Trouble-Free Well Integrity Management

Introduction

A Well Integrity incident and breach of Well integrity envelope have the potential to escalate into catastrophic events. The event can result in harm to people, damage to Assets and the environment, and to the reputation of the Operator. It can easily be either of them or in case of a major event, all of the above.

The financial impact can be very high; loss of revenue of the hydrocarbons that escape, damage to the reservoir as a result of the uncontrolled flow and collateral damages has the potential to bring an Operator in financial dire straits.

Several incidents in the recent past have shown that even the largest Operator can barely manage such a financial drain. It is therefore of critical importance that the well integrity envelope is properly designed, constructed and maintained during it life cycle: Sustained Well Integrity Management (WIM).

This Master Class combines several engineering disciplines involved in the design, construction, operation, and maintenance of wells and their interaction on assuring well integrity.

It illustrates a large extent in the organization and its effects on well integrity. It aims to enable a common understanding of the often-conflicting targets within the disciplines in achieving this. It touches on Failure Mode and Effect Analyses (FMEA), barrier testing and record keeping.

The knowledge and skills to make a critical decision throughout well life cycle is vital, not only for WIM purpose as well as for economic value. Focus is on the Well Integrity management systems and interfaces with other teams in the organization. Integrity barriers are defined, Well Failure Model and how to establish one is discussed as well how to create an efficient well integrity organization.

Objectives

The ultimate objective is to optimize productivity at the lowest unit operating cost and to maintain mechanical integrity throughout well life cycle.

• DISCUSS completion design topics to create an “integer” well with lowest life cycle maintenance cost from a WIM perspective.
• FAMILIARIZE with concepts and principles of Well Integrity Management system and IDENTIFY who is accountable for what.
• IDENTIFY different well integrity issues and the causes.
• DETERMINE management system to follow up on the well integrity issues emerging from tests in the field.
• EXPLORE different techniques to prevent internal and external well integrity issues.
• DEVELOP preventive maintenance strategies to manage the well integrity issues.

Training Methodology

The course is delivered in a combination of lecture-style and computer-based training. In addition, a significant amount of time is set aside for small working group activity when addressing case study problems. Extensive use is made of case study material to underline the key aspects of the course and to give the delegates exposure to current best practice.

Who Should Attend?

This course is specifically designed for personnel directly responsible and/or involved in Well Integrity for both onshore and offshore field:

• Production Engineers
• Production Technologies
• Production Supervisors
• Offshore Installation Managers
• Operations Supervisors
• Drilling Engineers
• Drilling Supervisors
• Drilling Superintendents
• HSE Personnel
• Senior Technicians
• Technicians
• Control Room Operators
• Rig Contractors
• Service Company Engineers

Course Outline

DAY 1:

Fundamentals of Well Integrity

• Definition of the various components of the well and showing the integrity barriers.
• Designing Integrity in Wells-Completion Design-Life expectancy
• Capex and Opex affects Well Integrity Management
• How each has an influences on Well Integrity and why it needs managing
• Preventive maintenance reduces Operating cost and optimizes production
• Maintenance Processes and Differences
• External well integrity maintenance
• Internal well integrity maintenance
• Technology & tools for internal well integrity diagnostic & monitoring
• PLT Logging Techniques.
• Securing internal integrity, reservoir reconciliation, leak detection etc.
• Caged Full-bore Flow meter (6 arm CFBM) for horizontal applications
• Multi Finger Caliper.
• Establishes tubing base line wall thickness and corrosion over life cycle of the well.
• Non-intervention less investigations like Pressure testing.
• Cheap methods to confirm internal integrity.
• Pony tail leak detection; cheap fit for purpose.
• Fiber Optic internal integrity management.
• Low cost alternative to CTU on horizontal wells.
• Detects leaks.
• Production profile
• Exercise and wrap-up of the day

DAY 2:

Catastrophic failure of well integrity as a result of externals influences

• How to Prevent Catastrophic Failure of a well caused by external corrosion
• Calculation of corrosion and point of failure
• Internal corrosion and subsequent integrity failure
• Risk to the completion string from internal sources
• Barrier understanding
• Understanding of barriers.
• Show different types of wells
• Monitor for and understand mechanical integrity problems preventing potential production rates.
• Sand removal.
• Wax Milling
• Scale removal.
• Leaking gaslift valves, its remedy and solution
• Blocking of unwanted water production

DAY 3:

• Consequences of loss of integrity of one well to its surrounding wells and potential financial exposure.
• Evaluating Well Integrity issue resulting from the blowout of another well
• Producing well started to flow mud to the surface
• GROUP EXERCISE: In the Emergency Control Room: Producing well started to flow mud into the environment.
• CASE STUDY: Drilled well knowingly not to design specifications.
• The increasing amount of Underground blowouts: As a result of older wells.
• Abandonment: Do not take this task lightly

DAY 4:

• Well Integrity and Barrier Philosophy
• Barrier definition.
• Explain barriers.
• Explain how testing is done
• Well Failure Model
• How to arrive at the document
• [GROUP EXERCISE]:
• Referring to the barriers discussed above, make a plan to test and verify the barriers
• Risk-Based Well Integrity Management and Testing
• The management of Barrier testing.
• -Discuss testing methods of the barriers in the well
• Failure Mode and Effects Analyses Diagram (real case document).
• Show barriers, function and severity in case of failure.
• Discuss testing and managing the data.
• Monitoring plan.
• Active Management Model.
• Provide systems and procedures, which ensure that the integrity of the well is assured
• Ensure that the well is maintained with reference to appropriate procedures and specifications
• Ensure that the risks of operating the well are as low as reasonably practicable
• The basis for the development of asset-specific well maintenance and integrity standards, policies, procedures and performance targets

DAY 5

• Well Integrity management Manual.
• Discuss actual document and what should be in a good manual
• Life cycle risk management.
• Well Integrity Software and use Optimize well completion to optimize well integrity during the lifespan of the wells, based on lifetime and possible intervention frequencies assessments.
• How to build an organization with sufficient Well Integrity competence and capability.
• Understanding of lowest unit cost, as opposed to cheapest.
• Competent staff.
• The right contracts.
• Spare parts.
• Example of Well Head Maintenance Manual
• Wrap up of the class and evaluation
• Real Life Documents used and handed-out during the Masterclass:
• Well Failure Model
• Failure Modes and Effect Analyses
• Risk-Based Well Maintenance
• Well Hand Over Form
• Well Head Check Sheet