SPE/IADC-189412-MS

A Systematic Approach to Monitoring and Management of Annulus

Pressures

Manish Srivastava, Abeer A. Al Ali, Ali S. Alshehhi, Amit Kumar, Oleksandr Spuskanyuk, Walid M. Abdulhai, and
Chee Lam Gan, ADNOC Offshore

Copyright 2018, SPE/IADC Middle East Drilling Technology Conference and Exhibition

This paper was prepared for presentation at the SPE/IADC Middle East Drilling Technology Conference and Exhibition held in Abu Dhabi, UAE, 29-31 January 2018.

This paper was selected for presentation by an SPE/IADC 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 or the International Association of Drilling Contractors and are subject to correction
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Abstract
Annuli pressure if not controlled and managed may result in uncontrolled release of high-pressure
hydrocarbon fluids from reservoir to the surface. This may cause loss of life, damage to environment, and
tarnish the reputation of the company. In this paper, two potential pathways for reservoir fluid to reach the
surface through annuli have been examined, and recommendations were provided to diagnose and manage
annulus pressures within safe operating limits.
Integrated well integrity assessment to diagnose the root-cause of annulus pressure involved using various
tools to measure key parameters needed to make an accurate assessment of root-cause of annulus pressure.
For example, thermal numerical models and lab tests were conducted to simulate thermal effects in the well
and analyze annulus fluid samples, respectively. Furthermore, echometer was used to measure fluid-level
in the annuli, whereas logging tools such as spectral noise, high-precision temperature etc. were used to
identify source of any reservoir fluid ingress.
Multiple diagnostic, surveillance and management workflows for outer and inner annuli have been
developed. Experiences in implementing these workflows for hundreds of wells in the field have been
described and lessons learned have been discussed. Special attention has been paid to the cases with
confirmed or suspected lost barriers. Appropriate, cost-efficient levels of diagnostics have been selected
and employed to ensure safe operations. Decision trees on how to manage wells with annulus pressures
have been discussed, in particular related to planning and execution of pressure bleed-offs, annulus top-ups
with heavier fluids, etc. Based on decision trees, cost-efficient levels of diagnostics have been selected and
employed to ensure safe operations.
This work provides insights on various tools to diagnose and cost-effectively manage the pressure in the
annulus by combining the available tools and software. Company-specific annulus pressure management
strategies have been developed and successfully employed to safely operate wells with annulus pressure.
2 SPE/IADC-189412-MS

Background
Sustained pressure in the annuli is a concern in managing integrity of the wells during its life cycle. The
pressure needs to be monitored routinely with the increased monitoring frequency for older wells. All type of
wells must be operated within the designed operating envelope. As outlined in the company's Well Integrity
Management System (WIMS), a minimum of two independently tested mechanical barriers should be in
place at all the times, which means that all wells with known barrier issues, sustained casing pressures or
structural integrity problems are required to be evaluated, risk assessed and mitigated.

Barrier
The barrier ensures that an uncontrolled release or flow of reservoir fluids to the atmosphere / environment
or an underground flow is prevented. Two types of barriers, i.e., primary and secondary should be in place
during all operational scenarious for an integral well. The primary barrier is defined as the barrier in first
contact with reservoir fluids and pressure; the secondary barrier is activated to secure the well in case of the
primary barrier failure. Figure 1 shows examples of barrier requirement during well production.

Figure 1—Schematic of well barriers

Operating limits
Presence of high pressure in the annulus may cause undesired consequences. The operating limits and
standards related to the annulus pressure value should be defined for easy reference for the production
operator to take timely action and guide the well integrity engineer to initiate suitable action for diagnostics /
mitigation. Three pressure levels can be distinguished:

• the trigger value below which the wells is considered integral,

• the maximum allowable annular surface pressure (MAASP) which is defined as the maximum
pressure that can be applied at surface before the weakest affected component in the relevant
annulus breaks down and
• the maximum allowable working pressure (MAWOP). For A-annulus it is defined as 80% of the
MAASP for A-annulus or 100% of the MAASP value for B-annulus, which ever is lower. For B-
annulus MAWOP is defined as 80% of its MAASP
Schematic of the three operating pressure regimes is given on Figure 2.
SPE/IADC-189412-MS 3

Figure 2—Annulus pressure levels to be monitored

Annular Casing Pressure Management. Annuli pressure occurs primarily due to the following reasons:

• Thermal expansion of the trapped fluid

• Operator induced

• Sustained pressure because of barrier failure

Sometimes a pressure may occur due to more than one reason, which makes diagnostics more difficult and
time-consuming. Annular casing pressure management for a newly drilled and completed well is slightly
different from that of an existing well, as during startup of the well the annuli pressure may increase rapidly
and may damage the barrier if not bled. While actively managing the annulus pressure during the well
startup, all the information on types of fluids, volume bled, etc., should be gathered. This is essential for
future diagnostics, should a problem occur during the life cycle of the well. The paper describes cases for
annuli pressure for reasons other than thermal or operator-induced.:

• Annuli pressure in A-annulus or inner annulus or casing to tubing annulus

• Annuli pressure in B-annulus or outer annulus or casing to casing annulus

Annuli pressure management can be divided into 4 distinct phases during the lifecycle of the well
Pre-Production/Injection stage
In some instances, elevated casing pressures may occur during the drilling phase when the next section is
drilled. In most cases, this pressures may be attributed to thermal expansion caused primarily by heating of
drilling fluid as it comes in contact with the formation at a higher temperature. Prior to well handover from
the drilling to production operations, the Annular Fluid Expansion (AFE) volumes need to be calculated
to estimate the expected pressure build up and required bleed-off volumes. It can be done by a variety of
commercially available software packages. when the well is put on production. A brief description of the
computer-based thermal modeling is given below. Note that the modeiling will also include calibation steps
that can be only performed during the next stages after well startup and production.
The process starts with data gathering, constructing the well model, calibration and history matching with
the actual well data, calculation of AFE, and reconciliation of the discrepancies in order to create the fully
calibrated thermal model. Once the model is created then the annular pressure management process can be
designed. The workflow for creating a computer based model [1] will normally include:
Gather data:

• Well construction (schematic, survey, etc.)

• Detailed information about annular fluids, cementing operations, pressures observed in the well
during drilling and completion operations
• Cement tops including uncertainties and cement bond logs

• Pressure history for annuli A, B and C

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• Daily production rates, fluid composition

• Downhole and surface pressures and temperatures

• Thermal gradient of the formation

• Thermal properties of formation layers: thermal conductivity, heat capacity

• Thermal properties of annular fluids

• Details on operational history of the well

• Bleed off data that includes dates, volumes and fluid analysis for all bleed offs during and before
production operations
Construct model of the well using thermal modelling software:

• Create production operations for distinct periods of well operation with fairly constant rates,
pressures, temperatures. Separate periods of long shut-ins.
• Starting from the initial production operation, match the following key points:

• Bottom hole pressure and temperature

• Wellhead pressure and temperature

• Calculate incremental AFE volumes and pressure, taking into account all recorded bleed-offs and
flowing condition changes. If AFE pressures do not match field data, further investigate reasons
for discrepancies. Possible reasons are incorrectly reported bleed-off volumes, wrong assumptions
about cement tops in the annuli, incorrect temperature/pressure readings, etc.
• Reconcile all discrepancies. If impossible, generate multiple scenarios and run sensitivities on
parameters with large uncertainties, i.e., top of cement (TOC).
• Once the first operation is matched, proceed to the second operation matching, etc.

• Fully calibrate the model (model pressures, temperatures, volumes are matching respective field
measurements), then proceed to model possible future production scenarios or well operations,
such as, for example, steady state production with current production conditions, increased water
cut, etc.
• If necessary, recommend annular pressures management process

Operating limits for the well such as MAASP and MAWOP are calculated for all wells. This requires
periodic update based on the WIMS guidelines. Workflow for this stage is described below on Figure 3.
SPE/IADC-189412-MS 5

Figure 3—Work Flow for ‘A & B' Annulus Pressure Management for Pre-Production/Injection stage

Initial production/Injection phase

During the well flow-back for cleanup, the hot reservoir fluids further increase the temperature of the
tubulars, the surrounding fluids and the formation as it moves up to the surface. During this phase there is a
need to actively manage annuli pressure to avoid breach of the operating limits. Thermal analysis performed
before the well startup may indicate that the pressure may reach above the MAASP and damage the barriers
in case pressure is not managed timely, thus allowing to develop pro-active instructions for the operator
for annulus pressure management through bleedoffs. Valuable data should be captured during this stage:
the volume and type of fluid bled while managing the annuli pressure. This information can be fed back to
further calibrate the thermal model. Workflow for this stage is descriped in Figure 4.
6 SPE/IADC-189412-MS

Figure 4—Work Flow for ‘A & B' Annulus Pressure Management for Initial production/Injection phase

Post initial production/ well clean-up

After the well cleanup it may continue to produce if it is a producer or injection may be commenced if it is
an injector. The producer well may continue to heat the formation and further increase in A-annulus and B-
annulus pressures due to increase in temperature of the fluid. The pressure needs to be observed and bled
and checked if there is a sustained pressure.
Whenever there is an increase in pressure above the trigger pressure, assessment to ascertain its cause
has to be initiated. The first step is to compare the operating limit with the annuli pressure and then follow
the diagnostics steps described below for specific cases. For producers, a low monitored annulus pressure
is recommended to avoid ingress of oxygen into the annulus due to cooling of wellbore when the well is
shutin. In addition, this ensures that the barrier is in place. However, in case of injectors with well shutin,
there will be a likely wellbore heating that causes annulus fluid expansion and pressure increase. This would
require close monitoring and bleed-offs if close to the MAWOP pressure.
Some times no pressure in the B annulus could be misleading. By pressure testing the annulus, the
integrity of the barrier can be confirmed. In some cases it has been observed that upon testing the B-annulus
fluid return was observed outside the casing. Fluid level can be checked using Echometer can help in
SPE/IADC-189412-MS 7

determining the probable point of leak. Detailed workflows to investigate non-thermal pressures are given
on Figure 5.

Figure 5—Annulus pressure management after initial production / well clean-up

Temporary abandonment
8 SPE/IADC-189412-MS

During temporary abandonement the hydrocarbon source is shut-off by way of cement / mechanical plug as
per company policy. Temporary abandoned wells must be inspected to ensure that no changes have taken
place that could lead to well integrity issue, the annuli pressure needs to be monitored and documented.
Frequency of monitoring should be as defined in the WIMS. If there is pressure observed in annulus it needs
to be bled and further investigations to be carried out as discussed below.
Pressure in A-annulus. Most of the wells in the company have been completed as single or dual producers
or injectors. Typical well diagram for a single well is shown on Figure 6. A high number of wells have annuli
pressure due to packer failure. Some of the old wells were completed with the expansion (or travelling)
joint. This forms as a weak point in the completion and it is no longer used for the new completions.

Figure 6—Typical Well Completion Diagrams (Dual and Single)

Some of the potential leak paths which may cause in A-annulus pressure have been captured below:
SPE/IADC-189412-MS 9

• Cement seal integrity failure in B-annulus combined with a casing leak in the production casing.

• Un-cemented section in the B-annulus combined with a casing leak in the production casing.

• Production tubing connection leak.

• Hole in production tubing or parting of the production tubing string.

• Leak in gas lift mandrels, expansion joint, chemical injection mandrels, SCSSV and control lines.

• Leak through Production packer, seal assembly, polished bore receptacle.

• Leak from Production casing hanger.

• Tubing hanger leak (neck / body seals).

• Seal, penetrations, connection leaks in the Christmas tree.

• Production casing collapse.

• Production liner top pressure integrity failure.

Integrity assessment requirements for A-Annulus. If a well exhibits pressure in A-annulus, the following
diagnostics separately or in combination may be required:

• Monitor the pressure trends for various flow regimes. Annulus pressure can be monitored for
various flow regimes such as well shut-in, change in choke setting. This might give some indication
if thermal effect is causing the change in temperature. As the formation fluid comes to surface it
heats whatever comes in contact and by conduction heat is transferred to the fluid in the annulus
which expands. Similarly, for injectors, the surface temperature water is injected cooling the well
bore. When the injection is stopped the temperature of the fluid in annulus increases because it tries
to be close to the geothermal temperature. If there is no correlation of annulus pressure with the
change in operating parameters then there would be other reasons causing the pressure and would
require further investigations.
• Evaluate the bleed-off and pressure build-up survey. If the pressure in the A-annulus bleeds quickly
and builds slowly to a lower level this indicates the pressure is mostly due to thermal reasons
and there is no loss of barrier. If the pressure doesn't bleed and builds back quickly then it would
indicate that the annulus is connected to a pressure source.
• Analyze the bleed-off samples. The collected samples can indicate if it is injected water or produced
fluid. If the bleed-off sample is formation fluid then action should be taken to mitigate the influx of
formation fluid into the annulus as this may cause irreparable corrosion of the production casing.
Detailed analysis of the bleed-off samples may throw some light on the possibility of corrosion
taking place in the A-annulus. Presence of iron ions, hydrogen gas is the main indicator of the
corrosion.
• Tubing pressure testing by setting a down-hole plug. A simple way to check the integrity of the
tubing is to pressurize the tubing after setting a plug. In case there is a leak the pressure will not
hold. If a corresponding increase in A-annulus pressure is observed then the leak in the tubing is
confirmed. If the pressure in tubing doesn't hold and there is no increase in A-annulus pressure
then it could be assumed that the plug is leaking.
• Communication test (Surface / Down-hole). It could be a simple surface communication or
downhole communication test. Surface communication test is carried out by shutting the well,
bleeding the tubing pressure, annuli pressure and observing if there is any build up in the annuli
pressure. Down hole communication test would require setting of a plug in the tubing, pressurizing
the tubing and bleeding the annuli. The pressure below and above the plug along with the annulus
10 SPE/IADC-189412-MS

pressure is monitored to observe if there is any correlation which may indicate probable cause of
the leak.
• Evaluate annulus fluid level. Echometer can be used to determine the air gap and the fluid level in
the annulus. It would be helpful in planning for mitigation by bleed-and lubricate of the annulus
with a heavier inhibited fluid to reduce the pressure in the annulus. The echometer can also be used
to detect a hole in tubing by pumping gas in the A-annulus until it can be observed in the tubing. By
doing a fluid level check at this time the location of the leak point in the tubing can be ascertained.
• Noise log. A leak in tubing can be heard by a noise tool while bleeding the annulus. Noise is
generated when the fluid enters in the annulus from the leak point and is picked up by the logging
tool. This would determine the location of the leak in the tubing / completion. Identifying multiple
leaks is easy by this tool.
• Corrosion log along with Multifinger caliper log have been used effectively to understand the
condition of the tubing. The logs provide information about the loss of metal, whether the loss is
internal or external and if there are any holes in the tubing which may cause communication to the
A annulus. A mockup test was conducted by the company to detect metal loss due to corrosion
for multiple casings while running the tool in the tubing. The results of the test did not give a
quantitative measurement with high level of accuracy. However, a qualitative judgment can be
made by using the tool to measure the time lapse corrosion.
• Temperature log or distributed temperature sensing (DTS): A temperature log will be able to pick
any temperature anomaly when compared to the geothermal and would be able to identify a leak
in the tubing. Newly completed gas lift wells have been completed with fiber optic cable outside
the tubing. This can be used to obtain temperature profile across the length of the tubing to detect
any leak.

Pressure in B-annulus
It is possible that B annulus has pressure or has no pressure. Zero pressure in the B-annulus doesn't ensure
that the barriers are in place. Specific tests are needed to ensure that the barriers are in place.
Some of the leak paths for B-annulus are as below:

• Cement seal integrity failure causing flow from hydrocarbon reservoir from below.

• Large un-cemented sections behind outer casing causing flow from shallow reservoir through shoe
into the B-annulus.
• Inner casing string leaks causing pressure from A-annulus.

• Casing head pack-off/seal leaks.

• Settling of annular fluid solids may cause loss of hydro-static head.

Integrity assessment requirements for B-Annulus

• Quality of the cement behind the production casing has a big impact of the annuli pressure. If the
height of the cement is below the surface casing and a permeable zone is exposed then to mitigate
the annuli pressure in the B annulus would be challenging as the fluid available for expansion is
quite large. It has to be ensured that the effluent samples do not have hydrocarbon or corrosive fluid.
• Monitor the pressure trends for various flow regimes: annulus pressure trend when monitored
over a period of time for various flowing conditions or shut-in can give an indication whether the
pressure is due to thermal reasons or it's a sustained pressure or a combination of both.
Depending on the pressure build up, rate of bleed-off, and build-up rate the severity of the
pressure can be estimated / defined.
SPE/IADC-189412-MS 11

• Evaluate the bleed-off and pressure build-up survey. The pressure may be bleedable or un-
bleedable. Even if the pressure is un-bleedable following scenarios' can happen.
➢ Quick bleed-off and quick build-up with very low effluent volume recovered
➢ Quick bleed-off but slow build-up
➢ Slow bleed-off but quick build-up
➢ Slow bleed-off and slow build-up
The volume of effluent collected should be measured to have the total volume recorded which
can be compared with the estimated volume from AFE estimation.
• Analyze the bleed-off samples
➢ Physical analysis, liquid or gas. If liquid, water or brine or oil. Salinity, H2S, CO2 can be
measured at site. At site basic tests like salinity water percentage etc. can be carried out if
available
➢ Chemical composition. Compositional analysis of gas, water or oil need to be performed. For
gas it has to be estimated if there is presence of hydrocarbon or any corrosive gas like H2S
or CO2. For water a quick check for salinity will tell if the water is brine, formation water or
injected water etc. For oil a quick finger printing will help us understand if its base oil from
drilling fluid or formation oil. To confirm the correct reservoir source of oil a biomarker analysis
or isotope analysis may be required.

• Evaluate annulus fluid level: echometer can be used to determine the fluid level in the annuli to
check if its liquid filled or there is some air gap.
• Noise and temperate logs were successfully used to determine the entry point of the fluid from
a formation which was feeding in the annulus. Planning for the job required thermal modeling
to estimate the stabilization time required and then to start the bleed-off and start the logging to
increase the chance of picking the sound and the temperature deflections from the thermal gradient.
Distributed temperature sensing was used in wells equipped with fiber-optic cable.
• Water flow log have been performed successfully to detect movement for water behind casing and
identify the zonal communication problem. In certain cases where the noise level may be low and
may go undetected Water flow log may prove to be useful

Conclusions
Various diagnostic tools have been discussed in the paper, which may be used alone or in combination
in a cost-effectively way to manage the pressure. Each job has an approved program which is enhanced
based on experience. Company-specific annulus pressure management strategies have been developed and
successfully employed to safely operate wells with annulus pressure. Some of the advanced tools have been
used for annuli pressure behaviour prediction after the model has been caliberated.
Risk Assessment is the initial and most important step in risk management in case of a sustained annuli
pressure. It is the formal process for evaluating and quantifying the potential to harm the people, the
environment or equipment / facilities. With complete available information from the diagnostics its easy to
carry out an accurate risk analysis to enable the management to take appropriate action.

References
[1] M. Srivastava, O. Spuskanyuk, W. Abdulhai and A. Alshehhi, "Advanced well modeling and
diagnostics to manage annulus pressure," SPE-189412, 2016.