid
Silenced safe vent
Data Acquisition System (DAS) for automated ASBP control
Surface Readout Downhole Gauge (DHG)

Other critical equipment was:

Continuous circulation sub allowing for continuous circulation on connections
Downhole PWD sensor to provide real time at the bit BHP readings
Downhole nitrogen casing injection valve

Fig. 5 MPD Equipment Set Up.

8 SPE/IADC 168946

Environmental Considerations
During MPD operations, gases from the separation package were conducted to a vertical vent stack equipped with noise
silencer. A fit-for-purpose silenced, safe nitrogen vent system was designed to specifically meet the requirement for the
Bergermeer MPD project.
The exhaust stack was designed to accommodate the exhaust flow from two distinct streams, a pressure control valve and
a pressure safety valve. Two noise level requirements were specified, namely 70 dB(A) at 5 m and 50 dB(A) at 300 m and
the exhaust stack was located at three positions within the site. It was found that a silencer was necessary in the exhaust stack
to enable both the noise requirements to be met. It was found that the noise requirement to meet a sound pressure level of 70
dB(A) at 5 m from the vent stack was the governing condition.

Well Control
A consequence of two-phase circulation is a loss in well monitoring sensitivity. The presence of compressible two-phase
fluids requires trend monitoring analyses to interpret well status and identify well control events, as instantaneous surface
parameter readings cannot be used to interpret well status. Thus, conventional kick detection methods are no longer valid.
Fig. 6 details the MPD Operations Matrix and the actions to be taken by the MPD supervisor in communication with the
driller who is the designated focal point for all communication.

Fig. 6Bergermeer MPD Operations Matrix.

In a well control situation, no drilling or injecting of mud and nitrogen will immediately occur. If a well control situation
develops, then the rigs flowline and choke manifold, termed the secondary flow path, tested to 345 bar (5000 psi) should be
used. The secondary flow path has the rigs annular preventer closed and well flow is routed via the rig choke manifold. It
was recommended to perform an FIT to determine the BHP the well could competently hold for well control purposes.

Results
Since the predicted fracture gradient of the reservoir was relatively low, below 0.9SG (7.5 ppg), two-phase MPD was
selected to drill with a reduced BHP. FITs were used to determine if the depleted reservoir could withstand a column of
conventional drilling fluid.
The main objectives of the two-phase MPD were to: drill the wells and reach TD safely; have no recordable accidents, no
incidents; no major spills;maintain the BHP within a certain window as per requirements; test the fracture gradient of the
Weissliegend formation with a dynamic FIT to determine if the fracture gradient was high enough for future wells drilled
with one less casing string; test the fracture gradient of the Rotliegend formation with a dynamic FIT to determine if the
formation was suitable for single-phase drilling; successfully install the completion assembly while remaining below fracture
pressure and minimize NPT by reducing drilling problems such as losses and stuck pipe events.
A concentric casing string well profile was designed for these wells to inject nitrogen at a fixed point in the annulus in
conjunction with a continuous circulating system for liquid injection down the drill pipe, all to provide continuous circulation
and maintain a constant BHP throughout the drilling process.
SPE/IADC 168946 9

A tapered 7 in. x 9-5/8 in. concentric casing string was designed to facilitate higher velocities for hole cleaning and as
conduit to allow injection of nitrogen at a fixed point into the drilling annulus. This ability for continuous nitrogen injection
was supported by the ability to continuously circulate drilling mud down the string via subs incorporated into each stand of
the drill string giving an uninterrupted/separated circulating system for the two-phases (drilling mud and nitrogen) into the
wellbore.
This design of uninterrupted/separated two-phase circulation provides the ability to maintain a constant BHP throughout
the drilling process. The downhole gauge (DHG) was installed directly above the injection point to provide real-time
measurements of the pressure in the drilling annulus.
Two wells were drilled using the two-phase MPD techniques: BGM 24 and BGM 29, and the corresponding results are
summarized in the next paragraphs.

BGM-24
BGM-24 was drilled S-shaped with the portion below 1380 m MD continuing vertical. The maximum vertical section from
the surface position was 166 m. BGM-24 was drilled vertically with MPD successfully from 2072 m MD to TD at 2201 m
MD for a total of 129 meters of open hole.
Prior to MPD operations, a 9-5/8 in. liner was hung and cemented in the 13-3/8 in. casing with a top of liner (TOL) at
1640 m MD. The bottom of the liner was landed in the lower portion of the Weissliegend shale just above the Rotliegend at
2069 m MD.
Dynamic FITs were performed at 2090 m MD successfully testing the Weissliegend to 1.1 SG ECD for future casing
string requirements.
Dynamic FITs were also performed at 2127 m MD and 2201 m MD in the Rotliegend to 0.87 SG and 1.1 SG
respectively. The test that reached 0.87 SG has been determined to be inconclusive as the dynamic FIT was being performed
at a faster rate of closure before letting pressures stabilize.
The well pressures were controlled within 2 bar +/- of the BHP targets, either with manual choke operations or automated
choke pressure settings. The average ECD achieved for drilling this section was 0.61 SG (5.08 ppg).
At the end of drilling, the MW was down to 0.92 SG and nitrogen injection rates of 4,000 scf/min were required to
maintain BHP in the 117 to 127 bar target window with a mud pump rate of 950 lpm. At this time it was found that 2 of the 3
in. power chokes had to be opened to 80% with a resulting well head pressure of 6-7 bar (87 to 100 psi).
Figs. 7 and 8 show the stable MPD parameters for pressure and flow which were maintained through out the reservoir
drilling phase. At 13:45 a dynamic FIT was successfully performed to a 1.1 SG equivalent before returning back to MPD
parameters.

Fig. 7 Pressure Data MPD Two-phase Operations 11-05-13.

10 SPE/IADC 168946

Fig. 8 Flow Rate Data MPD Two-phase Operations 11-05-13.

BGM-29
BGM-29 was the second well drilled with MPD and the first horizontal well of the gas storage project. Prior to MPD the well
was kicked off near surface, built to a 68 angle and held f/ 2000 m MD t/3044 m MD between 63 and 68. The well was
kicked off a second time and built to 90 at 3377 m MD. BGM-29 was successfully drilled horizontally with MPD from 3377
m MD to TD at 3944 m MD for a total of 567 meters of open hole. The maximum vertical section from surface position was
2411.5 m.
A 9-5/8 in. liner was hung and cemented in the 13-3/8 in. casing with a TOL at 2171 m/MD 1796 m TVD. Within the 9-
5/8 in. liner a second 7 in. liner was landed at 2897 m MD/2091 m TVD. The bottom of the 7 in. liner was landed in the
Weissliegend sandstone at 3376 m MD/2207 m TVD.
This well differed from BGM-24 by using a dual-string concentric casing consisting of 2153 m MD of 9-5/8 in. casing
and 744 m MD of 7 in. casing to stab into the Polished Bore Receptacle PBR at the top of the 7 in. liner at 2897 m MD. This
was done to get the nitrogen injection point deeper into the well which was necessary to sufficiently reduce the BHP when
circulating in two-phase drilling operations. The nitrogen injection choke had been modified from lessons learnt on well
BGM 24 by having the internal sand screen and the check valves removed.
Prior to MPD, the well was drilled out conventionally 3m into the Weissliegend and a FIT was conducted to 1.15 SG with
0.9 SG MW. After the FIT, the concentric casing was partly displaced with nitrogen where a small amount of gas was
channeled into the drilling annulus. A bottoms up was circulated to the MPD system to remove the nitrogen and the hole was
partly filled to prevent further channeling.
The SOBM density peaked at 0.97 SG due to the inability to maintain a 0.9SG OBM with the correct solids profile during
the course of operations ; this resulted in an upper pressure limit of the MPD window being extended to 160 bar. Due to the
increase in mud weight, the original target BHP of 117-127 bar was changed to 130-135 bar and MPD operations were able
to maintain the required BHP. With the CaCO3 profile required for the reservoir, the mud weight could not be maintained at
0.9 SG and steadily increased from the accumulation of fine particles. The mud weight built to 0.94 SG and gradually rose to
a 0.965 SG at TD.
Fig. 9 shows that stable MPD parameters for pressure and flow were maintained from approximately 2:00 to 12:00; the 6
in. section was TDd at about 20:00. Fig. 10 shows that a dynamic FIT was successfully performed and the well was
subsequently bled off.
SPE/IADC 168946 11

Fig. 9 Pressure Data MPD Two-phase Operations 19-06-13.

Fig. 10 Pressure Data MPD Two-phase Operations 20-06-13.

Conclusions
Two wells were successfully drilled using MPD techniques with two-phase fluid. During drilling, the BHP was maintained
within the requested limits at all times. No major instances of pressure spiking, loss circulation, or well kicks occurred.
Due to the strength of the final FIT, MPD was not required for the completion runs. MPD crews and equipment remained
on standby until completion of a conventional FIT was successfully performed using the screen deployment fluid.
For further dynamic FIT operations prior to the start, the nitrogen rate should be lowered to increase the hydrostatic
pressure and reduce the ASBP on the RCD.
Throughout the operation the minimum controllable ASBP was maintained to conserve nitrogen use.
Specific monitoring equipment can greatly assist in trend monitoring. Trend monitoring of such variables as surface/down
hole annular pressures, active surface mud volumes, and standpipe pressures allow reasonable predictions of the two-phase
circulation system and well control events.
Computer simulations had been performed to investigate parameters for MPD operations. A DAS was installed to
monitor data throughout the MPD operations. Information was also collected by other means, downhole pressures, borehole
diameter and directional information was gathered and transmitted by the MWD tool in the BHA. Throughout the operation,
data was compared with modelling predictions from the wellbore hydraulics simulators. In this way, operational data could
be used to assist in model calibration. Data was also used to generate trend analyses, necessary to replace conventional kick
monitoring procedures.

Acknowledgements
The authors would like to thank TAQA for their participation in this project and for allowing publication of this paper. They
would also like to thank the drilling contractor and all other contractors and consultants involved for helping to make this
project a success. The authors would also like to thank Halliburton Energy Services, Inc. for their support during the project
and for permission to publish this paper.
12 SPE/IADC 168946

Nomenclature
ASBP= Applied Surface Back Pressure
BHA = Bottom Hole Assembly
BHP = Bottom Hole Pressure
BOP = Blow Out Preventer
CCS = Continuous Circulation Sub
Cv = Flow coefficient or flow capacity range
DAS = Data Acquisition System
DHG = Down Hole Gauge
ECD = Equivalent Circulating Density
ESD = Emergency Shut Down
FIT = Formation Integrity Test
HAZID = Hazard Identification
HAZOP = Hazard and Operability
MCC = Mechanical Completion Certificate
MPD = Managed Pressure Drilling
MW = Mud Weight
MWD = Measurement Whilst Drilling
NPT = Non-Productive Time
PBR = Polished Bore Receptacle
PLC = Programmable Logic Controller
PWD = Pressure While Drilling
RCC = Remote Choke Control Console
RCD = Rotating Control Device
SG = Specific Gravity
SOBM = Synthetic Oil-based Mud
TVD = Total Vertical Depth
TOL= Top of Liner
UBD = Underbalanced Drilling
UT = Ultrasonic Thickness
WBM = Water-based Mud

References
Gas Storage Bergermeer MPD Basis of Design. Martyn Parker. 2011
BGM-24 and BGM-29 Drilling Programs.
BGM-24 and BGM-29 End Of Well Reports.