Well Integrity

Management
and failure case
Studies

Sanjay Bhatt
Head Regional
Crisis
Management
Team, ONGC,
Mumbai

India’s only Energy Company in Fortune’s ‘World’s Most Admired’ List

 Production distribution

Crude Oil
Oil Production
Production Natural Gas Production
KG 6%
KG 1%
Cauvery 5%
Assam 2% Tripura 1%
Assam 5% Cauvery 1%
Rajasthan 2%

Offshore Offshore
69% 76%

Western onshore 24% Western onshore 8%

Majority of Oil & Gas Production is from Offshore fields

 Wellofdetails
Definition Well Integrity

Application of technical, operational and organizational solutions to

reduce risk of uncontrolled release of formation fluids throughout the
life cycle of a well (NORSOK D-010)

India’s only Energy Company in Fortune’s ‘World’s Most Admired’ List

 Well details
Well Integrity Life Cycle

• Design
& Construct Design Drill Complete

• Operate Produce

• Maintain Repair Work over + Side-track Produce

• Abandon Temporary / Permanent

India’s only Energy Company in Fortune’s ‘World’s Most Admired’ List

 Well Integrity
WellManagement
details System
• Accountability & Responsibility

• Well Operations

• Well Interventions

• Tubing / Annulus Program

• Wellhead / Tree Maintenance

• Safety Valve Program

India’s only Energy Company in Fortune’s ‘World’s Most Admired’ List
 Well Integrity
WellManagement
details System
• Accountability : Accountable, responsible and Team Approach
& Responsibility
• Well Operations : Well operation & Handover, Personnel Competence
Procedures: Startup, operating, shutdown Corrosion & Erosion
Management
• Well Interventions :Well ownership & Handover, Personnel Competency
Procedure, Records, Document well service event
• Tubing / Annulus Program : Assigned operating pressure limit
Report anomalies, Respond to anomaly reports
Every well is different – need to understand the risk of continued
operation
• Wellhead / Tree Maintenance :Tree & Well head valves serviced twice per year
Wellhead team to handle wellhead leaks
• Safety Valve Program : SSV on all producers
Downhole safety valve on gas injectors & offshore wells and Tested
every 6 months
India’s only Energy Company in Fortune’s ‘World’s Most Admired’ List
 Well Integrity Management system
Ageing Barrier Diagram for Avoidance and Mitigation of HC leaks, Fire and Explosion
Process
Damage to
Ignition
Corrosion, Erosion, Hydro Equipment, Injury to
Fatigue, Vibration, Source,
carbon Escape, Personnel
Degradation of Fire &
Leak Evacuation
Material, Blockage of explosion
& Rescue
Hydrocarbon System

Barrier System

- Historic 1 2 3 4 5 6 7 8 9 10 11

- Subject to
1. Good Material Choice 7. Fire & smoke detection
Ageing Process
2. Proper design for corrosion protection 8. Active fire protection
3. Good fatigue design 9. Passive Fire Protection
4. Inspection & Maintenance 10. Blast Walls
5. Gas Detection system 11. EER Facility
6. Emergency Shut Down System
India’s only Energy Company in Fortune’s ‘World’s Most Admired’ List
Age Statistics of Jackets and Wells WO
 Design life of all platform is 25 years except
 Design life of Platform NG(F0, NA,ND,NC,NE,NF,NB,NK,NI IS 20 YEARS.
All these Jackets were commissioned before 1980
 Design life of B-173A is 10 years

 Platform Installed in mid seventies and most are still in place.

 More than 40% of platforms have exceeded initial design life.

 Design Life:- The assumed period for which a structure is to be used for
its intended purpose with anticipated maintenance but without
substantial repair from ageing processes being necessary.
 Life Extension: Continued operation of an installation beyond the design
life assumed at the time of design or revised following a reassessment
with reference to a new base line to reflect changes through prior
service.

 IMR group/ IOT/Engg Services is doing recertification of Jackets for Life

Extension

India’s only Energy Company in Fortune’s ‘World’s Most Admired’ List

 Loss of well integrity & ONGC’s Concern for mitigation

Leaks in Casing hanger seals

A high level committee after analyzing well integrity
Leaks caused by erosion / related issues have prepared a detail report with
corrosion / fatigue / suggestion for improving well integrity
vibration
• To implement solutions for sustained casing
Leaks caused by
burst/collapsed casings pressure in the wells.
• Improve historic barrier in new wells
Leaks caused by degraded
cement quality • Managing SCP in accordance with API-RP-90
• Modalities to be adopted in future wells
Leaks caused by failing • Measures to Prevent SCP in existing wells & New
valve / packer
Wells

India’s only Energy Company in Fortune’s ‘World’s Most Admired’ List

 Well Well
Case History-I details
Integrity Failure
Well Drilled : 28.03.1997
Drilled Depth :1055 mtrs

2 7/8”
tubing 13 5/8” C/S @
255.32 M

Cement Rise 7” @ 793mts

Packer @ 883.5 Mtrs Perforation 915.5-920 Mtrs ( Khuila Sand)

7” Bridge plug @ 923.0 Mtrs
7” C/S @ 982.6 M

India’s only Energy Company in Fortune’s ‘World’s Most Admired’ List

 Case History
Well–IIdetails
Well Integrity Failure
KHAS
KHAZ

5.5M

13-3/8” 600 m 13-3/8” 598 m

KOP 657 m

9-5/8” 1850 m 9-5/8” 1900 m

KOP 1897 m

SOURCE zone (2413-2403m) Tubing 3270m

Tubing 3139m
5-1/2” 3288m
5-1/2” 3149m
Drilled Depth 3241 m Drilled Depth 3288 m
 Case History –III Well Integrity Failure C

Gas Leakage from surface casing # NSBX

B

 Observed activity of Gas flow from 30’x20” Annulus and Gas

A
was gushing Horizontally from outside of 30” casing at well
NSBX.
 On closely observing of leakage point it revealed that 20”casing
has hole 2m below well head deck. Gas is gushing out from 20”
and coming out from 30”casing horizontally,
 “A” section flowing pressure was 290psi

India’s only Energy Company in Fortune’s ‘World’s Most Admired’ List

Case History –III Well Integrity Failure C

Gas Leakage from surface casing

B

India’s only Energy Company in Fortune’s ‘World’s Most Admired’ List

 Reason for Gas leakage
30” Conductor 153m
HT of well NS#2Y was leaking and had shallow ST

20” 294m

396m
374m
405m
394m
455m

7” HT 965m

13 3/8” 1063m

95/8” 1165m

7”Liner 1288m

6” Drain hole 1810m

India’s only Energy Company in Fortune’s ‘World’s Most Admired’ List

 Case –IV Integrity Failure In EOR-Air Injector Well BALOL#45

TW4 TW7 TW1 TW14 TW2 TW5

TW13 TW8 TW6 TW9 TW18 TW3 TW10 TW GGS 2(NEW)

Bal45
•Balol#45 (BL#45) Was a air
injector well Tuing Punctured at 273m
•plan was to abandonment and
Csg Damaged at 346m
drill a substitute vertical well
just 11 meter away
•Well could not be subdued
with CTU. Felt obstruction from
300-525m
•Tubing punctured at 273 with
firing gun BALOL # 45
•Observed activities in 3 nearby
tube-wells within 300m radius
0n 23/11/2007
India’s only Energy Company in Fortune’s ‘World’s Most Admired’ List
Case –IV Integrity Failure In EOR-Air Injector Well BALOL#45

TW#2: 27/11/07 TW#2: 28/11/07

India’s only Energy

TW#8: Company in Fortune’s ‘World’s
24/11/07 Most Admired’
TW#8: 28/11/07List
TW#8: 24/11/07
 Case –IV Integrity Failure In EOR-Air Injector Well BALOL#45

TW#3 : 27/11/07 14:28 TW#3 30/11/07

TW#1: 01/12/07
TW#5: 30/11/07 India’s only Energy Company in Fortune’s ‘World’s Most Admired’ List
TW#8: 24/11/07
 Cave Creation, Algeria

India’s only Energy Company in Fortune’s ‘World’s Most Admired’ List

 Indonesia Mud Volcano

India’s only Energy Company in Fortune’s ‘World’s Most Admired’ List

 Remedial Measure- Detection of SCP VSEB#5H

C STHP 1050 psi

• C-section pressure was bled off from 1200 to 160psi. B- 1200 psi
sec Pressure remained constant at 850psi. Further B 1200 psi B
and C-sec pressure build up to 1200 & 1250psi
respectively was observed. 0 psi A
30” Conductor 147m
• B-sec was bled off to 0psi.
20” 405m

• Annulus pressure build-up was again observed (B- 13 3/8” 1016m

sec=1200psi & C-sec=1250psi). Pressures were again
bled off. 95/8”1820m

• A, B & C section well head seals were tested at 500psi,

2000psi & 3500psi, respectively and found OK. 7”Liner 2135m

• Again annulus pressure build-up was observed (B-

sec=1200psi & C-sec=1250psi).

India’s only Energy Company in Fortune’s ‘World’s Most Admired’ List

 Remedial Measure- Detection of SCP VSEB#5H
Detection for Cause of SCP
1. B section Bled off 1150 psi to 0 within 5 minutes. kept psi
C STHP 1050
open and observed feeble gas . 1200 psi
2. C section Bled off from 1200psi to minimum (700 psi). 1200 psi B
Pressures build up observed in B section during
bleeding off of C section and STHP remain unchanged. 0 psi A
3. Flow the well with 1 inch bean size FTHP 450 -600 psi. 30” Conductor 147m
4. After 48 hrs of flow of well with 1” bean size,
20” 405m
a. A section pressure-0
b. B section pressure- 1050 psi 13 3/8” 1016m
c. C section pressure-1125 psi
d. FTHP -575 psi ( with 1 inch bean) 95/8”1820m
5. Well was shut again and following pressures are
recorded:
a. A section pressure-0 7”Liner 2135m

b. B section pressure- 1200 psi

c. C section pressure- 1200 psi
d. STHP - 1050 psi

India’s only Energy Company in Fortune’s ‘World’s Most Admired’ List

 Remedial Measure- Detection of SCP VSEB#5H
Analysis of BOBU for Cause of SCP
C STHP 1050 psi
1200 psi
1. B & C section Pressure were higher than FTHP No
Communication from tubing & packer . 1200 psi B
0 psi A
1. Two possibilities
30” Conductor 147m
a. Formation pressure migrating upward due to poor
cementation behind 7” liner and further in to “C” 20” 405m

section via 7” hanger.( i.e.7” hanger is leaking).

13 3/8” 1016m
b. Formation pressure migrating upward due to poor
cementation behind 7” liner and further upward in
95/8”1820m
to 13 3/8”/ 12 ¼” OH x 95/8” annulus and entering
“C” section from the compromised 95/8” casing
joint. 7”Liner 2135m

2. “B” section bleeds off very quickly and suggest liquid

level is maintained in “B” section annulus. After bleeding
pressure raises in “C” section first then in ”B” section

India’s only Energy Company in Fortune’s ‘World’s Most Admired’ List

 Remedial Measure- Detection of SCP VSEB#5H
ALFA Log for Cause of SCP
C STHP 1050 psi
1200 psi
1. Perform ALFA( Acoustic leak Flow Analyzer) log in 1200 psi B
static and dynamic condition( i.e. keeping all TH,C,B
closed and while keeping TH pressure in closed 0 psi A
condition and bleeding “C” section pressure and 30” Conductor 147m

similarly keeping TH & “C” section closed and “B” 20” 405m

section bleeding/open) to determine exact point of

leakage. 13 3/8” 1016m

95/8”1820m

1. Based on diagnosis by ALFA tool work over plan

shall be made accordingly 7”Liner 2135m

India’s only Energy Company in Fortune’s ‘World’s Most Admired’ List

 Remedial Measure- Detection of SCP VSEB#5H
ALFA Log for Cause of SCP
APPLICATIONS C STHP 1050 psi
• Leak Detection (tubing/casing/packer leaks) 1200 psi

1200 psi B
• Diagnosis of Sustained Casing Pressure
0 psi A
• Location of open perforations 30” Conductor 147m

20” 405m
• Identification of flow zones & channeling behind pipe
13 3/8” 1016m

FEATURES
• Ability to detect flows through multiple tubular. 95/8”1820m

• Ability to distinguish flow behind pipe from flow inside pipe.

7”Liner 2135m

• Combinability with other logging tools to provide a complete well

evaluation in a single run

• Slim tool design allowing safe and easy deployment through the
smallest completion tubing and restrictions
India’s only Energy Company in Fortune’s ‘World’s Most Admired’ List
 VSEB#5H Annulus Pressure Communication Path Detection
The Result

Accountability & Responsibility

Surface Noise

Well Operations
Possible SSV
Leal
Well Interventions
Tubing / Annulus Program
Wellhead / Tree Maintenance
Safety Valve Program

India’s only Energy Company in Fortune’s ‘World’s Most Admired’ List

 VSEB#5H Annulus Pressure Communication Path Detection
The Result

Surface Noise
Accountability & Responsibility
Well Operations
Well Interventions
Possible SSV
Tubing / Annulus Program Leal

Wellhead / Tree Maintenance High Frq noise of 26 kHz

across the entire
surveyed interval
Safety Valve Program associated by micro
annulus channeling

Intense noise in the

High Amplitude noise frequency range of 0-24
recorded in the entire kHz and temp
frequency range perturbation indicating
indicating 7” liner 13 3/8” csg shoe leak at
hanger leak the depth of 1015 m TH

India’s only Energy Company in Fortune’s ‘World’s Most Admired’ List

Corrective Measure: Replace aged casing above boat landing Deck

India’s only Energy Company in Fortune’s ‘World’s Most Admired’ List

Corrective Measure: Replace aged casing in badly corroded casings

Slot recovery using Deflecting Conductor Sleeve

Slot recovery by Milling 20” Casing

India’s only Energy Company in Fortune’s ‘World’s Most Admired’ List

 Why Well Integrity is Important

• Injury

• Environment

• Cost

• Liability

• Future generations „

India’s only Energy Company in Fortune’s ‘World’s Most Admired’ List

India’s only Energy Company in Fortune’s ‘World’s Most Admired’ List
Bliss