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ABSTRACT
ZADCO owns more than 500 wells operating in UZ, UA
& ST fields to contribute in achieving the production
targets as set by the Shareholders. To ensure that wells
operate as designed for their assigned life (or greater)
with all risks kept as low as reasonably practicable or as
mentioned, it is important to insure individual wells
integrity. Hence, ZADCO developed an in-house Well
Integrity Management System (WIMS), which defines &
provides the operating standards & guidelines for
maintaining the well integrity parameters, ensuring safe
well operations and securing well potential availability
during its life cycle so that return on investment is
maximized without the sacrifice of safety and
environment.
The implementation of ZADCOs well integrity process
follows the cycle assurance testing, preventive
measures, monitoring, evaluation / assessment, control
& remedy, audit / verification.
This paper reviews WIMS in ZADCO. WIMS is
structured to include wellhead (surface) equipment,
downhole equipment and operational (process control).
WIMS places much emphasis on the requirement of
barriers for safety and environmental protection.
Key Words:
Well Integrity Management System, Well Barriers,
Wellhead Equipment, Sub-surface Equipment, Scale
& Corrosion Management, Risk Management.
INTRODUCTION:
The objective of developing Well Integrity Management
System (WIMS) is to provide standard guidelines to
ensure that technical integrity of all the wells is
maintained throughout their life cycle, they operate
under safe condition and are capable to function
continuously to achieve the targeted production/injection
requirements. Well integrity is based on the
establishment and maintenance of confinement barriers
in the particular well. As per WIMS standards, a well is
considered integral if at least two separate and sound
confinement barriers across each flow path between the
potential reservoir and surface are available all the time.
WIMS very much emphasis on the problem prevention
based approach (endeavour to predict & solve the
problem before it happens) that can accommodate
several direct advantages and benefits like reduction in
operating down time, enhancement in well control and
safety aspects, minimized unplanned repair intervention
& cost impact etc.
Major well issues that would have impact on the
technical integrity and operability of a well viz; Surface
Completion Components (Wellhead & X-mass tree),
Sub-surface Completion Components (downhole safety
valve (DHSV), Gas lift valves, electric submersible pump
(ESP), Well Construction (Casing & Annulus),
Communication Problems, Corrosion, Scaling, Nonhydrocarbon Effluents / Products, Well Operation
Suspension, Well Intervention Services (Electric/Slick
Line, Stimulation, coiled tubing unit (CTU), Risk
Management Process & Auditing System, etc. have
been thoroughly discussed in the WIMS manual.
WELL BARRIERS:
The barrier is a protection measure to prevent an
uncontrolled release of hydrocarbons to surface via
production strings or from reservoir to well annulus.
Primary barriers always control immediately the wells
up-stream side pressure, whereas secondary barriers,
which normally have no well-bore pressure against
them, immediately supplement the primary barriers
(Fig.1). A barrier that loses its integrity is classified as
SPE 88696
Seals Integrity:
PRIMARY BARRIER
SECONDARY BARRIER
X-MASS TREE
RING GASKET
NEEDLE VALVE
PRODUCTION
ANNULUS
CONTROL LINE
7 LINER TOP
CEMENT
FLOW UPPER ZONE
7 PERMENANT PKR
The gates, seats, stem packing and gate valve plugs are
classified as mobile components. These components
can be tested hydraulically or against wellhead shut-in
pressure. In case of hydro test, 110% of the maximum
expected operating pressure of the component and in
other cases; maximum achievable wellhead shut-in
pressure for 10 minutes at least is considered the test
limits. The acceptable criterion should be no visible
external leak & zero pressure drops. Testing frequency
for x-mass tree valves is recommended to be the 6
months and for annuli valves to be the one-year.
Valves Integrity Failure Causes & Cures:
Malfunction
Cause
Cures
Wells
pressure
leaks
past
valve.
Line
fluid
leaks between
valve
body
and bonnet.
Downhole
eqpt. will not
Disassemble the
valve and reinstall
the gate and seat.
SPE 88696
pass through
open valve.
Valve jumps
open
when
pressure
is
applied
to
actuator.
Valve
does
not close.
Hard
operate.
to
properly.
Excessive
pressure
differential
across
valve
gate.
Pressure
remains
in
actuator
cylinder.
Excessive
friction on gate.
Hydrates or ice
in valve body.
Insufficient
lubricant.
Restriction
body cavity.
in
Erratic
operation.
Iced up due to
restricted flow,
hydrates or low
temperatures.
Accumulation of
mud, sand or
other
foreign
matter in valve
body.
Stem threads
damaged.
Shear
pin
dragging
on
bearing cover.
Stem or stem
nut is broken or
threads
are
stripped.
Sheer pin is
broken.
Gate
not
properly aligned
with bore of
seats.
Stem threads
damaged.
Leaking
bonnet flange.
Leaking
around stem.
Bearing needs
to be lubricated.
Bearings
are
broken.
Leaking bonnet
seal ring.
Packing and/or
stem damaged.
Worn
Hand-wheel
not working.
Restriction in
bore of valve.
or
gate position on
stem.
Pressurize
downstream flow
line to approx.
75% of existing
well pressure.
Bleed off actuator
pressure.
Lubricate
valve.
the
Grease fitting
leaking.
Tighten cap
replace fitting.
or
Preventive Maintenance:
Preventive maintenance is aimed at maintaining the
wellhead equipment as per procedures specified by the
manufacturer, extend the components life cycle and
avoid harsh fluid entrapping inside gate valves cavity.
Preventive maintenance is further divided in two
categories viz routine-based and non routine-based.
Routine-based preventive maintenance at regular
interval is purposed to flush out the sludge/debris from
body cavity and provide lubrication to valve stem
threads, bushing & gate/seat sealing surface in addition
to protection against corrosion. On the other hand, non
routine-based preventive maintenance is purposed to
protect the x-mass tree and valves internals from the
expected corrosion attack as result of stimulation, killing,
injection and descaling or polymer treatment operations.
General guidelines for the preventive maintenance are
highlighted as following:
Repair or replace.
Realign pin.
SPE 88696
Where,
Q
P2
P
T2-T1
=
=
=
=
Leak rate of 6.3 USG/hr. for oil wells and 400 USG/hr.
for water wells is considered to be acceptable. In case of
gas wells, acceptable leak rate depends on tubing size.
For example, 124 psig/hr. pressure build-up in a 3
tubing is considered acceptable in ZADCO. Any test
failure is to be recorded in the prescribed Failure Report
form as provided in the WIMS manual.
Preventive Maintenance:
In order to avoid any risk in operating DHSV due to any
solids, scale or asphaltene deposition on its body or due
to packing deterioration, it is imperative to replace the
DHSV every year in gas wells and every 2-3 years in oil
or water wells. Besides, every time when the DHSV is
pulled out of hole during any down hole operation, it
must be thoroughly inspected, serviced or even
replaced if its overall condition is found deteriorated.
DHSV should be repaired and function tested in an
SPE 88696
Mechanical System
b.
CORROSION MANAGEMENT:
This section addresses corrosion management of wells.
It is known that corrosion is a major threat to wells.
Hence, strenuous efforts are made to contain corrosion
in all its ramifications. Emphasis is, therefore, put on
corrosion management as a means to assure asset
integrity.
Corrosion management is divided broadly into corrosion
control and corrosion monitoring.
Corrosion Control:
Zadco has developed Simulation Model (software
program) to predict the wells/ strings that might have
scaling tendency.
Produced water analysis
parameters are loaded in the model on monthly
basis as well as the wet strings are further updated
for mechanical monitoring to confirm the potential of
scale deposition. Proactive scale treatment is
planned on model prediction results.
Scale Prevention & Remedial Process:
Frequent wireline gauge cutter / scratchier runs should
be made in the strings, producing water or have scale
potential, to prevent / remove scale deposits. In case
wireline tools fail to remove the scale deposits then
following two methods should be used to remove the
scaling.
a.
Material Selection:
Material section for completion string, casing and x-mass
tree depends on the reservoir and process operating
conditions, the stings are either carbon steel (L-80) or
13% Cr (L-80). After gas breakthrough (GBT) in Upper
Zakum the string material may be upgraded. Selection
of material for the strings is generally carried out by the
aid of software ZADCORE, the ZADCO down hole
corrosion model. Casing is made of carbon steel (Grade
C-75) and x-mass tree material selection is based on
API6A. ZADCOs current x-mass tree grade is EE trim.
SPE 88696
IMPLEMENTATION OF WIMS:
Caliper Survey:
Multifinger caliper surveys were extensively conducted
inside the tubing in the past to produce a model for
tubing corrosion. The surveys provided very useful data
about tubing metal loss with emphasis in corrosion
inhibitor efficiency and effectiveness. It shall be used
whenever this is required to establish a particular tubing
condition.
SPE 88696
COMPONENT
FUNCTION /
INTEGRITY TEST
MAINT. /
INSP.
FREQUENCY
3 months
Corrosion
Monitoring (Oil
Producers)
Monitor Corrosion
in tubing by WL
(installation
of
corrosion
coupons).
Carryout
CI
squeeze treatment
in the wells that
might
have
corrosion
tendency
Sticky Material
Monitoring
(Gas Injectors)
WL checks to
monitor
sticky
material presence
in tubing, DHSV,
nipple
profile.
Collect
samples
and analyze
3 months
H2/H2S
Monitoring
Monitor
annuli
gas,
collect
samples
and
analyze to check
for any presence
of H2 /H2S gas in
the annuli
Closely
monitor
near by producers
for
gas
break
through in gas
injection area.
6 months
Gas
Break
Through
Monitoring
3 months
SPE 88696
Severity
People
Assets
Environment
Reputation
5. Catastrophic
Mulitiple
fatalities or
permanent
total
Extensive damage
> 10 Million
Massive
effect
International
impact
4. Severe
Single fatality
or permanent
total disability
Major Damage
< 10 Million
Major
effect
National
impact
3. Critical
Major injury or
health effects
Local Damage
~ 0.5 Million
2. Marginal
Minor injury or
health effects
Minor Damage
~ 0.10 Million
Minor
effect
Minor
impact
1. Negligible
Slight injury or
health effects
Slight Damage
<0.01 Million
Slight
effect
Slight
impact
Happens
Has occurred Has occurred Has Occurred Several times Happens several
per year in
times per year
in World-wide
in other
in specific
industry but ADNOC Group ADNOC Group specific ADNOC in same location
Group
or operation
not in ADNOC
Company
Company
Company
HIGH RISK
Localised Considerab
effect
le impact
MEDIUM RISK
LOW RISK