Annular Barrier as an Alternative to Squeezes in Challenging Wells: Technology Review and Case Histories

2016 ◽  
Author(s):  
Joseph Bagal ◽  
Gbenga Onadeko ◽  
Paul Hazel ◽  
Vibjørn Dagestad
Keyword(s):  
Hydraulic Pressure ◽  
Case Histories ◽  
Regulatory Requirements ◽  
Pump Failure ◽  
Advantages And Disadvantages ◽  
Second Stage ◽  
Well Integrity ◽  
Open Hole ◽  
Sustained Casing Pressure ◽  
Casing Pressure

ABSTRACT The drilling industry has always relied on cement as a primary barrier. Although the cement represents about 5% of the well cost, when squeezes are required, cementing averages 17% of the well cost. Only 50% of the squeezes achieve the objective of establishing a barrier for well integrity. A little bit more than half of the failures can be attributed to operational challenges (pump failure, cement contamination), or design oversights (cement recipe, centralizers). However there are still cement failures with perfect design and field execution. These failures typically exhibit some of the following characteristics: high deviation, high pressure, washouts, natural fractures, long casing section, heterogeneous sands. For these specific conditions, it is beneficial to add an assurance that would maintain the integrity of the well even in case of bad cement. Some of the assurances used include port collars, external casing packers (ECP) and swell packers. Port collars allow a squeeze above the first stage cement, while ECP serves as a base for a second stage cement, and swell packers provides a baffle for sustained casing pressure. A more recent technology is the well annular barrier that can form a combined barrier with cement, and can also be used as a stand-alone primary barrier. The well annular barrier is a metal-expandable barrier that is expanded with hydraulic pressure. It is full bore, highly customizable, and qualified to ISO 14310. The metallurgy allows the packer to shape fit into either an open hole with irregular geometry or inside a casing to preclude annular pressure build up by giving a life-of-well reliable seal. The well annular barrier has been deployed in a variety of wells to achieve well integrity with and without cement, protect the B-annulus from sustained casing pressure, or serve as a barrier between reservoirs that cannot be commingled. This paper performs a review of the technologies used for cement assurance, their advantages and disadvantages. Case histories of well annular barrier deployments are presented, including a case where the well annular barrier was used as a stand-alone well barrier element without the need for dispensation. This paper also discusses how the well annular barrier fits into the regulatory requirements for well construction providing to the drilling industry an alternative to cement for the purpose of well integrity.

Implementation of Factory Cementing Concept in the High-Intensity Drilling Environment of Khazzan, Sultanate of Oman

2021 ◽  
Author(s):  
Emmanuel Therond ◽  
Yaseen Najwani ◽  
Mohamed Al Alawi ◽  
Muneer Hamood Al Noumani ◽  
Yaqdhan Khalfan Al Rawahi ◽  
...  
Keyword(s):  
Shallow Water ◽  
High Intensity ◽  
Sultanate Of Oman ◽  
Cement Slurry ◽  
Short Term ◽  
Lost Circulation ◽  
Well Integrity ◽  
Sustained Casing Pressure ◽  
Zonal Isolation ◽  
Casing Pressure

Abstract The Khazzan and Ghazeer gas fields in the Sultanate of Oman are projected to deliver production of gas and condensate for decades to come. Over the life of the project, around 300 wells will be drilled, with a target drilling and completion time of 42 days for a vertical well. The high intensity of the well construction requires a standardized and robust approach for well cementing to deliver high-quality well integrity and zonal isolation. The wells are designed with a surface casing, an intermediate casing, a production casing or production liner, and a cemented completion. Most sections are challenging in terms of zonal isolation. The surface casing is set across a shallow-water carbonate formation, prone to lost circulation and shallow water flow. The production casing or production liner is set across fractured limestones and gas-bearing zones that can cause A- and B-Annulus sustained casing pressure if not properly isolated. The cemented completion is set across a high-temperature sandstone reservoir with depletion and the cement sheath is subjected to very high pressure and temperature variations during the fracturing treatment. A standardized cement blend is implemented for the entire field from the top section down to the reservoir. This blend works over a wide slurry density and temperature range, has expanding properties, and can sustain the high temperature of the reservoir section. For all wells, the shallow-water flow zone on the surface casing is isolated by a conventional 11.9 ppg lightweight lead slurry, capped with a reactive sodium silicate gel, and a 15.8 ppg cement slurry pumped through a system of one-inch flexible pipes inserted in the casing/conductor annulus. The long intermediate casing is cemented in one stage using a conventional lightweight slurry containing a high-performance lost circulation material to seal the carbonate microfractures. The excess cement volume is based on loss volume calculated from a lift pressure analysis. The cemented completion uses a conventional 13.7 - 14.5 ppg cement slurry; the cement is pre-stressed in situ with an expanding agent to prevent cement failure when fracturing the tight sandstone reservoir with high-pressure treatment. Zonal isolation success in a high-intensity drilling environment is assessed through key performance zonal isolation indicators. Short-term zonal isolation indicators are systematically used to evaluate cement barrier placement before proceeding with installing the next casing string. Long-term zonal isolation indicators are used to evaluate well integrity over the life of the field. A-Annulus and B-Annulus well pressures are monitored through a network of sensors transmitting data in real time. Since the standardization of cementing practices in the Khazzan field short-term job objectives met have increased from 76% to 92 % and the wells with sustained casing pressure have decreased from 22 % to 0%.

Prevention of Historically Challenging Sustained Casing Pressure from Shallow Gas Through Re-Engineered Cement Design and Execution Methodology

2021 ◽  
Author(s):  
Farah Shakina Ezani ◽  
Myat Thuzar ◽  
Avinash Kishore Kumar ◽  
Chee Hen Lau
Keyword(s):  
Mitigation Measures ◽  
Design Parameters ◽  
Two Stage ◽  
Shallow Gas ◽  
Second Stage ◽  
The Past ◽  
Sustained Casing Pressure ◽  
Dual Stage ◽  
Casing Pressure ◽  
Selection Of

Abstract Sustained casing pressure (SCP) is a very costly event for any operator either at production phase or at the end of a well’s lifecycle. SCP is a result of incomplete hydraulic isolation across hydrocarbon bearing zone. In one of the gas fields in Malaysia, notoriously known for shallow gas hazard, drilled development wells which have reportedly been suffering SCP. In the past, various improvements in cement slurry design and placement methods were deployed in order to provide complete zonal isolation, especially at the shallow gas sand, yet SCP issue was encountered occasionally. In the current development campaign, different strategy to providing annulus sealing was adopted. This paper discusses proactive steps taken in the slurry design, fit together with the dual stage cementing approach, as a primary means of placing cement above the shallow hazard interval. During the design phase, essential key parameters that would lead to successful placement of cement in the annulus as well as unique slurry design that suits for two stage cementing methods were studied. Risk involved in first stage cementing is one of the most important steps that should be analyzed in detail and put mitigation measures in place to ensure the second stage cement job can be performed as planned. In addition to the slurry properties, such as fluid-loss value, gas-tightness, etc., thickening time and top of cement (TOC) of the lead slurry in the first stage cement job has become enormously critical in designing dual stage cementing job in order to assure cement ports in the stage collar are not covered with hard cement forcing the termination of second stage job prematurely. Besides cementing design, careful selection of the stage collar location and casing annulus packer in the string is also of significant importance in leading to successful two stage cement job. Two development wells with above approached has been delivered and no sustained casing pressure has been experienced. This proactive approach to use two stage cementing as primary plan has proven to successfully eliminate the risk of SCP, which was a frequent struggle in their sister wells drilled with primary cementing in the past in the same field. The risk analysis combined with careful considerations of critical cementing design parameters and selection of stage tool location have become a novel approach to combat against SCP in this gas field.

Inherently safer sustained casing pressure testing for well integrity evaluation

2014 ◽  
Vol 29 ◽  
pp. 209-215 ◽  
Author(s):  
Tony Rocha-Valadez ◽  
Ray A. Mentzer ◽  
A. Rashid Hasan ◽  
M. Sam Mannan
Keyword(s):  
Pressure Testing ◽  
Well Integrity ◽  
Sustained Casing Pressure ◽  
Casing Pressure

Well Integrity Enabled by Digital Workflow

2021 ◽  
Author(s):  
B. Brechan (Wellviz) ◽  
A. Teigland ◽  
S. Dale ◽  
S. Sangesland
Keyword(s):  
Fiber Optics ◽  
Risk Level ◽  
Gas Migration ◽  
Digital Workflow ◽  
Well Integrity ◽  
Digital Format ◽  
Standard Procedures ◽  
Safety Margins ◽  
Sustained Casing Pressure ◽  
Casing Pressure

Abstract Emerging technologies are expected to provide step changes in many areas within planning, making and production of wells. The main topic of this paper covers in a digital workflow, where the different disciplines contributions to well integrity are expected to be on a fully digital format. All phases in the lifecycle of wells are integrated into one digital process, where possible improvements are enabled by the transition from a human oriented work process to a software oriented (human supported) process. This transition has taken place in several other comparable energy and capital-intensive industries. Today, some wells have the new fiber optics that enables a range of opportunities for improvement of well integrity. Distributed Acoustic Sensing (DAS) has measurements for every meter, which provides new aspects such as in situ measurements during cement jobs and drilling. Other applications of the new fiber optic technology are monitoring of gas migration, source of sustained casing pressure and other measurements which have the potential to develop into standard procedures or even regulatory requirements. With gas migration, corrosion and other changes affecting the integrity of the well construction, integrity can be re-modelled and updated automatically in a fully digital workflow to understand the safety margins. A part of this digital process is automating the risk level for each well and the entire asset. These processes and the prototype of the automated risk assessment are possible in a fully digital process, where planning and well construction commence with support from modern well planning and integrity software.

Optimising Depth Selection on Section Milling Operation to Secure Sustained Casing Pressure During Plug and Abandonment Operation

2021 ◽  
Author(s):  
Dianita Wangsamulia ◽  
Khresno Pahlevi ◽  
Simon Paulus ◽  
Gama Aditya ◽  
Heri Tanjung ◽  
...  
Keyword(s):  
Oil And Gas ◽  
Neutron Cross Section ◽  
Oil And Gas Industry ◽  
Gas Industry ◽  
Milling Operations ◽  
Milling Operation ◽  
Key Factor ◽  
Open Hole ◽  
Sustained Casing Pressure ◽  
Casing Pressure

Abstract D-01 was an exploration well requiring a Plug-and-Abandonment (P&A) procedure with sustained casing pressure up to 2,000 psi on the B annulus. The presence of Sustained Casing Pressure (SCP) is one of the major technical challenges to decommission and abandon the well safely. Several attempts to secure the well using the perforation-and-squeeze method were performed – but failed. It was decided to perform section milling operations to create a viable rock-to-rock barrier. In this operation, the key factor in determining success, is selecting the correct depth to mill safely and secure the annular pressure source. A comprehensive approach was taken to determine the optimum depth for the section milling by evaluating existing open-hole and cased-hole data. Additionally, triple-detector Pulsed Neutron Log (PNL) was also performed prior to the section milling operation. The triple-detector PNL tool offered not only behind casing porosity (TPHI) and sigma (SIGM) measurement, but also a relatively new measurement in the oil and gas industry called Fast Neutron Cross Section (FNXS), which were expected to provide more accurate gas detection and gauge the condition near the borehole. By combining all the logs and reservoir data, the milling interval was selected and the section milling and subsequent cement plug operations were performed. Evaluation of existing open-hole and cased-hole logs provided geological and petrophysical insights which were useful in determining the hydrocarbon source charging the B-annulus. Further analysis on PNL data provided indication of possible gas pockets in the B-annulus. This information was used to distinguish between shallower formation sources or gas pockets that were not yet bled off. The operation on D-01 successfully resolved the B-annulus issue and the well was properly abandoned per regulatory requirements. Considering the complexity and high cost of section milling operations, a thorough review of data and pre-job logging increases the probability of selecting the optimum intervals needed to successfully complete P&A operations on SCP wellbores.

scholarly journals Public data from three US states provide new insights into well integrity

2021 ◽  
Vol 118 (14) ◽  
pp. e2013894118
Author(s):  
Greg Lackey ◽  
Harihar Rajaram ◽  
James Bolander ◽  
Owen A. Sherwood ◽  
Joseph N. Ryan ◽  
...  
Keyword(s):  
New Mexico ◽  
Oil And Gas ◽  
The United States ◽  
Gas Leakage ◽  
Integrity Testing ◽  
Well Integrity ◽  
Regional Trends ◽  
Public Data ◽  
Sustained Casing Pressure ◽  
Casing Pressure

Oil and gas wells with compromised integrity are a concern because they can potentially leak hydrocarbons or other fluids into groundwater and/or the atmosphere. Most states in the United States require some form of integrity testing, but few jurisdictions mandate widespread testing and open reporting on a scale informative for leakage risk assessment. In this study, we searched 33 US state oil and gas regulatory agency databases and identified records useful for evaluating well integrity in Colorado, New Mexico, and Pennsylvania. In total, we compiled 474,621 testing records from 105,031 wells across these states into a uniform dataset. We found that 14.1% of wells tested prior to 2018 in Pennsylvania exhibited sustained casing pressure (SCP) or casing vent flow (CVF)—two indicators of compromised well integrity. Data from different hydrocarbon-producing regions within Colorado and New Mexico revealed a wider range (0.3 to 26.5%) of SCP and/or CVF occurrence than previously reported, highlighting the need to better understand regional trends in well integrity. Directional wells were more likely to exhibit SCP and/or CVF than vertical wells in Colorado and Pennsylvania, and their installation corresponded with statewide increases in SCP and/or CVF occurrence in Colorado (2005 to 2009) and Pennsylvania (2007 to 2011). Testing the ground around wells for indicators of gas leakage is not a widespread practice in the states considered. However, 3.0% of Colorado wells tested and 0.1% of New Mexico wells tested exhibited a degree of SCP sufficient to potentially induce leakage outside the well.

Avoiding Sustained Casing Pressure in Gas wells using Self Healing Cement

2011 ◽  
Author(s):  
Salim Taoutaou ◽  
Jorge Andres Vargas Bermea ◽  
Pietro Bonomi ◽  
Bassam Elatrache ◽  
Christian Pasturel ◽  
...  
Keyword(s):  
Self Healing ◽  
Gas Wells ◽  
Sustained Casing Pressure ◽  
Casing Pressure

Pipeline Corrosion Integrity Management by Direct Assessment

2015 ◽  
Author(s):  
Shailesh Javia
Keyword(s):  
Integrated Approach ◽  
Assessment Process ◽  
Regulatory Requirements ◽  
Integrity Assessment ◽  
Advantages And Disadvantages ◽  
Direct Assessment ◽  
Pipeline Segment ◽  
Integrity Management ◽  
Post Assessment ◽  
Pipeline Corrosion

Integrity management of pipelines is a systematic, comprehensive and integrated approach to proactively counter the threats to pipeline integrity. Pressure testing, in-line inspection and direct assessment methods are used to verify the integrity of a buried pipeline. The Paper Discuses Direct Assessment Methodologies for Hydrocarbon Non Piggable Pipelines. Advantages and Disadvantages of Direct Assessment methodology and DA Protocols. The DA process accomplishes this by utilizing and integrating condition monitoring, effective mitigation, meticulous documentation and timely structured reporting processes. DA is a structured, iterative integrity assessment process through which an operator may be able to assess and evaluate the integrity of a pipeline segment. TIME DEPENDENT THREATS INEVITABLY LED TO NUMEROUS FAILURES WITH A COMMON DEFINING MECHANISM OR SOURCE – CORROSION. This Paper will focus on internal, external and stress corrosion cracking direct assessment along with pre and post assessment, quality assurance, data analysis and integration, and remediation and mitigation activities. This paper will discuss some of the regulatory requirements for Pipeline Integrity Management System.

Sustained Casing Pressure Calculation of A Annulus Induced by Downhole Operation Load

2012 ◽  
Vol 430-432 ◽  
pp. 2067-2070
Author(s):  
Zhang Zhi ◽  
Tai Ping Xiao ◽  
Zheng Mao Chen ◽  
Tai He Shi
Keyword(s):  
Internal Pressure ◽  
Safety Evaluation ◽  
Calculation Model ◽  
Extrusion Force ◽  
External Diameter ◽  
Gas Well ◽  
Seal Failure ◽  
Theoretical Support ◽  
Sustained Casing Pressure ◽  
Casing Pressure

Currently the annulus pressure of gas well becomes more common, so the safe production of several wells has been seriously affected. The annulus pressure mechanism is relatively complex, and it can be approximately classified into annulus pressure induced by temperature effect, by ballooning effect and by leakage or seal failure etc. The article mainly focuses on the annulus pressure mechanism induced by ballooning effect and the corresponding calculation model. For the tubing column with two ends fixed and closed, when tubing internal pressure is larger than the external extrusion force, the external diameter of the tubing column balloons (i.e. ballooning effect). It reduces the annular volume between the tubing and the casing, and consequentially induces annulus pressure. Based on the fundamental theory of elastic-plastic mechanics, the tubing column is simplified into the thin walled cylinder so as to deduce the relation models between the internal pressure and its swell capacity and A annulus pressure value, which provide theoretical support for safety evaluation on annulus pressure and the next treatment program.

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