WELL INTEGRITY IN PRODUCTION OPERATION

DIDIT ACHMAD BARITO

REVISION MARCH 2024
 REFERENCES
➢ Norsok D-010, Well Integrity in Drilling and Well Operations, rev. 4

➢ ISO/TS 16530-2 Well Integrity Part 2: Well integrity for operational phase

➢ API RP 90-2 Annular casing pressure management for onshore wells

➢ 117 Offshore Norge recommended guidelines well integrity rev. 6

➢ 135 Offshore Norge recommended guidelines for classification and categorization of well
control incidents and well integrity incidents

➢ Step Change in Safety MAH Vlog Well Integrity

➢ Schlumberger well barrier presentation

Well Integrity in Production Operation Flyer, by Didit Achmad Barito 2

UNDERSTANDING WELL ANATOMY
❖ The well is the main conduit between
the reservoir and atmosphere
❖ The well consists of steel
components which make up the
pressure envelope designed to
prevent reservoir fluids from
escaping to the atmosphere
❖ The well is designed to have two
pressure envelopes (primary well
barrier and secondary well barrier)
to prevent the release of reservoir
fluids
❖ The pressure envelope is a
combination of casing, cement,
tubing, completion equipment,
packer, wellhead and Xmas tree
designed prior drilling of the well
and installed by a drilling rig,
❖ If well barrier component fail, the
leak could continue days, weeks,
months even years with unlimited
volume of reservoir fluids
Well Integrity in Production Operation Flyer, by Didit Achmad Barito 3
THE IMPORTANCE OF WELL INTEGRITY
❖ Well specificity,
❖ Most of well components are below the
ground, condition of casing, cement, packer,
completion equipment cannot be seen
❖ If those components fail, it cannot be
changed the same way as changing failed
surface equipment,
❖ Monitoring of those components can be done
in-situ
❖ Well integrity measure done starting from
❖ Well construction phase (pressure test
casing, cement, shoe bond test, leak-off test,
packer, completion equipment and wellhead &
Xmas tree test)
❖ Continuous with preventive maintenance
during production phase which includes leak
test and function test of downhole safety
valve, Xmas tree valve, annulus valve,
monitoring cavities on wellhead and pressure
in well annuli
❖ Corrective maintenance might be required to
restore well components failure
❖ Well integrity is every effort to ensure reservoir
fluids will not escape to atmosphere due to
barriers failure
Well Integrity in Production Operation Flyer, by Didit Achmad Barito 4
 WELL INTEGRITY ASSURANCE

At least two testable, independent (primary and secondary) barriers between a

hydrocarbon source and the environment shall be exist at all times.
Well Integrity in Production Operation Flyer, by Didit Achmad Barito 5
 WELL DESIGN REFERENTIALS – PRIMARY WELL BARRIER (BLUE COLOR)
❖ Tubing connection selection based on
working pressure, working temperature, fluid
type and presence of H2S
❖ Tubing material based on critical fluid
velocity, H2S partial pressure, CO2 partial
pressure
❖ Tubing burst, collapse and axial load design
factors
❖ Barriers for completed wells,
❖ Barrier's requirements per type of wells
❖ Down hole safety valve selection
❖ Down hole safety valve locking mandrel
requirement
❖ Down hole safety valve minimum setting
depth
❖ Annulus safety valve requirement (for
offshore gas lifted wells)
❖ Packer
❖ All completion equipment between packer
and safety valve nipple
❖ Side pocket mandrel
❖ Telescoping swivel
❖ Expansion joint
❖ Sliding side door/ sliding sleeve
❖ Landing nipple

Well Integrity in Production Operation Flyer, by Didit Achmad Barito 6

WELL DESIGN REFERENTIALS – SECONDARY WELL BARRIER (RED COLOR)
❖ Casing connection selection based
on working pressure, working
temperature, fluid type and
presence of H2S
❖ Casing material based on H2S
partial pressure, CO2 partial
pressure
❖ Casing burst, collapse and axial
load design factors
❖ Surface wellhead, surface Xmas tree
and MLS,
❖ Wellhead selection (casing head,
casing spool, tubing head)
❖ Xmas tree selection
❖ Number of side outlets and
valves on every annulus
❖ Number of master valve
❖ Actuators selection
❖ Side outlet valve configuration
❖ Primary casing cementing, for
minimum height of cement column
above the shallowest potential flow
zone in every annulus

Well Integrity in Production Operation Flyer, by Didit Achmad Barito 7

 PRIMARY WELL BARRIER ENVELOPE PREVENTIVE MAINTENANCE

Function test and leak test

frequency of active barriers

➢ down hole safety valve,

➢ check valve on gas lift

valve

Down hole safety valve

replacement frequency

Acceptable leak rate

Well Integrity in Production Operation Flyer, by Didit Achmad Barito 8

 SECONDARY WELL BARRIER ENVELOPE PREVENTIVE MAINTENANCE

Function test and leak

test frequency of active
barriers
➢ Xmas tree gate valves,
➢ Xmas tree actuators
➢ Automated annulus
gate valve (gas lift)
Monitoring frequency of
passive barriers
➢ vent port cavities
➢ test port cavities
Monitoring frequency of
well annuli
Acceptable leak rate

Well Integrity in Production Operation Flyer, by Didit Achmad Barito 9

WELL INTEGRITY DIAGRAM
At the end of well construction phase,
every well should have well integrity
diagram completed with the following
information:

➢ Xmas tree data (size and working

pressure, Xmas tree valves size and
working pressure)

➢ Xmas tree actuators data (size,

working pressure and type
(pneumatic/hydraulic))

➢ Wellhead data (annulus valves size

and working pressure)

➢ Maximum Allowable Wellhead

Operating Pressure for every annuli

➢ Primary well barrier element including

barrier elements test result

➢ Secondary well barrier element

including barrier elements test result

➢ Tubulars data (size, grade, internal

yield pressure, collapse pressure,
connection type)

➢ List of reservoir layers in every annuli

The above data should be updated if there

is a change in the parameter (ex.
Maximum Allowable Wellhead Operating
Pressure)

Well Integrity in Production Operation Flyer, by Didit Achmad Barito 10

WELL INTEGRITY SAFETY CRITICAL ELEMENTS NATURAL FLOW WELLS
Primary Well Barrier Elements
1. In-situ formation
2. Down hole safety valve
3. Production packer
4. Production casing from casing shoe to production packer
5. Cement from production casing shoe to production packer
6. Tubing from production packer to down hole safety valve
7. Any completion equipment between down hole safety
valve and top packer

Secondary Well Barrier Elements

1. In-situ formation
2. Production casing above production packer
3. Cement in between production casing and formation
above top packer
4. Production casing hanger with seal assembly
5. Wellhead annulus (A-annulus)
6. Tubing hanger (body seals)
7. Wellhead – Xmas tree connector
8. Tubing hanger neck seal
9. Xmas tree

Well Integrity in Production Operation Flyer, by Didit Achmad Barito 11

WELL INTEGRITY SAFETY CRITICAL ELEMENTS GAS LIFTED WELLS
Primary Well Barrier Elements
1. In-situ formation
2. Down hole safety valve
3. Production packer
4. Production casing from casing shoe to annulus safety
valve packer
5. Cement from production casing shoe to top of cement
production casing
6. Annulus safety valve
7. Any completion equipment between annulus safety valve
packer to down hole safety valve

Secondary Well Barrier Elements

1. In-situ formation
2. Intermediate casing cement,
3. Intermediate casing,
4. Intermediate casing hanger with seal assembly
5. Tubing head spool with A annulus valve
6. Casing spool with B annulus valve
7. Tubing hanger body seal
8. Wellhead – Xmas tree connector
9. Tubing hanger neck seal,
10.Xmas tree

Well Integrity in Production Operation Flyer, by Didit Achmad Barito 12

WELL INTEGRITY SAFETY CRITICAL ELEMENTS PREVENTIVE MAINTENANCE
Active barrier is an element which is normally
open, and which needs to be activated to close
and prevent flow
❖ DHSV
❖ Christmas tree valves
❖ Annulus valves
❖ Gas lift valves
Closing the valve can be done manual,
automated or self actuated
Active barrier requires periodic function test
and leak test

Passive barrier does not need to be activated

to prevent flow
❖ Cement
❖ Casing
❖ Ring gaskets on wellhead
❖ Wellhead seals
❖ Tubing
❖ Production packer
❖ Wireline plugs
❖ Closed SSD
❖ Side pocket mandrel with dummies
installed
❖ Expansion joint
❖ Left hand connector
❖ Telescoping swivel
❖ Snap latch
Passive barrier does not require periodic
function test and leak test

Well Integrity in Production Operation Flyer, by Didit Achmad Barito 13

WELL BARRIER ELEMENTS FUNCTIONS AND FAILURE MODES
Element Type Function Failure Mode

Surface safety Provides shut-down functionality and Leaks to environment

valve (s) or isolation of well to production
emergency process/flowlines based on operating Leaks across valves
shut down limits of the production system above acceptance
(ESD) valves criteria

Mechanical damage

Inability to respond to
process shutdown
requirement over
pressuring process
Surface A system of valves and flow conduits Leaks to the
production tree attached to the well head that provides environment
a method for controlling the flow out of
the well and into the production system Leaks across valves
above the acceptance
criteria

Inability to function
valves

Mechanical damage

Well Integrity in Production Operation Flyer, by Didit Achmad Barito 14

WELL BARRIER ELEMENTS FUNCTIONS AND FAILURE MODES
Element Type Function Failure Mode

Wellhead Provides mechanical support for the Leaking seals

suspending casing and tubing string
Leaking valves
Provides mechanical interface for
connection of a riser, BOP or Leaking connection
production Xmas tree between valve body and
wellhead
Prevents flow from the wellbore and
annuli to formations or the
environment
Production Provides a mechanical seal between Leak across the external
packer the completion tubing and the packing elements
casing/liner, establishing the A-annulus
above and preventing communication Leak across the internal
from the formation into the A-annulus seals
Surface- Safety valve device installed in the Lack of control line
controlled sub- production tubing string that is held communication and
surface safety open, usually by the application of functional control
valve hydraulic pressure in a control line. If
there is loss of control line hydraulic Leaking above
pressure, the device is designed to acceptance criteria
close automatically
Failure to close on
demand

Failure to close within

the acceptable closing
time

Well Integrity in Production Operation Flyer, by Didit Achmad Barito 15

WELL BARRIER ELEMENTS FUNCTIONS AND FAILURE MODES
Element Type Function Failure Mode

Annulus Safety valve device installed in the Lack of control line

surface- annulus that prevents high volume of communication and
controlled sub- gas injection release to atmosphere in functional control
surface safety case A-annulus valve broken.
valve Leaking above
acceptance criteria

Failure to close on
demand

Failure to close within

the acceptable closing
time
Liner top Provides a hydraulic seal in the Inability to maintain a
packer annulus between the casing and the pressure seal
liner, to prevent flow of fluids and
resist pressures from above and below
Tubing hanger Supports the weight of the tubing and Leak past tubing hanger
prevents flow from the tubing to the seal
annulus or vice versa
Mechanical failure

Well Integrity in Production Operation Flyer, by Didit Achmad Barito 16

WELL BARRIER ELEMENTS FUNCTIONS AND FAILURE MODES
Element Type Function Failure Mode

Wellhead/annulus Provides ability to monitor pressure Inability to maintain a

access valve and flow to/from annulus pressure seal, or leaking
above acceptance
criteria

Unable to close
Casing/liner Cement provides a continuous, Incomplete fill of the
cement permanent and impermeable hydraulic annulus being
seal along well bore between cemented, longitudinally
formations and a casing/liner or and/or radially
between casing strings
Poor bond to
Additionally, the cement mechanically casing/liner or
supports the casing/liner and prevents formations
corrosive formation fluids coming into
contact with the casing/liner Inadequate mechanical
strength

Allows flow from/to

formations behind
casing/liner

Well Integrity in Production Operation Flyer, by Didit Achmad Barito 17

WELL BARRIER ELEMENTS FUNCTIONS AND FAILURE MODES
Element Type Function Failure Mode

Completion Provides conduit for fluid to/from the Leak to or from the
tubing reservoir to/from surface annulus

Wall thinning from

corrosion and/or
erosion not resistant to
the load cases.
Completion Provides support to the functionality of Inability to maintain
string the completion, i,.e, safety valve nipple, differential pressure
component side pocket mandrel with valves or
dummies, sliding side door, ported Valves leaking above
nipple, landing nipple acceptance criteria

Seal bore on the nipple

eroded

Well Integrity in Production Operation Flyer, by Didit Achmad Barito 18

WELL BARRIER ELEMENTS FUNCTIONS AND FAILURE MODES
Element Type Function Failure Mode

Formation Provides a mechanical seal in an Leak through the

strength annulus where the formation is not formation
isolated by cement or tubulars
Not sufficient formation
Provides a continuous, permanent and strength to withstand
impermeable hydraulic seal above annulus pressure
reservoir
Not sufficient formation
Impermeable formation located above strength to perform
the reservoir, sealing either to hydraulic seal
cement/annular isolation material or
directly to casing/liner

Provides a continuous, permanent and

impermeable hydraulic seal above the
reservoir
Casing Contains fluids within the wellbore Leak at connection
such that they do not leak out into
other concentric annuli or into exposed Leak caused by
formations corrosion and/or
erosion

Parted connections

Burst casing

Well Integrity in Production Operation Flyer, by Didit Achmad Barito 19

RISK ASSESSMENT

Barrier Mitigation To Reduce

Failure Mode Consequence
Element Consequence
Surface Xmas External Pressure release to Install physical barrier
Tree impact atmosphere around wellhead
Pressure release to void
Leak across
with adequate None
valve
containment
Leaking Pressure release to Increase periodic
connector atmosphere external inspection
Pressure release to void
Leaking tubing
with adequate None
hanger neck
containment
Leaking valve Pressure release to Increase periodic
bonnet atmosphere maintenance
Install physical access
Pressure release to
Sabotage barrier around
atmosphere
wellhead

Well Integrity in Production Operation Flyer, by Didit Achmad Barito 20

RISK ASSESSMENT
Barrier Mitigation To Reduce
Failure Mode Consequence
Element Consequence
Tubing hanger Pressure release to void
Hanger pack-
with adequate None
off leak
containment
Pressure release to void
Leaking thread
with adequate None
connection
containment
Pressure release to void
Leaking tubing
with adequate None
neck
containment
Pressure release to void
Material
with adequate None
incompatibility
containment

Well Integrity in Production Operation Flyer, by Didit Achmad Barito 21

RISK ASSESSMENT
Barrier Failure Mitigation To Reduce
Consequence
Element Mode Consequence
Tubing Pressure release to void
Burst with adequate None
containment
Pressure release to void
Collapse with adequate None
containment
Pressure release to void
Corrosion with adequate None
containment
Pressure release to void
Erosion with adequate None
containment
Pressure release to void
Leaking
with adequate None
thread
containment
Production Pressure release to void
packer Burst with adequate None
containment
Pressure release to void
Collapse with adequate None
containment
Pressure release to void
Leaking
with adequate None
element
containment

Well Integrity in Production Operation Flyer, by Didit Achmad Barito 22

RISK ASSESSMENT
Barrier Failure Mitigation To Reduce
Consequence
Element Mode Consequence
Wellhead Lost secondary barrier,
External
pressure contained by None
impact
primary barrier
Leaking Lost secondary barrier,
connector pressure contained by None
seal primary barrier
Lost secondary barrier,
Sabotage pressure contained by None
primary barrier
Wellhead Lost secondary barrier,
Broken
access valve pressure contained by None
connection
primary barrier
Lost secondary barrier,
External
pressure contained by None
impact
primary barrier
Lost secondary barrier,
Leaking
pressure contained by None
valve
primary barrier
Lost secondary barrier,
Leaking
pressure contained by None
bonnet seal
primary barrier
Lost secondary barrier,
Sabotage pressure contained by None
primary barrier

Well Integrity in Production Operation Flyer, by Didit Achmad Barito 23

 ANNULUS PRESSURE CLASSIFICATION
➢ Thermally Induced Pressure, thermally induced casing
pressure is the result of thermal expansion of trapped wellbore
fluids usually caused by differential temperature between
static conditions and producing conditions when production is
initiated. All wells will exhibit thermal casing pressure when
the well is initially brought on production.
➢ Applied / Imposed Pressure, imposed pressure on casing
annulus is utilized for various purposes such as gas lift,
fracturing operation, well collision monitoring during drilling
adjacent well.
➢ Abnormal Annulus Pressure, abnormal annulus pressure is
usually the result of a well component leak that permits flow of
fluid across a well control barrier such as tubing connection
leak, packer leak, uncemented / poorly cemented formations or
damaged cement, completion equipment leak. Abnormal
annulus pressure can be divided as follow
➢ Sustained Casing Pressure, occurred if the leak resulting
positive pressure in the annulus due to hydrostatic
pressure in the annulus is lower than reservoir pressure.
➢ Vacuum Pressure, occurred if the leak resulting negative
pressure in the annulus due to hydrostatic pressure in the
annulus is higher than reservoir pressure which in turn
creating loss of fluid from annulus into reservoir.
Zero pressure in annulus does not guarantee there is no leak in
annulus!!!

Well Integrity in Production Operation Flyer, by Didit Achmad Barito 24

 WELL INTEGRITY CATEGORIZATION
Category Green Yellow Orange Red
Principle Healthy well, no or One barrier degraded, One barrier failure and One barrier failure and
minor issues the other is intact the other is intact, or a the other is
single failure may lead degraded/not verified
to leak to surface or leak to surface
Compliance with The well is in full Well has an increased Typically, will be Typically, will be
regulation compliance with risk, its condition is outside the regulations outside the regulations
double barrier within regulations
philosophy
Typical actions Typically, will not Repairs and/or Repairs and/or
require any repairs or mitigations will be mitigations will be
mitigating measures required before the required before the
well can be put into well can be put into
normal operation normal operation and
there will usually be an
immediate and urgent
need for action

Well Integrity in Production Operation Flyer, by Didit Achmad Barito 25

 WELL HEAD MAINTENANCE ACTIVITIES
Preventive Maintenance
❖ Carried out at a predefined frequency
based on working condition.
❖ Might involved the following equipment
❖ Dwyer tester, to check leak rate
❖ Unseating tool, to check pressure
build up inside wellhead cavities
❖ Echometer, to check fluid level in the
annulus
❖ Grease gun for routine greasing
Well Integrity in Production Operation Flyer, by Didit Achmad Barito
Corrective Maintenance
❖ Activities to rectify well integrity status
which was triggered by preventive
maintenance findings, such as
❖ Visible leak on wellhead and Xmas
tree components
❖ Pressure gauge failure
❖ Xmas tree gate valve leak rate
exceed 15 scfm for gas or 24 liters
per hour for liquid
❖ DHSV leak rate exceed 15 scfm for
gas or 24 liters per hour for liquid
❖ Gate valve stem seal leaking
❖ Leaking on wellhead cavities
❖ Actuator closing time exceeding
the required standard
❖ Might involved the following
equipment or unit
❖ Pipe wrench
❖ VR lubricator
❖ BPV lubricator
❖ Crane
❖ Well intervention unit such as
slickline, electricline, snubbing,
coiled tubing
26
PERFORMANCE STANDARD FOR WELL SAFETY CRITICAL ELEMENTS
Minimum Acceptance Criteria Assurance Measure Units of Measure
Well Head / Tree Inspection Acceptable visual No leaks
There shall be no leaks / weeps of the well inspection
head/ tree, cavities, valve and instrument
connections (visual inspection)
Wellhead / Tree valve operability Acceptable test / Number of turns
All wellhead/tree valves shall be operable operate on demand
in accordance with manufacture defined as per manufacture
specification (number of turns) specification
Wellhead / Tree valve Actuations Acceptable response Time
Actuated wellhead /tree valves shall close test
within the required time as defined in the
well hook up cause and effect requirements
for shutdown based on API 14
Wellhead / Tree valves Leakage Rate Acceptable test / leak Ambient
The valve leakage rate is not greater than rate volume/time
the corresponding allowable leakage rate
as specified based on API 14
Annular Safety Valve Integrity Acceptable test Pressure limit
The ASV performs within the parameter
specified based on API 14 Operates on demand
records available

Well Integrity in Production Operation Flyer, by Didit Achmad Barito 27

PREVENTIVE MAINTENANCE SUMMARY
Manual Gate Valve Actuated Gate Valve Pneumatic Actuator Hydraulic Actuator

Inspect piston, top cap, inside surface housing,

Body cavity
Body cavity lubrication top shaft, safety valve and spring for any Cycle open and close
lubrication
deterioration

Thrust bearing Close and open SSV. Operation should be Replace actuator
lubrication smooth and consistent in both direction seals

Inspect top shaft,

Inspect top cap and control line fitting for leaks.
head, housing &
Remove any debris from fitting
piston

Visually inspect for external damage such as

dents, scratches, etc. If scratched or chipped,
Replace safety relief
touch up with paint to prevent rust. If dented,
device (if applicable)
disassemble and inspect actuator to ensure the
damage does not affect actuator’s performance

Clean debris from

Replace seals vent or breather
holes

Replace seals and safety valves

Clean debris from vent or breather holes

Always consult manufacturer’s maintenance manual for recommended preventive maintenance program

Well Integrity in Production Operation Flyer, by Didit Achmad Barito 28

 PROBLEMS REQUIRED CORRECTIVE MAINTENANCE
Manual Gate Valve Actuated Gate Valve Pneumatic Actuator Hydraulic Actuator
Fluid leaks past the
Well pressure leaks Control pressure in Control pressure in
gate and seat
past valve actuator will not build actuator will not build
assembly
Actuator will not stroke Actuator will not stroke
on a valve whether or not on a valve whether or
Line fluid leaks valve is pressurized. not valve is
Fluid leaks around the
between valve body Gate valve does not pressurized. Gate valve
valve stem
and bonnet stroke open when control does not stroke open
pressure is applied to when control pressure
actuator is applied to actuator
Downhole equipment
Fluid leaks at the Actuator will not attach Actuator will not attach
will not pass through
bonnet flange to bonnet assembly to bonnet assembly
open valve
Valve “jumps” open Actuator will not stroke Actuator will not stroke
Fluid leaks from
when pressure is to full closed or “fail to full closed or “fail
bonnet grease fitting
applied to actuator safe” closed position safe” closed position
Handwheel is hard to Valve will not drift after Valve will not drift after
Valve does not close
turn actuator is installed actuator is installed
Handwheel turns
without opening or
closing the valve

Always consult manufacturer’s maintenance manual for corrective maintenance steps

Well Integrity in Production Operation Flyer, by Didit Achmad Barito 29

WELL INTEGRITY FAILURE REMEDIAL
There are service companies who provide services that
can restore well integrity failure.

They are:

Kinetics Controls & Innovation

➢ Isolation Gel Fluid Piston, for repairing control line

leak

➢ Isolation Gel Heavy, for repairing micro porosity in

cement sheath

➢ Mac Seal, repair leaking casing hanger sealing

assembly

➢ Mac Pac, protect and repair gate valve leaking

Seal Tite

➢ Repair micro annulus

➢ Repair control line leak

➢ Repair split control line

➢ Repair tubing hanger seal leak

➢ Repair leaking tubing connection

➢ Repair leaking casing connection

Quality Intervention

➢ Annulus intervention service

Wellbore Integrity Solutions

➢ Sustained casing pressure remediation

Well Integrity in Production Operation Flyer, by Didit Achmad Barito 30

WELL INTEGRITY HISTORY
Every well should have well integrity
history which contain information such
as:

Preventive maintenance activities:

➢ Xmas tree valve leak test result
➢ Xmas tree valve function test result
➢ Downhole safety valve leak test result
➢ Xmas tree valve greasing
Corrective maintenance activities
➢ Replacing Xmas tree valve actuator
➢ Replacing Xmas tree valve stem
packing
➢ Replacing Xmas tree valve grease
fitting
Monitoring activities
➢ Annulus pressure survey
➢ Cavity check result
➢ Echometer survey
Frequent corrective maintenance on
individual well should trigger alarm there
is something wrong with the well.

Well Integrity in Production Operation Flyer, by Didit Achmad Barito 31

 OFFSHORE NORGE WELL INTEGRITY INCIDENTS MATRIX

Well Integrity in Production Operation Flyer, by Didit Achmad Barito 32

 Hopefully you gain
additional knowledge
of well integrity

Well Integrity in Production Operation Flyer, by Didit Achmad Barito 33