Well Integrity Management

Classroom Training Course

(29 Oct-02 Nov 2023 & 12-16 Nov 2023)

Mahmoud Farag Radwan

Subsurface & Integrity Operations Lead
https:\\www.linkedin.com/in/mahmoud-farag-radwan-a9266626
 Mahmoud Farag Radwan
Mahmoud Radwan is a Subsurface & Integrity Op. Lead with 16 years of
experience in oil & gas industry. Mahmoud worked in Well Engineering,
Intervention, Integrity & Work-over at several companies, including AMAL
Short Petroleum Co. (AMAPETCO), KDT Global Solutions, CUDD Well Control, Badr
El-Din Pet. Co. (BAPETCO), Qarun Pet. Co. (QPC) and Wadi El-Sahel Petroleum
Biography Co. (WASPETCO).
Also, a freelance instructor at upstream Oil & Gas in Egypt & GCC since 2008.
Mahmoud received a BSc degree in Petroleum Engineering from Al-Azhar
University in 2007.
o Evaluating Sustainable Annulus Pressure (SAP) in Sour Wells and the Possible
Causes to Avoid Recurrence to the Well Integrity Annual Middle East
Conference in Abu Dhabi; UAE in Apr 2015
o Implementing NDT methods for maintenance and inspection to the Asset
Integrity Management North Africa Conference in Cairo; Egypt in Nov 2015
o Feasibility Evaluation of Using Downhole Gas-water Separation Technology in
gas Reservoirs with Bottom Water; paper number: SPE-183739-MS to the 20th
Middle East Oil & Gas Show and Conference in Mar 2017
Publications http://dx.doi.org/10.2118/183739-MS
o Managing the Operational Challenges in Corroded Wells through Well Integrity
Management System to the Improving Brownfield Performance Technical
Convention, in Cairo; Egypt in Dec 2019
o Safe and Economic Attractive Rigless Operations Using a Digital Slickline in
Unmanned Platform with Low Structure Loads and Spacing; paper number:
SPE-202857-MS to the Abu Dhabi International Petroleum Exhibition &
Conference (ADIPEC) in Nov 2020 https://doi.org/10.2118/202857-MS
Objectives
❑ Improve the delegates’ appreciation of the well
design and construction
❑ Provide knowledge and understanding of the
guidelines and standards that when observed
and implemented effectively will ensure well
integrity
❑ Establish an increased awareness of well
integrity issues and how they are
controlled/managed and by whom
Mahmoud Farag Radwan
Outlines
❑ Well Integrity Definition
❑ Well Life Cycle
❑ Why is Well Integrity Important?
❑ Well Integrity Failures - Case Histories
❑ API Series, NORSOK D-010 & ISO 16530 part 1 & 2 Standards
❑ Well Integrity Critical Requirements Minimum Standards
❑ Well Integrity Team
❑ Well Construction Principles, Planning & Procedures
❑ Well Control for drilling, Workover & Intervention Theory / Barriers
❑ Wellhead & Xmas Tree Integrity
❑ Annulus Pressure Management
❑ Reservoir Monitoring & Surveillance (Production Logging, Noise logging,
temperature logging, etc.)
❑ Cement Integrity/Quality Evaluation
❑ Corrosion, Erosion and Casing / Tubular integrity
❑ Scale, Paraffin, Hydrate & Sand Control
❑ Well Failure Model
❑ Key Performance Indicator (KPI)
❑ WIMS Workflow, Policy, Assurance Documentation & Toolkit
Mahmoud Farag Radwan
Well Integrity – What does it all mean?
• There are different definitions of well integrity.
• The most widely accepted definition of well integrity is
given by NORSOK D-010:
“Application of technical, operational and organizational
solutions to reduce risk of uncontrolled release of
formation fluids throughout the life cycle of a well”.
• Another accepted definition is given by ISO T.S 16530-2:
“Containment and the prevention of the escape of fluids
(i.e. liquids or gases) to subterranean formations or
surface’’.

Keep the hydrocarbons in the pipe!

Mahmoud Farag Radwan
Well Integrity is a condition where subsurface fluid are
contained within designed boundaries throughout the well
life-cycle.
“Reduce risk of uncontrolled release of formation fluids”
Mahmoud Farag Radwan
 Why is Well Integrity Important?
A successful WIMS has significant
positive impacts. These include:
• Improved QHSE
• Protection of asset reputation and
rights to operate
• Extended well life and increased
production
• Reduced workover and intervention
costs
• Improved well documentation
• Enhanced cross-organizational
communication
• Enhanced engineering.

Mahmoud Farag Radwan

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 Any issues with
this well?
▪ Missing tree valves
▪ Located in populated area?
▪ Missing lockdown screws
▪ Missing annulus valves
▪ Exposed VR plug
▪ Harsh environment?
▪ Who is accountable for
this well?

Mahmoud Farag Radwan

What Are the Outcomes ?
When Process Safety Management (PSM) is not Performed or Goes Wrong

Back to
Home
Safely!
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Failure Assessment (Cont’d)

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 Well Control Preparation

Human Equipment Wellbore

• Trained in Well Control. • BOP should be Rated for • Casing Burst should be
• Know Kick Causes & Well Pressures. known and posted on rig
Warning Signs. floor.
• Monitor well for Kick • Equipment should be • Formation integrity should be
Detection. pressure tested on regular known and MASP should be
• Communicate with Team basis. posted on the rig floor.
Members. • Detection equipment should • Formation pressure should be
• Know Responsibilities be maintained in good working monitored and mud weights
& Station Bill. order. adjusted accordingly.
Mahmoud Farag Radwan
 success OF Well Control
Three factors govern the Success of Well Control:
1. Human
2. Equipment 3. Plans & Procedures

1. HUMAN 2. EQUIPMENT

• Fitness (Physical & Mentally) • Full Inventory

• ASK (Attitude, Skill & Knowledge) • Independent Inspection

• Team Effort • Machine Suitability

• Democratic approach • Function and/or Pressure Test

• Communications & Coordination • Back-up & Spares
• Responsibility • Preventive Maintenance
Mahmoud Farag Radwan
success OF Well Control
3. PLANS & PROCEDURES
• Well Plan & Consider All Aspects

• Back-up Plans & Procedures

• Procedures Tailored to Site

Mahmoud Farag Radwan

 WELL CONTROL THEORY
Barrier Definition:
 Barrier is any device, fluid or substance that prevents flow of
wellbore fluids.

Barrier Classification:
1. Primary Barrier
2. Secondary Barrier
3. Tertiary Barrier

Barrier Requirement :
1. Drilling & Workover – Double Barriers Protection
2. Well Intervention – Triple Barriers Protection

Mahmoud Farag Radwan

 STUFFING BOX

BARRIER TYPE
1. Mechanical Barrier Lubricator

Advantage:
- Reduces formation potential
damage & cost efficient.
BOP

Disadvantage: XMAS TREE

MUD
- Working under pressure.
Tubing
Casing

2. Hydrostatic Barrier DHSV

Advantage:
-Working in dead well. FORMATION FLUID

Disadvantage:
- High potential of formation PACKER
WL PLUG
damage.
Mahmoud Farag Radwan
 WELL CONTROL THEORY
Definition
• Overbalance Greater pressure than formation pressure
• Underbalance Less pressure than formation pressure
• Inflow Test Bleed pressure from ▲ & monitor build-up
• Positive Plug Hold pressure from ▼ & ▲
• Barrier Device, Fluid or Substance that prevent flow of hydrocarbon

Mahmoud Farag Radwan

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 API 6A (ISO 10423)
is the recognized industry standard for Wellhead and
Christmas Tree Equipment
• API Specification 6A covers Wellhead and Christmas Tree Equipment as
follows:

Mahmoud Farag Radwan

Product Specification Levels (PSLs)
API Specification 6A defines standard service conditions and introduces the concept of PSLs, which are referred to
throughout the document. The PSLs define different levels of documentation, or levels of technical requirements, which
may be specified for a product. Generally, these levels represent the industry practice for various service conditions. The
selection of a PSL should be based on a quantitative risk analysis, which is a formal and systematic approach to
identifying potentially hazardous events and estimating the likelihood and consequences to people, environment, and
resources—and of accidents developing from these events. The decision tree shown below is designed to assist the
purchaser in selecting the minimum PSLs for primary parts of wellhead and tree equipment.

Mahmoud Farag Radwan

 Markings
• Section 8 of Specification 6A and the chart below describe marking instructions for equipment. The marking
requirements include the following:

Note:
• For API monogrammed equipment, the API monogram is also marked along with the license number of the API
approved manufacturing facility.

Example:
• A product marked FF-1,5 indicates material class FF and a 1.5 PSIA maximum allowable H S partial pressure.
Mahmoud Farag Radwan
Wellhead API Trim Guide

Mahmoud Farag Radwan

 How to Order
General Wellhead Equipment Data Sheet

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 Leak Rate Criteria
Leak rates based on API 14 B at 15 SCF / min for gas or 400 cc / min for liquid
The following table shall be used to determine allowable leak rates for valve and down-
hole equipment leaks

Test results below the rates described above are not classed as a leak so test result
and should be assigned a 'Pass'
Mahmoud Farag Radwan
Example of Allowable PBU for SSSV &
Xmas Tree Valves

Mahmoud Farag Radwan

API Composite List and Inspector Status
Verification
1- API Composite List
It is not reasonable for oil and gas companies to deal with
manufacturers or suppliers of drilling, completion, intervention,
and production equipment/tools without certificates of standard
specifications or with fake certificates.
Please use this here below link to verify. The API Composite List is
a real-time directory that provides access to information about
API Monogram™ Licensees and organizations with Registered
Management Systems, such as API Spec Q1®, API Spec Q2®, ISO
9001, ISO 14001, and API 18LCM.
https://mycerts.api.org/Search/CompositeSearch

Mahmoud Farag Radwan

2- API Inspector Status Verification
API strives to maintain accurate, reliable, and
current information on certification. However,
inadvertent mistakes may exist in the database.
If you discover an apparent mistake or
discrepancy, please contact the Individual
Certification Programs at 202-682-8064
immediately.

https://inspectorsearch.api.org/

Mahmoud Farag Radwan

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 Types of Annular Pressures
1 Thermal Pressure (TP)
• Wells with fluid filled enclosed annuli will exhibit thermal pressure changes during warm-
up and cool down periods. It is important to recognize this fact and to monitor annulus
pressure closely during start up of new wells. Pressure should not be bled off in this
instance unless MAWOP is breached. It is vital to monitor annulus pressure closely during
initial start up of new wells as pressure can build up rapidly and result in over-pressurized
annuli.
2 Applied Pressure (AP)
• Pressure may be applied on an annulus for various purposes, including gas lift,
compensating for bullheading loads or to assist in annulus monitoring.
• This pressure may also come from pressure containment tests as part of preventative
Subsurface Integrity Test (SIT) activities. Care must be taken to ensure this pressure is
bled down after testing to a suitable value to ensure that thermal pressure does not result
in MAWOP being breached.
3 Sustained Annulus Pressure (SAP)
• This pressure comes from a pressure source such as reservoir, adjacent annulus etc and
shall be investigated using the WIMS whenever suspected or where observed pressure
cannot be proven to be either AP or TP.

Mahmoud Farag Radwan

What is Sustainable Annulus Pressure (SAP)?

➢ Definition:

SAP is defined as a pressure in any well

annulus that is measurable at the
wellhead and rebuilds when bled down,
not caused solely by temperature
fluctuations or imposed by the operator
(e.g., gas-lift pressure, gas- or water-
injection pressure).
Mud cake leaks
Casing SAP Sources
leak

Well-head leak APB

CSG
Burst
Tensile cracks in cement
caused by temperature Tubing leak
& pressure cycles
Payne - SPE Forum
Low pressure sand
Corrosion Damage
High pressure sand

Underground blowout
Channel caused by flow
after cementing

Figure from “A Review

of Sustained Casing
Pressure (SCP)
Occurring on the OCS”
Micro-annulus caused
by Bourgoyne et al
by casing contraction
Mahmoud Farag Radwan
(March 2000) Harper - KDHE
 Cement Quality/Integrity Evaluation
1. Non-petrophysical Methods
❑ Surface cement samples
❑ Pressure / rate / density record
❑ Returns observation
❑ Pressure tests
❑ Leak Off Test (LOT) / Formation Integrity Test (FIT)

2. Petrophysical Methods
❑ Temperature Log
❑ Neutron Log
❑ Acoustic Logs
– Sonic Log (CBL / VDL)
– Ultrasonic Log
– Combination Log
Mahmoud Farag Radwan
 MAASP
Maximum Allowable Annulus Surface Pressure
❑ MAASP values need to take into account
the current status of the following :
- Burst/collapse/tri-axial rating of the various
tubing and casing strings
- Incorporate any information from pressure
tests, corrosion or casing wear
• Wellhead pressure rating
• Potential for leak off at casing shoe
• Relevant reservoir data
Mahmoud Farag Radwan
 Triggers & Working Pressure
Casing Burst

MAASP
Watch Out !
MAWOP

50%
Working 100% Blowdown
Pressures Range
50%
Watch Out ! Top-up
MINAP / MINDAP

Zero

Annulus Pressure Management - Triggers

Mahmoud Farag Radwan & Working Pressure
 Maximum Allowable Wellhead
Operating Pressure (MAWOP)
➢ MAWOP from API RP 90 for an annulus is the
lesser of the following:
• 50% of the MIYP of the casing being
evaluated; or
• 80% of the MIYP of the next outer casing;
or
• 75% of the MCP of the inner tubular pipe
body
• The outermost pressure-containing casing
MAWOP can not exceed 30% of its MIYP
Mahmoud Farag Radwan
 MAWOP Example
API RP 90
50% 75% 80% %
Annulus MIYP Collapse MIYP Collapse MIYP MWOP MIYP
PSIG PSIG PSIG PSIG PSIG PSIG
Prod Tubing 3.5", 12.9#, L-80 15,000 15,310 11,483 N/A
"A" 7 5/8",39#, Q-125 14,340 12,060 7,170 9,045 7,170 50%
"B" 9 5/8", 53.5#, Q-125 12,390 8,440 6,195 6,330 9,912 2,760 22%
"C" 13 3/8", 68#, K-55 3,450 1,950 1,725 1,463 2,760 1,725 50%
"D" 18 5/8", 87.5#, K-55 2,250 630 1,125 1,800 675 30%
 Management of Change (MOC)
The direct and underlying cause of many incidents is the
failure to properly recognize and/or manage change.

Management of Change (MOC) falls into three broad

categories, these being:

• Program change

• Work instruction change

• Equipment change

Mahmoud Farag Radwan

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 Plugging and Abandonment (P&A) Regulations
❑ Most countries have their own regulations in place. Modern regulatory standards
require specific provisions for plugging and documenting oil and gas wells before
they are abandoned. Plugging and abandonment (P&A) regulations vary to some
degree among countries, but all regulations prescribe the depth intervals which must
be cemented as well as the materials that are allowable in plugging practices.
 WIMS Workflow
Action Items
Kick-off Meeting & Presentation
Answering on WIMS Questionnaire
..\..\WIMS Sheets & Docs\WIMS Questionnaire.xlsx
Gap Analysis
Well Integrity Management Policy / Strategy
* Accountability & Responsibility
* Wellhead, Xmas Tree & SSSV Testing & Maintenance
* Well Risk Assessment Criteria
* Annulus Management
Well Integrity Assurance Management System
Well Integrity Contingency Plan
Well Integrity Report Template
Well Integrity Checklists & Routine Testing Format
Mahmoud Farag Radwan
 Well Integrity KPI Definition

Is the outcome of good design, drilling, workover,

intervention and operating practices. It requires the
integrated management of Barriers designed to reduce
the risks associated with Major Accident and
Environmental Events. Such Barrier management
addresses all stages of the well lifecycle. It also
addresses the behavior and training of people and the
suitability and correct application of processes used
in conjunction with these activities

Mahmoud Farag Radwan

Thank You
Mahmoud Farag Radwan