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LCA Application for Casing Design Well Integrity: Case Study Aquifer External
Corrosion Attack in Middle East

Article · January 2011

DOI: 10.2118/142129-MS

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SPE 142129

LCA Application for Casing Design Well Integrity: Case Study Aquifer External
Corrosion Attack in Middle East
Ardian Nengkoda, Schlumberger, Pajang Priyandoko, Petroleum Development Oman, Mia Wimala Soejoso,
Hiroshima University

Copyright 2011, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE Projects and Facilities Challenges Conference at METS held in Doha, Qatar, 13–16 February 2011.

This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents of the paper have not been reviewed
by the Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessarily reflect any position of the Society of Petroleum Engineers, its officers, or
members. Electronic reproduction, distribution, or storage of any part of this paper without the written consent of the Society of Petroleum Engineers is prohibited. Permission to reproduce in print is
restricted to an abstract of not more than 300 words; illustrations may not be copied. The abstract must contain conspicuous acknowledgment of SPE copyright.

Abstract
For many years, casing has reported failed rapidly in some Middle East oil and gas wells due to external corrosion casing. Repairs
of casing failures are not efficient and costly. Mitigation of external corrosion as a part of well integrity on well casing is important
to prevent from such water attack, H2S bacterial activity, electrolytic effects, and cathodic reaction. The alternative solutions based
on LCA (Life Cycle Analysis) have been studied with objective to understand the casing leak and failure based on statistical data
and to see the economic solutions over the life of the well by option of the use of coatings, dual casing or increase the thickness of
casing materials. Casing corrosion will result not only in the loss of the casing but also in the interruption of production, loss of the
well, or even permanent damage to the reservoir. Some of the statistic from study showed that 60% of single casing wells failed
within less than 8 years while the external corrosion confirmed as an evidence from corrosion log run in some wells, due to
shallow aquifer corrosivity. The studied summarized that coated casing is attractive solution for life of the well and the field trial to
see the abrasion and water corrosion resistance showed this conclusion. Future sidetracking and surveillance need to be considered
for the coating protection.

Introduction
For many years, casing has reported failed rapidly in some Middle East oil and gas wells due to external corrosion
casing. Repairs of casing failures are not efficient and costly. Mitigation of external corrosion as a part of well integrity on well
casing is important to prevent from such shallow water aquifer attack, H2S bacterial activity, electrolytic effects, and cathodic
reaction. The alternative solutions based on LCA (Life Cycle Analysis) have been studied with objective to understand the casing
leak and failure based on statistical data and to identify the economic solutions over the life of the well by option of the use of
coatings, dual casing or even increase the thickness of casing materials.

Casing Corrosion
Casing corrosion will result not only in the loss of the casing but also in the interruption of production, loss of the well,
or even permanent damage to the reservoir. Some of the statistic from Middle East case study showed that 60% of single casing
wells failed within less than 8 years while the external corrosion confirmed as an evidence from corrosion log run in some wells,
due to shallow aquifer corrosivity. Figure 1 explaining a typical root caused of well integrity in Middle East where external
corrosion attack play crucial damage.
The interesting question then, Why most of the leaks are at shallow depth? A part of Figure 1, corrosion logs job have
been performed and confirmed external corrosion, the typical of aquifer water across the area can be vary such from Umm er
radhuma / UER with depth 150 m below ground level), Fars or Dammam with depth of 100 m, however it was found that oxygen
level are exist in shallow water sources and contain possible SRB bacteria. The depth of corrosion especially in well located in the
affected area may reach around 100 m or be slightly deeper.
As definition refer to IS0 80441, corrosion is interaction between a metal and its environment that results in changes in
the properties of the metal or detoration and which may lead to significant impairment of the function of the metal, the
2 SPE 142129

environment or the technical system of which these form a part, meanwhile a corrosion allowance is designed addition to the
thickness of a component to allow for reduction in thickness of that component by corrosion during its design life, while ensuring
continued safe operation.
A significant approach in the evaluation of solutions can be approached by the complementary use of the
methodologies of life-cycle assessment (LCA). General applications of the LCA methodology are the development and
improvement of such technical products, and processes as well as services and the strategic planning (as the instrument allows for
the identification of the most critical life stage or the most critical emission of the functional unit).
The LCA procedure itself has been laid down in ISO 14040 as a normative reference, shown at Figure 2. It is a
stepwise procedure with mandatory and optional elements.
1. In the first step, the ultimate goal and the application of the results have to be defined. It has to be laid down as to whether a
comparative assertion disclosed to the public will be performed since such a scope triggers several sub-steps and the final
results presentation. Additionally, system boundaries have to be laid down as they, to a great extent, will finally influence
the LCA results.
2. The second step comprises the input and output analysis. Any material and energy flow within the system boundaries and
also entering and leaving the system is documented. “Material”, in this context, can be products alternative to protect
external casing corrosion.
3. The third step is the impact assessment being divided into several sub-steps. First, the inventorized material and energy
flows are assigned to environmental problems operationalized as impact categories (classification). The second sub-step, the
characterization, tries to assess the contribution of the assigned input/output data to the respective impact category to result
finally in an impact profile. This can be achieved by using models, which combine the input/output data from the inventory
and a so-called indicator expressing the environmental effects or damages. In general, the indicators allow, in terms of being
“units”, for an aggregation of all emission-based contributions within each impact category. If appropriate, characterization
factors are used to quantify the contribution of each single emission to the respective category. The models range from
quantitative and internationally accepted ones to expert- or even value-based individual models.
The last step of an LCA is the interpretation phase. Value choices for the impact categories with their subsequent weighting can,
for example, be made in order to focus on a single aspect that has been documented in the goal definition

In regard to the casing integrity review solutions, total corrosion cost is given by the sum of the corrosion costs
associated with four aspects of the life of a facility: Capex, Opex, cost of lost production caused by equipment failure and material
residual value. Specifically as applied to the LCA evaluation for material selection and corrosion protection, all aspect need to be
identified to the contributors to the cost of corrosion for materials, equipment and operation by examining:
a) capital cost (CAPEX)
b) operating cost (OPEX)
c) material residual value
d) cost of lost production caused by equipment failure

Casing Failure Data Review

With a challange on the availability of statistical data, from the snap shoot of Middle East (3 Countries) and some data
of casing failure it is found that:
• Failure percentage of single casing is higher than dual casing (Avg/yr 6 % Vs 3.3%)
– 50% of Single casing wells failed within 8 years.
– Linear failure trend with time, as Figure 4.
• External corrosion confirmed from corrosion log run in some wells, due to shallow aquifer or shallow water disposal.
• 91% of leaks in field area are located above 250m as describe by Figure 3, where it is indicate shallow aquifer water
corrosion attack.

While in another hand, some lesson learnt and practices have been gathered as:
• Choice of completion depends on
– Life cycle
– Desire for sidetracking and surveillance
• Coated casing is an attractive solution based on cost and have been applied in more than 20 wells, however still contain
some possible risks such as:
– Assuring 100% coverage including couplings
– Longevity of coating beyond 5 years
• Single casing Vs Multi casing, which one is giving more longer life
SPE 142129 3

To prevent a corrosion attack and integrity problems such abrasion, the requirements of casing coating and wrapping need to
follow a very tight standard such below matrix:

LCA Analysis
A complete set of LCA Analysis are developing by below completions scenarios:
• Do nothing (Single casing 9-5/8)
• Two casing design 13-3/8 x 9-5/8
• Two casing design 9-5/8 X 7
• Single- Coated 9-5/8 Csg
• Single- Coated 7 Csg

And the results are as follows:

Do nothing : Single 9-5/8 Csg.

Cost :
Horizontal 9-5/8”deep set: $892,792
Current casing design:
Has 33% integrity failure
Proven repair option
High life cycle cost

2nd Option: Two casing design 9-5/8 X 7

Cost :
9-5/8 Shallow set casing : $914,965
Packer : -$ 16,823
Running and cementing 7, 0.5 days : $ 9,025
7” casing and accessories : $ 25,272
Cementing Annulus 9-5/8 – 7” : $ 12,000
Total cost : $ 944,439
Advantage:
Slim design
Proven integrity
Limited repair option
Limited conventional side track
4 SPE 142129

3rd Option: Single- Coated 9-5/8 Casing

Cost :
Horizontal 9-5/8”deep set : $892,792
Coated 250 m (20 x $868) : $ 17,360
Additional to run coated casing : $ 5,000
Total cost : $ 915,152
For coating 500m estimated $937,512 as explain by Figure 5.

4th Option: Single- Coated 7 Casing

Cost :
Horizontal 7”deep set : $738,058
Coated 250 m (20 x $756) : $ 15,120
Additional to run coated casing : $ 5,000
Total cost : $ 758,178
For coating 500m estimated $ 778,298
Advantage:
Cheapest Solution
Limited conventional S/T
Limited repair option

Conclusion
Casing corrosion in Middle East due to external corrosion casing aquifer water is increasing phenomena and the
alternative solutions based on LCA (Life Cycle Analysis) to identify option such of coatings is a reliable and promising
(economics). Casing corrosion will result not only in the loss of the casing but also in the interruption of production, loss of the
well, or even permanent damage to the reservoir. The studied summarized that coated casing is attractive solution for life of the
well and the field trial to see the abrasion and water corrosion resistance showed this conclusion. Future sidetracking and
surveillance need to be considered for the coating protection.
A key finding based on LCA study above are:
• Single coated 9-5/8” casing design is good for long life well with option to sidetrack. Can accommodate dual strings
• Single coated 7” well is also suitable but with limited conventional sidetrack and no dual strings.

Acknowledgments
Special thanks are given to Schlumberger to publish this technical study.

References

1. Dethlefs, J. et al.: “Near Surface External Casing Corrosion in Alaska; Cause and Mitigation,” paper SPE 100432 presented
at the 2006 SPE Western Regional/AAPG Pacific Section/GSA Cordilleran Section Joint Meeting held in Anchorag e,
Alaska, 8-10 May 2006
2. Loveland, MJ. Et al.: “Well Integrity Assurance: A Successful Method for External Corrosion and Damage Detection on
Outer and Middle Concentric Strings of Casing,” paper SPE 108698 presented at the 2007 SPE Annual Technical
Conference and Exh ibition held in Anaheim, California, 11-14 November 2007.
3. R.G. Blakney, SPE, New Mexico Institute of Mining & Technology; M.J. Loveland, SPE, P. Klein, SPE, Conoco, Case
Study: Shallow Surface Casing Corrosion Mitigation Evaluation, SPE 130395, 2010
4. PDO Teams, Casing Leak Study, 2006
SPE 142129 5

Apendix

Figure 1. General Root Causes of Well Integrity in Middle East

Figure 2. Phases of LCA (Guinee 2002, ISO14000, 2000)

6 SPE 142129

Figure 3. Statistical Single Casing Leak Depth

Figure 4. Single Casing Fail Frequency

SPE 142129 7

Figure 5. 3rd Option – Coated Casing Application

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