Saudi Aramco recently drilled a gas well using Managed Pressure Drilling (MPD) as part of its exploration program. This well was the third exploratory well drilled with the objective to test the hydrocarbon potential of the sandstone reservoirs of Lower Permian era. Since a narrow drilling window between the reservoir gradient and the fracture gradient was expected, Constant Bottom-hole Pressure (CBHP) variant of MPD was planned to be utilized in this well. There was no Nonproductive Time (NPT) during the MPD phase, hydrocarbon gas from the target formation was measured by the Gas Chromatograph (GC) and properly circulated out via the Automated MPD Control System without the need of conventional well control procedures. Average Rate of Penetration (ROP) increased by three-folds compared to the nearest offset well. Based on the real-time GC analysis, four zones within the target hole section show the most potential for hydrocarbons and further delineations are being planned for these intervals. This paper summarizes Saudi Aramco's experience gained during the drilling of this well. It further highlights the operational complexity and the challenges faced during the implementation of this technology while drilling the exploratory well with very little offset information. The paper also elaborates on the lessons learned and how they were implemented continuously with regards to Health, Safety and Environment (HSE) during the MPD operations. It is concluded that the use of an Automated MPD control system integrated with GC in Saudi Aramco's deep gas drilling project represents a technological improvement that will enable the company in achieving its goals in a safer and a more efficient manner.

The increasing need for completions to be capable of withstanding higher treating pressures, combined with complex well geometries and cementing requirements, led to the development of a new 4 1/2-in. completion system that includes liner systems to facilitate isolation objectives, and upper completion systems to create a monobore conduit. This new monobore completion system is rated for 15,–KSI target surface treating pressures. Traditionally, cementing and isolation objectives have been achieved using liners and liner hangers capable of deploying those liners and also isolating the target zone. To achieve a monobore completion design, an integral tieback receptacle (TBR) is used to tie the liner back to surface. The integral TBRs currently used are either too short to enable the necessary tubing movement stroke, or rated too low to enable the required treating pressure. A solution was developed integrating a lower polished bore receptacle (PBR) below the liner hanger that is capable of withstanding the pressure requirements, and using a compression-set anchoring system to anchor a seal assembly inside the PBR. To account for tubing movement and help reduce mechanical loading on the tubing and upper completions components, a PBR is placed above the compression-set anchor. This arrangement enables the liner hanger systems to be isolated from treating pressures, which helps remediate limitations associated with traditional completion systems. Considering that the liner hanger is isolated from tubing treating pressures and that the compression-set anchor does not isolate annular pressure, the TBR on the liner hanger is pressure-balanced, no longer exceeding the pressure limit. Furthermore, tubing-casing annulus (TCA) pressure that is normally applied during stimulation can now support the liner hanger and lower tieback seals.