This paper was selected for presentation by an SPE Program Committee following review of
information contained in an abstract submitted by the author(s). Contents of the paper, as
A total of sixty days and US$1.4 Million have been
presented, have not been reviewed by the Society of Petroleum Engineers and are subject to saved using the above practice in the first five wells (8½” and
correction by the author(s). The material, as presented, does not necessarily reflect any
position of the Society of Petroleum Engineers, its officers, or members. Papers presented at 6½” hole sections). As a result, PDVSA will continue
SPE meetings are subject to publication review by Editorial Committees of the Society of
Petroleum Engineers. Electronic reproduction, distribution, or storage of any part of this paper
applying the technique in the San Joaquin field. The well bore
for commercial purposes without the written consent of the Society of Petroleum Engineers is stability study is currently under evaluation for the 12 ¼” hole
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 section to enable the MPD application in an effort to optimize
acknowledgment of where and by whom the paper was presented. Write Librarian, SPE, P.O.
Box 833836, Richardson, TX 75083-3836, U.S.A., fax 01-972-952-9435.
time and costs in the upper section too.
This paper describes how the planning and operational
Abstract procedures have been performed in order to obtain savings
The San Joaquin field was discovered in the 1930's and is one during the drilling activity in San Joaquin wells and How the
of the largest oil-gas fields in the eastern Venezuela. It field improvements in the production are being achieved following
currently including over 240 wells producing from 662 a great step forward in today's industry needs for recovering
different reservoirs. The average daily production is about 800 production from complex reservoirs.
MMSCFGD and 8000 BOD of condensate.
Due to the reservoir characteristics and the natural Introduction
decrease of the reservoirs virgin pressure, drilling operations IADC UBO/MPD committee has defined MPD (Accepted by
applying conventional overbalanced methods have induced committee vote, March 16th, 2004) as an adaptive drilling
significant Operational Problems and formation damage. process used to (more) precisely control the annular pressure
To reduce initially the operational problems (average profile throughout the wellbore. The objectives are to
fluid losses, which were more than 2,000 barrels per well) and ascertain the downhole pressure environment limits and to
to decrease Productivity Index damages due to differential manage the annular hydraulic pressure profile accordingly.
pressures on the depleted formations, the Near/Under MPD is an advanced form of primary well control
Balanced technique was considered. typically employing a closed, pressurizable fluid system that
Several months of reservoir evaluations with allows greater and more precise control of the wellbore
geomechanical and stability studies were spent, before the pressure profile than mud weight and mud pump rate
decision to use Managed Pressure Drilling through-out adjustments alone. As opposed to a conventional open to
shale/sandstone-layered gas payzones formations was taken. atmosphere returns system, MPD enables the circulating fluids
Twelve wells have been performed up to date using system to be viewed as a pressure vessel.
proactive Managed Pressure Drilling (MPD) & Underbalanced MPD is a collection of tools and techniques that offers
Drilling (UBD) techniques in the Merecure and San Juan incredible advantages to drill in a safer mode. The Reactive
formations (8½” and 6½” hole sections respectively). Nitrogen MPD involves tooled up to more efficiently react to downhole
injection has been applied in the San Juan formation to surprises. In a Proactive MPD System the fluids and casing
achieve the required ECD below 6.0 ppg. programs are designed, from the start, to drill with ability to:
These types of wells were the first of their kind drilled in • Adjust BHP with minimum interruptions to drilling
Latin America using these techniques in conjunction with the ahead
Down Hole Deployment Valve (DDV). • Achieve a deeper open hole
The application of the MPD technology to solve the • HSSE performance
varied range of operational problems that had been The closed system utilized in MPD and UBO operations has
experienced in the San Joaquin field, began in December 2004 the potential for safer well control due to: More sensitive kick
in the 8½” section of the G-92 well, with an excellent detection, the influx is stopped faster and we can perform a
operational and production result. After this milestone, the faster kill in the case this will be mandatory.
MPD program has included the performance of the following During a conventional circulation, annulus friction
pressure is added to hydrostatic pressure and increase total
2 SPE 100927
BHP. In a Constant Bottomhole Pressure variant of Managed The field is formed by a sequence of three aligned domes
Pressure Drilling (CBHP), reduced surface annulus pressure in the N50E direction caused by an important influence of
compensates for increases in annulus flowing pressure during compressive and tensile stresses that form the rises and
circulation. foldings in the structure. The Proactive Managed Pressure
The Presence of pressure differentials of more than 3,000 Drilling and Underbalanced Drilling Application have been
psi between contiguous layers involve the frequent risk of lost performed in the Merecure and San Juan formations (Fig. 2).
circulation and well control combination that was typical These are considered the most prolific zones, from a gas
during drilling operations in the productive zones of the San production point of view, with permeability in the range of 50
Joaquin Field and it has been a very important issue on well and 500 md, porosity between 5% and 20% and pressure less
construction costs. than 4,000 psi. These reservoirs produce gas condensates and
Industry studies have shown that drilling costs and non recover injected gas from the oil ages, which have specific
productive time (NPT) increase as reservoirs become depleted. gravity of about 0.7 and API gravity that varies from 40 to 60
The top two causes of NPT and the related additional costs API units. The Merecure formation (Oligocene) is composed
associated with drilling depleted areas in San Joaquin Field by a repetitive alternation of consolidated sands and narrow
are: Differential sticking and lost circulation incidents. With shales with abundant lignites of great lateral extension (Fig.
MPD & UBD, related incidents and associated costs have 2). The sandstone reservoirs are layered and have great
been reduced or avoided in this specific Field. extension. Some wells have been drilled through up to 28
Field General Information diverse reservoirs with pressure differentials that range from
The San Joaquin field (Fig. 1) is located 400 km south east of 700 to 4,000 psi.
Caracas in Eastern Venezuela covering an approximate area of The San Juan formation is a gas condensate reservoir
450 km2 and being part of a very important hydrocarbon from the Cretaceous, constituted by three major consolidated
producing province called Anaco District. The field has been sands that present scarce shale layering and a clay matrix. The
an oil producer since 1938 and from the year 2001 it has been upper layers are depleted and fractured and lower layers can
transformed from a marginal oil field into the most important have pressures in excess of 2,000 psi greater than the depleted
gas field in Venezuela. This has been achieved through an layers.
aggressive drilling and workover campaign in the last five
years.
produced openhole, the Merecure formation had to be covered continuation of the Drilling program shows eleven more wells
to cement during the casing process. To maximize production uptoday, all with excellent real results.
and take advantage of the fact that minimal damage was done One of the associated main problems to drill this kind of
to the formation while drilling because of the at-balance nature wells in this area is the loss of recurrent circulation in the
of MPD, it was decided that the well should be cemented members of San Juan, formation catalogued like the primary
using the latest in lightweight cementing technology. To objective of production. On the other hand, the severe losses
isolate the Merecure from the San Juan, a 7 5/8-in. liner is of circulation observed in the Merecure formation, in whose
normally selected to case off this exposed portion of the sandstone due to the high differential pressure, existing
wellbore. between the multiple layers, it has been worked with high
Production Curve, Mature Field values of overbalanced. Additionally, these types of events
Introduction of a New Technology have been also observed in the members Amarillo and
COSTS (US$ MM)
Real Case History, San Joaquin Field MPD Colorado from the Oficina Formation.
This kind of problems, common in zones where
sandstone packages are drilled with different pressure levels as
it is the case of Oficina, Merecure and San Juan formations,
entails great loss of time and economic resources for its
solution when it is drilled in a conventional way, combined to
a constant formation damage due to the fluid invasion towards
to the payzone. On the other hand, the great flexibility that
MPD has, generating and maintaining a specific value of
Equivalent Circulating Density (ECD), constitutes a
fundamental tool to handle in a more efficient way these
problems.
TIME This has been demonstrated effectively during the
Fig. 3– Behavior of a mature field costs Managed Pressured drilling program in San Joaquin
Because many of the problems of drilling depleted zones performed on the last 18 months. These wells were drilled,
(and the associated extra costs) are avoided with MPD, the observing minimum losses of mud in the worse of the cases.
real advantage of this technology could be observed later in More recently, the JM-237 and JM-238 wells used MPD to
the life of a field, after reservoir depletion has occurred. This drill the members Naranja, Verde, Amarillo and Colorado
can be best observed in Figure 4. When the reservoir life cycle from the Oficina formation with great successful.
has advanced and the New Technology start operating on the In San Juan Formation, characterized to have the
right side of the dashed line, the additional increase rate superior layer (SJ-A) with a very low equivalent pressure (3.2
associated with MPD is often significantly overshadowed by ppg), the UBD is constituted in the best option as much to
the increase in trouble drilling costs. reduce the inherent costs of circulation losses like to reduce
the formation damage induced by the high degree of
overbalanced used on these sandstones when they are drilled
conventionally.
In the present paper, the different alternatives for the
application of this technology are analyzed as much
considering the particular conditions of each well and based
on the available information concerning to the formation
pressures profile and reservoir characterization. On the same
way, technical, Operational and QHSSE considerations are
included,in order to perform the operation in a successful way.
The 12 ¼” section throughout the members Naranja,
Verde, Amarillo and Colorado from the Oficina formation,
this include 4,500 feet approximately. The objective for this
section is to Rig up the MPD equipment, and to drill in
Fig. 4– Relationship of relative field development drilling costs conventional form until signs of instability from the well
appear, which commonly happens in form of gas kick, at level
medium sandstones from the Amarillo member. From that
Operational Drilling Considerations in order to Drill 12 moment on, to circulate through control and separation system
¼”, 8 ½” and 6 ½” hole sections in the San Joaquin and of Weatherford Controlled Pressured Drilling & Testing
Guario Wells Using Proactive MPD and UBD Systems. Services, being continued the drilling operation using Flow
The application of MPD & UBD in their diverse Drilling. On this way, it is persecuted to drill the section with
modalities to solve the varied range of operational problems the smaller possible ECD in bottom, to avoid losses of
that were experienced during the conventionally drilling circulation normally observed as the CO-A sandstone level.
campaing in San Joaquin field, began with Guario-92 well, This last one has an equivalent of 2.5 ppg frecuently. When it
with excellent operational and production results. The is drilled conventionally, this sand is susceptible to loss of
circulation, since this one is put under a high level of
SPE 100927 5
overbalanced when heavy muds near to 12 ppg, are necessary Based Mud. The injection of this inert gas (nitrogen) is
to control the sandstones such as CO-K, which has generally performed through the drilling string. On this way, an ECD of
pore pressures about 11.5 ppg. 5.5 ppg could be reached, avoiding and/or eliminating losses
In main lines, the objectives to drill the 12 ¼” hole of circulation and minimizing the problems of operational
section in the modality of near balanced/flow drilling are: type.
• To allow the formation gas flow to controlled rates. As secondary objectives We had:
• To conduct the operation with an Equivalent • Once, the SJ-B formation is targered, to allow that
Circulation Density that minimizes the risks of this one flows to controlled rates, in the case of gas
circulation losses towards the sandstones of smaller inflow.
pressure as well as to avoid stuck pipe by differential • To Minimize or to eliminate the possibility of
pressure sticking. differential sticking.
• To avoid the fluid invasion towards the potentially • To increase the rate of penetration ROP).
producing formations. • To increase the productivity of the SJ-A and SJ-C
For the case of the 8½” hole section, in which about formations that are primary objectives.
1,250-1,500 feet of the Merecure formation are drilled, from Additionally, is highly recommended to use in this kind
ME-A sandstone to the Base of the Vidoño formation, it has a of wells, Downhole Deployment Valve (DDV) which is
package of 29 diferents members, which have a very little installed in order to reach the following objectives:
information concerning to their pore pressures. Nevertheless, • To avoid having to balance the well in order to
taking in consideration the information available from make the pipe trips.
previous wells drilled in the area, it has been observed in most • To optimize the pipe trips being diminished the
of those sandstones of high pressure, like ME-Q and ME-T1, length of string to be RIH or POOH with well head
2; have a rating from 9.6 ppg to 10 ppg in some cases. On the pressure.
same way, there are other sandstones with lower pressure like • To reduce the operational times and therefore the
ME-F, ME-J1L and ME-T4, 5 frequently; with equivalent associate cost.
pressures equivalent fewer than 4.0 ppg. • To allow making electric logs, to run to liner and the
This differential pressure is the cause of the great completion string in live well condition.
difficulty to drill this zone with a conventional technology. On • To have a safer condition in surface during most of
the other hand, the application of the MPD & UBD technology the pipe trips time and while the string remains
allows to work with a fluid of a smaller density to the one outside the hole.
normally used in a conventional overbalanced drilling and Wellbore Stability Issues. The stability study of holes to be
simultaneously permit to handle the formation inflow with all drilled in San Joaquin field threw as result that the minimum
the mandatory safety of the case in real time. Taking density to be used during the drilling of the 8½” hole section
advantage of this same situation the modalities of near must be about 6.5 ppg to avoid hole collapse. Also it notices
balanced and flow drilling are used to drilling ahead in the 8 on this study that with ECDs below to 8.0 ppg cavings could
½” hole section, making use of the gas that can possibly presented in the shales of the SJ-A, SJ-B y SJ-C formations by
flowed from the pressurized sandstones or layers, without breakouts present in the interval due to the release of the
losing the operational window defined by the geomechanical efforts without this means that the hole is going to collapsed.
study already made, which recommends the minimum weight Therefore the precaution of constantly returns monitoring
of mud to be applied in each one of these hole sections. Other must be applied during the operation in order to determine if
drilling objectives for the 8½” hole section in the modality of the hole is being effectively cleaned or not. However, within
near balanced/flow drilling are: the operational recommendations it has not been considered to
• To allow the formation gas flow to controlled rates. reduce the ECD below 7.0 ppg during the drilling of this
• To conduct the operation with an Equivalent section.
Circulation Density that minimizes the risks of In whatever to the 6½” hole section to be drilled through
circulation losses towards the sandstone of smaller SJ-A, SJ-B and SJ-C layers, the geomechanical study
pressure as well as to avoid stuck pipe by recommended to use the smaller fluid density that it does not
differential pressure sticking. jeopardize the properties of suspension and transportation of
• To increase the rate of penetration (ROP). itself without lowering belloe to 4.5 ppg. Also, for mud
• To avoid the fluid invasion towards the objective weights smaller to 8.0 ppg cavings could be presented in the
formation, and consequently, to increase the sahles of SJ-A, SJ-B and SJ-C formations. According to this,
productivity. the minimum ECD recommended for this section is of 5.0
In the case of the 6½” hole section about 700-800 feet ppg.
are drilled through the San Juan formation. The SJ-A (3.2-3.5 For the 12 ¼” hole section has not been made study of
ppg), SJ-B (6.2-6.5 ppg) and SJ-C (5.6-6.0 ppg) are normally hole stability to evaluate the effects of the near/underbalanced
the members to be drilled in this productive gas zone. In this condition. Nevertheless, the exposition for the drilling of this
section the first layer to be drilled presents a very low pore phase does not contemplate to lower the ECD below to 8.5-9.0
pressure for that reason, it is needed from the beginning to ppg, reason why is not hoped to observe instability problems.
generate a near balanced condition to control the losses of Nevertheless, it is recommended to maintain Straits
circulation, which is obtained using nitrified Mineral Oil monitoring of signs or indications of possible instability.
6 SPE 100927
IADC Classification of the Operation Executed in the San • Maximum rate of gas flow (Erosion in the line
Joaquin Wells. of flow) = 12 MMSCFD.
Under the standards of the IADC (International Concerning to these parameters, the flow control matrix
Association of Drilling Contractors), the MPD, Flow Drilling establish the actions of control in surface based on the rate of
and UBD operations to be performed in 8½” hole section to gas flow and the flowing well head pressure. The colors
solve the lost of circulation problems at the level of the indicate the valuation of the risk level. The adjustment regions
Merecure formation is catalogued like 4-B-5. LEVEL 4 - (yellow areas) are established to allow a safe time of reaction
Hydrocarbon production: Maximum pressure of well closing to return the operations to the condition indicated by the box
smaller than the operating pressure of the equipment, having of green color. The areas of red color indicate situations in
catastrophic consequences in case of fault of some equipment which a well control procedure is re
or component. CONDITION B: Wells to be drilled in
underbalanced condition. Type of drilling fluid 5: Fluids of a
single phase (liquid). 1,250-2,000 psi > 2K
The 6½” hole section in the San Juan formation can get
to have two classifications, first of them applies for sand SJ-A
in the case of being drilled with nitrified Oil Based Fluid
would have a IADC Classification of 2-A-4. LEVEL 2: Well
able to flow naturally until surface but being possible to
control it with conventional methods, having limited 12-
22.5
catastrophic consequences in case of fault of some equipment.
CONDITION A: Wells to be drilled in near balanced
condition. Type of drilling fluid 4: Gasified fluids. The second > 22.5
classification it applies for the drilling of SJ-B and SJ-C
formations which will be drilled in Under Balance condition
using Flow Drilling. In this case an equal classification to the Table 5. Drilling time for the 6 ½-in. hole section (MPD)
one of the Section of 8½” hole section must be obtained 4-B-
Surface and Downhole Equipment
5.
Surface equipment is divided in three basic systems:
The Risk Analys for each one of the hole section have
a. Compression/Injection system (for special
been determined too. The level of risk obtained was of 5.7 and
requirements): it is composed by 2,500 SCFM of air
5.4 for the 8 ½” and 6½” hole section respectively, in the scale
package, the 1,250 SCFM nitrogen generating unit
from 1 to 10, the which means that exists a manageable
(membrane type) and pressure elevators to 1800 psi and
moderate risk with the equipment and the technology to be
4000 psi. It is responsible for producing and injecting
applied on these cases.
the nitrogen taken from air with a maximum quality of
98% at the discharge.
Flow Control Matrix for MPD & UBD
b. Separation system: it is composed by a four phase
Pressures in well Head and manageable gas flow rates
horizontal separator responsible for segregating gas,
will have to be determined to assure and continous and safer
crude oil, water and solids (drilling cuttings). The
drilling operation. The flow control matrix defines these
separation package has a three way UBD Choke
parameters for drilling operations. Therefore, the design of
Manifold incorparated. The gas separated is diverted to
this matrix is required based on the risk. This matrix will have
vertical burner (flare stack) after being measured; crude
to be cradle in:
oil is deviated to a storage tank; and, water, drilling fluid
• A safety factor based on maximum flow capacity of and drilling cuttings are diverted to the discharge flow
the separation system in surface. line through the solids control equipment and are cycled
• Pressure rating of the flow control equipment, as in the circulation system as in conventional drilling.
Emergency Shutdown Valve -ESDV (If this is c. Well control system: it is made up by the rotating
installed), primary flow line and UBD choke control diverter with a double stripper rubber that
manifold. adjusts directly for security while drilling, oil lubricator
• Erosion rates of flow line in surface and choke equipment, a remote, modular and explosion proof
manifold. power unit, and a remote console for control and
• Maximizing the interval on service for the Rotating monitoring.
control Diverter. Downhole equipment is composed by floating valves for
Tactically important points of safety safe and fast connections and the surface operated downhole
1. Rotating Control Diverter: Williams model 7100, Deployment valve. The DDV in San Joaquin wells is installed
2,500 psi in dynamic condition and 5,000 psi in permanently and, therefore, cemented with the casing previous
static condition. to the payzone section.
2. Separation Equipment:
• Maximum rate of gas flow (separator) = 30 Conclusions
MMSCFD • ROP increase, lost circulation control and reduction of
normalized drilling time present the clear opportunity to
SPE 100927 7
Acknowledgments
We thank to the PDVSA Gas Anaco Management for the
permission to share this case history; and to all the Engineers
from the Reservoir, Drilling and VCD department, who
worked vigorously in supporting and promoting this MPD &
UBD project in San Joaquin and Guario Fields. We also thank
to our Weatherford CPD & Testing personnel involved in the
planning and execution of these proactive MPD & UBD jobs.