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Abstract
The Sajaa field in Sharjah, United Arab Emirates, is a deep,
low-pressure gas field that has been a prolific producer since
the first wells were drilled in the 1980s. Initial field
development was through a series of vertical wells drilled
overbalanced with conventional drilling rigs. As field pressure
and production declined, it became necessary to access
additional reserves not being drained efficiently by these older
wells. As a result of this need, a campaign to drill horizontal,
multilateral sidetracks from the existing wellbores was started
in March 2003 using coiled tubing. From a standpoint of
production, cost, health, safety, and environment, the results of
the program thus far have been excellent.
This paper examines the surface and downhole equipment
and operational best practices used in the Sajaa coiled tubing
(CT) underbalanced drilling (UBD) campaign. It also reviews
some of the key details that make a safer, more efficient dayto-day operation and created a highly successful project that
has drilled 27 wells, comprising more than 90 laterals and
more than 212,000 ft drilled.
Introduction
The Sajaa field was discovered in 1980 by Amoco Sharjah Oil
Company; since that time a total of 41 wells have been drilled
in the Sajaa field. Initial reservoir pressures were 7,500 psi or
greater; these pressures have since declined substantially, with
most wells now being drilled with equivalent circulating
densities of 1.5 to 2.0 lb/gal. Initial completions were polished
bore receptacle tubing completions, but with corrosion and
packer leaks, these were changed to packerless 5-in. tubing
completions with wells that have 7 -in. liners tied back and
cemented to surface in most cases. Production trees are, for the
most part, 5-1/8-in., 10,000-psi sour-service trees.
The initial drive to perform CT UBD in this field came
about because data on the Sajaa field showed that valuable
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Every item that is lifted has a lift plan associated with it.
Included in this is the risk assessment for that particular lift,
certifications for slings and shackles used, and a copy of the
layout diagram that shows where that equipment goes and its
orientation. A green-tag system is used with the tag signifying
that a piece of equipment is designated ready by the
appropriate supervisor and the lift plan has been given to the
lift supervisor. Once tagged, the equipment is handed over to
the lift supervisor for movement. This system eliminates the
problem with miscommunication and uncertainty whether
something is ready to be moved.
Once the rig move has been initiated, manpower is tripled.
Very strict job allocations and responsibilities are identified
and made. Risk assessments are all in place and discussed and
appropriate toolbox meetings are held while the rig move is
ongoing.
To ensure that the move is safe, one lift supervisor and
assistant lift supervisor are assigned at each site. One truck
boss at each site is also employed, and one overall supervisor
is also appointed to each location.
Immediately after the move, a lessons-learned meeting is
held to capture experience and action improvements. From
past lessons learned, some of the equipment has been modified
to become more modularised to reduce the amount of work
required to rig it up and down.
Milling Windows
Window milling and windows, in general, have been the most
challenging part of the project, and the one that has improved
the most. The pre-spud design called for milling the window
underbalanced with water and nitrogen, which had never been
done before. This was tried on the first well and briefly on the
second but abandoned after high attrition rates in the BHA
inventory. The BHA used on this project is meant for
openhole drilling and is not able to survive for long the severe
vibration encountered during two-phase window milling.
Therefore, the first windows were milled single phase with
water in a routine fashion and presented few difficulties. A
step change during this phase of the project was the use of a
choke sub above the motor to hold a fluid column in the CT
while milling. In this way, stalls could be detected at the
surface using pump pressure. This eliminated entirely the need
for any electronics in the BHA while milling and, as a result,
greatly improved the service life of the electronic components
in the toolstrings.
A serious drawback to this method was the huge amount of
water used, which was lost to the formation. The low BHP did
not allow any returns while window milling and, in fact, most
of the windows and subsequent 10 ft of rathole were milled
with the wells shut-in, always losing several thousand bbls of
water to the formation in the process. This presented some
problems when it was time to start drilling the sidetrack. With
the motherbore and surrounding area saturated with water, it
was often difficult to start the well flowing again.
To mitigate this, nitrogen was bullheaded down the kill
line of the well while milling the window to energize the fluid
lost to formation or at least push it far enough down or away
from the motherbore so it wouldnt be a problem. This
strategy was successful in allowing UBD to start in the nearwellbore area.
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Pres
OB
Pwf
r
Fig. 3Idealized plot of pressure vs. distance drilled.
Overbalanced conditions (OB) are encountered at some point as
the leg is extended.
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