Document Name: EGYWELLS-WP-007

Annulus Operation Procedure

Annulus Operation Procedure

EGYWELLS-WP-007

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 Document Name: EGYWELLS-WP-007
Annulus Operation Procedure

1. SCOPE
This procedure supports the rational that, throughout the life of a well, functional responsibility for well
oriented activities, which include control and monitoring of well annuli and their integrity, can rest with
different departments. These departments’ roles and accountabilities are given within the procedure.

2. OBJECTIVE
2.1 To define the requirements for the regular surveillance of all platform and subsea wells and their
annuli, to ensure their safe operation and integrity within predetermined operating standards and
parameters.

2.2 To give guidance when there is suspected leakage into the production casing/liner (‘A' annulus) on
platform and subsea wells, and the intermediate/surface casing annuli (‘B' and ‘C' annulus) on
platform wells and also to give guidance on corrosion control in the conductor annulus.

2.3 To define classifications of well capable of self-flow in respect of controlling leakage into the ‘A'
annulus.

2.4 To provide the definition and method of calculating Maximum Allowable Annular Surface Pressure.

3. APPLICABILITY

This policy shall apply to all wells.

4. DEFINITIONS
4.1 General
4.1.1 Annulus Configuration
Annulus configuration shall be identified by alphabetic progression from internal to external casings,
with the ‘A' annulus defined as the annulus within the production casing/liner. In the case of a well having
an extra annulus between the production casing and the tubing, this shall be identified separately, e.g.
an artificial lift well using hydraulic pumping will have a ‘drive' annulus.

4.1.2 MAASP or Maximum Allowable Annular Pressure

The maximum pressure at which an annulus will be operated under normal production conditions. It may
be referred to as the 'Production MAASP' to avoid confusion with the Design or Well Control MAASPs
used at other times in the well's life.

The Production MAASP may change with time in a well, especially for the 'A' annulus where it is
dependent on the density of the packer fluid.

All references to MAASPs in this and associated documents shall mean the 'Production MAASP'.

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Annulus Operation Procedure

4.1.3 Trigger Pressure

The trigger pressure for an annulus is the pressure at which remedial action is required to be initiated
to prevent the pressure rising above MAASP, or to flag that it has risen above Flowing Tubing Head
Pressure (FTHP) for the A annulus.

For the B and C annuli it is normally set at a value below MAASP but above the pressure at which the
annuli will naturally stabilise, to prevent unnecessary blowdowns.

4.1.4 Minimum Desirable Annulus Pressure (MinDAP)

The minimum pressure at which an annulus should normally be operated. Failure to maintain this
pressure does not immediately endanger the integrity of the well, but may be an indication of a failure
that, if left unattended, could result in a loss of integrity.

4.1.5 Minimum Annulus Pressure (MinAP)

The minimum pressure that an annulus shall be operated at for a given annular fluid.
Normally, this is only relevant for gas lifted wells that were not originally designed for gas lift, where
the 'A' annulus may not be able to sustain evacuation to atmosphere without the potential for casing
collapse.
It may also apply to cuttings re-injection and other wells where original design assumptions did not
include the specific load cases under which the well is now required to operate or to which it may be
exposed.

4.2 Well Categories

4.2.1 Hydrocarbon Producing Wells
These will include oil wells, gas wells and water wells where a significant probability of hydrocarbon
production exists.

4.2.2 Water Only Wells

Those wells where the risk of hydrocarbon production is assessed to be negligible.

4.2.3 New Wells

New or worked-over wells that have only recently been started-up, and that may not have achieved
their production/injection potential yet and their annulus pressures may not yet have stabilised.

4.2.4 Routine Wells

Existing wells that have accurately defined potentials and their annulus pressures are stable and are
being operated within pre-determined parameters. This category shall include wells that have been
closed-in and that have not been identified as problem wells.

4.2.5 Sub Sea Wells

Existing wells (as above), that are completed as subsea wells and whose annuli are monitored
remotely.

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4.2.6 Problem Wells

Existing wells deviate from the previously observed ‘routine' performance.
Wells that have been suspended in the Drilling or Completion phase are included in this category.

5. PRACTICE

5.1 New Wells

5.1.1 When the well is formally handed over to Production Operations prior to first production /
injection, the Well Analyst shall provide detailed instructions of the well annulus monitoring /
sampling aspects and precautions to be taken during the initial well start-up. These shall be
identified and included in the Well Start-up Programme.

5.1.2 The well start-up time span shall be from the first perforating of the well until the well is
considered stable.

5.1.3 The specific parameters of each well shall be analysed in order to define the contents of a
Well Start-up Programme. All annulus pressures shall be closely monitored during the initial
warm-up period of the well, to avoid over-pressuring and shall be monitored continuously
until the rate of increase of pressure has stabilised in all annuli.

5.1.4 All annulus pressures on Platform Wells shall be controlled at a level that avoids any
unplanned injection of fluid into the formation.

5.1.5 The Well Start-up Programme shall specify the ‘MAASP' for each annulus, the "Trigger
Pressure" (at which blow-down shall commence), and the figure that the pressure should be
taken down to (normally 60% of MAASP).

5.1.6 NOTE: During initial start-up, the pressure may be bled to a lower value, circa 10% of
MAASP, to limit the frequency of blowdown.

5.1.7 On subsea production wells, after an initial indication of pressure build-up has been
observed on the annulus in excess of the FTHP, the x-over valve may be left open until the
well has built up to a near constant tubing head temperature, and most of the thermal
expansion in the annulus has occurred. The well should then be closed in and the annulus
pressure bled off to leave only flowline pressure trapped. This should provide a positive
pressure differential across the tubing when the well is brought back on stream to monitor for
any tubing leaks.

5.1.8 The Start-up Programme shall also specify the monitoring frequency and blow-down
instructions. This shall include confirmation of annular pressure response after 2 or 3 tubing
volumes have been produced when the well has started to heat up.

5.1.9 NOTE: Any failure of annular pressures to increase in production wells shall be investigated
IMMEDIATELY, and if not resolved, the well shall be shut in forthwith.

5.1.10 The MAASPs for each well are calculated by the Well Engineer, and are maintained in a
data base available on the network servers as part of the Well Integrity Status Tool (E-
WIMS) which is managed by the Well Integrity Engineer. Commented [CJ1]: Does this exist???

5.1.11 MAASPs shall not be exceeded during normal production operations. If exceeded, even
momentarily, this shall be reported and the maximum pressure recorded in the Well History.

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5.1.12 Annulus blow-down returns shall be sampled, where possible, and reported.

5.1.13 Where a well annulus is being tested for or used for cuttings re-injection, the annulus
pressure(s) shall be controlled in accordance with the design parameters for this operation.

5.1.14 Well growth / shrinkage shall be closely monitored and recorded during the initial warm-up or
cool-down period of the new well, in order to predict the final well position at the normal
flowing / injection Tubing Head Temperatures. This data will facilitate the early recognition of
abnormal well growth or shrinkage in order to avoid fouling of Xmas Trees and wellheads
with fixed structures and the generation of abnormal flowline support stresses. It will also
assist in the analysis of any change in behaviour over the life of the well.

5.1.15 To allow detection of a loss of integrity in the well, each annulus shall be maintained at a
measurably different pressure to its neighbours, including the outer annulus where a small
positive pressure shall be maintained. This pressure is referred to as the 'Minimum Desirable
Annulus Pressure' (MinDAP), and shall be stated in the Well Start-up Programme.

5.1.16 NOTE: On wells where there is a requirement to maintain a minimum annulus pressure to
prevent failure of a casing string under collapse loads, a Minimum Annulus Pressure
(MinAP) shall be specified and the fact highlighted in the Well Start-up Programme.

5.1.17 If the pressure falls below the MinAP for whatever reason, this shall be recorded and
reported, and an evaluation of any follow-up requirements made.

5.1.18 Where an annulus leaks off over time to produce a vacuum or zero pressure, then once per
year the annulus shall be re-pressured slightly to confirm the basic integrity of the casing. A
change in the leak-off characteristics (pressure decay) indicates the possible development of
a problem. Excessive injection should be avoided to protect the formations at the shoe.

5.1.19 Where a well is closed in and the annulus pressure declines due to cooling, no immediate
action is required. However, if the well is not brought back on stream within one year of
being shut in, and the pressure differentials re-established, then each annulus shall be
treated as in 6.1.13 above.

5.1.20 The ‘A' annulus pressure shall be maintained as low as practically possible within the above
constraints (gas lift wells excepted) and preferably below the Flowing Tubing Head Pressure
(FTHP).

5.1.21 The ‘B' and ‘C' annuli shall be operated as near zero as practically possible, again within the
above constraints.

5.1.22 All annulus blowdown and operating data shall be forwarded daily to the Well Integrity
Engineer and the Operations Reservoir Engineer onshore for recording and analysis. The
operating data shall be recorded and trended graphically on a minimum weekly frequency.

5.1.23 NOTE: When blowing down and sampling annulus contents, there should be an awareness
of the possible existence of H2S.

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5.1.24 The changes in other annuli (and tubing), whilst blowing down shall be monitored and
recorded.

5.2 Routine Wells

The activities detailed below are required as a minimum to maintain an up-to-date record of the individual
well's annular integrity, but do not immediately endanger the optimum performance or Well integrity if
not executed in a timely manner.

5.2.1 Scheduled Activities:

5.2.2 Annulus pressures on all wells shall be logged on a daily basis by production operations.
Logging may include automatically recording on a Real-Time Monitoring System where a
minimum of one manual record per day is retained for the life of the well. The exceptions to
this is that:

5.2.3 Where the 'A' annulus of platform gas lifted wells that have been 'gassed up' but are not
being actively gas lifted (intermittent gas lift requirement). No routine daily monitoring or
logging is required while the annulus is closed in.

5.2.4 The ‘A' annulus pressure shall be maintained as low as practically possible (gas lift wells
excepted), subject to any Minimum Annular Pressure (MinAP) requirements, and preferably
below the Flowing Tubing Head Pressure (FTHP).

5.2.5 Where possible the ‘B' and ‘C' annuli shall be operated as near zero as possible, but always
subject to any MinAP requirements, and maintaining a measurable pressure differential
across each casing string under normal operating conditions.

5.3 Regular Testing

5.3.1 When testing the SSSV of any non-gas lifted well, if any of the annuli exhibits a pressure
significantly in excess of the minimum desirable A, B, or C annulus pressure, it shall be bled
down to this minimum pressure at a similar rate to the THP. Record details as in "Reporting
Requirements" below.

5.3.2 NOTE: For gas lifted wells, the ASV and GLVs are tested according to the requirements laid
out in the Well Integrity Policy.

5.3.3 If a pressure increase is observed the results shall be analyzed to identify the source of
pressure and leak rate.

5.4 Reporting Requirements

5.4.1 When testing an annulus for pressure build-up during routine testing activities, including the
long term inflow test on gas lifted annuli, the following shall be recorded in Maximo: Commented [CJ2]: ??

a. Initial pressure in the Tubing and each Annulus prior to blowdown.

b. Initial pressure in the Tubing and each Annulus at start of test.
c. Final pressure in the Tubing and each Annulus.
d. Test duration.
e. On blowing down an annulus, the following shall be recorded and reported on the morning
operations report:
f. Date and time of blowdown.
g. Pressure before and after blowdown.

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h. Record the changes in other annuli and tubing whilst blowing down. When a problem has been
identified with an annulus (i.e. by repeatedly requiring blowdown), the following additional
information shall be recorded:
i. An accurate measurement of the volume returned.
j. A sample of the returned fluid. Where the presence of hydrocarbons is suspected, a portable
meter shall be used to check for the presence of H 2 S and gas.
k. If a leak is identified, the Operations Reservoir Engineer, with the support of the Well Integrity
Engineer, shall issue an Annulus Investigation Proposal / Programme in accordance with this
document.

5.5 Ad-hoc Activities

5.5.1 When restarting a well that has been closed in, the annulus pressures shall be monitored on
a continuous basis until any increase in pressure due to thermal expansion has stabilised in
all annuli.
5.5.2 Following the shutdown of a WI well, the annulus pressures shall be monitored on a
continuous basis until any increase in pressure due to thermal expansion has stabilised in all
annuli.

5.6 Well Integrity

5.6.1 When an annulus pressure is noted to be unstable and requires to be blown down frequently
to stay within the Trigger Pressure, an annulus Well Investigation Programme shall be
issued by the Operations Reservoir Engineer / Well Integrity Engineer.
5.6.2 If the annulus is found to be ‘live', the well will fall under the category of a Problem Well.

5.7 Problem Wells

5.7.1 These wells will have been observed to deviate from the previous ‘ROUTINE' performance.
Generally this is the result of the development of a leak(s) and the build up of annular
pressure that may exceed the MAASP and threaten the wells integrity.
5.7.2 Whenever a leak is suspected, a Well Investigation Programme issued by the Well Integrity
Engineer, shall be initiated. On confirmation of a leak, the well will be handled as detailed in
the Annulus Leakage procedure.
5.7.3 The Well Investigation Programme shall ensure the well is given a high level of attention in
gathering information to establish the cause and location of any suspected leak.

5.8 Sub Sea Wells

5.8.1 The design of production casing (‘A' annulus) in a subsea well shall ensure that gas to
surface at full reservoir pressure can be contained above a fluid column.

5.8.2 The ‘B' and ‘C' annuli of subsea wells cannot be monitored or bled off. Therefore, the design
of these casings/annuli shall consider the ability to contain undetectable leakage, including
pressures that are due to thermal effects.

5.8.3 The partial displacement of annulus fluid into the formation via the casing shoe may be
included in the specific design criteria for certain annuli in subsea wells.

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5.8.4 In subsea gas lifted wells, where gas is injected directly into the ‘A' annulus thereby making
it ‘live', then consideration shall be given to designing the ‘B' annulus as a secondary barrier
to contain the well. The maximum gas injection pressure shall be used to calculate the
minimum acceptable casing shoe depth from formation strength data, taking into account
that the 'B' Annulus may be displaced to a gas column, as per 6.4.3. above.

5.9 Accountability
5.9.1 Production Operations Offshore

5.9.1.1 Carry out monitoring, blowing down and controlling and investigating well annuli.

5.9.1.2 Provide feedback on programmed activities to allow support departments to analyse

results.

5.9.1.3 Ensure that all instrumentation used or associated with the routine surveillance and
monitoring of well annuli pressures is properly maintained and calibrated.

5.9.2 Well Engineering Support

5.9.2.1 Carry out programme preparation for well construction, intervention, workover and
abandonment.

5.9.2.2 Programmes shall ensure that the well is technically sound, operable and
maintainable.

5.9.2.3 Establish the MAASP of each annulus, using information derived from leak-off data,
shoe depths, annulus completion fluid, casing weight and strength and the pressure
tests applied during well construction. Record the MAASPs in the Well Integrity
Management System (E-WIMS) data base, and advise the Well Integrity Engineer.

5.9.2.4 Specify and record in WIST the Minimum Desirable Annular Pressure (MinDAP) for
each annulus, and in the case of gas lifted wells, specify and highlight if a Minimum
Annular Pressure (MinAP) is to be applied once the 'A' annulus is displaced to gas.
This shall also be applied to other wells, e.g. cuttings re-injection, where a pressure
is required to maintain the integrity of the well in the particular circumstances.

5.9.2.5 Periodic review of the MAASP and MinDAP / MinAP, and revision as required
reflecting changes in the well characteristics.

5.9.3 Reservoir Engineering Support

5.9.3.1 Produce the well completion design parameters and well testing and treatment
requirements.

5.9.3.2 Carry out well performance and surveillance evaluation.

5.9.3.3 Develop annulus investigation programmes with support from Well Integrity
Engineer / Well Analyst / Well Engineering as required.

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5.9.4 Production Operations Onshore Support

5.9.4.1 Well Analyst (Asset Specific)

a. Manage the performance and surveillance of wells and their annuli within the design
parameters.
b. Co-ordinate well performance related activities as data custodian for all performance
related well data.
c. Review and routinely trend annulus pressure performance, and identify anomalous
behavior for investigation.

5.9.4.2 Well Integrity Engineer

a. Manage the Operational Well Integrity Assurance Procedure.
b. Co-ordinate well integrity related activities as custodian and source of all well
integrity operating and control parameters, and the current well integrity status data,
using E-WIMS.

5.10 Annulus Leakage

5.10.1 In all hydrocarbon wells capable of natural flow to atmosphere where a leak has developed
above the SSSV, the SSSV leak test frequency shall be increased as follows:

5.10.2 Manned Installations - once every month

5.10.3 Subsea wells - once every 3 months.

5.10.4 In all water injection wells capable of natural flow to atmosphere where a leak has developed
above the SSSV, the SSSV leak test frequency shall be once every 3 months. This is to
establish that no leak below the SSSV has developed, which would provide a leak path that
bypasses the SSSV.

5.10.5 In hydrocarbon wells capable of natural flow to atmosphere where a leak has developed
below the SSSV with a leak rate greater than the allowable SSSV leak rate, the well shall be
made safe at the earliest opportunity. The activity shall be included in the planning sequence
within one month of the leak being discovered, and execution must take place within a
further:

5.10.6 one month on platforms, or

5.10.7 Three months on subsea wells.

5.10.8 NOTE: If either the plan is not committed to within one month, or the work is planned to
extend or is delayed beyond the overall timescale, a dispensation shall be raised as an audit
trail.

5.10.9 The method for dealing with annular leaks, both above and below the allowable leak rate, is
contained in the following document. - Annulus Leakage Procedure

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5.11 Annulus Fluid

5.11.1 The basic design of the production casing shall ensure that gas to surface at full reservoir
pressure above a fluid column can be contained. This design will also ensure that wells can
be bullhead killed as design criteria for this are less stringent.

5.11.2 The ‘A' annulus fluid for all of these wells can be underbalanced, and is normally inhibited
sea water or fresh water. The exception to this will be gas lift wells where the ‘A' annulus is
used for injection purposes.

5.11.3 NOTE: In gas wells with very low reservoir pressures, where sea water or fresh water could
cause damage if it were released to the formation, base oil or condensate may be used as
the 'A' annulus fluid.

5.11.4 Gas lifted wells shall be designed to accommodate complete evacuation of the 'A' annulus to
atmosphere down to the lowest gas lift mandrel.

5.11.5 In certain circumstances, such as gas lifted wells that were not originally designed for gas
lift, or the design load was not considered, the ('A') annulus may not be able to sustain
evacuation to atmosphere without the potential for casing collapse. A Minimum Annulus
Pressure (MinAP) shall be specified for these wells for a given annular fluid, and a warning
shall be placed on the Well Status Diagram. This warning shall include the value above
which pressure shall be maintained for that annulus. The annulus pressure of these wells
shall not be bled down to less that the MinAP without compensation for the loss in pressure
by the prior introduction of a column of fluid into the annulus of sufficient vertical height to
compensate for the reduction in surface pressure.

5.11.6 Lubrication of fluids into any annulus shall be with a compatible and suitably inhibited fluid.

5.11.7 A floating corrosion inhibitor shall be placed in the "Conductor" annulus on platform wells to
prevent corrosion of the surface casing and conductor at the fluid / air interface.

5.11.8 Where the surface casing is breached at the fluid / air interface, sufficient inhibitor shall be
placed in the conductor annulus to fully cover the hole and prevent ingress of air to the inner
annulus. Due account shall be taken of relative density and tidal effects where the conductor
is open to the sea.

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