Copyright of Norske Shell A/S DRAUGEN SURFACE CASING CORROSION Well Integrity Seminar 2014 Oddvar Husby Well, Reservoir and Facilities Management Lead 1 June 2014 Use this area for cover image (height 6.5cm, width 8cm)
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DRAUGEN SURFACE CASING CORROSION
Well Integrity Seminar 2014
Oddvar Husby
Well, Reservoir and Facilities Management Lead
1June 2014
Use this area for cover image(height 6.5cm, width 8cm)
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DRAUGEN
2
� 6 platform producers, 5 operational
� 8 subsea wells, 7 operational
� Water injection, 2 templates
Draugen 6407/9, PL093
Water depth 251 m
Reservoir Type shallow marine, upper shore face sandstone reservoir
Structure low relief N-S trending anticlinal structure
Areal extend 20 x 6 km
Max Vertical closure 50 m
FWL 1640 TVDSS
Reservoir Upper Jurassic Rogn/Garn
Porosity 28-32 %
Permeability 5+ Darcy
Initial Reservoir Pressure 165 bara, hydrostatic
Reservoir Fluid light under-saturated oil, with no associated gas cap
A/S Norske Shell (44.56%)
Chevron Norge AS (7.56%)
Petoro AS (47.88%)June 2014
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COMPLETION A-1, A-2, A-3, A-6
Standard completion:
� 7” x 5.5” tubing
� 10 ¾ x 9 ⅝” production casing
� 13 ⅜” intermediate casing
� 18 ⅝” surface casing – load bearing
� 26” conductor
� Open hole with 6 ⅝” slimpack screens,
300 µ
� 1 GLV: PTC high reliability valve
� Below SSSV;
� Part of primary barrier
3June 2014
PSV
KWV PWV
PUMV
PLMV
A
A GLIS
SOV
B SOVs
B SOV
C
SSSV
177 Barg
Formation
Strength
GLV
246,4 Barg
Formation
Strength
Packer
Slimpack
Screen
(281m)
Well 6407/9 A1
Platform Well - Gaslifted (via A ann)
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DRAUGEN CONDUCTOR/SURFACE CASING SCHEMATIC
� All wells located within the GBS
(Gravity based structure)
� Water level in GBS follows sea level
� Fluids in D-annulus holds a
temperature of 40 – 50 ⁰C
4June 2014
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A5 WELL DROP EVENT 2002
December 2002:
� Shut in the well for coiled tubing rig up
� Thermal contraction did not take place -the well hung up near surface
� Sudden release of well
� Initial 26 cm drop, total of 44 cm over 7 days
Root causes:
� Port left open on conductor
� Splash zone corrosion of surface casing
� Centraliser mounted in proximity of top conductor
� Hang up of centraliser
� Shock load on the well
5June 2014
Xmas Tree Platform
Water level in shaft
~50 m
2. Hang up at top conductor, 10 cm above cold position
4. Failure of 18 5/8” casing
3. Release at hang up point
1. Shut in well, thermal contraction
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A5 RECOMMENDATIONS AND ACTIONS
1. Prevent further corrosion on A-5
� Experience transfer from Brent-field
� Separate water-air interface with vegetable oil
2. Seal the port in the conductor
3. Inspect the other Draugen wells
� Wells A-1, A-2, A-3, A-4 and A-6 inspected, no wear found
� Conductor ports confirmed closed
4. Recommend to keep conductors water filled
5. Consider implementing corrosion protection on surface casing
6. Consider periodic wall thickness monitoring
7. Study contributing factors to wellhead growth
6June 2014
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PEC INSPECTION PROGRAM
The Pulsed Eddy Current (PEC) tool
(developed by Shell) measures average
wall thickness (over a footprint of 4cm)
without need for direct contact with the steel
7June 2014
2003: Inspection of platform wells showed
casings and conductors in good order,
except for A-5 that showed significant wall
loss (up to 60% at failure point)
2008: D-PEC surveys carried out, lower
sections (around sea level depth) completed
and OK. Upper sections not surveyed due
to access problems or time restrictions
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A-4 PEC RESULTS 2013
8June 2014
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A-6 PEC RESULTS 2013
9June 2014
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PHOTOS AND BOROSCOPE VIDEO SNAPSHOTS
10
Conductors photos from the weather deck
Surface casing corrosion; Photos from Upper Mezzanie deck; Corrosion products preventing access
June 2014
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A4 LEAK
11
� A4 leak in the 18-5/8” casing,
0.5 - 1 m from top of the
conductor
� Discovered during D-annulus
top up;
� Detected by boroscope;
June 2014
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RESULTS – PEC MEASUREMENTS 2013
PEC and Boroscope Measurements carried out on conductor and outer 18-5/8”
(surface) casing in November/Desember 2013
� A small leak discovered in 18-5/8” casing on A-4
� PEC og borsoscope access difficult because of corrosion products present in the annuli,
no measurements in large parts of the casings
� Samples taken of water in the annuli for analysis, indicate significant amounts of salts –
presence of untreated sea water that could cause microbiological corrosion
� Solid samples have been collected and analysed – mainly corrosion products with
minor additives (<5%), such as calcite (CaCO3), Halite (KCl), Sylvite (KCl)
12June 2014
DepthWall thickness loss
A1 A2 A3 A4 A5 A6
0-10 m 23 % 8 % 24 % 11 % N/A 43 %
10-35 m 10 % N/A N/A 7 % N/A N/A
35-65 m 4 % 6 % 7 % 6 % 21 % 5 %
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RESULTS – AXIAL LOAD SAFETY FACTORS
Surface casing Conductor
Axial SF Wall loss Axial SF1 Wall loss
A-1 1.82 23 % 6.31 11 %
A-2 2.61 9 % 6.26 11 %
A-3 1.77 24 % 6.21 11 %
A-4 2.27 12 % 6.75 15 %
A-5 N/A2 21 % > 6 10 %
A-6 1.28 43 % 6.04 12 %
13June 2014
� Results are for corroded pipe body; connection performance has not been analysed.
� Results assume well shut-in sufficiently long to reach undisturbed geothermal temperature gradient.
� Axial SF at interventions, e.g. scale squeeze, will be significantly lower
1Assuming that the conductor takes all of the surface casing load
2The permanent platform suspension structure protects the surface casing from axial load
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RESULTS – CORROSION MECHANISM
Direct causes
� Oxygen induced corrosion
� Splash zone introduced by regular
water-top ups: Relatively stable water
level with good access to oxygen
� The difference in corrosion between
wells is not fully understood
Indirect causes
� Insufficient understanding of risk
� Unclear responsibilities
� Well design
14June 2014
Estimated D-annulus water level
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OVERVIEW OF ACTIVITIES UNDERTAKEN
1. Short-term mitigating actions
� Procedures for well operations
� Secure wells A-4 and A-6 with clamps
2. Capture learning
� Incident investigation
� Update operational procedures and practices
3. Understand and mitigate corrosion mechanism
� Rape seed barrier in all wells
� Monitoring, inspection and maintenance program to ensure effectiveness of the corrosion inhibition
4. Further map the corrosion extent
� Data acquisition, review additional or alternative measurements
� Clean-out of D-annulus to ease access for new inspections will be evaluated
5. Long term solution for securing the wells
� Team nominated to develop a plan for long term solutions for all wells at risk
� The plan must be aligned with the abandonment plan for the field
15June 2014
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DRAUGEN A6 CLAMP INSTALLATION – DECEMBER 2013
16June 2014
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PRELIMINARY REPAIR OPTIONS FOR A-6
� Proposal 1 – Grout filled section of conductor
� Proposal 2 – Grouted enclosure over section of surface casing
� Proposal 3 – Composite wrapped surface casing with support on conductor
� Proposal 4 – Composite wrapped surface casing with support on main deck
June 2014 17
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SUMMARY
� A-5 well drop event led to focus on surface casing corrosion
� PEC and boroscope inspection programme from 2003
� Severe corrosion of A-6 surface casing discovered in 2013
� Corrosion inhibition through barrier fluid on top of water filled D-annulus
� Repair of A-6 surface casing under planning
June 2014 18
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Q & A
June 2014 19
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CONCEPT 1 - GROUT FILLED SECTION OF CONDUCTOR
Advantages:
� Economic
� Standard Furmanite components
Disadvantages:
� Grout adhesion
� Weight and size
June 2014 21
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CONCEPT 2 - GROUTED ENCLOSURE OVER SECTION OF SURFACE CASING
Advantages:
� Axial Support
� Standard Furmanite components
Disadvantages:
� Length of enclosure
� Weight and size
June 2014 22
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CONCEPT 3 – COMPOSITE REPAIRED SURFACE CASING WITH SUPPORT ON CONDUCTOR
Advantages:
� Restores structural integrity
� Flexibility in composite length
Disadvantages:
� Large gripper assembly
� Grippers reliance on friction
23June 2014
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CONCEPT 4 – COMPOSITE REPAIRED SURFACE CASING WITH SUPPORT ON MAIN DECK
Advantages:
� Restores structural integrity
� Flexibility in composite length
Disadvantages:
� Large gripper assembly
� Grippers reliance on friction
24June 2014