Ocean Engineering & Oceanography 12

Mahmoud Khalifeh
Arild Saasen

Introduction
to Permanent
Plug and
Abandonment
of Wells
Ocean Engineering & Oceanography

Volume 12

Series Editors
Manhar R. Dhanak, Florida Atlantic University SeaTech, Dania Beach, USA
Nikolas I. Xiros, University of New Orleans, New Orleans, LA, USA
More information about this series at http://www.springer.com/series/10524
Mahmoud Khalifeh Arild Saasen
•

Introduction to Permanent
Plug and Abandonment
of Wells
Mahmoud Khalifeh Arild Saasen
Kjølv Egenlands hus Kjølv Egenlands hus
Stavanger, Norway Stavanger, Norway

ISSN 2194-6396 ISSN 2194-640X (electronic)

Ocean Engineering & Oceanography
ISBN 978-3-030-39969-6 ISBN 978-3-030-39970-2 (eBook)
https://doi.org/10.1007/978-3-030-39970-2
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Acknowledgements

The book is based on research and literature review conducted on permanent plug
and abandonment of hydrocarbon wells. Special thanks to the Norwegian Oil and
Gas Plug and Abandonment Forum (PAF) for supporting the publication and
helping the authors to publish the book as open access. We are also grateful for
several colleagues helping and encouraging us to continue with the work and finally
to publish it.
We hereby would like to thank them by listing their names:
Arne G. Larsen
Atle J. Sørhus
Dave Gardner
Egil Thorstensen
Farzad Shoghl
Helge Hodne
Ivar Blaauw
Lars Hovda
Martin K. Straume
Michael T. Skjold
Nils Opedal
Odd G. Taule
Øystein Arild
Rune Godøy
Steinar Strøm
Tove Rørhuus
Alex Osorio
Arild Rasmussen
Colin Beharie
John Dale
John Donachie
Laurent Delabroy
Luca Carazza

v
vi Acknowledgements

Matus Gajdos
Max B. Baumert
Steffen K. Lindsø
Steffen Kristiansen
Sylvain Bedouet
Tu N. Tran
Vidar Rygg
Contents

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Abandonment Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Asset Retirement Obligation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Prepared for Permanent Plug and Abandonment . . . . . . . . . . . . . 3
1.3.1 Plug and Abandonment Challenges . . . . . . . . . . . . . . . . 3
1.4 Past, Present, and Future of Plugged and Abandoned
Wells on the NCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.5 Digitalization in Plug and Abandonment . . . . . . . . . . . . . . . . . . 4
1.6 The Regulatory Authorities . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.7 P&A Barrier Philosophy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.8 The Beginning of the End—Decommissioning . . . . . . . . . . . . . . 7
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2 General Principles of Well Barriers . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1 Well Annuli . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2 Well Barrier Envelope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2.1 Primary and Secondary Well Barriers . . . . . . . . . . . . . . 13
2.2.2 Environmental Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.3 Well Barrier Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.4 Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.4.1 Bridge/Mechanical Plugs . . . . . . . . . . . . . . . . . . . . . . . 16
2.5 Well Barrier Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.6 Prerequisites for Well Abandonment Design . . . . . . . . . . . . . . . . 17
2.6.1 Well Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.6.2 Stratigraphic Sequences . . . . . . . . . . . . . . . . . . . . . . . . 18
2.6.3 Logs and Cementing Operation Data . . . . . . . . . . . . . . . 19
2.6.4 Formations with Suitable Well Barrier Element
Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 19
2.6.5 Specific Well Conditions . . . . . . . . . . . . . . . . ....... 20
2.7 Well Abandonment Phases . . . . . . . . . . . . . . . . . . . . . ....... 26

vii
viii Contents

2.7.1 Phase 1: Reservoir Abandonment . . . . . . . . . . . . . .... 27

2.7.2 Phase 2: Intermediate Abandonment . . . . . . . . . . . .... 27
2.7.3 Phase 3: Wellhead and Conductor Removals . . . . . .... 27
2.8 Disconnecting the Christmas Tree and Assembling Blowout
Preventer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.8.1 Wellhead Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.8.2 The Christmas Tree Systems . . . . . . . . . . . . . . . . . . . . . 35
2.8.3 Assembling BOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.9 Special Considerations in Abandonment Design . . . . . . . . . . . . . 47
2.9.1 Control Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.9.2 Well Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.9.3 Well Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.9.4 Horizontal Wells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.9.5 High-Pressure High-Temperature Wells . . . . . . . . . . . . . 56
2.9.6 Shallow Permeable Zones . . . . . . . . . . . . . . . . . . . . . . . 57
2.9.7 Multilateral Wells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.9.8 Slot Recovery Sidetracks . . . . . . . . . . . . . . . . . . . . . . . 59
2.9.9 Multiple Reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.9.10 Slotted Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.9.11 Inflow Control Device . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.9.12 Tubing Left in Hole . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.9.13 Hydrocarbons in the Overburden . . . . . . . . . . . . . . . . . . 62
2.10 Requirements for Designing Permanent Barriers . . . . . . . . . . . . . 63
2.10.1 Well Cross Sectional Barrier . . . . . . . . . . . . . . . . . . . . . 63
2.10.2 Plug Setting Depth—Formation Integrity . . . . . . . . . . . . 63
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3 Specification for Permanent Plugging Materials . . . . . . . ......... 71
3.1 Material Requirements for Permanent Barriers . . . . . ......... 71
3.2 Functional Requirements of Permanent Well Barrier
Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.2.1 Sealing Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.2.2 Bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.2.3 Placeability of Permanent Barrier Material . . . . . . . . . . . 85
3.2.4 Durability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
3.2.5 Reparability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3.3 Qualification of New Plugging Materials . . . . . . . . . . . . . . . . . . 92
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4 Types of Permanent Plugging Materials . . . . . . . . . . . . . . . . . . . . . . 97
4.1 Setting Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
4.1.1 Portland Cement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
4.2 In Situ Formation (Formation as Barrier) . . . . . . . . . . . . . . . . . . 104
4.2.1 Durability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Contents ix

4.3 Non-setting (Grouts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

4.3.1 Unconsolidated Sand Slurries . . . . . . . . . . . . . . . . . . . . 114
4.4 Thermosetting Polymers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
4.4.1 Main Degradation Mechanisms . . . . . . . . . . . . . . . . . . . 121
4.4.2 Long-Term Integrity of Thermosetting Resins . . . . . . . . 121
4.5 Metals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
4.6 Modified In Situ Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.6.1 Barrier Establishment . . . . . . . . . . . . . . . . . . . . . . . . . . 131
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
5 Different Categories of Working Units . . . . . . . . . . . . . . . . . . . . . . . 137
5.1 Onshore Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
5.1.1 Conventional Land Rigs . . . . . . . . . . . . . . . . . . . . . . . . 138
5.1.2 Mobile Land Rigs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
5.2 Offshore Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
5.2.1 Submersible/Barge Rigs . . . . . . . . . . . . . . . . . . . . . . . . 140
5.2.2 Semisubmersible Rigs . . . . . . . . . . . . . . . . . . . . . . . . . 140
5.2.3 Drillship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
5.2.4 Jackup Rig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
5.2.5 Platform Rigs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
5.2.6 Tendered Rigs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
5.2.7 Vessels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
5.3 Types of Offshore Wells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
5.3.1 Subsea Wells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
5.3.2 Platform Wells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
5.4 Types of Offshore Production Units . . . . . . . . . . . . . . . . . . . . . . 148
5.4.1 Bottom Supported and Vertically Moored
Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
5.4.2 Floating Production Systems . . . . . . . . . . . . . . . . . . . . . 150
5.5 Manned and Unmanned Platforms . . . . . . . . . . . . . . . . . . . . . . . 152
5.5.1 Manned Platforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
5.5.2 Unmanned Platforms . . . . . . . . . . . . . . . . . . . . . . . . . . 152
5.6 Mooring Systems for Floating Units . . . . . . . . . . . . . . . . . . . . . 154
5.6.1 Spread Mooring Systems . . . . . . . . . . . . . . . . . . . . . . . 155
5.6.2 Turret Mooring Systems . . . . . . . . . . . . . . . . . . . . . . . . 157
5.6.3 Conventional Buoy Mooring System . . . . . . . . . . . . . . . 157
5.6.4 Offshore Mooring Patterns . . . . . . . . . . . . . . . . . . . . . . 158
5.6.5 Dynamic Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . 159
5.7 Anchoring Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
5.8 Moonpool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
x Contents

6 Work Classification and Selection of Working Units . . . . . . . . . . . . 165

6.1 P&A Code System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
6.1.1 Well Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
6.1.2 Abandonment Phases . . . . . . . . . . . . . . . . . . . . . . . . . . 166
6.1.3 Abandonment Complexity . . . . . . . . . . . . . . . . . . . . . . 168
6.2 Time and Cost Estimation of a P&A Operation . . . . . . . . . . . . . 172
6.2.1 Description of Factors . . . . . . . . . . . . . . . . . . . . . . . . . 173
6.2.2 Traditional Method for Time Estimation . . . . . . . . . . . . 175
6.2.3 Probabilistic Method for Time Estimation . . . . . . . . . . . 176
6.2.4 Regression Method for Time Estimation . . . . . . . . . . . . 183
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
7 Fundamentals of Plug Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
7.1 Openhole Plug Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
7.1.1 Fluid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
7.1.2 Milling Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
7.1.3 Hydraulic Mud Removal . . . . . . . . . . . . . . . . . . . . . . . 187
7.1.4 Mechanical Filter Cake Removal . . . . . . . . . . . . . . . . . . 187
7.2 Cased Hole Plug Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
7.2.1 Qualified Annular Barrier . . . . . . . . . . . . . . . . . . . . . . . 190
7.2.2 Disqualified Annular Barrier . . . . . . . . . . . . . . . . . . . . . 190
7.3 Plug Placement Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
7.3.1 Balanced-Plug Method . . . . . . . . . . . . . . . . . . . . . . . . . 190
7.3.2 Two-Plug Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
7.3.3 Dump Bailer Method . . . . . . . . . . . . . . . . . . . . . . . . . . 194
7.3.4 Coiled Tubing Method . . . . . . . . . . . . . . . . . . . . . . . . . 195
7.4 Mud Displacement During Cementing . . . . . . . . . . . . . . . . . . . . 198
7.5 Verification of Placement Operation . . . . . . . . . . . . . . . . . . . . . . 204
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
8 Tools and Techniques for Plug and Abandonment . . . . . . . . . . . . . . 213
8.1 Casing Cut and Removal Techniques . . . . . . . . . . . . . . . . . . . . . 213
8.1.1 Cut-and-Pull Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
8.1.2 Casing Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
8.1.3 Casing Section Milling . . . . . . . . . . . . . . . . . . . . . . . . . 215
8.1.4 Upward Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
8.2 Perforate, Wash and Cement Technique . . . . . . . . . . . . . . . . . . . 219
8.2.1 Concept Behind the Technique . . . . . . . . . . . . . . . . . . . 219
8.3 Explosives to Establish Annular Barrier . . . . . . . . . . . . . . . . . . . 222
8.4 Melting Downhole Completion . . . . . . . . . . . . . . . . . . . . . . . . . 224
8.5 Plasma-Based Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
8.5.1 Concept Behind the Technology . . . . . . . . . . . . . . . . . . 224
8.5.2 Scientific Background of the Technology . . . . . . . . . . . . 225
Contents xi

8.6 Wellhead Cut and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

8.6.1 Explosive Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
8.6.2 Hot Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
8.6.3 Mechanical Methods . . . . . . . . . . . . . . . . . . . . . . . . . . 236
8.6.4 Abrasive Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
8.6.5 Laser Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
9 Barrier Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
9.1 Annular Barrier Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
9.1.1 Acoustic Logging of Annular Barrier . . . . . . . . . . . . . . 250
9.1.2 Noise Logging Measurements . . . . . . . . . . . . . . . . . . . . 259
9.1.3 Temperature Logging . . . . . . . . . . . . . . . . . . . . . . . . . . 260
9.1.4 Hydraulic Pressure Testing . . . . . . . . . . . . . . . . . . . . . . 263
9.2 Internal Barrier Verification/Plug Inside Openhole or Casing . . . . 266
9.2.1 Hydraulic Pressure Testing . . . . . . . . . . . . . . . . . . . . . . 266
9.2.2 Weight Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
9.3 Hydraulic Pressure Equivalent to Drillpipe Tag Weight . . . . . . . . 271
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
About the Authors

Mahmoud Khalifeh is Associate Professor at

University of Stavanger (UiS). He holds a Ph.D. in plug
and abandonment of wells with a focus on materials
optimized for permanent P&A. He has developed the
permanent P&A (Plug and Abandonment) subject (MSc
level) at UiS. He has published several articles in
scientific journals and conferences. He represents UiS as
observer at Norwegian Plug and Abandonment Forum
(PAF) since 2012.

Arild Saasen has a position as Adjunct Professor at

the University of Stavanger. Parallelly, he works for
other companies including his own company ALKAS
Atlantic AS. He has previously worked as drilling and
well fluid specialist in Det norske oljeselskap (now
named AkerBP) and Statoil (now named Equinor).
Earlier, he worked for Rogaland Research (now named
Norce). He holds an MSc in fluid mechanics from the
University of Oslo, Norway, and a Ph.D. from the
Technical University of Denmark. Throughout the last
three decades, he has published numerous articles about
drilling and drilling fluids. He has been awarded the
Nordic Rheology Society’s Carl Clason Rheology
Award in 2012 and the SPE North Sea Regional
Drilling Engineering Award in 2018.

xiii
Abbreviations

ΔPf2 Frictional Pressure Drop Between Displacing and Displaced Fluids

sav Average Shear Bond Strength
A Pre-exponential Constant
AFE Authority for Expenditure
AHT Anchor Handler Tug
AHV Anchor Handling Vessel
ANP The Brazilian National Agency of Petroleum, Natural Gas and Biofuels
Ap Surface Area of Plug
AP Annular Preventer
API American Petroleum Institute
ARO Asset Retirement Obligation
ASV Annular Safety Valve
AWJC Abrasive Water-Jet Cutting
BHA Bottom Hole Assembly
BHTC Bottomhole Circulating Temperature
BOP Blowout Preventer
BSEE The American Bureau of Safety and Environmental Enforcement
BSR Blind Shear Ram
C2S Dicalcium silicate
C3A Tricalcium aluminate
C3S Tricalcium silicate
C4AF Tetracalcium aluminoferrite
CBL Cement Bond Log
CBM Conventional Buoy Mooring
CCL Casing Collar Locator
CDF Cumulative Distribution Function
CLT Central Limit Theorem
C-S-H Hydrated Silicate and Calcium
CSR Casing Shear Ram
DAS Distributed Acoustic Sensing

xv
xvi Abbreviations

DC Direct Current
DEA Danish Energy Agency
DHSV Downhole Safety Valve
Di Inner Diameter of the Geometry Plug Placed Inside
DNRM The Australian Department of Natural Resources and Mines
DP Dynamic Positioning
DPR The Nigerian Department of Petroleum Resources
DTS Distributed Temperature Sensing
Ea Activation energy
ECD Equivalent Circulating Density
EMAT Electro-Magnetic Acoustic Transducers
EOR Enhanced Oil Recovery
EPDM Ethylene Propylene Diene Monomer
ESP Electrical Submersible Pump
F Failure force
FAB Formation as Barrier
Ffc Filter cake – Formation Friction Force
FFKM Perfluoroelastomer
FKM Fluoroelastomer
FPSO Floating, Production, Storage, and Offloading
FR Reservoir Force
Fsb Shear Bond Force
H Reservoir Depth
hMSD Minimum Setting Depth Of Plug
HMV Hydraulic Master Valve
HPHT High-Pressure High-Temperature
HSE Health, Safety and Environment
HSE The British Health and Safety Executive
HWU Hydraulic Workover Unit
ICD Inflow Control Device
IFT Interfacial Tension
IOR Improved Oil Recovery
KV Kill Valve
Lp Plug Length
LPWH Low-Pressure Wellhead Housing
LVR Lower Variable Ram
LWIV Light Well Intervention Vessel
MMF Mud Mobility Factor
MMH Mixed Metal Hydroxide
MMV Mechanical Master Valve
MODU Mobile Offshore drilling Unit
MPE Ministry of Petroleum and Energy
MSD Minimum Setting Depth
MVR Middle Variable Ram
NA Not Available
Abbreviations xvii

NCS Norwegian Continental Shelf

nD NanoDarcy
NIOC National Iranian Oil Company
NPD Norwegian Petroleum Directorate
NPT Non-Productive Time
OBM Oil-based Mud
OD Outside Diameter
P&A Plug and Abandonment
PDF Probability Distribution Function
PE Pulse Eco
PEEK Polyether Ether Ketone
PFP Final Reservoir Pressure
Pfrac. Fracture Pressure Gradient
Pg Gas Gradient Pressure
PMF Probability Mass Function
PNGRB The Indian Petroleum and Natural Gas Regulatory Board
POB Personnel on Board
Pp Pump Pressure
ppg Pounds per Gallon
PPS Polyphenylene Sulfide
PSA The Norwegian Petroleum Safety Authority
PSD Particle Size Distribution
PTFE Polytetrafluoroethylene
PUE Polyurethane Elastomers
PVDF Polyvinylidene fluoride
PWC Perforate, Wash and Cement
PWV Production Wing Valve
RDT Radial Differential Temperature
RIH Run in Hole
ROV Remotely Operating Vehicle
SCP Sustained Casing Pressure
SCSSV Surface Controlled Subsurface Safety Valve
SEM Scanning Electron Microscopy
sk Sack
SW Swab Valve
Tg Glass transition temperature
TLP Tension Leg Platform
TOC Top of Cement
TVD True Vertical Depth
UNMIG Ufficio Nazionale Minerario per gli Idrocarburi e le Georisorse
(National Office for mining, Hydrocarbons, and Geothermal Resources)
UVR Upper Variable Ram
VDL Variable Density Log
WBAC Well Barrier Acceptance Criteria
WBE Well Barrier Element
xviii Abbreviations

WBM Water-Based Mud

WBS Well Barrier Schematic
Wdp Drillpipe Tag Weight
XMT Christmas Tree
YP Yield Point
Chapter 1
Introduction

Every beginning has an end. This book covers the beginning of the end of well
life. When a well reaches the end of its life, it must permanently be plugged and
abandoned. Plug and abandonment can easily contribute to 25% of the total cost of
drilling exploration wells offshore Norway. The cost of running a plug and abandon-
ment operation on some offshore production wells may have a cost impact similar
to the cost of the original drilling operation. Therefore, cost efficient plug and aban-
donment technology is a necessity without compromising the scope of the operation.
The occasion that dictates the end of a well life could be integrity issues, subsidence
induced well failure, depleted reservoir, water/gas coning, negative cash flow, or fin-
ished data gathering from exploration. In addition, there are other circumstances that
force the wellbore(s) to be permanently plugged and abandoned. For instance, a plat-
form in the Gulf of Suez, Egypt, was struck by a cargo vessel on December 1989. Due
to the massive damage, the nine wells were forced to be plugged and abandoned and
a field re-development had to be performed [1]. A question rises; what is the purpose
of a plug and abandonment operation? Why are not wells left behind as they are? One
answer is establishment of barriers for preventing flow of hazardous fluids to sur-
roundings. The surroundings can be the marine environment, groundwater, ground
or atmosphere. The objective of plug and abandonment operations is to restore the
cap-rock functionality, securing the well-integrity permanently. In order to succeed,
an appropriate permanent barrier shall be placed across a suitable formation through
the utilization of relevant equipment to fulfill the local requirements.
Now a comprehensive definition of Plug and Abandonment (P&A) could be given
as a collection of tasks and actions taken to isolate and protect the environment and
all fresh water zones and surroundings from a source of potential inflow. The source
of potential inflow is a formation with permeability and it may be either a water or
a hydrocarbon bearing zone. The outline of a P&A operation varies a little; whether
the well is offshore or onshore, or if the well is going to be abandoned permanently
or temporarily, although the main goal is to secure all formations which have the
potential to leak. Therefore, we begin the discussion of plug and abandonment with
some basic definitions.
© The Author(s) 2020 1
M. Khalifeh and A. Saasen, Introduction to Permanent Plug
and Abandonment of Wells, Ocean Engineering & Oceanography 12,
https://doi.org/10.1007/978-3-030-39970-2_1
2 1 Introduction

1.1 Abandonment Types

Once the downhole activities or production is discontinued, the well status needs to be
clarified. Generally, three different statuses may be defined; suspension, temporarily
abandoned or permanently abandoned [2]. When a well is subjected to construction
or intervention, the operation may need to be suspended without removing the well
control equipment. In this scenario, the well status is called suspension. The operation
could be suspended due to waiting on weather, workover on another well, waiting
on equipment, rig skidded to do short-term work on another well or batch drilling
(top section of hole only), or to accommodate pipe lay activities in the field.
Temporarily abandoned is a status where the well has been abandoned and the
well control equipment is removed with the intention of later re-entry or permanent
abandonment. Another phrase for temporarily abandoned could be long-term sus-
pension. Temporary abandonment could be through a long shutdown, waiting on
a workover, waiting on field development, re-development, etc. Temporarily aban-
doned status begins when the main reservoir has been fully isolated from the wellbore
and may last from days up to several years. Different regulatory authorities have their
own requirements with respect to the maximum period of temporary abandonment.
A temporarily abandoned well may be with or without monitoring a system which
depends upon the requirements of the regulatory authority, and well location.
Permanently abandoned is a status where the well or part of the well, has been
permanently plugged and abandoned with the intention of never being re-used or
re-entered.

1.2 Asset Retirement Obligation

Asset Retirement Obligation (ARO) addresses legal obligations and associated costs
related to future retirement of long-lived assets. According to ARO, operators are
obliged to demonstrate that sufficient assets have been allocated to cover the cost of
future P&A operations [3, 4]. An ARO liability includes downhole abandonment,
surface abandonment, facility site abandonment, infrastructure dismantling, and site
decommissioning [5]. One of the main reasons to bring the ARO mechanism into
action is the reported failure to properly abandon wells and facilities which create
serious issues for environment, safety, and security. Dry wells or improperly aban-
doned wells or fields that are left behind require huge public funds to be allocated;
however, operators were supposed to be in charge. The ARO, however, does not
apply to unplanned clean-up costs such as cleaning up of an accident.
1.3 Prepared for Permanent Plug and Abandonment 3

1.3 Prepared for Permanent Plug and Abandonment

When a well reaches the end of its life-cycle, it must be permanently plugged and
abandoned. In addition, there are many other reasons for a well to be partially or fully
plugged. A safe production operation is primarily about maintaining well integrity
and sufficient barriers throughout the well life-cycle. It is common practice to per-
form risk assessments for all wells. Once risks are identified, wells are assigned
color codes. Based on the color codes, whenever well integrity is not maintained or
is compromised, the well should be economically repaired or alternatively be perma-
nently plugged. A wellbore that has not encountered hydrocarbons of a commercially
viable quantity is usually plugged. These types of wellbores are called either dry-
holes or dusters even though they may contain water. Generally, most dry holes are
exploratory wells. Regardless of was an exploration success or not, a common pro-
cedure for exploratory wells is to permanently plug and abandon them after data
gathering is complete. This is due to their inappropriate well design for production
and the costs and risks associate with modifying their design (e.g. uncertainties in
the sealing capabilities of the intermediate and production casings, unknown cement
tops and damaged formation nearby casing shoes).
Occasionally a sidetrack needs to be drilled to bypass an unusable section of the
original wellbore or to explore a nearby geologic feature. Prior to beginning such a
sidetrack the borehole below the sidetrack should be permanently plugged.
Slot recovery, re-development and well integrity issues are some other reasons
that may initiate a permanent plug and abandonment operation. Slot recovery is a
process of recovering an existing drilling or template slot to reach a new target. Slot
recovery may be done due to limited rig skidding capacity, an irretrievable fish in a
slot, not hitting the target with the original well, or a limited number of slots on a
drilling platform or template.

1.3.1 Plug and Abandonment Challenges

Every well is unique and the associated challenges with it as well. The main chal-
lenges which have been reported associated with the P&A of wells, can be categorized
as high temperatures, unconsolidated formations, changes in formation strength as
a result of depletion, uncertain ultimate reservoir pressure after abandonment, for-
mation permeability, tectonic stresses exerted by formation (e.g. shear stress and
subsidence), sustained casing pressure (SCP), lack of data from old drilled wells,
deep section milling, and verifying the casing cement behind the second casing
string. These are the main challenges that industry moat deal with; however, all of
these may not be applicable to a specific well.
4 1 Introduction

1.4 Past, Present, and Future of Plugged and Abandoned

Wells on the NCS

Since the first discovery in the Norwegian sector of the Norwegian Continental Shelf
(NCS) in 1966 until June 2015, nearly 5600 wells have been drilled to date. Of these
wells, 4037 are development wells and 1542 are exploration wells. Of the exploration
wells, 1480 have been permanently plugged and abandoned. Of the development
wells, approximately 1400 have been permanently abandoned and 467 have in a
temporarily abandoned status. It is estimated that 2637 development wells need to
be plugged and abandoned in the near future. In addition, the number of future wells
that will be drilled should be added to these statistics [6]. Availability of a database
for permanently plugged and abandoned wells could be beneficial for industry, gov-
ernment, and tax payers. This could result in knowledge sharing, optimized planning,
and a better understanding of strategies and technology development related to the
P&A of wells [7]. Figure 1.1 presents an overview of the status of all the wells drilled
in the Norwegian sector of the NCS.

1.5 Digitalization in Plug and Abandonment

Digitalization is a process in which information and knowledge are converted into

a digital format [8]. In this way, it is organized into discrete units of data, known
as bits. Digitalization has already been implemented by different industries such
as the automobile industry. It is not a new concept in the oil and gas industry;

(a) Total number of all drilled wells. (b) Total number of all drilled
development wells.
Fig. 1.1 A status overview of all wells drilled on the Norwegian sector of the NCS
1.5 Digitalization in Plug and Abandonment 5

the upstream industry has been relying on digital technologies for many years. Of
these, one can refer to seismic data processing from the 1980s and monitoring and
optimizing critical production processes from the 1990s [9]. Digitalization has some
core benefits including access to data, data management, improving accuracy in
engineering by implementing the latest theories and models, optimal planning and
operation, minimizing human error or human factors which contribute to failures or
incidents, changing human involvement to a supervisory role and finally leading to
the automation of the drilling process [10]. But digitalization creates big data volumes
and it has associated challenges including data capturing, data storage, data analysis,
search, sharing, transfer, visualization, querying, updating and information security
[11]. These challenges need to be considered along the way of digitalization in the
oil and gas industry. Digitalization of standards may also be considered in different
ways; integration of standards and regulations in software programs to “police” the
plans and operations or inclusion of standards as help files [12].
Applying digitalization in P&A can be differentiated for old wells and new wells.
Perhaps, the most challenging part will be the digitalization of old wells; new wells
can be equipped with sensors to monitor the wells and track them from the day
of design and construction to abandonment. When considering digitalization of old
wells, it is possible to register the well location, well status, well schematic, mechan-
ical failures, HSE issues, previous rig footprints, and archiving the well data. One
of the “low-hanging fruit” benefits of digitalization is having an updated overview
of well numbers and their status. This has been implemented properly in the oil and
gas sector of Norway by the Norwegian Petroleum Directorate.

1.6 The Regulatory Authorities

Regardless of abandonment type, operators must leave wellbores behind which are
secured in accordance with local regulations. Figure 1.2 maps some regulatory
authorities managing petroleum activities in their own territories. Different regu-
latory bodies have their own requirements and operators must strictly adhere to local
well-abandonment regulations. Local regulations are the minimum requirements and
have changed considerably over the years to facilitate P&A operations in a safe man-
ner. Nevertheless, some operators have their own internal requirements and tend to
follow them where the regulatory authorities do not provide minimum requirements.
The North Sea could be divided into four sectors; the United Kingdom, the Nor-
wegian, the Danish and the Dutch. The Health and Safety Executive (HSE) is the
appropriate department that oversee the petroleum activities in Britain. In the Dan-
ish sector, the Danish Energy Agency (DEA) is the regulatory authority. The Dutch
Supervision of Mines and the Norwegian Petroleum Directorate (NPD) are the reg-
ulatory authorities for the Dutch and Norwegian sectors, respectively. The NPD is
the governmental specialist directorate and administrative body for the NCS. The
NPD acts as an adviser to the Ministry of Petroleum and Energy (MPE) of Norway.
In the Norwegian maritime territory, there is an independent government regulator,
6 1 Introduction

Fig. 1.2 Regulatory authorities, oversee their own petroleum activities

which is known as the Petroleum Safety Authority (PSA) Norway with responsibility
for safety and emergency preparedness in the Norwegian petroleum industry. The
PSA is the legislative authority for P&A activities and reviews the proposed P&A
plans for the NCS. The PSA is the responsible organization for overseeing the P&A
operations.

1.7 P&A Barrier Philosophy

There is a generally accepted philosophy for well barriers that the well should be
equipped with sufficient well barriers to prevent uncontrolled flow from the potential
sources of flow. In addition, it is generally accepted that no single failure of a well
barrier component should lead to unacceptable consequences. This means that, in
practical terms, the well should be equipped with two independent well barriers;
a primary and a secondary barrier. This is also known as “hat-over-hat” principle
whereas the secondary barrier acts as a back-up to the primary well barrier, as shown
in Fig. 1.3.
The function of the barrier philosophy could be slightly different in circumstances
where the P&A operation is ongoing or a well has been permanently plugged and
abandonment. For a well P&A operation, some barrier elements need to be in an open
position to allow access to the borehole and perform the P&A operation. It is critical
that these elements close in circumstances when it is necessary to halt the operation.
So the primary and secondary barrier elements may vary based on the pre- or post-
abandonment status. The P&A barrier principles will be discussed thoroughly in the
next chapter.
1.8 The Beginning of the End—Decommissioning 7

Cap rock holds the pressure Primary barrier hold the pressure Secondary barrier is independent
of primary and acts as back-up

Fig. 1.3 Two-barrier philosophy shown using the “hat-over-hat” representation

1.8 The Beginning of the End—Decommissioning

All the activities conducted to shut down and remove facilities from service is defined
as decommissioning. Decommissioning of facilities is highly complex, often even
more so than the original installation. Decommissioning is a generic description and
it is applicable for both offshore and onshore facilities, and it could be regarded
as the beginning of the end of the facilities. Decommissioning can be challenging
especially for offshore facilities and particularly in deep waters; a decommissioning
process can be monumental and requires detailed considerations by specialized crews
[13]. Decisions about when and how to decommission platforms involve complicated
issues of environmental protection, safety, technical feasibility and associated costs.
Prior to conducting decommissioning, a decommissioning plan needs to be pre-
pared and submitted to the competent authority. A decommissioning plan may consist
of two main parts; a disposal plan and an impact assessment. The impact assessment
provides an overview of the expected consequences of the disposal such as envi-
ronmental consequences. According to the Norwegian Act 29, issued in November
1996 No. 72 relating to petroleum activities [14], the cessation of petroleum activi-
ties, Sect. 5.1; “the decommissioning plan shall be submitted at the earliest five years,
but at the latest two years prior to the time when the use of a facility is expected to
be terminated permanently”.
A decommissioning plan generally includes descriptions of [15, 16]:
• Results of a documentary survey relating to facility design, fabrication, installation,
commissioning, etc.;
• Possible risks during and after facility removal;
• Intended methods and strategies to be used during decommissioning, including
re-floating of structures;
• Intended analyses which are planned to be carried out;
• Operations planned to be carried out in the event of a possible removal;
• Possible impacts of a removal on adjacent fields and facilities;
• Methods of waste control; and
8 1 Introduction

• Possible monitoring systems which may be designed to secure the area against
possible future pollution from permanently abandoned wells or polluted cuttings
deposits.
The remaining issues regarding decommissioning are the associated cost and the
question of who holds the liability; and according to the OSPAR Convention,1 the
ultimate responsibility of decommissioning remains with the facility owner.

References

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history in the Gulf of Suez. In SPE international conference on health, safety, and environment
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Petroleum Engineers. https://doi.org/10.2118/46589-MS.
2. NORSOK Standard D-010. 2013. Well integrity in drilling and well operations. Standards
Norway.
3. Merryman, A. 2002. Fair value: What your accountant wants to know. In SPE annual tech-
nical conference and exhibition. SPE-77508-MS, San Antonio, Texas: Society of Petroleum
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5. Austin, D.G. 2007. Strategy for managing environmental liabilities in an onshore oil field. In
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108784-MS, Bangkok, Thailand: Society of Petroleum Engineers. https://doi.org/10.2118/
108784-MS.
6. Khalifeh, M. 2016. Materials for optimized P&A performance: Potential utilization of geopoly-
mers. In Faculty of science and technology. University of Stavanger: Norway. http://hdl.handle.
net/11250/2396282.
7. Myrseth, V., G.A. Perez-Valdes, and S.J. Bakker, et al. 2016. Norwegian open source P&A
database. In SPE Bergen one day seminar. SPE-180027-MS, Grieghallen, Bergen, Norway:
Society of Petroleum Engineers. https://doi.org/10.2118/180027-MS.
8. Carpenter, C. 2017. Digitalization of oil and gas facilities reduces cost and improves main-
tenance operations. Journal of Petroleum Technology 69 (12): 62–63. https://doi.org/10.2118/
1217-0062-JPT.
9. Dekker, M., and A. Thakkar. 2018. Digitalisation—The next frontier for the offshore industry. In
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Conference. https://doi.org/10.4043/28815-MS.
10. Brechan, B., A. Teigland, and S. Sangesland, et al. 2018. Work process and systematization of a
new digital life cycle well integrity Model. In SPE Norway one day seminar. SPE-191299-MS,
Bergen, Norway: Society of Petroleum Engineers. https://doi.org/10.2118/191299-MS.
11. Murray, J., and K. Eriksson. 2018. Data management and digitalisation: Connecting subsea
assets in the digital space. In Offshore technology conference. OTC-28997-MS, Houston, Texas,
USA: Offshore Technology Conference. https://doi.org/10.4043/28997-MS.

1 The Convention for the Protection of the marine Environment of the North-East Atlantic (the
OSPAR Convention) is the current legislative instrument regulating international co-operation on
environmental protection in the North-East Atlantic. It was open for signature at the Ministerial
Meeting of the Oslo and Paris Commissions in Paris on 22 September 1992.
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12. Brechan, B., S.I. Dale, and S. Sangesland. 2018. New standard for standards. In Offshore tech-
nology conference. OTC-28988-MS, Houston, Texas, USA: Offshore Technology Conference.
https://doi.org/10.4043/28988-MS.
13. Ekins, P., R. Vanner, and J. Firebrace. 2006. Decommissioning of offshore oil and gas facilities:
A comparative assessment of different scenarios. Journal of Environmental Management 79
(4): 420–438. https://doi.org/10.1016/j.jenvman.2005.08.023.
14. Norwegian Petroleum Directorate. 1966. Act 29 November 1996 No. 72 relating to petroleum
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15. Petroleum Safety Authority Norway. 2001. Regulations relating to health, environment and
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27235-MS.

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Chapter 2
General Principles of Well Barriers

The principle of well integrity is primarily occurred with maintaining well control
with sufficient barriers. Well integrity is defined as “application of technical, opera-
tional and organizational solutions to reduce risk of uncontrolled release of formation
fluids and well fluids throughout the lifecycle of a well” [1]. To control the well, two
qualified independent well barrier envelopes should be present at each stage of a
well’s life. The petroleum industry has employed the principle of a two-barrier phi-
losophy since 1920s [2]. Generally speaking, the overbalance from the drilling fluid
is the primary barrier and the blowout preventer (BOP) with casing string comprise
the secondary barrier during well construction. Over time, the petroleum industry has
entered into more complex and challenging environments, and therefore, the need to
clarify and standardize the well barrier integrity has been increasing. In practice, the
application of the well barrier philosophy is more complicate due to technical and
operational limitations. Figure 2.1 illustrates the two-barrier philosophy of a well
throughout its lifecycle, and Table 2.1 presents examples of barrier systems through
its lifecycle of the given well.

2.1 Well Annuli

An annulus is any void space between two strings, or a string of casing and for-
mation. When a well is completed, different annuli might be distinguished. In well
engineering, the annular space between production tubing and production casing is
called A-annulus. The annular space between production casing and intermediate
casing is called B-annulus. The naming procedure is continued until the last annular
space, which is between the conductor and formation (see Fig. 2.2) [1]. Generally,
these annuli should not have any connection to wellbore fluids. But the annuli are
filled with completion fluid or drilling fluid for protection of steel and maintaining
the pressure to ensure the integrity of the strings [3].

© The Author(s) 2020 11

M. Khalifeh and A. Saasen, Introduction to Permanent Plug
and Abandonment of Wells, Ocean Engineering & Oceanography 12,
https://doi.org/10.1007/978-3-030-39970-2_2
12 2 General Principles of Well Barriers

Fig. 2.1 Illustration of the two-barrier philosophy throughout a well’s lifecycle [2]

Table 2.1 Examples of barrier systems through the lifecycle of the well given in Fig. 2.1
Example Primary Barrier Secondary Barrier
Drilling Overbalanced mud with filter cake Casing cement, casing, wellhead,
and BOP
Production Casing cement, casing, packer, tubing, and DHSV Casing cement, casing, wellhead,
(Downhole Safety Valve) tubing hanger, and Christmas tree
Intervention Casing cement, casing, deep-set plug, and Casing cement, casing, wellhead,
overbalanced mud and BOP
Plug & Abandonment Casing cement, casing, and cement plug Casing cement, casing, and cement
plug

During coiled tubing well intervention operations, the annular space between the
coiled and production tubing should be considered as an annulus and distinguished
with a name.
2.2 Well Barrier Envelope 13

Fig. 2.2 Distinguished

annuli in a completed well

2.2 Well Barrier Envelope

2.2.1 Primary and Secondary Well Barriers

To understand the subject of well barrier philosophy, it might be beneficial to start

with the following question: What is a barrier? The word barrier has its roots from
Middle French barrier, which can be traced back to Anglo-French, from barre bar,
in 14th century. Merriam-Webster dictionary defines barrier simply as “something
(such as a fence or natural obstacle) that prevents or blocks movement from one
place to another”. Different professional disciplines have established their version
of the concept, in particular when it comes to operational and organizational bar-
rier elements. Therefore, the term “barrier” is defined in many ways such as human
barrier, non-technical barrier, operational barrier, non-physical barrier, or organiza-
tional barrier [4]. In the context of well integrity, a barrier is an impenetrable object
that prevents the uncontrolled release of fluid. Two-barrier philosophy considers two
independent well barrier envelopes; primary well barrier and secondary well bar-
rier. Primary well barrier is the first enclosure that prevents flow from a potential
source of flow. Secondary well barrier is the second enclosure that also prevents flow
from the potential source of inflow. The secondary well barrier is a back-up to the
primary well barrier and it is not normally in use unless the primary well barrier
14 2 General Principles of Well Barriers

fails. The principle of the two-barrier philosophy has already been shown in Fig. 2.1;
primary well barrier shown as blue line and secondary well barrier as red. For situa-
tions where a formation with normal pressure is present, a one-barrier methodology
could be acceptable for the abandonment design.

2.2.2 Environmental Plug

In the context of the well integrity operating philosophy, one major difference is
present between a permanent P&A operation and other activities (e.g. well con-
struction, production, and workover) and that is, the environmental plug. During a
permanent P&A operation, in addition to primary and secondary barriers, a supple-
mentary plug is installed close to the surface. It is the shallowest well hindrance that
isolates openhole annuli from the external environments that broadly is known as the
environmental plug. It has also been given, in different literature, other names such
as surface plug, openhole to surface well barrier, and openhole plug. These different
names have originated due to the definition and functionality of the environmental
plug. Some engineers claim that environmental barrier does not provide a well bar-
rier envelope as the surrounding formation cannot hold high pressures and may be
bypassed and therefore, it acts as a plug rather than a barrier.
The main function of the environmental plug could be described as to permanently
disconnect the open annuli, which are created where casings are cut and retrieved
near the seabed, from the external environment. In this manner, three main objectives
are achieved; swabbing fluid from sea into the formations through the created annuli
is minimized, exposure of surrounding environment to preceding potential hazardous
fluids (e.g. drilling fluids) in different annuli is avoided, and potential conduits for
leakage from near surface unidentified sources are sealed (Fig. 2.3). However, the
obligation to install the environmental barrier is debatable as the cut and retrieval of
conductor induces movements that cause the loose sediments to fall down and fill
the wellbore. Some authorities do not require the installation of environmental plugs
in wells without oil-based fluids in annuli and without zones capable of flow.

2.3 Well Barrier Element

A well barrier envelope consists of different well barrier elements. Well Barrier
Element (WBE) is a physical element, which in itself may or may not prevent flow but
in combination with other WBEs forms a well barrier. Figure 2.4 shows a schematic
of primary and secondary barriers and the listed WBEs of a platform well, which is
in temporarily abandoned status. The WBEs of a permanent well barrier envelope
with its best practices is shown in Fig. 2.5.
2.3 Well Barrier Element 15

Fig. 2.3 Functions of an environmental barrier shown here in green color

Fig. 2.4 Schematic of well barriers showing well barrier elements for primary and secondary
barriers [1]
16 2 General Principles of Well Barriers

Fig. 2.5 Well barrier elements of a permanent abandonment barrier with its best practices [5]

2.4 Plug

Any object or device which is installed inside the wellbore to block a hole or pas-
sageway is called a plug. In the context of petroleum engineering, plugs are usually
categorized into two main groups; non-mechanical plugs and mechanical plugs.
Non-mechanical plugs will be discussed comprehensively in the subject of perma-
nent plugging materials (see Chap. 4). Mechanical plugs are commonly referred to
either bridge plugs or mechanical plugs.

2.4.1 Bridge/Mechanical Plugs

Bridge plug (mechanical plug) is a mechanical device installed and used to provide
a seal inside the casing or production tubing. Bridge plugs are categorized as per-
manent, retrievable, or repositionable [6]. A permanent bridge plug has no design
feature for intact removal from the conduit. For its removal, a substantial destruction
process is necessary. However, a retrievable bridge plug possesses a design feature
that facilitates removal from the conduit intact [7]. A repositionable bridge plug
includes a design feature that facilitates its relocation inside the conduit (without
removal) while re-establishing its intended function.
Throughout the abandonment process, a deep-set bridge plug can be used as a
WBE for temporary abandonment. They provide easier and quicker plug retrieval.
However, their utilization as a WBE during permanent abandonment should be
avoided due to concerns associated with the long-term durability of mechanical
plugs. Nevertheless, mechanical plugs can be used to establish a foundation for plac-
ing materials (e.g. Portland cement, thermosetting polymers, geopolymers, etc.) to
minimize the risk of contamination while setting.
2.5 Well Barrier Illustration 17

2.5 Well Barrier Illustration

Well barriers and their role in preventing or acting upon leakages from wells may be
illustrated in two main different ways; well barrier schematics and barrier diagrams.
The concept of documenting well barrier using schematics was introduced to the
Norwegian oil and gas industry in 1992 [8]. A Well Barrier Schematic (WBS) is a
static illustration of a well and its main barrier elements, whereby all the primary
and secondary well barrier elements are marked (Fig. 2.4). A well barrier diagram is
a network illustrating all possible leak paths from the reservoir to the surroundings.
The surroundings could be the sea for subsea wells, platform deck for a topside
Christmas tree, flowline from a subsea well, ground for onshore wells, etc. Figure 2.6
shows the well barrier diagram for the production well in Fig. 2.4. A well barrier
diagram describes the status of barrier elements after a leak occurs. One of the
major differences between well barrier diagrams and WBSs, although they have their
own specific applications, is the quantification of the barrier diagrams. Well barrier
diagrams are widely used to evaluate the likelihood of the consequences illustrated
in the diagram.
Hence, in the petroleum industry, well barrier schematics and well barrier dia-
grams are important tools for reliability and risk assessments of a well in all phases
of its lifecycle and for well integrity assessments.

2.6 Prerequisites for Well Abandonment Design

To perform a competent and efficient abandonment practice, the P&A needs to be

considered during well design and well construction in order to reduce the associated
risks and saving costs. When a well is selected as a candidate for P&A, the abandon-
ment design is initiated. It is usually recommended to start the planning five years
ahead of commencement of the P&A operation. This is due to information gathering
regarding changes to the well status, the clarity of work scope and accuracy of time
estimation. Detailed planning will require the determination of a detailed sequence
of all activities and the resources required to perform the job. In the abandonment
design stage, it is necessary to study and document the following: well configura-
tion, stratigraphic sequences of each wellbore, cement logs and cementing operation
data and documents, formations with suitable WBE properties, and specific well
conditions [1].

2.6.1 Well Configuration

It is necessary to know the original and current well configuration. The well config-
uration includes depths and inclinations, specification of formations that are sources
18 2 General Principles of Well Barriers

Fig. 2.6 Barrier diagram for the production well in Fig. 2.4

of inflow, casing strings, casing cements and top of cements, casing shoes, and
wellbores. In addition, all the active sidetracks, and temporarily and permanently
abandoned sidetracks are mapped [1].

2.6.2 Stratigraphic Sequences

Stratigraphic sequence of each wellbore is identified and documented. The strati-

graphic report includes reservoir(s) and information about their current and future
2.6 Prerequisites for Well Abandonment Design 19

production potential and their containing fluids. In addition, the initial, current and
eternal perspective pressures of each flow potential need to be distinguished and esti-
mated. The identification of flow potentials in the overburden is necessary in order to
minimize the risk of leaks or kicks over time. It is also necessary to study and adjust
the formation fracture gradients for depleted formations [9].

2.6.3 Logs and Cementing Operation Data

Cement logging is one of the most commonly used verification methods that the
petroleum industry relies on to qualify casing cement. It is common practice to
log and document the casing cement behind the intermediate casing, and production
casing strings; however, not the cement behind the surface casing. There are different
types of logs that are used for evaluating casing cement, such as cement bond log
(CBL), variable density log (VDL), temperature logs, and sonic logs [10]. In addition,
displacement efficiency based on the record from the cement operation (e.g. volumes
pumped, returns during cementing, differential pressure, slurry rate, density, etc.) is
another set of data which is studied to check the quality of casing cement and identify
the Top of Cement (TOC). Figure 2.7 shows the recording output from a primary
cement job. All of these data are considered during P&A design, in addition to the
remedial cement jobs performed on the well throughout its lifecycle.
Considering well cementing log data from old wells during P&A design is a
concern as the old logging data are less reliable due to their availability and quality.
However, there are P&A designs that rely on old CBL-VDL logs reports. Experience
shows that casing cement quality of wells constructed 10–15 years ago are still intact
when re-evaluated recently.

2.6.4 Formations with Suitable Well Barrier Element

Properties

Identifying an appropriate formation, for establishing the primary and secondary

well barriers across, is a key factor. A suitable formation should possess cap rock
properties. It should have sufficient strength to keep the hole in gauge during hole
conditioning, hold the exerted hydrostatic pressure of the barrier before it sets (e.g.
cement, etc.), and be impermeable or have very low permeability to minimize the
risk of integrity loss or providing a conduit for leak around the barrier. Absence of
fractures and faults are other properties which in combination with those previously
mentioned properties qualify a formation as a suitable candidate for establishing
barriers across.
20 2 General Principles of Well Barriers

Fig. 2.7 A typical recording output from a primary cement job (Reprint from Well Cementing)
[10]

2.6.5 Specific Well Conditions

To establish a permanent barrier for securing a flow potential, it is necessary to get

access to the required depth. However, sometimes there are well conditions that
dictate contingency plans. Scale build-up, casing wear, collapsed casing, fill, H2 S
and CO2 corrosion, asphaltene deposition, erosion, and hydrates are common specific
well conditions to be considered in abandonment design [1].

2.6.5.1 Scale Build-up

Scale is mineral salt deposits or coating that precipitates and adheres to the surface of
metal, rock, or other materials [11]. The precipitation is the result of different factors:
a chemical reaction with the surface, a change of pressure or temperature, a change
2.6 Prerequisites for Well Abandonment Design 21

Fig. 2.8 Scale deposit

caused a restricted access to
downhole (Courtesy of
Schlumberger)

in the composition of a solution, or a combination of these factors [12]. In severe cir-

cumstances, scale build-up creates a significant restriction, or even completely plugs
the production tubing. Typical scales are barium sulfate, calcium sulfate, strontium
sulfate, iron sulfate, calcium carbonate, iron oxides, iron carbonate, various phos-
phates, silicates and oxides, and any compounds that are insoluble or slightly soluble
in water. For scale removal, a wide range of mechanical (e.g. milling), chemical
(e.g. acid wash, non-acid scale dissolver), and scale inhibitor treatment options are
available [13]. Figure 2.8 shows a scale build-up in a production tubing.
Scale build-up is a concern for production tubings due to reducing the effective
drift, consequently, limiting wireline activities such as running puncher, cutter, caliper
log, etc. As production or injection is through the production tubing, the scale build-
up does not occur inside the production casing. Retrieval of the production tubing
with occurred scale needs special handling of the scale and its disposal, one feasible
solution to minimize the effect of scale on P&A activities could be to leave as much
pipe in the well as possible. This approach may lead to a rigless P&A operation as
retrieval of production tubing requires high pulling capacity, a rig or a jack.

2.6.5.2 Casing Wear

Casing wear is often a problem in deep and highly deviated wells where doglegs
and large tensile loads on the drill string combine to produce high lateral loads
where the drill string contacts the casing. It is a complex process involving variables
such as temperature, drilling fluid type, percentage of abrasives in the drilling fluid,
tool joint hardfacing, revolutions per minute, tool joint diameter, contact load, and
many other factors. In the course of P&A operation, casing wear can compromise
22 2 General Principles of Well Barriers

the integrity of casing and result in blowouts, lost circulation, and other expensive
and hazardous problems [14]. Therefore, it is necessary to measure and analyze the
casing wear that has occurred over the lifetime of a well (e.g. during construction
and intervention operations) and consider it in the abandonment design. The risk of
induced casing wear while the P&A operation is performed also needs to be studied
in the abandonment design.

2.6.5.3 Collapsed Casing

In all wells, there are natural forces and occasionally induced forces, which may cause
casing to collapse. The principle cause of casing collapse is compaction of formations
and the resultant subsidence of the overlying sediments. Figure 2.9 illustrates casing
loads resulting from compaction of reservoir rock. The natural forces are created
because of tectonic stresses, subsidence, and formation creep. Subsidence widely
occurs in large chalk formations where the depleted chalk reservoir is not able to
hold the weight of the overburden; however, the intensity in small chalk reservoirs
is not high. To visualize the influence of the size of chalk reservoir on subsidence,
consider a beam as representing a reservoir with the overburden acting by the load A
(Fig. 2.10). A large reservoir cannot withstand the load of the overburden; however,
if the reservoir is small, then it can withstand the load of the overburden without
experiencing a compaction effect.
The formation creep is intensified and more subjective in plastic salt zones where
a non-uniform formation movement exerts point loading on the casing string and
causes collapsed casing. In addition to the natural forces, the induced circumstances

Fig. 2.9 Effect of formation compaction and subsidence on casing string and liner
2.6 Prerequisites for Well Abandonment Design 23

Fig. 2.10 Influence of

reservoir size on the
compaction load in a chalk
basin

such as temperature change, and excessive matrix acidizing, play role as well. Tem-
perature change is one of the bases of the induced forces. Temperature changes
encountered during the life of the well are small usually and negligible. However,
there are situations where temperature variations are not small. Examples of these
large temperature variations that can be encountered include geothermal wells used
in extracting steam from volcanic areas of the earth, steam-injection wells used in
thermal recovery processes, deep gas wells, and wells completed in abnormally hot
areas. Excessive matrix acidizing could result in a lack of lateral support around the
casing and consequently lead to buckling as the casing is loaded in compression. Fur-
thermore, when the effects of wear, corrosion, and fatigue are added to the stresses
on the casing, the potential for failure increases. Casing collapse imposes limited
access to downhole and usually requires section milling.

2.6.5.4 Fill

Drill cuttings, collapse fragments, and settled barite may accumulate around the
uncemented casing strings and require more force when pulling the casing string. In
most cases during P&A operations, the required force is beyond the pulling capacity
of the working unit or exceeds the tensile strength of casing. Therefore, collapsed
casing situation usually dictates section milling.

2.6.5.5 Corrosion

Hydrogen sulfide corrosion. The general mechanism for hydrogen sulfide (H2 S)
attack may be expressed as follows:
24 2 General Principles of Well Barriers

H2 S readily dissolves in water and partially dissociates:

H2 S(g) + H2 O ↔ H2 S (aq) (2.1)

In H2 S corrosion of mild steel, polymorphous iron sulfide is formed:

H2 S (aq) + Fe2+ → FeS + 2H+ (2.2)

A research study [15] shows that for H2 S corrosion of mild steel, polymorphous
iron sulfides can form iron sulfide (FeS), mackinawite (Fe, Ni]1 + x S where x =
0–0.11), cubic ferrous sulfide (FeO4 S), troilite (Fe(1 − x) S where x = 0–0.2), pyrite
(FeS2 ), greigite (Fe3 S4 ), marcasite (FeS2 ). The formed iron sulfide sets up a galvanic
cell in which the steel pipe becomes the anode. This reaction is generally assumed
to be responsible for the deep irregular pitting observed in sulfide corrosion.
H2 S corrosion can create cracks in steel pipe in two distinct ways; sulfide stress
cracking, and stress corrosion cracking. Sulfide stress cracking occurs near room
temperature, and it affects the upper parts of wells. This phenomenon occurs during
periods of shut-in and cooling down. Sulfide corrosion cracking is encountered at
high temperatures which occurs at the bottom of wells [16].
Carbon dioxide corrosion. CO2 corrosion is encountered in both gas wells and
oil wells and it is reported in different areas such as Louisiana, the North Sea, Ger-
many, the Netherlands, and Gulf of Guinea. Some of the crucial factors which extend
CO2 corrosion of steel include: temperature, pressure, CO2 content, salt concentra-
tion, basic sediments and water, flowing conditions, etc. [16]. The solubility of CO2
increases as pressure increases and subsequently the pH decreases. However, as
the temperature increases, the solubility of CO2 decreases and as a result, the pH
increases. Certain minerals may act as a buffer preventing the pH reduction. The
general mechanism of CO2 attack in the presence of water may be expressed as [17]:

CO2 (g) + H2 O → H2 CO3 (aq) (2.3)

H2 CO3 (aq) + Fe2+ → FeCO3 + H2 (2.4)

It has been reported that the CO2 corrosion of steels is highly localized corrosion,
which appears in the form of pits, gutters, or attacked areas of various sizes [16].
Figure 2.11 shows a corroded tubing caused by incompatibility between the tubing
type and injection water quality.
Retrieval of a corroded production tubing may cause tubing rupture and it may
require a multiple fishing operation. Another scenario is when a kill fluid is pumped
through the corroded production tubing, the fluid will be exposed to the production
casing before killing the well.
Usually corrosion does not attack production casing as only the production tubing
is exposed to production or injection fluids. However, production tubing corrosion
may indirectly compromise the well integrity during pressure testing. Consider a
2.6 Prerequisites for Well Abandonment Design 25

Fig. 2.11 Corroded

production tubing due to
incompatibility between
injection water and tubing
type [18]

bridge plug which has been installed in tail pipe of production tubing. The bridge
plug is going to be pressure tested and therefore, a fluid is injected through the
production tubing. A corroded production tubing with holes exposes the production
casing to high pressure and consequently, the casing may burst due to the imposed
pressure. Therefore, good knowledge of production tubing condition is necessary
prior to starting the P&A operation.

2.6.5.6 Asphaltene Deposition

Asphaltenes are the most aromatic components of crude oil with a high-molecular
weight solids, and are insoluble in light alkanes and soluble in aromatic solvents [19].
Several factors such as changes in pressure, temperature, and crude oil composition
cause asphaltenes to precipitate from the oil as a black sticky solid material [20].
Traditional methods of removing asphaltene deposits involve mechanical removal,
injection of dispersant and solvents, and heat treatment. In P&A operations, in the
case of an asphaltene issue, it is a common practice to remove asphaltenes mechani-
cally via scrapers, cutters, coiled tubing deployed jetting tools, or a milling operation
[21].

2.6.5.7 Erosion

Erosion is the process of removing material by mechanical action such as particle

or droplet impact. The velocity of the particles (e.g. unconsolidated formation) or
droplets, which are carried by producing or injecting fluid, provides the energy for
erosion of the steel pipe. In addition, fluid flow through the pipe with high velocity
creates enough energy for erosion of steel by the fluid. This concept is used for
abrasive cutting.
26 2 General Principles of Well Barriers

2.6.5.8 Hydrates

Natural gas hydrates are solid crystalline compounds in which molecules of natural
gas are trapped in water molecules under pressures and temperatures considerably
above the freezing point of water. Hydrates tend to form in the near surface envi-
ronment where the temperature is low such as the wellhead, pipelines, and other
processing equipment [22]. In the early phase of P&A, mechanical removal via scrap-
ers, cutters, coiled tubing deployed jetting tools, and milling are common hydrate
removal practices.

2.6.5.9 Containment Assurance of the Abandoned Wells or Fields

Subsurface containment assurance is defined as the identification and mitigation of

elements that could result in the potential loss of containment of subsurface fluids.
The goal of subsurface containment assurance is to ensure no harm is caused to
the environment and operated assets, or no impact on well operations due to the
leakage of production or injection fluids from their intended zones [23, 24]. One may
claim that the subject of subsurface containment assurance fulfills the well integrity
requirements, however, in fact it is more comprehensive than the well integrity.
It includes well integrity, subsurface integrity, and any aspect of deepwater and
surface facilities which are directly relevant to upstream exploration, production,
and abandonment operations [25]. As an example the well integrity of abandoned
wells or fields might be influenced by nearby injector wells influencing the pressure
regime. So possible monitoring of permanently abandoned wells or fields regarding
containment assurance may need to be considered.

2.7 Well Abandonment Phases

When the abandonment design is ready, the operator submits the program to the local
regulatory body. The authority reviews the program and asks for changes or approves
it. Once the program is approved, the operator can commence the P&A operation.
Approval of the program does not necessarily load any responsibility on the local
authority as all responsibilities during P&A and post-abandonment operations are in
the hand of the operator.
Generally, a P&A operation may be divided into three phases; phase 1—reser-
voir abandonment, phase 2—intermediate abandonment, and phase 3—wellhead and
conductor removal. This categorization is regardless of the well location (e.g. off-
shore, or onshore), well type (e.g. exploratory, producing, injecting, etc.), and the
well status (e.g. partially abandoned, shut-in, etc.).
2.7 Well Abandonment Phases 27

2.7.1 Phase 1: Reservoir Abandonment

Reservoir abandonment starts primarily by inspecting the wellhead and rigging up

a wireline unit. The wireline unit is employed to check the access to wellbore by
drifting and evaluating the condition of the production tubing by running a caliper
log. This preliminary investigation can be regarded as Phase 0—well intervention,
and it has a significant influence on time reduction during a P&A operation [26]. In
addition, waste handling systems are established for liquid and solid phases. This
phase proceeds with an injection test to examine the well integrity. If integrity is
maintained, cement slurry is bullheaded to plug the main reservoir and once the
cement plug has achieved sufficient strength, its quality is determined by pressure
testing. So far, this part of the job is a rigless operation. However, if well integrity is not
maintained, a rig needs to be mobilized and a BOP nippled up. Figure 2.12 illustrates
a well status where the bullheaded cement is qualified as primary and secondary
barriers after conducting the reservoir abandonment phase. Generally speaking, phase
1 is completed when the permanent primary and secondary barriers secure the main
reservoir. The production tubing may be retrieved or left in the hole as a part of the
well barrier envelope. This phase is completed when the reservoir is fully isolated
from the wellbore.

2.7.2 Phase 2: Intermediate Abandonment

Intermediate abandonment phase includes milling, retrieving casing, setting barriers

to isolate intermediate hydrocarbon or water-bearing permeable zones, and installing
an environmental plug. The production tubing may partly be retrieved if it has not
been retrieved in phase 1. Phase 2 is complete when all the flow potentials identified
in the overburden are secured.

2.7.3 Phase 3: Wellhead and Conductor Removals

In this phase, the conductor and wellhead are cut below the surface or seabed and
retrieved. The reason is to avoid any future incident with other marine activities (e.g.
fishing activities). In the Norwegian sector of the NCS, this phase is usually regarded
as a marine job and not a drilling operation.
28 2 General Principles of Well Barriers

Fig. 2.12 Well status after

completing the reservoir
abandonment. The
assumption prior to
bullheading the cement plug
is that, the well integrity was
maintained and full access to
the wellbore was achieved

2.8 Disconnecting the Christmas Tree and Assembling

Blowout Preventer

It is a common practice to bring the well to temporarily abandoned status or shut-in

prior to commencing the permanent P&A operation or after the reservoir abandon-
ment phase. The reason is to reduce the risk of a kick or release of uncontrolled flow
while nippling down the Christmas tree and nippling up the BOP. Nipple-down is the
activity of disassembling well-control equipment on the wellhead. Nipple-up is the
process of assembling well-control equipment on the wellhead. So, as we discussed
earlier in this chapter, it is necessary to have two independent well barrier envelopes.
2.8 Disconnecting the Christmas Tree and Assembling Blowout … 29

This means that when the Christmas tree is disassembled still two intact well barrier
envelopes need to be in place. Therefore, it is crucial to understand wellhead and the
Christmas tree systems for disconnecting the reservoir from the environment until
the BOP is rigged up.
In October 2016, a serious well control incident occurred on a production well in
the Troll field, in the North Sea. This incident began after permanently plugging the
existing flow paths in the well. Then, a sidetrack was about to be drilled. In connection
with pulling the tubing hanger, the completion string with the top drive was suddenly
raised six meters without control. Large quantities of fluid and gas flowed out through
the rotary table. The blowout lifted the 2.5 tons hydraulic slips and threw some two
tons of bushings several meters across the drill floor and the liquid column reached
the top of the derrick about 50 m above the drill floor. Fortunately, nobody suffered
physical injury, but it could have led to a major incident with loss of several lives.
The Norwegian Petroleum Safety Authority investigated the incident and concluded
that the direct cause of the incident was the release of a large quantity of trapped
reservoir gas underneath of the tubing hanger. Although a BOP wellhead connector
test had been performed six hours before the incident, a gas leak that occurred during
these six hours, caused the incident [27] (Fig. 2.13).
Another crucial factor that might be considered is wellhead fatigue loads that will
be exerted by the BOP stack during P&A operations. Therefore, wellhead systems
and their advantages and limitations are reviewed in this chapter.

2.8.1 Wellhead Systems

A wellhead system is the surface termination of a wellbore and it is composed of

spools, valves, and assorted adaptors that provide pressure control of a production
well. Wellhead systems incorporate facilities for installing casing hangers, tubing
hanger, and Christmas tree. The wellhead systems can be categorized depending
on the place where the wellhead is installed as surface wellhead systems and sub-
sea wellhead systems [28, 29]. There are two types of wellheads used for surface
applications; spool type and compact type. Other names used for the compact type
wellheads are speed head, unitized head, bowl head, multi-bowl head, and unihead.
Each of these configurations have their own advantages and challenges in the course
of P&A. Table 2.2 lists advantages and challenges for each system. As the subject
of wellheads is an extensive area, wellhead systems will be reviewed based on the
first classification system.
As wellhead type is related to the number of connections or components and
consequently the risk of leakage, it is important to analyze the wellhead condition. In
March 2012, on Elgin installation (approximately 200 km east of Aberdeen, Scotland)
located in the North Sea experienced a major incident of uncontrolled release of
hydrocarbons to atmosphere. In this incident, reservoir gas from the Chalk formation
leaked to the A-annulus and in a further step from A-annulus to B-annulus, and then to
C-annulus. Due to poor sealing capability of wellhead components and connections,
30 2 General Principles of Well Barriers

Fig. 2.13 Leak path which caused trapped gas beneath the tubing hanger in Troll field [27]
2.8 Disconnecting the Christmas Tree and Assembling Blowout … 31

Table 2.2 Advantages and limitations of wellhead systems with respect to P&A operations
Wellhead type Advantages Disadvantages
Spool type • The relative simplicity of the • Requires removal and the
suspension and sealing systems re-installation and testing of the
BOPs for the removal of each
casing head spool
• They have more connections and
consequently more risk of leakage
Compact type • Less height • Lack of tolerance of damage to the
• Fewer potential leak paths hanger sealing areas

the gas leaked to the conductor, D-annulus [12]. As the conductor annulus, D-annulus,
is not connected to any barrier for preventing leaks, the gas leaked to the environment
uncontrollably, Fig. 2.14. This incident had no loss of life and well control was
achieved by killing the well by pumping kill mud [30].

2.8.1.1 Surface Wellhead

Surface wellheads are used both onshore and offshore. Primary functions of the sur-
face wellhead include pressure isolation, pressure containment, casing and tubing
weight suspension, and the Christmas tree housing. shows a surface wellhead model
and its main sections; starter head at the bottom, spools for casing hangers, spool for
tubing hanger, adaptor, and valves for access to different annuli. There are several
factors to be considered in selection of a wellhead during well construction; value,
field history, operator preference, lifespan, temperature range, fluid environment,
pressure range, mechanical configuration, external loading, and installation or ener-
gization method. Some of these factors may endanger the wellhead condition and
its performance during the P&A. Therefore, investigating the wellhead quality and
running a fatigue analysis are crucial in the P&A design phase (Figs. 2.15 and 2.16).

2.8.1.2 Subsea Wellhead

The main functions of subsea wellheads are the same as surface wellheads. Neverthe-
less, due to subsea conditions, there are some additional functions such as serving a
structural and pressure-containing anchoring point on the seabed for the drilling and
completion system, and facilitating guidance, mechanical support, and connection of
the systems used to drill and complete the well. A standard subsea wellhead system
(Fig. 2.17), typically consists of drilling guide base, low-pressure housing (typically
30-in.), high-pressure wellhead housing (typically 18 ¾-in.), casing hangers, metal-
to-metal annulus sealing assembly, bore protectors and wear bushings, and running
and test tools. In the course of drilling subsea wells, the Low-Pressure Wellhead
Housing (LPWH), conductor, and guide base are run at the same time.
32 2 General Principles of Well Barriers

Fig. 2.14 The schematic of the leak path from Elgin, platform well [30]
2.8 Disconnecting the Christmas Tree and Assembling Blowout … 33

Fig. 2.15 Surface wellhead model with its main different sections. (Courtesy of TechnipFMC)

The subsea wellhead is placed on the seabed and the BOP is installed on top of
it. Waves and current forces acting on the marine riser during drilling, production,
intervention or P&A operation will cause movements. A subsea wellhead will be
exposed to external loads: static and cyclic combinations of bending and tension
(compression). The cyclic loads can cause fatigue damage to the well and create
well integrity issues. If the subsea wellhead fails then its pressure vessel function
will be lost, which can lead to HSE issues [31].

2.8.1.3 Special Consideration for Wellhead Systems

Casing/tubing hanger lockdown—The incident occurring on Troll field [27], could

have been prevented if the well was completed with a horizontal Christmas tree rather
than a vertical Christmas tree. The horizontal and vertical X-mas tress are discussed in
more detailed in this chapter. In offshore wells, casing/tubing hanger is installed and
locked down inside a horizontal Christmas tree and the pressure beneath the tubing
34 2 General Principles of Well Barriers

Fig. 2.16 Surface wellhead

with vertical XMT.
(Courtesy of TechnipFMC)

hanger can be measured. However, when a vertical Christmas tree is selected for well
completion, the casing/tubing hanger is installed and locked down to the wellhead
prior to installation of the tree. For onshore wells, the lockdown and installation of
casing/tubing hanger is similar to the scenario for vertical trees.
Fatigue life of a wellhead system—One of the challenges during P&A design and
operation, especially for subsea wells, is the fatigue loading exerted on wellheads
by the BOP. Some of the older wells, drilled two to three decades ago, have been
drilled with BOPs that were smaller and lighter than current designs; therefore, the
wellhead design was different and subsequently the wellheads response to induced
fatigue. Another challenge linked to the afore-mentioned challenge is BOP pressure
rating requirements legislated by some authorities. Consider an old well where its
wellhead connector has been pressure rated for 5 kpsi but requirements ask for the
utilization of a 10 or 15 kpsi BOP, although a depleted well may require a lower BOP
pressure rating. In addition, the challenges associated with fatigue life of wellhead
systems is more of a concern in subsea wells due to sea currents. Another concern
regarding fatigue is updated regulations. For example: in 1975, a 13 3/8-in. BOP
could have an approximate weight of 20 metric tons, however, in 2016, a 18 5/8-in.
BOP could weigh up to 400 tons. Therefore, nowadays, the fatigue introduced to the
wellhead is much higher compared to old BOPs. In addition, there are wells designed
2.8 Disconnecting the Christmas Tree and Assembling Blowout … 35

Fig. 2.17 A standard subsea wellhead system and its main sections. (Courtesy of SPE)

and completed for a specific service life with regards to time, however, the service
life has extended more (up to a decade) than the design life. These wellheads are a
point of failure for wells with strong aquifers where the current reservoir pressure is
approximately equal to the initial reservoir pressure.
Recently, a new generation of BOP system being developed is electrical based,
which does not require a hydraulic accumulator (Koomey) unit. This system is lighter
compared to previous and available BOP systems.

2.8.2 The Christmas Tree Systems

The equipment at the top of a well is called “Christmas tree”. The Christmas tree
is assembled of valves, spools, pressure gauges and chokes which is fitted to the
wellhead (see Fig. 2.16) of a completed well. The Christmas tree (XMT) provides
a controllable interface between the well and production facility. It is also called by
other names such as cross tree, X-tree, or tree. The functions of a tree are addressed
as follows: allowing reservoir fluid to flow from wellbore to the surface facilities in a
safe and controlled manner, safe access to the wellbore to perform well intervention
36 2 General Principles of Well Barriers

procedures, allowing injection of fluids, providing access to a hydraulic line for a Sur-
face Controlled Subsurface Safety Valve (SCSSV), providing the electrical interface
for instrumentation and the possible electrical wiring for an Electrical Submersible
Pump (ESP). The XMT is installed on the last casing spool, tubing head adaptor,
or high-pressure wellhead housing for a subsea well. They are available in a wide
range of sizes and configurations, such as low-or high-pressure capacity and single-
or multiple completion capacity. It is a norm to purchase the XMT and wellhead
from the same manufacturer due to compatibility. Generally, there are two different
approaches to categorize the trees; depending on the place where the XMT is installed
or based on the arrangement of the valves and gauges. The first approach divides
the trees into two main groups; surface trees (dry trees) for land/platform wells, and
subsurface trees (wet trees) for subsea wells. The second approach divides the trees
into two main classes based on the configuration of the valves and gauges; vertical
trees and horizontal trees. Figure 2.18 illustrates four different configurations of tree

Land or platform Subsea

Vertical tree

Horizontal tree

Fig. 2.18 Four different configurations of XMT valves for land/platform and subsea wells [3]
2.8 Disconnecting the Christmas Tree and Assembling Blowout … 37

valves. For simplicity and relevancy to P&A, the second approach is preferred and
used for discussion in this book.

2.8.2.1 Vertical Christmas Tree

Figure 2.19 shows a drawing of a surface vertical tree. The master valve is located
above the tubing head adaptor and its function is to allow a well to flow or to shut-in
the well. Typically, there are two master valves; lower master valve, and upper master
valve. The two valves are often used because they provide redundancy; if one valve
cannot function properly, the other valve is engaged. The upper and lower master
valves are shown in Fig. 2.19. Tee type fitting (known as T-block) provides diversion
of the vertical flow to the horizontal flowline. Usually a wing valve is located on
the side of the tree and used for controlling or isolating production from the well
to surface facilities. Based on the tree design, which is the operator requirement,
one or two wing valves can be fitted to the tree. As a common practice, usually
operators require two wing valves; one for production, known as Production Wing
Valve (PWV), and another one as backup or as a Kill Valve (KV). After the wing valve
a small restriction, which is referred to as the choke, is used to control the production
rate of the well. On the Christmas tree, the topmost valve is called the Swab Valve
(SV). The swab valve provides access to the borehole for well intervention operations

Fig. 2.19 Typical surface vertical Christmas tree

38 2 General Principles of Well Barriers

Fig. 2.20 A dual-bore vertical subsea tree which allows to monitor annulus pressure. (Courtesy of
Schlumberger)

performed by wireline, slickline, coiled tubing, or a snubbing unit. The inlet of the
swab valve is covered by a flange that is called a T-Cap, which allows a wireline
lubricator, snubbing unit BOP, or coiled tubing to connect to the well. Finally, a
top pressure gauge sits on top of the T-Cap to show the well pressure. The vertical
trees can be used for both surface and subsea wells. However, the subsea application
needs different interfaces with respect to manipulating the tree valves and access to
the A-annulus (Fig. 2.18). It is notable that the configuration of valves on the vertical
trees for subsea and surface trees are the same; however, due to the subsea conditions
and remotely manipulating the valves, the interface of a subsea well is different (see
Fig. 2.20). The vertical subsea tree can be a single-bore or dual-bore (see Fig. 2.18)
and this can make a difference to the P&A operation.
Throughout construction and completion of land/platform wells or subsea wells
with the vertical XMT, the tubing hanger is installed inside the wellhead (see
Fig. 2.15) and then the vertical XMT is installed on top of the wellhead. Therefore,
in order to retrieve the production tubing, the vertical XMT must be nippled-down.
Accordingly, to maintain well integrity during the tubing retrieval, the BOP must be
installed.

2.8.2.2 Horizontal Christmas Tree

The advent of horizontal trees has initially been linked to completion of subsea wells.
It is necessary to mention, before any comparison of horizontal and vertical subsea
trees is made, the parts and subassemblies are very similar. In horizontal trees, the
valves are positioned on the sides of the tree body (Fig. 2.21). The difference between
2.8 Disconnecting the Christmas Tree and Assembling Blowout … 39

Fig. 2.21 Illustration of a

horizontal Christmas tree

horizontal and vertical trees arises largely from the configuration of the valves rather
than novel design. One of the main reasons that persuades operating companies
toward using horizontal trees are challenges related to subsea well intervention oper-
ations. Mostly, a subsea well intervention arises from problems related to the tubing
and SCSSV and therefore, ready access to the production tubing and SCSSV, without
disassembling the tree, are primary design criteria. Thus, the position of valves on a
vertical tree are moved to the sides of the tree and the tubing hanger sits inside the
horizontal tree. In this manner, during a subsea well intervention, the BOP is posi-
tioned above the horizontal tree and tubing is retrieved without nippling down the
tree. Consequently, the workover operation is easier performed, and more efficient.
In addition, concerns regarding nippling the tree down/up are minimized. Table 2.3
presents the notable differences between the subsea vertical and horizontal trees.
Figure 2.22 depicts a horizontal subsea XMT.
During drilling of a subsea well, the following are run at the same time: LPWH,
conductor, and guide base. If the well is planned to be completed with a horizontal
XMT, after installation of the subsea wellhead system, the horizontal XMT is installed
and subsequently the BOP is installed on top of it and then drilling is resumed. Then
in the completion phase, the tubing hanger sits inside the horizontal XMT. In other
words, tubing retrieval does not necessitate the removal of the horizontal XMT.
40 2 General Principles of Well Barriers

Table 2.3 The most notable differences between subsea trees; vertical and horizontal
Vertical XMT Horizontal XMT
• Master and swab valves in bore • No valves in the vertical bore of the well
• Tree run after tubing (tree lands on and • Tree run before tubing (tubing hanger lands
stabs into the tubing hanger) in tree body)
• Tubing hanger orients via wellhead • Tubing hanger orients directly from tree
• External tree cap run after tree landed/tested (limits tolerance stack-up)
• Tubing hanger seals normally isolated from • An internal tree cap is used as a secondary
well fluid pressure barrier above the tubing hanger,
two crown plugs are installed by wireline
unit
• The tubing hanger seals are continuously
exposed to well fluids

Fig. 2.22 A horizontal

subsea Christmas tree

Where the installation of a BOP is required, it is nippled-up on top of the horizontal

tree.
In order to perform an efficient and safer permanent P&A operation, it is necessary
to understand the strength and weakness of each type of tree system. Table 2.4
tabulates the advantages and concerns regarding the tree systems.

2.8.3 Assembling BOP

In the course of a P&A operation, regardless of the well type (i.e. land/onshore or off-
shore) and the XMT type (i.e. horizontal or vertical), at some point, the utilization of
a BOP is unavoidable. Therefore, the primary and secondary temporary well barrier
envelopes shall be established and maintained to secure the well while disassembling
the XMT and assembling the BOP. Theoretically, this procedure may be considered
2.8 Disconnecting the Christmas Tree and Assembling Blowout … 41

Table 2.4 Comparison between advantages and concerns of subsea vertical and horizontal tree
systems
Tree system Advantages Concerns
Vertical • Lighter than horizontal trees • Seldom accommodate larger than 5
• To nipple-down the tree, there is no ½-in. production tubing
need to retrieve production tubing • Not designed to take the load from
BOP
• Tubing/casing hanger is locked to
the wellhead before tree is installed;
consequently, pressure under the
tubing hanger cannot be measured
Horizontal • BOP is installed on top of the tree • Heavier than vertical trees
• The tree has a lower height • Inaccessibility to different annuli
• Work efficiency is improved (e.g. except A-annulus
nippling down/up and testing the tree
during well intervention is avoided)
• Accommodate up to 7-in.
production tubing
• Tubing/casing hanger is locked in
the tree itself; consequently pressure
under the tubing hanger can be
measured

for four different well completion scenarios (Fig. 2.18); a land/platform well com-
pleted with the vertical tree, a subsea well completed with the vertical tree, subsea
well completed with the horizontal tree, and a land/platform well completed with the
horizontal tree. However, the latter scenario is less likely to be accomplished due to
some practicality issues such as large weight of the horizontal tree, inaccessibility to
different annuli except the A-annulus, etc.

2.8.3.1 Assembling BOP—Land/Platform Well with the Vertical Tree

Consider a platform well which has been completed with the vertical tree (Fig. 2.23).
To establish the primary temporary barrier, there should be enough casing cement
below and above the production packer in the B-annulus and no reported sustained
casing pressure in the A-annulus (see Fig. 2.14 for definition of A-, B-, and C- annuli).
If these assumptions are valid, the primary barrier envelope is achieved by installation
of a bridge plug in the tail pipe. The bridge plug and primary well barrier envelope
are pressure tested for assurance that well integrity is maintained. The primary well
barrier elements, illustrated in Fig. 2.23, are listed and marked with a blue line.
For establishing the secondary temporary well barrier envelope, there should be
enough casing cement above the production packer in the B-annulus, no sustained
casing pressure in the B-annulus, and production casing maintains integrity. Note that
the same interval of casing cement, which is used as an element for the primary barrier,
42 2 General Principles of Well Barriers

Fig. 2.23 List of well barrier elements of a platform well with the vertical tree

cannot be used as an element for the secondary barrier (see Fig. 2.23). If the above-
mentioned assumptions are valid, the secondary barrier envelope is achieved by
installation of a bridge plug inside the tubing hanger. The bridge plug and secondary
well barrier envelope are pressure tested prior to commencing nippling-down the tree.
The secondary barrier elements are listed and marked with a redline in Fig. 2.23.
Where a well has been completed with a Downhole Safety Valve (DHSV), the
DHSV can be used as a well barrier element in the primary well barrier envelope
when it is qualified by a function and pressure test.

Example 2.1 A platform well (Fig. 2.24) has been drilled and completed with the
vertical tree in 1985. The TOC in the B-annulus is below the permanent packer and
the well suffers from sustained casing pressure in the A- and B-annulus. Caliper
log shows big holes along the production tubing (shown with triangle on Fig. 2.24).
Operator decided to permanently plug and abandon the well. Through the operation,
a BOP is necessary to control the well pressure. Make a list of the primary and
secondary well barrier elements for nippling-down the tree and nippling-up BOP.
2.8 Disconnecting the Christmas Tree and Assembling Blowout … 43

Fig. 2.24 WBS of a

platform well with the
vertical tree

Solution It is recommended to squeeze cement the perforations and extend it up

to the liner packer. Pressure test the cement plug and if it is qualified, bleed off the
A-annulus and the B-annulus. If the A-annulus and the B-annulus pressures do not
build up, a plug is installed inside the tubing hanger. Then, the primary and secondary
well barrier elements, temporary barriers, could be as follows:
44 2 General Principles of Well Barriers

But if the squeezed cement is not qualified and the A-annulus and B-annulus pres-
sures are building up, then a bridge plug should be installed inside production tubing,
below the permanent packer, and A- and B-annuli need to be killed by unconsolidated
sand slurries or heavy fluid. Here the assumption is that the SCSSV has successfully
passed the pressure test. A plug is installed inside tubing hanger. Then, the primary
and secondary well barrier elements, temporary barriers, could be as follows:
2.8 Disconnecting the Christmas Tree and Assembling Blowout … 45

2.8.3.2 Assembling BOP—Subsea Well with the Vertical Tree

Vertical subsea trees may be divided into two main groups considering their tub-
ing hanger configuration: single-bore (mono-bore), and dual-bore trees. Figure 2.25
shows configuration of single-bore tubing hanger with an annulus valve and penetra-
tions for control lines and chemical injection lines. Nowadays, single-bore vertical
subsea trees are barely used for the completion of subsea wells; however, dual-bore
vertical trees are more commonly used for the completion of subsea wells as they
provide access to the A-annulus.
Figure 2.26a is an illustration of a subsea well which has been completed with
a single-bore vertical subsea tree. It is a conventional procedure to bullhead cement
into the main reservoir through the production tubing when the production tubing
is in good condition. Then, the cement plug is pressure tested. If it passes the test
successfully, it can be used as primary temporary barrier and primary permanent
barrier (Fig. 2.26b). However, if it does not pass the pressure test, the primary and
secondary well barrier envelopes are established by rigging up a wireline unit. A
wireline BOP is positioned on top of the tree, and a bridge plug is installed in the
tailpipe. The envelope is tested and if it maintains its integrity, a secondary temporary
barrier is established by placing a bridge plug inside the tubing hanger and verified
by pressure testing the barrier envelope (Fig. 2.26c).
Dual-bore vertical subsea trees provide direct access to the production and annulus
bores via a completion riser. As there is more than one bore inside the tubing hanger,

Fig. 2.25 Configurations of

tubing hanger for subsea
well completed with the
vertical trees. (Courtesy of
Dril-Quip)
46 2 General Principles of Well Barriers

Fig. 2.26 Subsea well completed with the single-bore vertical tree

two bridge plugs are required to establish the secondary barrier and consequently, a
dual-bore riser is required. A wireline BOP is installed on top of the tree and bridge
plugs are installed and eventually, the envelopes are pressure tested. It is noteworthy
to know that a dual-bore tubing hanger does not affect establishment of the primary
temporary barrier (see Fig. 2.27).

2.8.3.3 Assembling BOP—Subsea Well with the Horizontal Tree

Often, it is assumed that nippling up the BOP for wells completed with horizontal
trees is not as complex as for wells completed with vertical trees; however, that is
not true. Maybe the reason for this belief is rooted in the reality that the BOP is
installed on top of the horizontal tree and there is no need to nipple-down the tree
and consequently, there is no need to establish the primary and secondary temporary
barriers. Indeed, to get access to the wellbore, the high-pressure tree cap needs to
be removed (see Fig. 2.28), and pressure underneath of the tree cap needs to be
controlled. Therefore, a well control equipment is necessary and will be employed.
2.9 Special Considerations in Abandonment Design 47

Fig. 2.27 Subsea well with the dual-bore vertical tree

2.9 Special Considerations in Abandonment Design

2.9.1 Control Lines

A control line is a small-diameter hydraulic line used to channel fluid from surface to
operate downhole completion equipment such as the SCSSV. Wellhead is designed in
such way that provides penetrations for control lines to go through. Figure 2.29 shows
48 2 General Principles of Well Barriers

Fig. 2.28 Subsea production well with a horizontal tree

Fig. 2.29 Control lines with and without electrical line

2.9 Special Considerations in Abandonment Design 49

Fig. 2.30 Full-scale test set-up used for investigating the sealing ability of cement plug when tubing
and control lines are left in hole [32]

two different types of control lines; a control line equipped with four small-diameter
hydraulic lines, and a control line equipped with two small-diameter hydraulic lines
and one conductor line (electric line to the right). Two major concerns exist regarding
control lines that persuade engineers to plan for control line retrieval; flow potential
of hydraulic line(s) and quality of the bonding between plugging material and surface
of the control line. During cement plug placement, a variety of fluids are pumped and
each has its own function. These fluids adhere to the surface of downhole equipment
(e.g. control line) and its removal is challenging due to wettability of the control line
surface. Therefore, the bonding between the cement plug and the control line surface
is a concern.
Nowadays most wells are completed as smart wells, meaning control lines and
electric lines are part of the well completion to control Inflow Control Devices (ICDs).
There are different opinions regarding the risk of leakage or well integrity issues
concerning control lines as part of the well barrier envelope. Aas et al. [32] performed
a full-scale test on the sealability of annulus cement when tubing is left in hole with
control lines. In this study, a 7-in. production tubing and a 9-in. production casing
were used in the experiments. Figure 2.30 shows the schematic of the full-scale test
assembly used in the study. In this study, a 16.0 (ppg) conventional class G Portland
cement displaced a 10.0 (ppg) brine, and then the cement was cured for 7 days.
The 9-in. production casing was insulated and the temperature development due to
cement hydration was recorded. The maximum temperature was recorded as 75 °C
after 1 day of curing. The test assembly was 40 (ft) long and it was inclined 85° while
pumping cement and during curing. Cement was allowed to fill in the control line.
Then, the sealing ability of the cement plug was investigated by pressure testing.
Water was pumped at 725 psi to the A-annulus and 1450 psi to inside of the tubing.
Aas et al. [32] observed no leakage through the established barrier.
One of the challenges regarding leaving control lines in hole during P&A is related
to placing a plug inside the control lines at the desired depth interval. Control lines
have a small diameter (1/8 to 1-in. OD) and the fluid inside ranges from water-based
hydraulic fluid to a mixture of this fluid with reservoir fluid including formation
water. When plugging material is pumped through control lines, it is contaminated
in such a way that pressure testing will show a failure. Different plugging materials
(i.e. cements, resins, and silicone materials) have been tested for sealing the annuli
of control lines [33]. The compatibility of fluid inside control lines and plugging
50 2 General Principles of Well Barriers

material appear to be the key to success and there is an interest for more research on
this subject.

2.9.2 Well Design

One of the best and most cost effective solutions for P&A is to consider the P&A sce-
narios during the well design phase. The consideration of the following parameters
during well design may strongly influence permanent P&A operations: proper pri-
mary cement jobs, depth of TOC, qualification and documentation of primary cement
jobs, depth of control lines, and identification of pressure sources in the overburden.
Primary cement job—Consider a well with two different well design scenarios,
Fig. 2.31. In the first scenario, the well has been designed and constructed in such
a way that there is high enough qualified cement across a suitable formation, in the
B-annulus, and the primary cement has been qualified and documented, Fig. 2.31a.
In the second scenario, the same well has been designed in such a way that there
is neither cement in the B-annulus across a suitable formation nor has the cement
been qualified and documented, Fig. 2.31b. For the first scenario, if the well does not
experience SCP, then the tubing may be retrieved (i.e. if control line is present at the
plugging depth) and then a cement plug is placed inside the production casing and
across the casing cement. In the second scenario, as there is an uncemented casing,
access to the suitable formation requires section milling or other techniques, and
then the cement plug can be placed across the formation. The first scenario may take
1 day per plug while the second scenario may take several days per plug due to the
required access to the formation.
When there are more than one well to be plugged and abandoned in a field and
all of them fulfill the circumstances of the given well in Fig. 2.31a, a common
practice may be accepted, which is based on experience. According to the practice,
production tubings of two or three wells are retrieved, fully or partially, and their
casing cements in the B-annulus are logged. If the casing cements are qualified, then
an assumption is made for all the wells in the field. As the wells do not experience
any sustained casing pressure, the assumption is that, since the casing cements of
the selected wells have been qualified during P&A operations by logging, the casing
cement of the other wells are intact and qualified as well. Therefore, tubings are left
in hole and the A-annulus and the inside of the production tubings are filled with
cement. Furthermore, the new cement plug is tested and if qualified, it is verified and
documented. It is necessary to remember that in this scenario, there is no control line
in the well barrier envelope.
Pressure in overburden—Identification of pressure sources in the overburden dur-
ing P&A operations is a challenge with a high uncertainty. Therefore, it is recom-
mended to identify and document all pressure sources in the overburden during
well construction. Experience shows that unidentified formations with flow poten-
tial, in the overburden, can create challenges to qualify permanent barriers below the
unidentified influx formation.
2.9 Special Considerations in Abandonment Design 51

Fig. 2.31 A production well in two different scenarios: a high enough qualified cement in the
B-annulus, b not enough cement in the B-annulus

Well objectives—Wells are drilled with different objectives; exploration, delin-

eation, appraisal, development, production, or injection (Table 2.5). When investi-
gating new areas, the interpretation of seismic data helps find areas where there are
probable hydrocarbon reserves. The goal of an exploration well is to confirm or reject
this hypothesis. In addition, the exploration well gathers the necessary information
for a better understanding of the area and its potential future production. As a result
of exploration, when the exploration well penetrates an accumulation of petroleum,
52 2 General Principles of Well Barriers

Table 2.5 Well types and

Well Type Objectives
their objectives
• Exploration • P&A or keepera [34]
• Delineation • Size of reservoir
• Appraisal • Reservoir characteristics
• Development/production • Reservoir drainage
• Injection • Pressure maintenance
• Cutting reinjection
• Disposal of unwanted fluids
a An exploration well intended for completion

a delineation well is drilled for estimating the size of the reservoir and its commer-
cial value. Appraisal wells are drilled for investigating the reservoir characteristics.
Development wells are drilled for reservoir drainage and production of petroleum.
Injection wells are drilled with different objectives; pressure maintenance, disposal
of fluids, and cutting reinjection. Pressure maintenance injection wells are drilled
for Enhanced Oil Recovery (EOR) and Improved Oil Recovery (IOR) processes
to increase the recovery factor of reservoirs. Disposal wells are drilled to reinject
unwanted fluids (e.g. connate water) produced with petroleum to a non-hydrocarbon
bearing formation. Cutting reinjection wells are drilled to dispose of drilling cuttings
and contaminated mud in a formation while drilling.
Drilling culture has been influenced by different time regimes and the above-
mentioned types of wells have been designed based on the needs over time, and
subsequently their design criteria has been changing with regards to the knowledge
of engineers. Figure 2.32 shows a timeline for different design criteria eras in well
construction. Perhaps from past to 1970s could be called as classic era of well design,
1980s as horizontal drilling and slot recovery era, 1990s as well integrity era, 2000s
as rotating liner and the last decade could be marked as era of P&A in well design
and it has been accelerated due to Macondo incident. There is an indisputable subject
which has been focused continuously over time, and that is cement and its properties.
There have been eras where wells were drilled and completed without compre-
hensively considering their future P&A. Therefore, each type of these wells which
have been drilled over decades, have their unique specific well design and need to
permanently be plugged and abandoned using a best practice.
Pore pressure and fracture pressure profiles—In a pressure depleted reservoir,
the reservoir pore pressure will be lower than the initial pressure and the fracture
pressure will also be reduced. Consequently, the margin between pore pressure and

Fig. 2.32 Timeline showing different eras for focusing on different subject
2.9 Special Considerations in Abandonment Design 53

Fig. 2.33 Effect of annular space on ECD and margin between pore pressures and fracture gradient
profiles

fracture pressure gradients will be smaller. In P&A operations, having a narrow

margin between pore pressures and fracture gradient profiles can be a challenge
and limiting factor, particularly in deep-water offshore wells. This narrow margin
results in limitations with respect to the selection of hole cleaning fluid systems,
swarf/cutting removal, cement design and its placement, etc. Compare a scenario
where a 5-in. drillpipe as a working string is performing section milling in a 9 5/8-in.
casing with another scenario where the same drillpipe is conducting section milling
on the same well at the same depth but milling a 12 ¼-in. casing, Fig. 2.33. As a
result of different pressure drop in the annulus, the Equivalent Circulating Density
(ECD) will change and the exposed formation may be fractured.

Example 2.2 Consider a 5-in. drillpipe is performing section milling of a 9 5/8-in.

casing at 8000 (ft) True Vertical Depth (TVD) with a mud weight of 10.8 (ppg)
whereas the annular pressure loss is 460 psi. Assume that the pore pressure and
fracture pressure at 8000 (ft) are 10.2 (ppg) and 11.7 (ppg), respectively.

a. Does the downhole pressure fracture the formation?

b. Consider the same situation where the casing is 12 ¼-in. and the annular pres-
sure loss is 340 (psi). Does the downhole pressure fracture the formation in this
scenario?

Solution
annular f rictional pr essur e loss ( psi)
EC D ( ppg) = mud weight ( ppg) +
0.052 × T V D ( f t)
54 2 General Principles of Well Barriers

(a) EC D = 10.8 + 0.052×8000

460
= 11.9 ppg
The ECD is higher than the fracture gradient and induces fractures.
(b) EC D = 10.8 + 0.052×8000
340
= 11.6 ppg
The ECD is slightly lower than fracture gradient.

Casing seats—It is the set point of the end of casing and generally it is based
on consideration of pore-pressure gradients and fracture gradients of formations to
be drilled. Casing seat is normally placed in an impermeable and stable formation.
Casing seat depth (also known as casing setting depth) can influence P&A operational
time; therefore, it should be considered and selected properly during well design with
regards to future P&A of the well. The example shown in Fig. 2.34 illustrates the
situation where a lost-circulation zone (DPZ 5) leads to a very low height of TOC
for the production casing. As the intermediate casing string has the right casing-seat

Fig. 2.34 Relationship among casing seat and permanent barrier establishment
2.9 Special Considerations in Abandonment Design 55

depth, an interval above the lost-circulation zone is provided to establish primary and
secondary barriers for the reservoir. But if the casing seat for the intermediate casing
was deeper, then barrier establishment for the reservoir could be more challenging.

2.9.3 Well Schematic

A well schematic is suggested to be produced and updated on a daily basis, during

P&A operations. It shows the actual phase of each well with its status. In this manner,
it becomes clear to a wider audience if the P&A operation is falling behind, or is
ahead of schedule, and if necessary, extra resources can be applied.

2.9.4 Horizontal Wells

A well with an inclination of generally larger than 85° is called a horizontal well.
The horizontal section of a horizontal well is in the pay zone and is not normally an
interesting interval for P&A. The build and tangent sections are important, Fig. 2.35.
It is recommended to establish the permanent barrier as close as possible to the
cap rock and across a suitable formation. Therefore, the build and tangent sections
are interesting intervals; however, the high angle of these sections imposes some
serious challenges. Performing wireline operations, hole cleaning, and cement plug

Fig. 2.35 Different sections

of a horizontal well
56 2 General Principles of Well Barriers

placement at high angles (usually more than 65°) are some of the challenges to be
considered, impacting the operation time and associated risks.

2.9.5 High-Pressure High-Temperature Wells

Over the years and across companies, definitions of High-Pressure High-Temperature

(HPHT) wells have varied and no industry-wide standard defines HPHT conditions.
The American Petroleum Institute (API) attempted to define HPHT terminology by
publishing guidelines for equipment used in HPHT operations. According to the
API Technical Report 1PER15K-1, a well having pressure higher than 15000 psi is
defined as a HP well; and a well having temperatures higher than 350 °F is defined as
a HT well [35]. However, NORSOK Standard D-010 [1] defines a well as a HP well
when the shut-in pressure is exceeding 10000 psi and a well as a HT well when the
static bottomhole temperature is higher than 300 °F. Figure 2.36 shows a proposed
system for the classification of HPHT conditions for well-service-tool components.
As HPHT conditions impose a unique situation, particular considerations should be
taken during the design and operational phase of P&A.
Usually HP conditions dictate the use of larger BOPs. A larger BOP means limited
space and handling capacity for offshore wells, more fatigue stresses on the wellhead,
and more time consumed function testing the BOP. In addition, HP wells impose the
need for a large increase in mud weight to control formation pressure; however,
hydrostatic pressure may then approach fracture pressure.
For high temperature conditions, the impact of thermal expansion of drilling fluid
on kick tolerance, effect of high temperature on equipment performance, and limited

Fig. 2.36 A proposed HPHT classification system [36]

2.9 Special Considerations in Abandonment Design 57

range of suitable plugging materials need to be considered during abandonment

design.
More challenging conditions exist where high pressure and high temperatures are
present together. Achieving adequate hydrostatic pressure while avoiding fracturing
the formation is a challenge for the HPHT mud engineer. Wellbore instability, in
milled sections, in high temperature and highly-depleted reservoirs is another chal-
lenge to be considered. Establishment of a cross sectional barrier (see Fig. 2.43) may
require section milling and where a pressure depleted, and high temperature reservoir
is the subject, there is the risk of wellbore instability due to changes of thermal elastic-
ity of porous medium. Subsequently, leading to narrowing the mud density window.
The reduced fracture gradient and drilling fluid loss are challenges which are rooted in
pore pressure depletion, reduction of wellbore temperature, and drilling fluid osmosis
in plugging and abandoning high temperature and highly-depleted reservoirs [37].
In HPHT and deep-water conditions, considerable temperature variations are seen
in the transition from circulating conditions to geothermal gradient conditions during
static periods. Generally, the milling interval of a wellbore experiences cooling as
cold mud is pumped down the drill string. The upper part of the wellbore experiences
heating as warm drilling fluid is circulated up, especially during hole cleaning. When
the circulation is stopped, the temperature profile will, by heat conduction, return
to geothermal conditions and subsequently, heat the mud in the milling interval and
cool the mud in the upper part of the wellbore. Heating and cooling of mud in lower
part and upper part of the wellbore in static conditions counteract each other. If the
heating process dominates the wellbore condition, then mud experiences a thermal
expansion and a gain in the mud pits will be observed. Consequently, hydrostatic
pressure of the mud column drops and well control will be a concern.
Cement plug placement of HPHT wells requires a higher cement density and
the situation imposes higher ECDs and therefore, low pumping rates are preferred.
Subsequently, due to a low pumping rate which may change the flow regime (i.e.
from turbulent to laminar), the mud displacement may be inefficient. In addition, a
low pumping rate requires a slurry design with longer thickening times which needs
more chemicals as retarders at high temperature conditions as high temperature
accelerates the hydration process. As a rule of thumb, the more retarders used the
more side effects on properties of the cement [38, 39]. So, HPHT wells require special
consideration during abandonment design.

2.9.6 Shallow Permeable Zones

Identification and sealing production potentials in the overburden formation are

assessed during abandonment. Shallow sources include shallow gas, coalbed
methane, and water bearing zones. Although protection of the surface environment
from any contamination caused by an abandoned well is the goal of P&A, protection
of drinking water sources (surface water and ground water) increases the importance
58 2 General Principles of Well Barriers

of permanent P&A. So, identification of shallow potentials during the initial life-
cycle of wells (drilling) and P&A is necessary. These potentials need to be sealed
properly, assessed, and finally documented.

2.9.7 Multilateral Wells

Where a well has more than one branch radiating from the main borehole, the well
is called multilateral well. Multilateral wells are an evolution of horizontal wells.
Permanent abandonment of multilateral wells requires a detailed study to design the
required number of permanent plugs per borehole. If possible some of the boreholes
may be regarded as one borehole to reduce the number of plugs to be installed,
Fig. 2.37.

Fig. 2.37 Cased and

cemented main bore with
openhole multilaterals
2.9 Special Considerations in Abandonment Design 59

2.9.8 Slot Recovery Sidetracks

Some regulators require, prior to slot recovery or sidetracking, the original wellbore
to be permanently plugged and abandoned, Fig. 2.38. The permanent barrier can be
a crossflow barrier or primary and secondary permanent barriers depending on the
pressure regimes, formation strengths and available window between the formations.
However, if at the time of sidetracking a permanent abandonment of the original
borehole is not feasible, the primary and secondary temporary barriers need to be
designed and established for the intended period. During the abandonment design,
all of these original boreholes need to be mapped.

Fig. 2.38 Permanent abandonment, multi-bore with slotted liners

60 2 General Principles of Well Barriers

Fig. 2.39 Permanent plug

and abandonment of multiple
reservoirs with the same
pressure regime

2.9.9 Multiple Reservoirs

Multiple reservoir zones located within the same pressure regime can be regarded
as one reservoir. In such a scenario, primary and secondary permanent barriers are
established above the upper potential, Fig. 2.39. If potentials are in the same pressure
regime but crossflow is not acceptable, then a barrier can be established between the
potentials, Fig. 2.40. In this scenario, the crossflow barrier may be regarded as a
primary barrier for reservoir 2 and the primary permanent barrier for reservoir 3
is regarded as secondary permanent barrier for reservoir 2, Fig. 2.40. In this case,
the reservoir 2 has three barriers including the crossflow barrier. A combination of
permanent plugs for different potentials, which are in the same pressure regime and
crossflow is acceptable, saves time and reduces costs. However, risk analysis needs
to be performed to investigate the long-term consequences.
When the potentials have different pressure regimes and crossflow is not accept-
able, each potential is secured with two barriers, primary and secondary barriers,
Fig. 2.40.

2.9.10 Slotted Liner

The screen or slotted liner is a mechanical device which may contain gravel-pack
sand in the annular space between it and the casing wall or openhole, Fig. 2.41.
Reservoirs or zones completed with a slotted liner or screen should be plugged
above the slotted liner or screen. One of the reasons is that screen or slotted liner acts
as filter for plugging materials. Consider a cement slurry which is pumped across a
screen, the screen acts as a filter and drains the water such that hydration of cement
2.9 Special Considerations in Abandonment Design 61

Fig. 2.40 Two flow potentials; same pressure regime but crossflow is not permitted, different
pressure regimes with no permitted crossflow

Fig. 2.41 Types of prepacked screens. (Courtesy of Baker Hughes)

would not be completed and consequently, poor chemical and physical properties of
the cement plug would be expected.

2.9.11 Inflow Control Device

An inflow Control Device (ICD) is a surface controlled device which is installed as

a part of well completion to help to optimize production by reducing water inflow
contribution. Usually, during completion multiple ICDs are installed along the well,
62 2 General Principles of Well Barriers

Fig. 2.42 Flow path of a typical ICD [40]

in horizontal sections. ICDs are frequently used with sand screens and in open-
hole completions. ICDs allow controlled inflow but prevent outward flow, Fig. 2.42.
Therefore, pumping cement slurry through ICDs is a challenge.

2.9.12 Tubing Left in Hole

Retrieval of production tubing is a time consuming and costly operation. Therefore,

leaving the tubing in hole is often a desired option. If the production tubing is in a
good condition, it can be used as work string for cementing. However, mechanical
strength of a tubing for being used as work string should be analyzed [32].

2.9.13 Hydrocarbons in the Overburden

It is important to identify all sources of inflow in the overburden, run a risk analysis,
and if necessary secure them by establishing of barriers. Due to uncertainty of old
data, it is necessary to use data obtained from recent wells drilled in the same reservoir
or field, to identify shallow sources of inflow. Retrieving the production tubing and
logging behind production casing and intermediate casing may be necessary as these
sources can contaminate ground water, soil or the marine environment. Hydrocarbons
in the overburden may exist naturally or form due to well integrity issues.
2.10 Requirements for Designing Permanent Barriers 63

2.10 Requirements for Designing Permanent Barriers

2.10.1 Well Cross Sectional Barrier

A permanent well barrier shall extend across the full cross section of the well while
sealing all annuli both vertically and horizontally, Fig. 2.43. It is placed across a
suitable formation; an impermeable formation with sufficient strength to hold the
maximum anticipated pressure from the source of inflow. The barrier is known by
different names such as cross-sectional barrier, or formation-to-formation barrier.

2.10.2 Plug Setting Depth—Formation Integrity

The adjacent formation to the permanent plug shall be capable of holding the maxi-
mum anticipated pressure from the source of inflow. The maximum anticipated pres-
sure is either the original (initial) reservoir pressure for reservoirs with strong aquifers
or an estimated final pressure that is below original reservoir pressure. The estimated
final reservoir pressure is defined in a time interval and obtained through simulations.
The maximum anticipated pressure is important for calculating the Minimum Setting
Depth of Plug (MSD). The minimum setting depth of plug is the shallowest depth
where the formation withstands the maximum anticipated pressure without being
fractured. As the secondary plug is a backup to the primary plug, the MSD is the
shallowest depth where the top of the secondary permanent plug can be placed. It
is a common practice to place the plug as close as possible to the source of inflow.
The MSD is estimated by using either pressure-gradient curves or a fluid gradient
concept. The gradient curve method is a quick and reliable estimation for finding the
MSD but the fluid gradient concept can also be used when several leak-off data are
available.

Fig. 2.43 Cross sectional

barrier seals all the annuli.
(Reprint from NORSOK
D-010)
64 2 General Principles of Well Barriers

2.10.2.1 Minimum Setting Depth—Gradient Curves

In this method, initial pore pressure, fracture pressure, minimum horizontal stress,
and overburden pressure curves are plotted. Then, a gas gradient line is drawn from
the reservoir pressure towards the surface. For drawing the gas gradient line, it is
necessary to know the final reservoir pressure and then subtract the hydrostatic effect
of the gas column. The intersection of the curve for a closed well filled with gas and
the minimum horizontal stress curve is the MSD, (see Fig. 2.44). The selection of
final pressure is a crucial decision whereby selection of a lower value shifts the gas
column curve to the left and consequently the MSD will be closer to the surface.
However, when the reservoir builds up pressure, the adjacent formation to the plug

Fig. 2.44 Pore pressure and fracture pressure gradient curves of a platform well
2.10 Requirements for Designing Permanent Barriers 65

is not able to hold the pressure and subsequently fractures. Selection of a higher
reservoir pressure shifts the gas column to the right and MSD will be further away
from the surface. As a result, the window for finding the appropriate interval for plug
to be placed is limited.

Example 2.3 The following gradient curves, Fig. 2.45, have been reported for a
well. Based on the given information estimate the minimum setting depth for the
plug and propose an interval for the plug placement.

Solution The gas gradient curve should be plotted and extended to overburden pres-
sure. The intercept point between the gas gradient curve and the minimum horizontal
stress curve is the MSD of secondary plug. It means that the top of secondary barrier
can be up to the depth of interception. However, it is recommended to install the per-
manent barriers, primary and secondary, as close as possible to the source of inflow.

Fig. 2.45 Pore pressure—Fracture pressure gradient curves

66 2 General Principles of Well Barriers

In this way, in case of barrier failure, if permanent barriers are not qualified, there
will be a window left to install new barriers.

2.10.2.2 Minimum Setting Depth—Fluid Gradient

In this method, the intersection between the fracture pressure and gas column is
obtained mathematically. The MSD is the unknown parameter while the final reser-
voir pressure, fracture gradient, fluid gradient, and TVD of the reservoir are known
parameters. The MSD is given by:

12
PF P − Pg × (H − h M S D ) ≤ × P f rac. × h M S D (2.5)
231
PF P − Pg × H
h M S D ≥  12  (2.6)
231
× P f rac. − Pg

whereas PFP is the final reservoir pressure (psi), Pg is the gas gradient pressure (psi/ft),
H is the TVD of reservoir (ft), hMSD is the minimum setting depth (ft), and Pfrac. is
the fracture pressure gradient (ppg).

Example 2.4 A platform well was drilled in the NCS in 1999 and the initial reservoir
pressure was 2915 psi. The well is an oil producer with a fluid gradient of 0.32 (psi/ft).
The reservoir is supported with a strong aquifer and the current reservoir pressure is
2755 psi. An average fracture gradient from leak off test is estimated to be 10.0 (ppg).
The production casing shoe was placed at 6050 (ft) TVD and the cap rock thickness
is 200 (ft) TVD. Calculate the minimum setting depth for primary and secondary
barriers. Assume a gas gradient of 0.1 (psi/ft).

Solution This question shows how the gas presence can create a small window for
placing the barrier.
The question mentions that the reservoir is supported by an active aquifer, which
means that the reservoir pressure can build up to initial reservoir pressure. If we
assume that the reservoir is under saturated, then oil is present and oil gradient is
used for calculations. By using Eq. (2.6):

PF P − Pg (H )
h M S D ≥  12 
231
× P f rac. − Pg
2915 − 0.32 × 6250
h M S D ≥  12 
231
× 10 − 0.32
h M S D ≥ 4575 ( f t) T V D

Now consider that the reservoir is a saturated reservoir, which means gas is present
in the wellbore.
2.10 Requirements for Designing Permanent Barriers 67

2915 − 0.10 × 6250

h M S D ≥  12 
231
× 10 − 0.10
h M S D ≥ 5452 ( f t) T V D

It means that the window to install both primary and secondary barriers is smaller.

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Chapter 3
Specification for Permanent Plugging
Materials

Portland cement is currently the prime barrier material used in the petroleum indus-
try for zonal isolation and permanent well abandonment. In addition, the industry
considers alternative plugging materials. Therefore, it is necessary to consider func-
tional requirements, operating conditions and qualification procedures for any newly
developed alternative plugging material.

3.1 Material Requirements for Permanent Barriers

In order to qualify the well barrier for its intended use, some requirements are neces-
sary to be defined. These requirements are called Well Barrier Acceptance Criteria
(WBAC) and include functional, and verification requirements of the well barrier
[1]. The main functional characteristics of permanent barrier materials are addressed
as [1, 2].
1. Very low permeability or impermeable,
2. Long-term durability at downhole conditions,
3. Non-shrinking,
4. Ductile or non-brittle,
5. Resistance to downhole fluids and gases, and
6. Sufficient bonding to casing and formation.

3.2 Functional Requirements of Permanent Well Barrier

Elements

A permanent well barrier element has to fulfill a number of functional requirements

including sealing capability, bonding properties, downhole placeability, durability,
and reparability. These requirements are discussed in this chapter in more detail.

© The Author(s) 2020 71

M. Khalifeh and A. Saasen, Introduction to Permanent Plug
and Abandonment of Wells, Ocean Engineering & Oceanography 12,
https://doi.org/10.1007/978-3-030-39970-2_3
72 3 Specification for Permanent Plugging Materials

3.2.1 Sealing Capability

The main function of a permanent barrier is to seal a potential and prevent the
movement of fluids. The sealability of a material is a function of its permeability and
bond strength. However, definition of impermeability is a controversial subject as
most, if not all, materials have some degree of permeability for some elements. For
example, cap rocks have some permeability within the range of 10−3 –10−6 millidarcy.
It means that in the context of permanent well barrier materials, it is inevitable that a
fluid within the well will ultimately migrate through a barrier, even though at a low
rate. Table 3.1 presents permeability of some materials.
In order for a leak to occur, fluids must be able to enter into a barrier and break-
through must happen. Then the definition and investigation of permeability gets its
meaning. A fundamental requirement for an effective seal is that the entry pressure
of the sealing material shall be higher than the capillary forces of fluids in the for-
mation beneath. The seal entry pressure, the seal capacity, is the capillary pressure
at which fluid pressure exceeds the capillary entry threshold and therefore, fluid
leaks into the pore space of the barrier material. This is dependent on both barrier
and fluid parameters. Barrier parameters include the size distribution of connected
pore throats. Fluid parameters include the present fluids (e.g. water, oil or gas), fluid
density, and Interfacial Tension (IFT) of the fluids.
The capillary entry pressure (dynes/cm2 ) is defined by Eq. (3.1) [5].

2σ (cos θ )
Pc = (3.1)
r
where σ is the interfacial tension (dynes/cm), θ is the contact angle of the water
with the pore surface (degrees), and r is the pore radius (microns). Capillary entry
pressure, also known as seal capacity, could potentially be defined as a means of
resisting permeation of WBE by fluids. Among the contributing factors in capillary
entry pressure, the contact angle and pore radii are prone to modification with time.
In the case of water as the entering fluid, the capillary entry pressure is only exceeded
when the contact angle between WBE and water is greater than 90°.

Table 3.1 Permeability of some materials [3]

Material Permeability (millidarcy)
Portland cement (neat class G) [4]a 10−2
Shale 10−3 –10−5
Granite 10−3 –10−4
Halite 10−7 –10−9
Anhydrites 10−5 –10−7
a Although neat class G Portland cement has such a permeability, use of cement permeability
reduction additives reduce the permeability significantly
3.2 Functional Requirements of Permanent Well Barrier Elements 73

3.2.1.1 Methods for Measuring Capillary Pressure

Due to the complex structure of pores, it is impossible to use Eq. (3.1) to calculate the
capillary pressure of porous media. Therefore, laboratory measurements have been
developed and are the most reliable methods for capillary pressure measurements.
Methods for measuring capillary pressure are categorized as:
• Mercury methods
• Porous-plate method, and
• Centrifuge method.
Mercury method—For experimental convenience, it is a common practice to use
air-mercury system for capillary pressure measurements. In the mercury method,
the specimen is dried and placed inside a cell and then the cell is vacuumed. Sub-
sequently, mercury is injected into the cell and the volume of mercury that enters
the specimen at increasing pressures is measured. To apply the proper overburden
pressure, a cylindrical specimen could be placed inside a confining sleeve and then
the overburden could be applied. Figure 3.1 shows a simplified schematic of the
mercury setup.
By measuring the displacement pressures for the assessment of WBE, seal capac-
ity could be assessed from capillary pressure curves. However, there are some dis-
advantages associated with this method: it is a destructive test, it is performed on
dried specimens which does not include fluid-surface interactions, and it may cause
collapse of accumulations of grain surface coating minerals. In addition, the HSE
issue related to mercury is a challenge. The advantages of the technique are that it is
rapid and irregular specimens can be used in the case with no overburden pressure
effect [6].
Porous-plate method—This technique can yield very accurate capillary pressure
relationships. In this technique, a cylindrical specimen is saturated with water. A
flat end of the specimen is then pressed against a flat porous plate, to make a good
contact, in a cell filled with gas. The porous plate is also saturated with water. To
improve the contact between the porous plate and the specimen, usually a moist
tissue is placed between them. Subsequently, the gas pressure above the specimen is

Fig. 3.1 Mercury is metered

into a vacuumed specimen
74 3 Specification for Permanent Plugging Materials

Fig. 3.2 Schematic of the

porous-plate setup. The
differential pressure between
the gas and the water must
not exceed the threshold
pressure of the porous plate

increased in small steps to force the gas to displace the water from the specimen. In
this procedure, the high displacement pressure of the porous plate allows brine from
specimen to pass through but prevents the flow of gas. The specimen is removed at
intervals and weighed until weight equilibrium is achieved. Considerable time may
be needed, often a week or more, for each displacement step to reach equilibrium
[7]. A diagrammatic sketch of this equipment is shown in Fig. 3.2.
Centrifuge method—Centrifuge measurements are more favorable as they take
less time compared to porous-plate measurements; however, the measurements are
not as quick as mercury measurements. In this method, a cylindrical specimen is
saturated with water and then it is placed inside a centrifuge. Subsequently, it is
spun in steps of increasing spin rate. The centrifugal forces force the water out of the
specimen, replacing water with gas. There is a collector system for the drained water.
The average saturation of water in the specimen, at each spin-rate, may be calculated
from the volume of accumulated water and the porous volume of the specimen [8].
The capillary pressure distribution, at each spin-rate step, is given by [9].

1  
Pc (r ) = ρω2 re2 − r 2 (3.2)
2
where re is the radius from center of rotation to the upper face of the specimen, r is
the radial distance to any point in the sample, ω is the rotational velocity (rad/s), and
ρ is the density difference between displaced and displacing fluids.
3.2 Functional Requirements of Permanent Well Barrier Elements 75

Table 3.2 Fluid flow properties for a reservoir and cap rock [10]
Property Reservoir Cap rock
Porosity (–) 0.125 0.05
Permeability (md) 2.028 1.11 × 10−3
Irreducible water saturation (–) 0.3 0.66
Entry capillary pressure (psi) 0 39
Maximum capillary pressure (psi) 145 924

3.2.1.2 Permeability

Permeability is a property of the material, representing the ability of the material to

transfer fluids. The WBE’s permeability is the property controlling the movement
and leak rate of formation fluids. As the rock permeability was first defined mathe-
matically by Henry Darcy in 1856 [5], the equation that defines permeability in terms
of measureable quantities is called Darcy’s Law and is given in Eq. (3.3). Darcy’s
Law shows that permeability, k, is directly proportional to flow rate, q, length of the
medium, L, and fluid viscosity, μ, and inversely proportional to cross-sectional area,
A, and the differential pressure across the medium, p.

q · μ · L  2
k=− m (3.3)
A · p

When a fluid with one centipoise viscosity and a pressure gradient of one atmo-
sphere per centimeter of length flows with a flow rate of one cubic centimeter per
second across a cross-sectional area of one square centimeter, the permeability is
unity. For the units described above, k has been arbitrarily assigned a unit called
Darcy in honor of Henry Darcy. One Darcy is a relatively high permeability as the
permeabilities of most reservoir rocks are less than one Darcy. Therefore, the term
millidarcy is normally used, where one millidarcy is equal to one-thousandth of one
Darcy [5]. Table 3.2 presents example of fluid flow properties of a carbonate reservoir
rock and a shale cap rock.

3.2.1.3 Acceptance Criteria for Fluid Flow Through Plugging Material

The goal of permanent P&A is to restore the cap rock in the wellbore or its func-
tionality by placement of a plugging material across a suitable formation. Although
the definition of a competent plugging material might be a matter of discussion, it is
reasonable to consider properties of cap rock as the acceptance criteria for selection
or design of any plugging materials. This adaptation is also valid for permeation
characteristics of any plugging material as all existing materials, have some degree
of permeability.
76 3 Specification for Permanent Plugging Materials

3.2.2 Bonding

Plugging materials should remain intact in place and block the migration of fluids.
Therefore, sufficient bond strength and hydraulic bond strength of plugging mate-
rials with formations and steel are required. For zonal isolation purposes, hydraulic
bonding is normally more important than bond strength.
Bond strength failure, debonding, may eventuate from two different loading sce-
narios; shear load, and tensile load. These loads can be induced by thermal cycling,
hydraulic forces, volume changes of material, tectonic stresses, or a combination of
these [11–13]. The volume change could be due to shrinkage and may occur either
during curing or after setting due to changes in downhole conditions. Shrinkage of
the plugging materials may impose sufficient tensile stresses on bonding between
the plugging material and steel or formation to compromise the bonding. Another
scenario that may result in tensile failure of bonding is the expansion of casing where
the plugging material is placed inside the casing. When a reservoir starts to build
up pressure underneath the plugging material, it may cause expansion of casing
and consequently, debonding may occur. Debonding due to expansion of casing is
predominantly for large casing sizes [2].
Hydraulic bond strength failure may eventuate from shrinkage or expansion of
plugging material or expansion of casing caused by reservoir pressure build-up and/or
due to interaction in the interface of casing and plugging material [14].
Bonding properties, bond strength and hydraulic bonding, are studied to improve
knowledge and determine bonding ability of plugging materials. In 1962, Evans
and Carter [15] published the result of their extensive study on shear bond and
hydraulic bond strength of oilwell cement covering the effect of closed-in pres-
sure, new mill varnish, uncoated pipe (wire-brushed, rusty, and sandblasted), dry
pipe surface, and pipe surface being wet with either water-based or oil-based mud.
Determining bond strength and hydraulic bonding of plugging materials considering
effects of the above-mentioned factors are necessary.

3.2.2.1 Shear Bond Strength to Pipe

Shear bond strength defines the bond that mechanically supports pipe in the hole,
and it is determined by measuring the force required to initiate pipe movement inside
a sealing material (Fig. 3.3). The force is applied parallel to the contact surface [16].
This force when divided by contact surface area between the plugging material and
casing, yields the shear bond [17].

Force
Shear bond strength = (3.4)
Contact area
The shear bond strength to pipe can be measured for two different scenarios;
plugging materials placed inside the casing and plugging material placed outside the
3.2 Functional Requirements of Permanent Well Barrier Elements 77

casing. The shear bond strength induced by a push-out test for cement outside casing
is calculated by:

F
τav = (3.5)
π · Do · L c

where F is the failure load which is applied on pipe, Do is the pipe outside diameter,
and Lc is the cement length. The shear bond strength of cement inside casing is given
by:

F
τav = (3.6)
π · Di · L c

where F is the failure load which is applied on pipe, Di is the pipe outside diameter,
and Lc is the cement length inside the pipe.
In one attempt, Evans and Carter studied shear-bond strength of cement to pipe
[15, 17]. Variation between brands of API class A cements (see Chap. 4), curing
temperature, condition of pipe, mud-wet and dry pipe, and closed-in pressure were
factors studied by them. According to their results, there are correlations between
compressive strength and shear bond on dry pipe. Closed-in pressure during setting
of cement is detrimental to shear bond of cement to pipe after pressure is released.
Shear bond strength is increased when cement is squeezed and wall pipe is water-
wet. Mill-coated finish surface is detrimental to shear bond strength. It is important to
mention that Evans and Carter applied both hydraulic and shear loads and therefore,
their true measured hydraulic-bond strengths are uncertain. Table 3.3 presents shear
bond strengths measured by Evans and Carter.

Fig. 3.3 Shear bond strength of cement to pipe a setup used by Evans and Carter [15], b setup used
by Khalifeh et al. [18]
78 3 Specification for Permanent Plugging Materials

Table 3.3 Examples of hydraulic- and shear-bonding properties of new and used pipe [15]
Casing type Time (Days) Hydraulic bond (psi) Shear bond (psi)
New 8h – 10
Used (rusted) 8h – 53
New 1 300 79
New (sandblasted) 1 500 123
Used (slightly rusty) 2 500–700 182
Used (wire brushed) 2 500–700 335
New (sandblasted) 2 500–700 395
Used (rusted) 2 500–700 422
New Pipe
Water-based mud 2 175–225 46
Dry 2 375–425 284
Used (slightly rusty)
Oil-based mud 2 – 75
Water-based mud 2 – 174
Dry 2 – 182
Latex cement
New 1 500 105
Used (slightly rusty) 1 360 58
• API Class A Cement
• Curing temperature: 80 °F
• Casing size: 2-in. inside 4-in.
• Cement-sheath thickness: 0.812-in.

Cement-pipe and cement-formation bond strength investigation shows that the

bond strength depends on the nature of the contact surfaces and the cement hydration
characteristics [16]. For a permanent plug, it is necessary to determine the appropriate
bond strength for supporting the plug inside either openhole or casing and test it when
the plug has set.
The shear bond strength to pipe is improved by use of expandable cement or
bonding agents such as latex and surfactants. Expanding properties of expandable
cements prevent the development of microannuli at the interface between casing and
formation and cement plug, and subsequently, ensure good bonding with casing [19].
The inclusion of latex additives to cement slurry lowers the surface tension between
the slurry and casing and helps cement adhere to casing while setting. Surfactants
treat the oil-wet surfaces by removing oil and allow better bonding contact [20].
3.2 Functional Requirements of Permanent Well Barrier Elements 79

Fig. 3.4 Experimental setup for measuring tensile bond strength of cementitious materials to steel

3.2.2.2 Tensile Bond Strength to Pipe

Tensile bond strength is defined as the force which acts normal to the contact surface
[16]. Tensile forces are applied perpendicularly to the contact surface of the supported
specimen. Few publications are available for tensile bond strength to pipe and this
area needs more attention [21]. Figure 3.4 shows an experimental setup for measuring
cement-steel tensile bond strength.

3.2.2.3 Hydraulic Bond Strength to Pipe

Hydraulic bond is defined as the bond between pipe and cement, which helps to
prevent the flow of fluids [15]. Hydraulic bond is determined by applying pressure at
the pipe-cement interface until leakage occurs at either end of the specimen, Fig. 3.5.

Fig. 3.5 Test setup for measuring hydraulic bond test; a the used setup by Scott and Brace [22],
b the used setup by Evans and Carter [15]
80 3 Specification for Permanent Plugging Materials

The hydraulic pressure when leakage appears is defined as the bond failure pressure.
Studies conducted by different researchers [15, 17] show that pressures at which
hydraulic bonding failure occur depends on the viscosity of the pressurizing fluid.
Hence, the choice of pressurizing fluid is an important parameter which influences
the breakthrough time and failure pressure. Therefore, gas bond tests and liquid bond
tests should be considered for hydraulic bonding measurements. The gases could be
compressed air, nitrogen, CO2 , methane, etc. and the liquids could be crude oil and
brine.
In 1966, Scott and Brace [22] studied the hydraulic bond strength at the casing-
cement interface for various conditions of the external surface of the casing, effect of
mud film on the casing surface, effect of temperature on the resin-sand coated pipe,
and effect of corrosive atmosphere on the resin-sand coating as important parameters.
Table 3.4 shows the relative hydraulic bonding strengths of casing-cement interface
with various surfaces measured by Scott and Brace.
Scott and Brace [22] found that excellent hydraulic bonding strengths are main-
tained at temperatures in the range to 350–400 °F. In addition, poor hydraulic bonding
resulted from untreated pipe where mud film remained and surfaces which were mill-
varnished. However, resin-sand coating greatly improves the casing-cement bond.
Figure 3.5 shows two different test setups used by different researchers for measuring
hydraulic bond strength of cement to pipe.
In another effort, Evans and Carter [15] studied hydraulic bonding strengths of
casing-cement (API class A cement) while measuring shear-bond strengths. Table 3.3
presents their results from these hydraulic- and shear-bonding tests. Evans and Carter
investigated the effect of surface finish, drilling fluid, pipe size and length, cement-
curing conditions, temperature and pressure on pipe, cement types, and the effect of

Table 3.4 Effect of mud film on hydraulic bonding strength of casing-cement interface [22]
Surface condition Surface coating Hydraulic bonding (psi)
Dry Mill varnish <20
Mud film Mill varnish <20
Dry Rusty 350–450
Mud film Rusty 20–50
Dry Acid-etched 250–400
Mud film Acid-etched 40–50
Dry Sandblasted 500–600
Mud film Sandblasted 50–60
Dry Epoxy coated, 6–12 mesh sand 700–950
Mud film Epoxy coated, 6–12 mesh sand 500–600
• Curing time: 24 h
• Curing temperature: 120 °F
• Cement type: not available
• Casing size: 4 ½-in. OD
3.2 Functional Requirements of Permanent Well Barrier Elements 81

squeezing. Their investigation concluded that the maximum reduction in hydraulic

bonding is caused by a fluid layer at the cement-pipe interface; and hydraulic bonding
strengths at cement-pipe interface are governed by surface finish of pipe, type of mud
wetting, and degree of mud removal. In addition, they concluded that there is no fixed
correlation between compressive strength and hydraulic bond strength to pipe. Low
hydraulic bonding strengths at the cement-pipe interface are also a function of the
pipe resiliency [15].

3.2.2.4 Shear Bond Strength to Formation

Shear bond strength of materials to formation depends on the nature of the contact
surfaces and the reaction characteristics of the materials. Shear bond strength to
formation maintains an intact barrier in place. Fluids only adhere to solids when
the fluid wets the solid material and therefore, bonding of cement to formation is
only possible if cement slurry filtrate is able to wet the wellbore wall. Roughness
of formation surface, mineralogy of formation, degree of cement hydration, water-
cement ratio, drilling mud and mud cake, downhole pressure and temperature, and
types of cement additives are important factors to be considered for measuring shear
bond strength of cement to formation [16]. Figure 3.6 presents a schematic of the
setup used for formation-cement shear bond strength measurements.
A study performed by Becker and Peterson on cement-formation bond shows that
the strength of the developed bond between cement and formation is mainly due to
wettability and the degree of cement hydration. In addition, contamination of cement
slurry with drilling mud, oil, or gas strongly deteriorate the shear bond strength to

Fig. 3.6 Experimental setup used for formation-cement shear bond strength measurements
82 3 Specification for Permanent Plugging Materials

Fig. 3.7 Shear bond strength of cement with various rock types [23]

the formation. Therefore, contamination must be eliminated and mud or oil films
on the formation surface should be removed totally. They also found that borehole
temperatures up to 250 °F accelerate the development of shear bond strength. Higher
temperatures can deteriorate the shear bond strength. However, the addition of silica
flour can prevent the bond deterioration [16].
Opedal et al. [23] studied the role of formation type in the development of shear
bond strength. A substantial reduction in shear bonding between cement and high
porosity rocks (sandstone, limestone, and chalk) was observed in the presence of
drilling fluid compared to the situation when low porosity shale was used as a forma-
tion. Existence of Water-based Mud (WBM) at the interface of rock and cement gives
slightly better bonding than presence of Oil-based Mud (OBM) [15, 23]. Figure 3.7
presents the shear bond strength of some types of rock with and without drilling fluid
film at the cement-formation interface.
When considering minimum shear bond strength (Fsb ) required by a plugging
material to avoid barrier movement, the resultant of two forces needs to be considered;
reservoir pressure which pushes the plug upward and barrier weight and hydrostatic
pressure above it, which act downward, Fig. 3.8. As a depleted reservoir may start
to build up pressure after abandonment, it is safe to use initial reservoir pressure as
the final reservoir pressure (FR ).
Cement-formation shear bond strength measurement—One of the main challenges
in bond strength evaluation is lack of any standard procedure on how to perform the
experiments. However, over the years, many researchers have followed the procedure
implemented in the 60’s by Evans and Carter [15, 17, 21]. In this method, a cylindrical
rock sample is placed in the middle of a mold and then cement slurry is poured in the
space between the rock sample and the mold, Fig. 3.6. The mold is covered with a
plastic cover to avoid water evaporation during curing. Depending on the size of the
test cell, the mold can be cured inside an autoclave to simulate downhole pressure
and temperature.
3.2 Functional Requirements of Permanent Well Barrier Elements 83

Fig. 3.8 Different forces

acting on a barrier to
dislocate it

It should be noted that the contribution of frictional force in real situations, at

downhole conditions, is not identical to laboratory testing as washouts and other
anomalies are not simulated in laboratory testing.

3.2.2.5 Tensile Bond Strength to Formation

Investigation of tensile bond strength of formation with any plugging material is an

area which has not been studied so far. In this case, the applied force is perpendicular
to contact surface; pulling the formation or the pipe away from the plugging material.
The tensile bond strength helps to stop debonding created by lateral tectonic stresses.

3.2.2.6 Hydraulic Bond Strength to Formation

Hydraulic bond is defined as the bond between cement and formation, which helps
prevent the flow of fluids [15]. The illusion of having similar cement-formation and
cement-pipe hydraulic bonding strengths is one the reasons that few researchers have
considered the cement-formation hydraulic bond strength measurement [15, 17].
Cement-formation hydraulic bond strength depends on the formation’s mineralogy.
Experimental works have shown that when cement is squeezed against a dry core,
a higher hydraulic bond strength is attained [15]. Obtained hydraulic bond strength
between cement and limestone shows higher pressure compared to obtained results
for cement-sandstone, in identical circumstances. The failure path is also dependent
84 3 Specification for Permanent Plugging Materials

on formation mineralogy. When limestone is used as a formation, the failure path is

at the formation-cement interface; however when sandstone is used as formation, the
failure path is within the core rather than the interface. Presence of drilling fluid in the
interface usually lowers the hydraulic bond strength, regardless of the formation type,
compared to dry core situations. Therefore, drilling fluid displacement is important
to be considered. Different types of mudcakes at the cement-formation interface
influence the hydraulic bond strength differently. When the mudcake is fresh and soft,
the failure pressure which cause leakage is lower than a situation where the mudcake
is old and rigid. In fact, a rigid mudcake does not make a higher bond strength but
as it is old and rigid, the mudcake has a higher resistance to flow. This phenomenon
occurs in both sandstone and limestone rocks [15]. Generally, when cement is placed
against a filter cake, the failure plane is within the filter cake and the flow path is
at the filter cake-formation interface [24]. Usually, spacers and chemical washes are
pumped ahead of the cement slurry for fluid separation and hole cleaning. Curing
pressure has also an influence on hydraulic bond strength. As the curing pressure is
increased, the hydraulic bond strength is increased.
Cement-formation hydraulic bond strength measurement—This type of test is
accomplished by placing a formation core inside casing and pouring cement on top
of it. Cement is allowed to set at the target pressure and temperature. An embedded
pressure port on top of the setup provides the pressure for simulating downhole
pressures, and the setup can be placed in a heating cabinet for simulating downhole
temperatures. A pressure port embedded below the setup guides the applied hydraulic
pressure across a predrilled hole along the formation rock to the cement-formation
interface, as illustrated in Fig. 3.9.

Fig. 3.9 Hydraulic bonding to formation [15]

3.2 Functional Requirements of Permanent Well Barrier Elements 85

As there are no standard methods available on how to perform the bond strength
measurements, different researchers select different loading rates which conse-
quently influences the reliability of the data. Therefore, it is necessary to consider a
realistic loading rate which may occur at downhole conditions.

3.2.3 Placeability of Permanent Barrier Material

The permanent barrier materials are going to be placed downhole and must therefore
displace existing fluids. Hence, optimizing displacement and placeability processes
of permanent barrier materials must be prioritized. Usually to minimize the instability
at the interface between cement and drilling fluid, a spacer fluid is pumped ahead of
cement slurry to separate it from drilling fluid. To remove drilling fluid and filter cake
by use of a spacer, the force resulting from interaction between viscosity, friction, and
buoyancy forces is the critical factor. In addition, the impact of rheological properties
of fluids (i.e. yield stress and gel strength), physical and chemical effects must be
considered.
To remove filter cake, the friction pressure introduced by displacing fluid (Pf2 )
must be higher than the adhesion force between filter cake and formation (Ffc ),
Fig. 3.10. The filter cake removal is affected by rock permeability, pressure drop
across formation and filter cake, properties of displacing fluid and filter cake, and
velocity of displacing fluid [25, 26].
Although turbulent flow regime is noted as a solution for the removal of the drilling
fluid and filter cake, achieving a turbulent flow regime for cement is challenging due to

Fig. 3.10 Spacer displaces filter cake when the differential friction pressure of fluids overcome the
friction force between filter cake and formation
86 3 Specification for Permanent Plugging Materials

restrictions on fluid velocities. The rheological properties and chemical composition

of spacers should be designed in such a way that a turbulent flow regime is achieved
and as it should be compatible with the cement slurry, the spacer should have minimal
effect on the properties of the cement [27]. It should be noted that a turbulent flow
regime may cause a higher ECD and consequently, a higher risk associated with
fracturing the in situ formation in open hole.
Downhole conditions dictate the plug placement techniques utilized but once
the barrier material is placed, the placement operation needs to be verified. These
operations are explained in Chaps. 7 and 9.

3.2.4 Durability

Durability means that the plugging material keeps its initial quality with respect
to mechanical integrity and hydraulic conductivity. To assess durability of a WBE,
aging tests are carried out in presence of fluids which represent the wellbore fluid at
different life periods. If modification of macroscopic properties of plugging material
occurs as a result of chemical evolution however it does not impair the mechanical
properties of the material, then it is acceptable and not considered as harmful.
Available standards and/or guidelines address durability of sealing materials for
production and abandonment periods together; however due to differences between
the two periods of well life, the availability of comprehensive standards (testing
procedure) or guidelines considering durability of plugging materials are necessary.
The two major differences between production period and abandonment period are
addressed as: mechanical loading scenario, and downhole environment [28].
Mechanical loading—During the production period, the stress variations caused
by thermal and/or pressure changes are exerted on the wellbore and consequently on
wellbore elements (e.g. casing, cement, and formation). When a well is depleted and
permanently abandoned, the mechanical loadings still exist but the stress variations
are slower compared to the production period.
Downhole environment—The nature of fluids in contact with plugging or sealing
materials are different during production life and post-abandonment period. Con-
sider a well which is operating under a sour gas re-injection process as the field
produces high contents of sour gases. Hence, the exposure time and rate is different
for the sealing material during the injection time of the well compared to its post-
abandonment. Generally, the nature of chemical species and their thermodynamic
state vary with time and type of well during production and post-abandonment [29].
Therefore, it is necessary to standardize the durability of plugging materials used for
P&A considering well location, well type, and the thermodynamic state of chemical
species.
Durability of a potential well barrier element is evaluated by considering its long-
term behavior when exposed to different chemicals at downhole condition and at
different time intervals, besides microstructure, volume, weight and permeability
changes. In addition, the role and behavior of interfaces between plugging material
3.2 Functional Requirements of Permanent Well Barrier Elements 87

and formation/steel caused by material deterioration, and role and behavior of inter-
faces between plugging materials and formation/steel caused by different mechanical
loads and rates require consideration during the durability analysis.

3.2.4.1 Exposure Time

Well barrier elements selected in well barrier envelopes are supposed to maintain
their integrity for a long time. NORSOK D-010 [1] suggests an eternal perspective
for durability of well barrier elements. Nonetheless, the definition of long time is a
matter of interpretation as an established definition has not been published. Some
researchers have selected 1-, 3-, 6-, and 12-month time intervals as the exposure
time in their studies [28, 30, 31]. However, it is recommended to continue for much
longer periods, even up to 5 years [2]. Long-term testing can be useful for better
understanding the properties of materials and material qualification for utilization as
permanent plugging material.

3.2.4.2 Downhole Condition

Any material used in well barrier envelopes must be selected carefully to withstand
downhole conditions. Bottomhole conditions include temperature, pressure, and for-
mation fluids. In addition, geographical location of wells may also be a guideline for
the selection of chemicals.

3.2.4.3 Chemicals

Well barrier elements of a permanently abandoned well experience chemical attacks

from different chemical substances over a long period of time. The chemical sub-
stances include crude oil, brine, hydrogen sulfide, hydrocarbon gas, and carbon diox-
ide. Obviously, in a single well, a well barrier element may not be exposed to all of
these chemicals after abandonment, hence, the chemical selection should be based
on the chemicals present in the target reservoir. For instance, sour wells are common
in the Republic of Azerbaijan and Russia. Therefore, the durability of WBEs in sour
wells is a priority in these countries.
Crude oil—For performing aging tests, selected crude oils should represent the
reservoir fluid. It is necessary to represent the chemical composition of crude oil and
its density.
Brine—It is a common practice to prepare an artificial seawater as representative
of brine. The most commonly used industrial standard for the synthesis of artificial
seawater is ASTM D1141-98 [32].
Carbon dioxide—Materials may be exposed to CO2 in gas state or dissolved in
brine or crude oil (liquid state). The exposure scenario should mimic the formation
88 3 Specification for Permanent Plugging Materials

fluids. When CO2 is dissolved in water, it is partly hydrated and subsequently carbonic
acid is formed [33].

CO2 + H2 O ↔ H2 CO3 (3.7)

The formed carbonic acid dissociated in two steps:

H2 CO3 ↔ H+ + HCO−
3 (3.8)

and:

HCO− +
3 ↔ H + CO3
2−
(3.9)

Formation of CO2−3 changes the pH value of brine and the resulting pH is a function
of the CO2 partial pressure. CO2 can corrode metal and deteriorate cement. In the
presence of CO2 dissolved in water, metal is unstable and as a result of the chemical
reactions between carbonic acid and steel, Fe2+ is released:

Fe + 2H2 CO3 → Fe2+ + 2HCO−

3 + H2 (3.10)

When concentrations of Fe2+ and CO2− 3 ions exceed the solubility limit, the
following reaction occurs and FeCO3 precipitates:

3 → FeCO3 (s)
Fe2+ + CO2− (3.11)

The precipitated compound occupies a different volume compared to the initial

compounds and it causes the casing to decompose.
High pH stabilizes the steel surface and prevents its corrosion but as explained,
the pH of the medium is lowered due to dissolution of CO2 in brine. Lower pH makes
the steel surface unstable and rust is formed (see Eq. (3.11)). Formation of rust causes
expansion and extensively deteriorates the cement [34]. Therefore, selection of steel
as a WBE for permanent P&A might be a concern in long term.
CO2 deteriorates cement through two different mechanisms: carbonation and
leaching. As presented in Eqs. (3.7)–(3.9), the presence of CO2 in brine produces
CO2− 2+
3 , the formed ion reacts with Ca and yields:

3 → CaCO3 (s)
Ca2+ + CO2− (3.12)

The source of Ca2+ is supplied in two ways: the dissolution of Ca(OH)2 broadly
known as CH, and decomposition of hydrated silicate and aluminate phases or broadly
known as calcium silicate hydrate (C-S-H) gel. The Ca(OH)2 becomes unstable at
a pH below 12.6 and Ca2+ is leached out and if the pH becomes less than 8, the
strength giving C-S-H phases are destabilized and Ca2+ is leached out [35]. Taylor
[34] explains the reactions as following:
3.2 Functional Requirements of Permanent Well Barrier Elements 89

Ca(OH)2 → Ca2+ + 2OH− (3.13)

xCaO · SiO2 (aq) + zH2 O → 2yCa2+ + 2yOH - +(x - y)CaO · SiO2 (aq) (3.14)

Taylor [34] showed that through decalcification of hydrated silicate and aluminate
phases, new crystals form with smaller volumes and these crystals are a highly porous
form of hydrous silica. The decomposition and formation of small crystals cause the
deterioration of cement.
Hydrogen sulfide—H2 S is a corrosive material which is produced biologically
(by the action of certain microbes) or geochemically (by the reaction of sulfurous
minerals). The dissolution of H2 S in brine acidifies the medium and can attack steel
and cement.
The electrochemical reaction of steel with H2 S undergoes a cathodic and anodic
reaction. The cathode reactions are as follows [36]:

H2 S → HS− + H+ (3.15)

2HS− + 2e → 2S2− + H2 (3.16)

The anodic reaction is the dissolution of steel and the formation of corrosion
product [36]:

Fe → Fe2+ + 2e (3.17)

Fe + H2 S → FeS1 − x + xHS− + (2 − x)H+ + 2e (3.18)

This is an electrochemical reaction of H2 S corrosion which is known as rust. Cor-

rosion causes enormous damage to tubulars and therefore, casing should be protected
by a sealing material in order to be accepted as a permanent well barrier element.
H2 S deteriorates cement through two major mechanisms: leaching and sulfidation
[37]. As presented in Eq. (3.15), the acidic medium created by H2 S attacks cement
and triggers the leaching of Ca2+ ions as follows:

Ca(OH)2 + 2H+ → 2H2 O + Ca2+ (3.19)

3CaO · 2SiO2 · 3H2 O + 6H+ → 3Ca2+ + 6H2 O + 2SiO2 (3.20)

It has been proven that H2 S does not drastically decompose the neat cement sheaths
but it does interact with the iron containing products of cement hydration such as
ferrites to form sulfides; aluminates, and unhydrated di-calcium silicate components
[37, 38].
Zhang et al. [39] studied rate of H2 S and CO2 attack on pozzolan amended class H
oilwell cement. Their results shows that that aqueous environment is more favorable
90 3 Specification for Permanent Plugging Materials

for H2 S to attack cement than H2 S in gas phase. In addition, they have shown that
in aqueous phase, H2 S penetrates into the cement matrix more rapidly compared to
CO2 .

3.2.4.4 Microstructure Analysis

In the petroleum industry, quantification of mechanical properties of materials have

been focused on and defined in different standards and guidelines. However, utiliza-
tion of advanced technologies for quantification and analysis of material microstruc-
ture has not been recommended as much as it perhaps should be. Of these technolo-
gies one could address light microscopy, X-ray powder diffraction, Scanning Electron
Microscopy (SEM), and Transmission Electron Microscopy (TEM) which are vital
for analyzing and quantifying microstructure of materials. It is necessary to study
the microstructure of materials suggested as WBE over time and their modification
at different conditions.

3.2.4.5 Volume Changes

A potential material to be used as a WBE should possess volume stability over

time. Any degree of expansion may fracture the adjacent formation and any degree
of shrinkage may cause microannuli and or debonding. The volume changes of a
WBE may diminish the formation radial stresses and if it falls below the formation
pore pressure, the risk of uncontrolled fluid flow is increased [31, 40]. Therefore,
measuring the volume changes of well barrier elements as one of the durability
parameters is vital.

3.2.4.6 Weight Changes

Degradation of WBE may lead to weight loss or weight gain. The weight change
should not compromise the integrity of the WBE and other elements present in the
well barrier envelope.

3.2.4.7 Permeability Changes

Any permanent plugging material should possess a very low permeability in the
range of cap rocks and maintain the low permeability with an eternal perspective.
Considering cement as a permanent plugging material, the permeability changes due
to chemical attacks are caused by transformation of C-S-H phases to other phases.
The newly formed phases are susceptible to occupying less volume or more volume.
Therefore, permeability changes may occur [41].
3.2 Functional Requirements of Permanent Well Barrier Elements 91

3.2.4.8 Role of Material Degradation and Tectonic Loads on Durability

of Interfaces

After a well is permanently plugged and abandoned, material degradation or induced

tectonic stresses may create a small gap at the casing-cement or cement-formation
interface, which is referred to as a microannulus. One of the processes which creates
microannuli is called debonding, but it can also be created by residual drilling fluid.
The microannulus creates pathways for fluids to escape. The risk of leakage through
them is much higher than the risk of leakage through the bulk cement or corroded
steel.
Studies show that alteration of the cement-formation interface is a complex prob-
lem which depends on rock type in addition to chemicals present in the medium.
Theoretical and experimental investigations show that when cement is placed across
stable shales in the presence of acidic brine (acidified by CO2 ), Portland cement
quickly adsorbs pore water present in the shale during the hydration process and
after setting. This reaction changes pH of the acidic brine and makes it more acidic.
The first and fast reaction which occurs is the dissolution of calcite whereas calcite
present at the cement-formation interface has almost disappeared and a microannu-
lus is created [42]. It should be noted that at downhole conditions, the dissolution
process of calcite may be slower as the amount of acidified water is less compared
to the laboratory case at which this study was performed.
The casing-cement interface is susceptible to degradation and hence, creation of
microannuli in acidic environments. Studies show that when CO2 finds a pathway
across cement to steel it starts to degrade the casing-cement interface. Leakage of
CO2 accelerates the degradation of the interface [43].
When tectonic stresses are exerted on formation-cement or casing-cement,
debonding may occur and consequently microannuli are created. This is due to
differences in elasticity of the materials.
There are models to simulate casing-cement and cement-formation interface
debonding. Most of these models are based on assumptions such as linear elasticity
of casing, cement, and formation. These models also assume no cement defects at
the initial condition [44]. Generally, these models are based on fluid-driven frac-
ture propagation [45] and Coulomb friction [46]. All of these models are developed
for well integrity analysis and modeling of cement interface debonding during the
production life of wells, and not for permanently abandoned wells. It is therefore
necessary to develop models addressing long-term integrity of casing-cement or
cement-formation interfaces.

3.2.5 Reparability

The permanent P&A operation is performed to seal the potential fluid flow zones
permanently with no intention of well re-entry. As, during the third phase of perma-
nent P&A operations (discussed in Chap. 2), wellhead and conductor are removed,
92 3 Specification for Permanent Plugging Materials

there will be no access to the well for repairing any well integrity issue. Therefore,
a candidate plugging material should withstand downhole conditions without com-
promising its sealing capability. There are some suggestions regarding self-healing
or self-repairing materials whereby the material starts to heal itself if some defects
are introduced over time. Self-healing cement products are one of these examples.

3.3 Qualification of New Plugging Materials

Any new plugging material designed for permanent P&A needs be qualified prior to
being applied in the field. The qualification process may be based on a systematic
approach including experimental work and theoretical analysis. The qualification
process includes preparation of the material and its placement, verification of its
intended functionality when it is in place, and its durability at downhole conditions.
The qualification process needs to be quantitative and documented. All the possible
failure modes need to be identified and analyzed based on the risks associated with
the failure of its functionality over time. When the failure modes and their associated
risks are considered, the failure modes are ranked based on the associated risk.
Whenever laboratory testing is possible to be carried out, it needs to be performed.
Confidentiality of the technology should not limit the availability of data required
for qualification.

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Chapter 4
Types of Permanent Plugging Materials

Portland cement is the prime material used for zonal isolation and permanent P&A
of wells. However, there are some concerns which persuade engineers to search
for alternative materials to Portland cement. Therefore, this chapter will focus on
different material types which might be used as permanent well barrier elements
during permanent P&A, Table 4.1 [1, 2]. Some of these materials have already been
used as permanent well barrier elements while some other have not. The criteria and
requirements for the selection of material types for the permanent P&A varies for
different authorities legislating P&A regulations.

4.1 Setting Materials

Throughout history, setting materials have played an important role and were used
widely in the ancient world. The Romans found out that a setting material could
be made which sets under water and it was used for the construction of marine
structures such as harbors. Throughout time and with the development of science,
different types of cementitious materials have been developed such as geopolymers,
slag, and hardening ceramics [1]. The most known and studied type of cementitious
materials is Portland cement.

4.1.1 Portland Cement

In 1824, Joseph Aspdin took out a patent on a setting material he produced by cal-
cining a mixture of limestone and clay at 2640 °F. The produced material looked like
Portland stone, a widely-used building stone in England, and therefore he called his
invention Portland cement. Since then, different types of Portland cement have been
developed for different applications. When limestone (or other materials high in cal-
cium carbonate) and clay or shale are calcined at 2640 °F, partial fusion occurs and
clinkers are produced. A few percent of gypsum (Ca2 SO4 ) is added to the clinker and
© The Author(s) 2020 97
M. Khalifeh and A. Saasen, Introduction to Permanent Plug
and Abandonment of Wells, Ocean Engineering & Oceanography 12,
https://doi.org/10.1007/978-3-030-39970-2_4
98 4 Types of Permanent Plugging Materials

Table 4.1 Different material types which might be used as permanent well barrier element [1–4]
Type Material Examples
1 Cements (setting) Portland cement, pozzolanic cements, blast
furnace slag-based cement, phosphate
cements, geopolymers, hardening ceramics
2 In situ formation Shale, salt, claystone
3 Grouts (non-setting) Unconsolidated sand or clay mixtures,
bentonite pellets, barite plugs, calcium
carbonate
4 Thermosetting polymers and composites Resins, epoxy, polyester, vinylesters,
including fiber reinforcements, urethane
foams, phenol
5 Thermoplastic polymers and composites Polyethylene, polypropylene, polyamide,
Polytetrafluoroethylene (PTFE), Polyether
Ether Ketone (PEEK), Polyphenylene
Sulfide (PPS), Polyvinylidene Fluoride
(PVDF), and polycarbonate, including
fiber reinforcements
6 Metals Steel, other alloys such as bismuth-based
materials
7 Modified in situ materials Barrier materials made from in situ casing
and/or formation through thermal or
chemical modification
8 Elastomeric polymers and composites Natural rubber, neoprene, nitrile, Ethylene
Propylene Diene Monomer (EPDM),
Fluoroelastomer (FKM),
Perfluoroelastomer (FFKM), silicone
rubber, polyurethane, PUE and swelling
rubbers, including fiber reinforcements
9 Gels Polymer gels, polysaccharides, starches,
silicate-based gels, clay-based gels,
diesel/clay mixtures
10 Glass

the blend is finely ground to make the cement. The gypsum controls the setting rate
and can be replaced by other forms of calcium sulphate [5]. The major components
of clinker are approximately 67% CaO, 22% SiO2 , 5% Al2 O3 , 3% Fe2 O3 , and 3% of
other components.1 The clinker mainly contains four major phases: alite, belite, alu-
minate phase, and ferrite phase. The alite phase is tricalcium silicate (3CaO·SiO2 or
“C3 S”) and constitutes 50–70% of normal Portland cement clinkers. The belite phase
is dicalcium silicate (2CaO·SiO2 or “C2 S”) and constitutes 15–30% of normal Port-
land cement clinkers. The aluminate phase is a tricalcium aluminate (3CaO·Al2 O3
or “C3 A”) and represents 5–10% of the most normal Portland cement clinkers. The
ferrite phase is a tetracalcium aluminoferrite (4CaO·Al2 O3 Fe2 O3 or “C4 AF”) and

1 Clinker for construction cement.

4.1 Setting Materials 99

represents 5–15% of normal Portland cement clinkers. Although there are several
other phases such as alkali sulfates and calcium oxides, they represent minor amounts.
API categorizes the identified cements into nine different classes [6]:
• API Class A: This an ordinary Portland cement which is intended for use from
surface to 6000 (ft) depth. It is not sulfate resistant and may be used when no
special properties are required and well conditions allow.
• API Class B: It is ordinary Portland cement which is intended for use from surface
to 6000 (ft) depth. It is available both as moderate and high sulfate-resistant.
• API Class C: It is called high early strength cement and used where early strength
cement is required. It is intended for use from surface to 6000 (ft) and available
as ordinary, moderate, and high sulfate-resistant types.
• API Class D: It is a retarded cement type which is intended for use from 6000
to 10000 (ft) depth and under conditions of moderate to high temperatures and
pressures. It is available both as moderate and high sulfate-resistant types.
• API Class E: This is a retarded cement which is intended for use from 10000 to
14000 (ft) depth and conditions of extremely high temperatures and pressures. It
is available both as moderate and high sulfate-resistant types.
• API Class F: It is intended for use from 10000 to 16000 (ft) depth and conditions
of ultra-high pressures and temperatures. This class is available both as moderate
and high sulfate-resistant types.
• API Class G: Intended for use as basic cement from surface to 8000 (ft) depth. It
is manufactured in such a way that accelerators or retarders can be used to cover
a wider range of well depths and temperatures. This class is available both as
moderate and high sulfate-resistant types.
• API Class H: It is intended for basic cement use from surface to 8000 (ft) depth and
can be used with retarders and accelerators to cover a wide range of well depths
and temperatures. It is only available as moderate sulfate-resistant type.
• API Class J: It is known as special order only and intended for use from 12000 to
16000 (ft) depth. This class is for ultra-high pressure and temperature conditions
and with accelerators or retarders wider ranges of well depths and temperatures
can be covered.
Table 4.2 tabulates the properties of common oil well cements identified and
classified by API. Cement class D, E, and F are seldom used for oil well cementing.
The cement classes G and H are now the most common.
Table 4.3 presents typical physical properties of the various API classes of cement,
given in Table 4.2, and cured at different pressures and temperatures.
There are some cementitious materials which have been or are used in oil well
cementing effectively but they do not fall into any specific API category. These mate-
rials include [7]: (a) pozzolanic-Portland cements, (b) pozzolan-lime cements, (c)
resins or plastic cements, (d) gypsum cements, (e) diesel oil cements, (f) expand-
ing cements, (g) calcium aluminate cements, (h) latex cement, and (i) cement for
permafrost environments.
Pozzolanic-Portland cements—This is a kind of blended cement which is pro-
duced by either intergrinding ordinary Portland cement clinker with gypsum and
100 4 Types of Permanent Plugging Materials

Table 4.2 API classification and properties of common oil well cements [7]
Type Range Static Water Slurry Volume Remarks
of usage temp. (°F) ratio weight (ft3 /sk)
(ft) (gal/sk) (lb/gal)
Class A 6000 60°–170° 5.2 15.6 1.18 No sulfate
(Portland resistance. May
cement) be used well
conditions allow
Class B 6000 60°–170° 5.2 15.6 1.18 Moderate sulfate
(Portland resistance
cement)
Class C 6000 60°–170° 6.3 14.8 1.32 Available in
(High early ordinary,
strength) moderate, and
high
sulfate-resistance
types
Class G 8000 200° 5.0 15.8 1.15 Compatible with
(Basic accelerators or
cement) retarders for
usage to cover
the classes A
through E
Class H 8000 200° 4.3 16.4 1.06 Higher density,
(Basic 8000 200° 5.2 15.6 1.18 higher and lower
cement) water volume

pozzolanic materials or preparing each part separately and then blending them.
Pozzolans are either natural or artificial reactive siliceous materials, processed or
unprocessed, which start to hydrate in the presence of lime and water and develop
cementitious properties. The source of most natural pozzolanic materials are vol-
canic ashes. The artificial pozzolans are produced by calcination of natural siliceous
materials such as for example: clays, shales, rice husk ash, and certain siliceous
rocks [8]. Fly ash is one of the artificial pozzolanic materials which is a combustion
by-product of coal. In oilwell cementing, fly ash is added to cement to improve its
strength and water-tightness.
Pozzolan-lime cement—Silica-lime or pozzolan-lime cements are blends of
siliceous materials (e.g. fly ash), hydrated lime, and small quantities of a chemi-
cal activator (e.g. calcium chloride), which hydrate with water to produce calcium
silicate. Their reaction rate is very slow at low temperatures compared to Portland
cements. Therefore, these type of cements are recommended for wells where mod-
erate to high temperatures are encountered. The use of these materials is not recom-
mended in wells where temperature is less than 140 °F [9]. The reaction can be either
accelerated or retarded by use of additives to cover a wide range of well conditions.
Light weight, strength stability at high temperatures, low slurry cost, and less CO2
emission are features of Pozzolan-lime cements.
4.1 Setting Materials 101

Table 4.3 Typical physical properties of the various API classes of cement [7]
Properties of API classes of cement
Class A Class C Classes G Classes D and E
and H
Specific gravity (average) 3.14 3.14 3.15 3.16
Surface area (range), cm2 /g 1500–1900 2000–2800 1400–1700 1200–1600
Weight per sack, lbm 94 94 94 94
Bulk volume, ft3 /sk 1 1 1 1
Absolute volume, gal/sk 3.6 3.6 3.58 3.57
Temperature Pressure (psi) Portland High early API Class API Retarded
(°F) strength G Class
H
Typical compressive strength (psi) at 24 h
60 0 615 780 440 325 a

80 0 1470 1870 1185 1065 a

95 800 2085 2015 2540 2110 a

110 1600 2925 2705 2915 2525 a

140 3000 5050 3560 4200 3160 3045

170 3000 5920 3710 4830 4485 4150
200 3000 a a 5110 4575 4775
Typical compressive strength (psi) at 72 h
60 0 2870 2535 – – a

80 0 4130 3935 – – a

95 800 4670 4105 – – a

110 1600 5840 4780 – – a

140 3000 6550 4960 – 7125 4000

170 3000 6210 4460 5685 7310 5425
200 3000 a a 7360 9900 5920
Depth (ft) Temperature (°F)
Static Circulating High-Pressure thickening time (hours: minutes)
2000 110 91 4:00+ 4:00+ 3:00+ 3:57 a

4000 140 103 3:26 3:10 2:30 3:20 4:00+

6000 170 113 2:25 2:06 2:10 1:57 4:00+
8000 200 125 1:40a 1:37a 1:44 1:40 4:00+
a Not generally recommended at this temperature

Resins or plastic cements—They are a mixture of either an API class A, B, G,

or H cement with a mix of water liquid resins and a catalytic converter. These
types of cements are used in small volumes for plugging open holes, and squeezing
perforations. The recommended range of temperature is between 60 and 200 °F.
Gypsum cements—These types of cements are a mixture of API class A, G, or
H cement with 8–10% of gypsum. The gypsum can be either in the hemihydrate
102 4 Types of Permanent Plugging Materials

form (CaSO4 ·½ H2 O) or the dihydrate form (CaSO4 ·2H2 O). The gypsum cements
set rapidly and they have high early strength with positive expansion properties. The
expansion is in the range of 0.3%. Gypsum cements are used in lost circulation zones.
The associated challenge with the use of gypsum cements is water solubility of the
hardened cement and they can therefore only be used in wells where water does not
exist. A solution for minimizing the water solubility of the hardened gypsum cements
is to use equal volume of cement and gypsum [7].
Diesel oil cements—The diesel oil cements have been developed to selectively
block off unwanted water production during drilling or in producing wells [10].
During the slurry design, an API cement class A, B, G, or H is mixed with diesel oil
with a surface-active agent. These types of cements have unlimited pumping time as
long as water does not meet the slurry. Water-in-oil emulsion cements are another
type of diesel oil cement in which cement is mixed in a liquid phase consisting of
oil as external or continuous phase and existing water as droplets. Low-fluid-loss
characteristic, less damage to the oil-producing zones, and less damage to water-
sensitive formations are some of the advantages of diesel oil cements and water-in-oil
emulsion cements [11, 12].
Expanding cements—One of the drawbacks of Portland cement is its shrink-
age which can create microannuli. Some degree of expansion can compensate the
wellbore stress changes and improve the hydraulic and shear bond strengths [13].
Therefore, expansive cements or additive agents such as sodium sulfate (Na2 SO4 ),
pozzolans, anhydrous calcium sulfoaluminate (4CaO·3Al2 O3 ·SO3 ), calcium sulfate
(CaSO4 ), and lime are introduced to the slurry. When sulfates and calcium aluminate
components of cement are present, ettringite crystals, which are a hydrous calcium
aluminum sulfate mineral are formed. As a result of the formation of the mineral
crystals, pressure is developed and is the main expansion mechanism [14].
Calcium aluminate cements—These types of cements are known as high-alumina
cements in which bauxite (aluminum ore) or other aluminous materials and limestone
are heated in a furnace to be liquefied. Compared to Portland cement, these types
of cements are low in silica content [5]. The calcium aluminate cements have high
resistance to corrosive environments, rapid hardening properties, and are stable at
high temperatures [15]. Addition of Portland cement to calcium aluminate cements
results in flash setting.
Latex cement—Latex is commonly used to control gas migration, fluid loss and
enhance the bonding properties of cements [16]. A latex cement is a blend of classes
A, G, or H cement with latex either in liquid or powder form. The identified latexes are
polyvinyl acetate, polyvinyl chloride, and butadiene styrene emulsions [7]. Butadiene
styrene latexes are commonly used in oil well cementing; however, they are sensitive
to temperature, mechanical energy, and free ions. As the latex has consisted of charged
particles, latex demulsifies and precipitates in the presence of salts such as sodium
chloride and calcium chloride [17]. One mitigation is the use of an anionic surfactant
as an additive to the cement slurry to stabilize the latex cement in the presence of
salts. Some investigators have shown the anti-corrosion ability of latex cements [18].
Cement for permafrost environments—Cementing conductor and surface casing
in sub-freezing zones is a challenging task as Portland cement freezes, or never sets,
4.1 Setting Materials 103

Table 4.4 Compressive strength of gypsum cement for sub-freezing temperatures [21]
Curing temperature, 20 °F
Pumping Sodium Water Ratio 4h 1 Day 3 Days 7 Days 14 Days
time (h) Chloride, (Ft3 /sk)
Percenta
(psi)
2 10 048 470 855 615 600 1095
Curing temperature, 15 °F
4h 6h 8h 24 h
(psi)
2 10 048 345 530 635 545
3 10 048 38 ND 530 632
3 18 048 195 540 555 690
a By
weight of mixing water
ND—Not determined

or permafrost melts as results of hydration heat [19]. There are some mitigations
such as adding calcium chloride salt, short-chain alcohols such as methyl, propyl,
or isopropyl to depress the freezing-point [20]. However, adding calcium chloride
accelerates the hydration reaction and causes fast setting. Therefore, when calcium
chloride is used to depress the freezing-point, retarders are used to postpone the set-
ting time. There are four different types of blended cements available for permafrost
environments; classes A and G API cements with calcium chloride, calcium alu-
minate cements with fly ash, refractory cements, and gypsum-cement blends [21].
Of these four, the gypsum-cement blends and refractory cements are mainly used
in sub-freezing environments. Shryock and Cunningham [21] measured pumpabil-
ity and compressive strength development of a gypsum-cement blend prepared for
permafrost zones and found recipes that are applicable in permafrost areas, Table 4.4.

4.1.1.1 Durability

A plugging material is intended to withstand downhole conditions in an eternal per-

spective. Therefore, as eternal perspective is impossible, use of long-term durability
knowledge of intended plugging materials is important. It is necessary to expose
plugging materials to downhole chemicals, at downhole conditions, for different time
intervals; sometimes up to a few years [22–25]. Then, the mechanical properties of
plugging materials are characterized at different time intervals. Unfortunately, there
is no international standard describing testing of plugging materials to qualify them
for an eternal perspective. Thus, different researchers have selected different chemi-
cals with different dosages to study the degradation of oilwell cements at downhole
conditions. Vralstad et al. [25] aged neat class G cement, at downhole conditions,
by exposing the samples to brine, crude oil, and H2 S dissolved in brine for different
104 4 Types of Permanent Plugging Materials

Fig. 4.1 Durability of neat class G cement exposed to downhole chemicals [25]

time intervals, up to 12 months. They also studied the weight and volume changes
of the cement. Figure 4.1 shows the obtained results by Vrålstad et al. [25].

4.2 In Situ Formation (Formation as Barrier)

In some hydrocarbon fields, traditional sonic logs and ultrasonic azimuthal bond
logs provide information of good bonding above the theoretical top of cement and
at depths where there is no cement or where a poor cement job has been reported.
4.2 In Situ Formation (Formation as Barrier) 105

In addition, performed extended leak off (XLOT) tests show qualified seals [26].
The question is how this could be happened? In all of these cases, the used drilling
fluids were known to have no setting properties. In addition, no casing collapses were
reported. The only main remaining parameter is in situ formations which may have
the potential to move toward or expand into the annular space and create a good seal,
see Fig. 4.2. If the in situ formation moves and creates a good seal with sufficient
strength, then it can be regarded as a most suitable permanent plugging material; as
it has been standing in the overburden with intact long-term durability.
In order for the formation to move and create a good seal in the annular space, it
should deform. Deformation is defined as changes in the shape or position of a rock
body in response to stress. Stress is the internal resistance of rocks against the forces
applied to deform the rock. Stress can be divided into two different stress types;
confining stress, and differential stress. Whenever stresses acting on a rock are larger
than its strength, rock can experience four different phenomena; folding, flowing,
fracturing, or faulting. In a confining stress scenario, rock experiences a uniform
stress in all direction. As a result of the acting confining stress, rock can expand or
contract. Consider an in situ formation adjacent to an uncemented annulus which
experiences equal stresses from overburden and the annulus fluid. The formation
would not be able to move toward casing to seal the uncemented interval, see Fig. 4.3.
So, confining stress is not the interest of this section and therefore, it is not discussed
further. In differential stress scenarios, rocks experience unequal stresses in different
directions. The resultant force acting on a rock may cause a compressional stress,
tensional stress, or shear stress. Compressional stress is applied inward and triggers
the rock to be squeezed, see Fig. 4.4a. Tensional stress is an outward stress which
acts on a rock, the rock is pulled and subsequently it is elongated (see Fig. 4.4b).
Shear stress is applied from one direction and cause movement of one part of the
rock to pass the other which is still, (see Fig. 4.4c).
When the differential stresses act on a rock sample over time, deformation occurs.
The deformation can be reversible or irreversible. Reversible deformation is a tempo-
rary shape change that is self-reversing after load is removed. In other words, the rock

Fig. 4.2 In-situ formation moves toward the casing and create a seal
106 4 Types of Permanent Plugging Materials

Fig. 4.3 Equal stresses

acting on a rock from all
directions; overburden and
annulus

returns to its original shape when the acting forces are removed. This type of defor-
mation is known as elastic deformation. Elastic deformation happens at low levels
of stress and it is recoverable after the stress is removed. In elastic deformation, the
bonds between individual atoms and lattices are stretched, allowing the material to
deform. Irreversible deformation is a permanent shape change that is not reversible
when the load is removed. In other words, the rock does not return to its original
shape when the acting forces are removed. The irreversible deformation is known
as plastic deformation. In plastic deformation, the applied stress on a material cause
microscopic dislocations such as edge and screw dislocations in the material lattices.
As we discussed earlier, when a differential stress is applied on a rock and the
stress is higher than the rock strength, the rock deforms. The change in length of the
rock, caused by stress, is called strain. In rock mechanics, a Stress-Strain diagram is
plotted to measure the mechanical properties of rocks including elastic and plastic
deformation limits. On a stress-strain diagram, when a stress is applied on a rock,
strain behaves proportionally to the applied stress. The region where the stress-strain
plot corresponds to an elastic deformation is linear, see Fig. 4.5. The slope is known
as modulus of elasticity, E:
4.2 In Situ Formation (Formation as Barrier) 107

Fig. 4.4 A rock sample which experiences unequal stresses from different directions; a compres-
sional stress, b tensional stress, and c shear stress
108 4 Types of Permanent Plugging Materials

Fig. 4.5 A stress-strain diagram showing the elastic region (red) and plastic region (green)

Str ess = E × Strain (4.1)

The stress where deformation shifts from elastic to plastic, is called the yield
stress. The yield strength is the stress that is required to cause plastic deformation. In
the plastic region, the stress-strain relationship is not linear and the material deforms
much more rapidly compared to the elastic region, (see Fig. 4.5).
When a material experiences compressive stress or tensile stress, stress exists
through the object, it can be elongated or shortened (see Fig. 4.6). The change in
length of the material is estimated by Young’s modulus.

1 F
l = × × l0 (4.2)
E A
where E is the Young’s modulus of the material, F is the applied force, A is the cross
section where the force is applied, and l0 is the initial length of the material.

Fig. 4.6 Changes in length of a sample; a experiencing a compressive stress, b tensile stress
4.2 In Situ Formation (Formation as Barrier) 109

Shear modulus—When a material experiences a shear stress, its length can be

shortened, Fig. 4.7. The length changes caused by a shear stress is characterized by
its shear modulus, also known as modulus of rigidity:

1 F
l = × × l0 (4.3)
G A
where G is the shear modulus of material, F is the applied shear force, A is the surface
area of material parallel to direction of the applied shear force, and l0 is the initial
length of sample.
Bulk modulus—When a material experiences confining forces, from all directions,
its volume can be reduced (Fig. 4.8). The volume change of the material is given by
its bulk modulus:
1 F
V = − × × V0 (4.4)
B A

Fig. 4.7 Shear stress acting

on a sample

Fig. 4.8 Compressional

forces acting on a material,
equally, from all directions
110 4 Types of Permanent Plugging Materials

where B is the bulk modulus of material, F is the confining pressure, A is the surface
which force is applied on, and V0 is the initial volume of the material. The volume
change can also be expressed in form of applied pressure or pressure change:

P
V = − × V0 (4.5)
B
Poisson’s ratio—When a material experiences longitudinal stress from one direc-
tion, it will experience lateral strain. Therefore, the material will contract in one
direction while elongating in a perpendicular direction, Fig. 4.9. The ratio of trans-
verse contraction strain to longitudinal extension strain, in the direction of stretching
force, is known as Poisson’s ratio, ϑ, given by:

dεtran
ϑ =− (4.6)
dεaxial

where dεtran is transverse strain (lateral strain), and dεaxial is axial strain (longitudinal
strain). Poisson’s ration of materials is 0 ≤ ϑ ≤ 0.5.
Failure of a material can occur in elastic region or plastic region of the axial
stress-axial strain curve. If the failure occurs in the elastic region, it is known as
brittle failure and if it occurs in the plastic region, it is known as a ductile failure,
Fig. 4.10.
In order to utilize in situ formations, which flow toward the annulus behind the
casing, as a permanent well barrier element, the in situ formation should deform
plastically and create a good seal. The plastic deformation which is time, stress and
temperature dependent is known as creep. The creep, in rocks, is a slow deformation
which can normally take long time. So it could be said that when in situ formation
creeps toward the casing, it can create a seal and the seal can be used as a permanent
plugging material.
If in situ formations experience a counter force from the annular pressure which is
higher than the overburden stress, creep will not occur. Therefore, a formation barrier

Fig. 4.9 Lateral strain and longitude strain acting on a sample

4.2 In Situ Formation (Formation as Barrier) 111

Fig. 4.10 Brittle failure

versus ductile failure

diagram is defined, Fig. 4.11. If the resultant stress of annular pressure and in situ
stress falls in the “closed gap” region, a seal is created. However, if the resultant
force falls in the “opened gap” region, then the annulus remains open and no seal is
created.
It is important to differentiate between two phenomena; creep and swelling.
Swelling is caused by the hydration of shales; heterogeneous porous media which
has a matrix mainly of clays. Different theories have been presented as the driving
mechanisms for swelling which include capillary pressure, hydraulic pore pressure
imbalance, osmosis pressures, and the polar attraction of water molecule by the
charged clay surfaces within the shale matrix [28–30]. According to the last theory,
when water molecules move into a saturated shale body which is under constant
contraction stress, the total volume of the body increases. Therefore, swelling strains
develop at boundaries of clay layers. The swelling phenomenon is a reversible pro-
cess upon dehydration. In other words, swelled shale is contracted as water molecules
are drained. So, if swelling shale creates a seal in the annular space behind casing, it
may not be a suitable material to be selected as a permanent plugging material.

Fig. 4.11 Formation barrier

map [27]
112 4 Types of Permanent Plugging Materials

It is worthwhile to mention that not every formation creeps naturally but some
do. As an example, in the Norwegian sector of the NCS a creeping formation has
been reported in Statfjord A and Grane fields; some degrees of formation creep has
been observed in all the fields North Sea and Norwegian Sea. However, no naturally
creeping formation has been reported in the central/eastern Barents Sea, see Fig. 4.12.
Six different displacement mechanisms are suggested as driving mechanisms of
formation movements [26, 31]:
• Shear or tensile failure,
• Compaction failure,
• Liquefaction,
• Thermal effect or expansion,
• Chemical effects,
• Creep.
Shear or tensile failure—Whenever exerted pressure by annular fluids is lower
than the in situ overburden pressure, the formation falls into an unstable condition.

Fig. 4.12 An overview of creeping formation and non-creeping formation on the Norwegian sector
of the NCS [32]
4.2 In Situ Formation (Formation as Barrier) 113

If the differential pressure is high enough, then the formation experiences shear or
tensile failure. Annular pressure drop is a common phenomenon in post-construction
periods as the mud density of the annular fluid is reduced over time due to segregation
of heavier components in the mud. Bond logs from some wells have shown that there
are some lithological layers, between advancing formations, which have not moved.
However, upper and lower formations behind have moved in the same well [26].
Thus, this driving mechanism alone is not the driver for formation movement.
Compaction failure—When a porous rock experiences a high hydrostatic pressure
or pore pressure change, the grains may loosen or break. The movement of grains into
the open spaces, which can be regarded as reorientation, results in a closer packing.
This process is known as compaction failure [31]. Compaction failure is common
in highly porous rocks such as sandstones. This mechanism is believed to be the
subsequent response to movement and not the triggering process.
Liquefaction—Generally, any process that causes a non-liquid phase to behave in
accordance with fluid dynamics is termed liquefaction. In rock mechanics, when a
highly porous rock, which is loose (uncompacted), is fully or partially saturated and
substantially loses its strength and starts to flow in response to any applied stresses,
the process is called liquefaction. Recorded bond logs have shown good bonding
which means that a solid material fills the annular space. Therefore, liquefaction is
not the driving mechanism.
Thermal effect or expansion—Generally, increasing the temperature eases rock
movement and causes some degree of expansion. However, during the production
life of wells, the temperature change is small and besides, formation movement has
been recorded in shallow depths where temperatures are not high. So, thermal effect
cannot be the triggering mechanism.
Chemical effects—The movement of formation toward casing has been recognized
in different wells which have been drilled with oil-based muds and water-based muds.
So, the chemical effect cannot be the major contributor or be regarded as the main
driving mechanism.
Creep—It is a time dependent parameter and happens over a long time. In some
fields, the process of rock movement has been observed to be slow, however, in some
wells is has been relatively quick. It can be concluded that creep can be regarded as
the main mechanism in some fields while in others a combination of creep and shear
failure can simultaneously be the driving mechanisms.
So far, in the North Sea, the lithology of identified creeping formations ranges in
age from Oligocene (upper Tertiary) to Upper Jurassic. Another example of the use
of creeping formation as well barriers is in the Gulf of Mexico where salt formations
are used commonly as an exterior barrier [32].
As utilization of creeping formations is cost effective and a safe method,
researchers have pursued an understanding of the mechanisms and conditions at
which formations may start to creep. Studies show that the following parameters
may activate or accelerate the formation creep: thermal treatment, chemical activa-
tion, changing annular fluid, and sudden pressure drop. Of these, sudden pressure
drop has shown the potential to be a swift activation mechanism [27]. Changing the
annular fluid may create a swelling effect and therefore, it might be of less interest.
114 4 Types of Permanent Plugging Materials

Table 4.5 Advantages and possible limitations for use of creeping formation as annular barrier
Advantages Possible limitations
• No section milling is required • Not every formation creeps
• Cost effective P&A method • Activation mechanisms of non-creeping
• Reliable and durable plugging material formations are not well understood
• No HSE issue • Required length of plug defined by authorities
• Durable • Qualification method is not clear
• Artificially activation of formation may
compromise its mechanical properties and
long-term durability

4.2.1 Durability

Formations have shown their long-term durability as cap rock. Therefore, no research
work is performed to analyze the durability of creeping formations. However it is
important to note that the artificial activation of a formation to creep may change
its properties. Therefore, it is recommended to investigate the mechanical properties
and the long-term integrity of activated formations. There are several advantages
associated with utilization of formations as annular barriers, but also some limitations
which are listed in Table 4.5.

4.3 Non-setting (Grouts)

Permanent plugging materials can be subjected to different stress scenarios during

abandonment and post-abandonment such as tectonic stress, reservoir compaction,
and temperature changes. Portland cement is the prime material used for perma-
nent P&A. However, the associated concerns regarding Portland cement include but
are not limited to brittleness, shrinkage, gas migration through the bulk material,
long-term degradation by exposure to high temperatures and chemical substances,
persuades researchers to seek for alternative materials. As solidified materials have
some degree of brittleness, engineered unconsolidated materials have been suggested
as an alternative plugging material [33]. These types of materials are also known with
other names such as grouts, and non-setting materials [1]. Of these materials, uncon-
solidated sand or clay mixtures [33], bentonite pellets [34], calcium carbonate [35],
and barite plugs [36] are the most well-known.

4.3.1 Unconsolidated Sand Slurries

Unconsolidated sand slurries consist of two phases; solid phase and liquid phase.
The solid phase is sand with engineered Particle Size Distribution (PSD). The liquid
4.3 Non-setting (Grouts) 115

phase, known as the conducting fluid, is an inert fluid consisting of water, a small
amount of dispersant and viscosifier which provides pumpability of the mixture. The
mixture usually consists of approximately 75% solid and 25% of carrier fluid by
volume [33], with a density of 17.9 (ppg). The slurry is a Bingham-plastic material
which behaves as a rigid body at low stresses but flows at high stresses, Fig. 4.13.
The particles are kept packed by the electrostatic forces (Zeta potential2 ) between
the solid particles and the conducting fluid [37]. Figure 4.14 shows a commercialized
unconsolidated sand slurry which has been used for both temporary abandonment
and permanent abandonment operations.
Figure 4.15 presents Scanning Electron Microscopy (SEM) image of a dehydrated
unconsolidated sand slurry; different particle sizes are obviously visible.
An unconsolidated sand slurry does not set after placement and subsequently
it does not shrink. As the material does not solidify, any introduced stress cannot
fracture the material. When the downhole shear forces exceed the material limit,
the material starts to flow and shear forces are reduced below the yield strength.
This eventuates reshaping the material and the whole process is mechanical. As the
unconsolidated sand slurry is made of quartz, it is thermodynamically stable and
in the absence of carrier fluid, the plug remains homogenous. Table 4.6 presents
advantages and possible limitations associated with unconsolidated sand slurries
with regards to utilization for permanent P&A.
As the slurry does not set, the material could be used for zonal isolation and also
during well construction provided a solid foundation exists. In addition, permeability
of the plug cannot be measured directly, therefore, the Blake-Kozeny model is used
[38]:

ε3 d 2p
k= (4.7)
(1 − ε)2 150

Fig. 4.13 Flow behavior of

a Bingham-plastic material

2 The potential difference between the surface of solid particles immersed in a conducting liquid.
116 4 Types of Permanent Plugging Materials

Fig. 4.14 Unconsolidated sand slurry as an alternative plugging material. (Courtesy of FloPetrol
Well Barrier)

Fig. 4.15 SEM images of dehydrated unconsolidated sand slurry. (Courtesy of FloPetrol well
barrier)
4.3 Non-setting (Grouts) 117

Table 4.6 Advantages and possible limitations associated with unconsolidated materials with
regards to permanent P&A
Advantages Possible limitations
• Flexible • High Yield Stress may cause difficulties with regards to
• Non-degradable pumpability
• Non-shrinking • It needs a permanent foundation to be used for permanent P&A
• Non-toxic • No chemical bond strength to formation nor casing
• Self-healing • No casing or formation seal if material is not confined
• Gas tight • Conventional verification methods may not be applicable to find
• No waiting on setting top of plug
• Ineffective pumping may cause pack-off

where dp is the effective particle diameter, ε is porosity of the medium, and 150 is an
empirical factor which includes the geometrical terms. The Blake-Kozeny shows that
the maximum permeability will be defined with micron-sized particles. By applica-
tion of Darcy’s law and substituting the permeability term from Eq. (4.7), the flow
velocity of an incompressible fluid through the medium is:

d 2p ε3 P
v= (4.8)
150μ (1 − ε) L
2

Example 4.1 Consider an unconsolidated sand slurry with a porosity of 0.25 and
an effective particle diameter of 1 and 0.1 micron. Estimate the permeability of the
slurry.

Solution By using the Blake–Kozeny equation with a porosity of 0.25 and effective
particle diameter of 1 micron, the permeability will be:

0.253 12
k= = 1.85 × 10−4 Dar cy
(1 − 0.25)2 150

By selecting the effective particle diameter as 0.1 micron, the estimated perme-
ability will be:

0.253 0.12
k= = 1.85 × 10−6 Dar cy
(1 − 0.25)2 150

4.3.1.1 Pumpability

Placeability of any plugging material at downhole conditions is a primary require-

ment. Research activities have shown that the pumpability of unconsolidated sand
slurries can be adjusted by adjusting the PSD design. The increase of conducting fluid
volume should be considered carefully as inappropriate liquid content may increase
118 4 Types of Permanent Plugging Materials

the distance between particles and consequently change the porosity and permeabil-
ity. As unconsolidated sand slurries possess a very high yield stress, imposed pump
friction may be challenging. Experiments have shown that the yield stress can be
controlled by adjusting the PSD of sand slurries without increasing the volume of
the conducting fluid [33, 39].

4.3.1.2 Durability

As permanent plugging materials are intended to withstand downhole conditions with

an eternal perspective, their long-term durability should be examined. The durability
should normally be tested in accordance with recognized standards, however, there
is no such standard for alternative materials to cement [37]. As unconsolidated sand
slurries consist of quartz sand, silica fume, and crushed rocks, their interactions with
downhole chemicals seems to be less probable.

4.4 Thermosetting Polymers

Thermosetting materials, also known as thermoset polymers, are organic compounds

which are characterized by their three-dimensional structures and low molecular
weight (<10000 g/mol). Figure 4.16 shows the chemical relationship between ther-
mosetting polymers in chemistry. The term polymer is used to describe a macro-
molecule made of many monomers, repeating units, Fig. 4.17a. The rheological and
mechanical properties of polymers depend on several factors including the monomer
unit, the linkages between each monomer, intermolecular, and intramolecular forces
which exists between polymers. Resins, synthetic polymers, are divided into two
categories: thermosetting resins and thermoplastic resins.
Thermosetting polymers are cross-linked to one another, Fig. 4.17b, and due to the
cross-links, these materials develop strength. The cross-links can break by heating or
chemical interaction however, to break these bonds the conditions need to be severe.
Thermosetting resins set in the presence of catalysts, by application of heat and
pressure or combination of these. The setting process is irreversible. It means that

Fig. 4.16 Relationship of

thermosetting materials in
chemistry science [40]
4.4 Thermosetting Polymers 119

Fig. 4.17 Structure of polymers made of macromolecules and monomers

the resin cannot be reheated and remolded after setting. Thermoset plastic polymers
are usually in liquid phase prior to curing, Fig. 4.18. The chemical reaction occurs
during heating and results in the formation of strong covalent bonds, cross-links.
Table 4.1 lists some examples of thermosetting plastic polymers. Thermoset plastic
polymers usually undergo permanent or plastic deformation under load.
The stability of thermosetting materials depends on the density of cross-links and
aromatic content of the polymer but generally speaking, there is a concern related to
brittleness of the product with increase of cross-link density [40].
The history of thermosetting polymers for use in petroleum industry goes back to
the 1960s when resins were suggested for remediating sand production [42]. Since
then, they have been proposed and used for mud-loss control, remedial operations
particularly for sealing tight channels, casing leaks, perforations and shoe and liner
top squeezes, sand control, and production of resin-based cement [4, 41, 43–45]. As
each wellbore is unique with respect to depth, downhole pressure and temperature,
inclination, wellbore geometry, and formation strength, a range of additive materials
are necessary to obtain the appropriate rheological and mechanical properties for

Fig. 4.18 Physical and color

appearance of a thermoset
resin [41]. (Courtesy of
WellCem AS)
120 4 Types of Permanent Plugging Materials

thermosetting polymers. These materials include catalysts, accelerators, inhibitors,

weight fillers, expansion agents and viscosifiers [46]. Catalyst or hardener is liquid
which promotes the chemical reaction without itself being consumed. By increasing
the concentration of catalysts, the rate of reaction of thermosets increases. The cata-
lysts used for thermosetting polymers used in well cementing are usually acid-based.
Accelerators are liquids which increase the rate of reaction at low temperatures. As
elevated temperatures increase the rate of reaction, inhibitors or retarders are used to
postpone the setting time of thermosetting polymers. The inhibitors are usually basic
solutions. Thermosetting polymers have a wide range of densities so to modify their
density, hollow spheres can be added to lower their density or heavy particles can be
added to increase their density. As thermosetting polymers have relatively low, con-
stant viscosity, addition of heavy particles may cause particle segregation. Therefore,
viscosifiers are introduced to the resin mix to increase the viscosity and consequently
the lifting capacity of the resin. Table 4.7 presents properties of thermosetting resins
used for zonal isolation.
In order to wash the batch mixer, pumps, lines and all equipment, cleaners are
used. Cleaners are chemical solutions, usually xylene or alcohol solutions, which
cannot be disposed to sea or surroundings. Therefore, cleaners need to be handled
and properly managed during and after use.
Table 4.8 presents a comparison between neat G Portland cement and a thermoset-
ting resin developed for zonal isolation of hydrocarbon wells. However, shrinkage
factor, shear bond strength, and hydraulic bond strength data for thermosetting resins
are not publicly available.

Table 4.7 Properties of a

Property Range
commercialized
thermosetting synthetic Density 6.2–20.8 ppg
polymer for cementing Viscosity 10–2000 cp
applications [46]
Right angle set Yes
Target temperature 68–300 °F
Pumpable through pipe Yes
Miscible with water or well No
fluids
Decomposition temperature 900 °F
Setting time Depends on curing
temperature
4.4 Thermosetting Polymers 121

Table 4.8 Properties of hardened thermosetting resins designed for zonal isolation versus Neat
G-cement [47]
Compressive Flexural E-modulus Failure Permeability (mD)
strength strength (kpsi) flexural
(kpsi) (kpsi) strain
(%)
Water Oil
Thermosetting 11.2 6.5 325 1.9 <0.5 × <0.5 ×
resin 10−6 10−6
Portland 8.4 1.4 537 0.32 1.6 × a

cement 10−3
a Not available

4.4.1 Main Degradation Mechanisms

Synthetic polymers degrade by different mechanisms depending on the structure and

exposure conditions. Generally, organic polymers have five main degradation mech-
anisms: (a) physical, (b) chemical, (c) thermal, (d) hydrothermal, and (e) biodegra-
dation [48, 49]. Physical degradation occurs as disruption of polymer morphology
due to mechanical stresses, temperature, and time. It results in physical property
changes which are reversible. Chemical degradation mainly occurs due to exposure
to elevated temperatures, pollutants and micro- and macro-organisms. This type of
degradation drastically changes the physical properties of organic polymers. This
type of degradation is irreversible and occurs at the molecular level. Thermal degra-
dation occurs above glass transition temperature and is irreversible. Hydrothermal
degradation occurs at high temperatures in the presence of moisture and results in
permanent physical property changes. In this condition, water molecules penetrate
into the polymeric matrix and, at elevated temperatures, degenerates the interaction
between polymer chains. One consequence could be swelling of the matrix and plas-
ticization of the polymeric matrix. Biodegradation mechanism includes microorgan-
isms to breakdown of thermosetting organic materials. With regards to utilization
of thermosetting organic polymers, in petroleum industry, for zonal isolation and
permanent P&A, a combination of these degradation mechanisms may be syner-
gistic or antagonistic. Significant research is needed to understand the durability of
thermosetting synthetic polymers at downhole conditions.

4.4.2 Long-Term Integrity of Thermosetting Resins

4.4.2.1 Exposure to Downhole Chemicals

Long-term durability of any suggested plugging material needs to be investigated

comprehensively as re-entry and repairing the barrier may be risky, time consuming
122 4 Types of Permanent Plugging Materials

and even impossible. Interactions of thermosetting resins with downhole chemicals

including brines, crude oil, H2 S, CO2 , and thermogenic gas at downhole conditions
must be documented.
Preliminary experiments have been performed and published on durability of
a commercially available thermosetting resin designed for oil well applications,
Table 4.9. Crude oil, CO2 , H2 S, and methane gas were used as representatives of
wellbore chemicals. Aging test results of thermosetting resin systems when exposed
to brine are not available. However, hydrothermal degradation is one of the main
degradation mechanisms.
Table 4.9 shows that crude oil degraded the thermosetting resin system at 212 and
266 °F but methane gas was inert and did not interact with the resin system. CO2 did
not affect the compressive strengths at both 212 and 266 °F but the flexural strength
was affected at 266 °F. H2 S reduced both the compressive and the flexural strengths
at 212 and 266 °F.
There is a need to study weight and volume changes of thermosetting resin
systems, during aging tests, when they are exposed to downhole chemicals.

4.4.2.2 Thermal degradation

Usually in crystalline polymers, upon heat, the material transits from a hard and
solid material to a liquid phase (see Fig. 4.19a). However, in amorphous polymers a
reversible transition from a hard and relatively brittle state into a viscous and rubbery
state occurs above specific temperatures (see Fig. 4.19b). This temperature is known
as the glass transition temperatures (Tg ). Degradation kinetics of thermosetting resins
above their glass transition temperature needs also to be evaluated.
For evaluation of thermal stability and degradation of thermosetting resins, two
main parameters are studied: the activation energy (Ea ) and the pre-exponential con-
stant (A). The Arrhenius equation is used to quantify Ea and A above the glass
transition temperature:

k = Ae− RT
Ea
(4.9)

where k is the rate constant (s−1 ) for a particular reaction, T is the absolute tempera-
ture (Kelvins), and R is the universal gas constant. The natural logarithm of Eq. (4.9)
yields:

Ea 1
ln(k) = ln(A) − (4.10)
R T

Equation (4.10) is the plot of a straight line with a slope of − ERa and an intercept
at ln(A), see Fig. 4.19. So, k is the required parameter to find Ea and A. The thermal
degradation of a resin system is modeled as a first order reaction as follows:
Table 4.9 Exposure of thermosetting resin to different downhole chemicals [47]
Temperature (°F) Property Initial value 1-month 3-month 6-month 12-month
Chemical: Crude oil 38° API (Curing pressure of 7250 psi)
212 Permeability (nD) <0.5 ND ND ND <4
212 Uniaxial compressive strength (psi) 11170 ± 725 7106 ± 1305 6091 ± 435 5800 ± 145 6526 ± 725
212 Flexural strength (psi) 6236 ± 435 4786 ± 725 3770 ± 145 3625 ± 145 3916 ± 145
266 Permeability (nD) <0.5 ND ND ND <20
4.4 Thermosetting Polymers

266 Uniaxial compressive strength (psi) 11170 ± 725 5511 ± 145 5221 ± 435 4931 ± 145 5366 ± 145
266 Flexural strength (psi) 6236 ± 435 3625 ± 145 3625 ± 145 3190 ± 145 2900 ± 290
Chemical: Methane 100% gas (Curing pressure of 7250 psi)
212 Permeability (nD) <0.5 ND ND ND <128
212 Uniaxial compressive strength (psi) 11170 ± 725 11458 ± 725 11312 ± 1015 11167 ± 725 13488 ± 580
212 Flexural strength (psi) 6236 ± 435 7687 ± 1015 6381 ± 2900 3335 ± 1595 7977 ± 1015
266 Permeability (nD) <0.5 ND ND ND Not possible1
266 Uniaxial compressive strength (psi) 11170 ± 725 11022 ± 1595 11748 ± 1885 12473 ± 1160 12183 ± 1305
266 Flexural strength (psi) 6236 ± 435 6816 ± 2900 8557 ± 3480 7832 ± 1450 8702 ± 435
Chemical: CO2 5% in N 2 gas (Curing pressure of 7250 psi)
212 Permeability (nD) <0.5 ND ND ND <79
212 Uniaxial compressive strength (psi) 11170 ± 725 10732 ± 870 11748 ± 1160 10587 ± 580 13343 ± 435
212 Flexural strength (psi) 6236 ± 435 4351 ± 1160 3770 ± 1450 3335 ± 1450 8122 ± 870
266 Permeability (nD) <0.5 ND ND ND Not possible1
266 Uniaxial compressive strength (psi) 11170 ± 725 7977 ± 435 Not possiblea 10732 ± 435 11022 ± 435
266 Flexural strength (psi) 6236 ± 435 2755 ± 1160 Not possible1 5076 ± 145 5511 ± 290
(continued)
123
Table 4.9 (continued)
124

Temperature (°F) Property Initial value 1-month 3-month 6-month 12-month

Chemical: H 2 S 5000 ppm (Curing pressure of 145 psi)
212 Permeability (nD) <0.5 ND ND ND Not possiblea
212 Uniaxial compressive strength (psi) 11170 ± 725 5511 ± 145 7251 ± 290 7396 ± 290 7832 ± 435
212 Flexural strength (psi) 6236 ± 435 1885 ± 1015 2320 ± 290 2755 ± 1450 4496 ± 1160
266 Permeability (nD) <0.5 ND ND ND 666
266 Uniaxial compressive strength (psi) 11170 ± 725 6961 ± 290 7832 ± 290 9282 ± 580 7251 ± 145
266 Flexural strength (psi) 6236 ± 435 2755 ± 1015 3190 ± 2755 2900 ± 1740 4206 ± 870
ND: Not determined
a Due to difficulties
4 Types of Permanent Plugging Materials
4.4 Thermosetting Polymers 125

Fig. 4.19 Heat-Temperature plot for crystalline and amorphous polymers

d[w]
− = k[w] (4.11)
dt
where [w] is the relative weight to the initial weight of resin at time zero [w]0 , t is
the time. An integration of Eq. (4.11) yields:

ln[w] = −kt + ln[w]0 (4.12)

So, a plot of ln[w] versus time yields the −k. Once the Ea , and A are known, the
lifetime of a resin system at any temperature can be estimated. Research studies con-
ducted on thermal characterization of different resin systems show that the lifetime
of a resin system might be a concern for permanent P&A applications where down-
hole temperature is above the glass transition temperature (Tg ) [49]. If downhole
temperature is above the glass transition temperature, the polymer has a higher free
volume and higher permeability. Jones et al. [49] studied experimentally the thermal
degradation of three resin systems at temperatures above their Tg . They estimated
that for these systems, it will take between 60 and 150 years for the resins to lose
10% of their weight. However, the effect of high pressure on thermal degradation
was not studied. They also concluded that above Tg , the resin degradation is intensi-
fied by increasing temperature. The Tg needs to be considered during the design of
resin systems particularly for application in permanent P&A of wells. Advantages
and possible limitations associated with the use of thermosetting resins for oil well
cementing are listed in Table 4.10.
126 4 Types of Permanent Plugging Materials

Table 4.10 Advantages and possible limitations associated with thermosetting resins with regards
to permanent P&A [47, 49, 50]
Advantages Possible limitations and disadvantages
• Gas tight (very low permeability) • Usually brittle in solid state. Their
• Strong bond to formation and steel brittleness is a function of polymer and
• Good mechanical properties curing pressure and temperature
• Chemically inert to wellbore fluids and • Partly unknown long-term durability
rocks behavior
• Outdoor storage has no detrimental effects • Interaction with brine and depolymerization
• No special equipment is required to prepare • HSE issue regarding toxicity
the mix • Limited data available on pumpability
• Low waiting on setting time • Unknown verification method when used
• High tensile strength for cementing casing
• The resins themselves are solid free (no • Possible interaction with workover fluid or
grains) mud
• High-pH medium can deteriorate
thermosetting polymers
• Chemical shrinkage
• No data available on hydraulic bond
strength to formation and steel

4.5 Metals

As discussed in Chap. 3, casing steel is not qualified as a permanent plugging mate-

rial unless it is protected internally and externally by cement or another suitable
material. There are some other types of metals with low melting point which have
been suggested as permanent plugging materials including metal Bismuth, Gallium,
Antimony, or low-melt-point eutectic alloys (Cerro alloys) [51, 52]. A eutectic alloy
is a formulation of metal elements which melts and solidifies at a single temperature,
which is lower than the melting points of the separate elements or of any combina-
tion. Eutectic alloys have no solidus or liquidus transition phases, completely solid
or completely liquid. The most known eutectic alloy in the petroleum industry is bis-
muth based alloy. There are some concepts which suggest the use of eutectic alloys
such as bismuth as a permanent barrier. Therefore, bismuth alloys are considered in
detail in the following.
Bismuth is a metallic element with symbol Bi and atomic number of 83. Bismuth
is brittle and a very weak radioactive material. Bismuth alloys have been laboratory
tested and tested in a few field trials for use as a permanent plugging material,
remediating sustained casing pressure, and shutting off water producing zones [52–
54]. Bismuth based alloys are developed to create a metal to metal seal and their
use in the petroleum industry goes back to the Schlumberger brothers in the 1930s.
Bismuth based alloys are metals with very low melting point compared to other
metals. A pure bismuth element has a melting point of 520 °F at ambient pressure
and it expands upon solidification by 3%. However its alloys are reported to have
much lower melting points, down to 174 °F, and with lower, albeit distinct, expansion
factors.
4.5 Metals 127

As the metal alloys have very high densities, the liquid metal requires a foundation
as a base. The expanding alloy is designed in a way that it has a melting temperature
which is higher than the maximum anticipated well temperature. There have been
two different techniques for placement of bismuth based alloys; the molten alloy is
lowered to the desired depth within a container or the solid alloy is lowered to the
desired depth and heated downhole. In the first technique, the molten alloy is carried
with a container which can provide temperatures above the alloy melting point. When
the alloy is at the desired depth, the container hatch is opened and the liquid alloy exits
the container. The second technique is the most common and carried out in different
ways including: heating once downhole using electric resistive or electromagnetic
induction, in situ exothermic chemical reaction, or heated steam injection [51, 55].
One of the challenges concerning bismuth based alloys is the control of vertical
heat propagation during installation of the plug when an in situ exothermic reaction is
applied. A recent development employs a wireline operation as a bismuth alloy plug
placement technique (see Fig. 4.20). The plug assembly consists of four main parts:
ignition system, alloy jacket, inner tube and skirt. The inner tube, filled with thermite,
passes through the bismuth alloy jacket. On ignition, the thermite reaction generates
heat and once heated, the bismuth alloy jacket is melted. As the melted bismuth
alloy has a high density and its positioning is not maintained, the skirt provides a
mechanical support until the bismuth alloy plug cools down and solidifies. Using
this method, the radial and vertical heat control is achieved more effectively.
Table 4.11 lists a wide selection of the expandable bismuth alloys with different
ranges of melting temperatures.
There are advantages and some possible limitations associated with the utilization
of alloy based plugging materials in permanent P&A operations, Table 4.12. As
bismuth alloys create no physical bonding with casing, it relies on expansion to take
mechanical and hydraulic loads. In addition, if the exerted force on the casing, due
to expansion, is high then potential deformation of casing cement may occur which
may put the integrity of the cement at risk.

Fig. 4.20 The bismuth alloy plug placement assembly [55]

128 4 Types of Permanent Plugging Materials

Table 4.11 Some typical

Alloys X: chemical formula Range of melting point
melting point temperature of
(°F)
bismuth based alloys [56–58]
Bi100−x Snx 0–5 464–520
Bi100−x Cux 0–45 520–1562
Bi100−x Hgx 0–45 530–520
Bi100−x Snx 5–42 280–520
Bi100−x Pbx 0–44.5 255–622
Bi100−x Cdx 0–40 284–610

Table 4.12 Advantages and possible limitations of bismuth based alloys for use in permanent P&A
Advantages Possible limitations and disadvantages
• Very low permeability or impermeable • No data available on sealing capability
• Rigless operation • No data available on durability
• Non-explosive • No chemical bonding to formation or casing
• No shrinkage • Uncertainty regarding downhole fluid
displacement
• Controlling vertical heat propagation during
installation
• No data available on hydraulic bond strength to
formation and steel
• Relatively brittle for a metal
• Barrier verification method is not clear
• Limited maximum length of barrier
• Toxic if mercury or lead is used in the alloy

4.6 Modified In Situ Materials

Recently a concept has been developed to do permanent P&A operations rigless and
efficiently. In this concept, a target interval, in the wellbore, is selected and all the
in situ elements are melted. Upon cooling, a solidified barrier is created from the
in situ materials, Fig. 4.21.
To melt the in situ materials, thermite is used as the source of energy to generate the
required amount of heat. The term “thermit” was first introduced by Goldschmidt in
1903 [60]. Thermite is a metal powder which produces an effect by heat. The reaction
is an exothermic reduction-oxidation reaction and it is ignited by heat. The reaction
is written in a general form as [60]:

M + AO → MO + A + H (4.13)

where M is a metal or an alloy, A is either a metal or a non-metal, MO and AO are

their corresponding oxides, and H is the generated heat during the reaction.
4.6 Modified In Situ Materials 129

Fig. 4.21 Conceptual

illustration of modified
in situ materials as
permanent barrier [59]

For example, the following is a well-known reaction:

2Al + Fe2 O3 → 2Fe + Al2 O3 + H (4.14)

The reaction is a single-replacement reaction in which aluminum reacts with

iron oxide and takes the place of iron in the compound. Aluminium is more reactive
compared to iron, it donates its electrons easier, and as a result of replacement, a large
amount of energy is generated. The above-mentioned reaction creates temperatures
in excess of 5432 °F. The reaction consumes small amounts of oxygen and it is self-
sustained, Eq. (4.14). Generally speaking, a thermite reaction requires fuel metals
and an oxidizer. The fuel metals include, but are not limited to, aluminium, titanium,
magnesium, boron, zinc, and silicon. Of these, aluminium is of most interest as it
has low cost and high boiling point. The oxidizers include, but are not limited to,
bismuth (III) oxide, boron (III) oxide, silicon (IV) oxide, iron (II) oxide, and copper
(II) oxide. Table 4.13 presents adiabatic temperatures for some thermite reactions,
Tad , and melting point of their products.
130 4 Types of Permanent Plugging Materials

Table 4.13 Adiabatic combustion temperatures and melting points of the product metals after
Wang et al. [60]
Reaction Tad (K)a Tmp of metal (K)b
I. Formation of common structural metals
Al + 21 Fe2 O3 → Fe + 21 Al2 O3 3622 1809
Al + 23 NiO → 23 Ni + 21 Al2 O3 3524 1726
Al + 4 TiO2 → 4 Ti + 2 Al2 O3
3 3 1
1799 1943
Al + 8 Co3 O4 → 8 Co + 2 Al2 O3
3 9 1
4181 1495
II. Formation of refractory metals
Al + 21 Cr2 O3 → Cr + 21 Al2 O3 2381 2130
Al + 10 V2 O5 → 10 V + 2 Al2 O3
3 6 1
3785 2175
Al + 10 Ta2 O5 → 10 Ta + 2 Al2 O3
3 6 1
2470 3287
Al + 2 MoO3 → 2 Mo + 2 Al2 O3
1 1 1
4281 2890
Al + 2 WO3 → 2 w + 2 Al2 O3
1 1 1
4280 3680
Al + 10 Nb2 O5 → 10 Nb + 2 Al2 O3
3 6 1
2756 2740
III. Formation of other metals and non-metals
Al + 21 B2 O3 → B + 21 Al2 O3 2315 2360
Al + 43 PbO2 → 43 Pb + 21 Al2 O3 >4000 600
Al + 4 MnO2 → 4 Mn + 2 Al2 O3
3 3 1
4178 1517
Al + 4 SiO2 → 4 Si + 2 Al2 O3
3 3 1
1760 1685
IV. Formation of nuclear metals
Al + 16 U3 O8 → 16 U + 2 Al2 O3
3 9 1
2135 1405
Al + 4 PuO2 → 4 Pu + 2 Al2 O3
3 3 1
796 913
a Adiabatic temperature
b Melting point temperature

Different combinations of the fuel metals and oxidizers generate different energy
levels in a controlled manner. This method is known as “dilution” to control the
amount of generated heat. When sufficient energy is produced, downhole equipment
such as casing, cement, control lines and a portion of the in situ formation is melted.
However, achieving high enough energy to melt the downhole equipment requires a
certain amount of thermite, depending on the type of fuel and oxidizer.
The product of the reaction is usually a heaver metallic phase and a lighter oxide
phase. Due to gravity, the lighter phase migrates upward and the heavier phase
moves downward. For oil well applications, the freezing point is critical whereas
solidification of the product prior to migration of the lighter oxide phase may result
in a discontinuous barrier.
4.6 Modified In Situ Materials 131

4.6.1 Barrier Establishment

A mechanical plug is required to be installed as a foundation for the molten materials

prior to cooling. Because the high temperature may damage a mechanical plug, sand
is placed on top of it. The wireline tool is equipped with a jacket which contains
thermite and an igniter. This method employs a wireline operation to establish the
barrier. The tool consists of four main parts: heavy load, separator, thermite pool,
and igniter, (see Fig. 4.22a). The wireline provides the electrical power required
to ignite the thermite mixture. When the thermite reaction is initiated, the thermite
available in the thermite pool gets consumed in the reaction, and the reaction heats
and melts the adjacent equipment. As the generated energy is high, rapid expansion
of downhole fluids, at shallow depths, may be a concern. Therefore, a heavy load is
applied to the thermite pool to compress the barrier while cooling (see Fig. 4.22b).
As the high energy may melt the heavy load, a separator protects it. When the barrier
is established, the heavy load and separator are retrieved (see Fig. 4.22c).
Controlled heat propagation, both in radial and vertical direction, is one of the
challenges associated with this method. When a barrier is established, the transi-
tion area between the modified and non-modified materials needs to be qualified.
Currently, there is no established methodology. In addition, limited data availability
is another potential limitation besides, concerns associated with durability of the
barrier, Table 4.14.

Fig. 4.22 Permanent barrier establishment by modified in situ materials method

132 4 Types of Permanent Plugging Materials

Table 4.14 Advantages and possible limitations concerned with modified in situ materials [59–62]
Advantages Possible limitations and disadvantages
• Rigless based concept • Barrier mainly consists of iron which
• Safe to handle and low equipment intensity associates to a long term durability concern
• Presence of downhole fluids may
compromise the sealability of barrier while
establishing barrier
• Maximum length of established barrier
• Minimum hole diameter to run the tool in
• Gravity force, in deviated sections, can cause
segregation of the plug when it is in liquid
phase
• Contraction upon cooling and solidification
may introduce micro cracks
• Limited data availability
• Not commercialized

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Chapter 5
Different Categories of Working Units

When considering permanent plug and abandonment of hydrocarbon wells, location

of the well plays a critical role; location can be either onshore or offshore. For onshore
wells, the well depth, downhole pressure, and complexity of operation dictate the
type of working unit. For offshore wells, type of facility, water depth, downhole
pressure, and working unit serviceability are the governing factors for selection of the
working unit. The facility can be either platform-based or subsea-based. This chapter
will familiarize the reader with different types of working units, for permanent P&A
purposes, based on the well location and type of facility (see Fig. 5.1). In addition,
to drilling rigs, vessels are also reviewed as a new generation of working unit but as
they are not counted as rigs, they are not included in Fig. 5.1.

5.1 Onshore Units

Land wells are the most common drilled hydrocarbon wells. History of the first
known land hydrocarbon well, goes back to China where the earliest well was drilled
in 347 CE [1]. Accordingly, many oil wells were drilled until 1859, when Edwin L.
Drake drilled the first commercially successful oil well. Since then, with the increase
of need for energy, drilling activities for hunting hydrocarbons have speeded up
and countless wells have been drilled. Subsequently, depth of penetration has been
increased and thus, different types of land rigs have been developed. Land rigs are
designed based on portability and maximum operating depth and are divided into
two main categories: conventional rigs and mobile rigs.

© The Author(s) 2020 137

M. Khalifeh and A. Saasen, Introduction to Permanent Plug
and Abandonment of Wells, Ocean Engineering & Oceanography 12,
https://doi.org/10.1007/978-3-030-39970-2_5
138 5 Different Categories of Working Units

Fig. 5.1 Different working units based on the well location

5.1.1 Conventional Land Rigs

Conventional land rigs are built on location and left on site after the well is completed.
The rig can be used for workover activities during the life-cycle of the well. However,
due to the high cost of rig construction, mobile rigs were introduced where the derrick
can be moved and reused. Figure 5.2 illustrates an onshore rotary drilling rig and its
main components.

5.1.2 Mobile Land Rigs

Mobile land rigs are categorized as jackknife and portable mast. The jackknife, also
known as cantilever derrick, is assembled on location, on ground, and then raised to
vertical position by utilization of the rig-hoisting equipment or the drawworks. The
portable mast is usually mounted on wheeled-trucks as a single unit and transported
to the location, and raised in the vertical position by using hydraulic pistons on the
carrier unit. Different types of land rigs are designed and available, depending on
well location, depth of operation, and horsepower requirement. Fit-for-purpose rigs
are a class of land rigs specially designed for remote areas where few people wish
to venture. These remote areas such as deserts, and arctic areas may have few or no
highways.
The main components of a rotary rig are: a power system, a hoisting system, a
circulating system, a rotary system, and a well control system [2]. All of these com-
ponents are necessary for drilling and permanent P&A operations and are therefore,
comprehensively discussed in this chapter.
5.2 Offshore Units 139

Fig. 5.2 Onshore rotary

drilling rig (Taken from
Weebly)

5.2 Offshore Units

With the increase in world energy needs for fossil fuels, exploration and produc-
tion of hydrocarbons have been extended to remote areas such as offshore locations.
Although the main intended purpose of a drilling rig and its main systems may not
be influenced by well location, the water depth requires modification of land rigs.
Consequently, mobile offshore drilling units (MODUs or rigs) or marine rigs were
developed and introduced. The main design features for offshore rigs are portabil-
ity and maximum water depth of operation. Offshore rigs are classified broadly as
floating or bottom support. The floating rigs are categorized as semisubmersible, and
drillship. Bottom supported rigs are categorized as barge, jackup, and platform rigs
[3].
140 5 Different Categories of Working Units

5.2.1 Submersible/Barge Rigs

These types of rigs are used for drilling at shallow water depths. The operational
water depth of these submersible barge rigs is less than 40 (ft) and where there is
no severe wave action. The rig is installed on a barge, large pontoon-like structure,
and towed to the location. When on location, the pontoons are filled with water, the
platform sinks partly or fully, and rests on its anchors. When the drilling operation is
completed, water is pumped out and the platform is ready to move to a new location.
If the barge rests on the seafloor, then it is counted as a bottom supported drilling rig.

5.2.2 Semisubmersible Rigs

Semisubmersible (see Fig. 5.3) rigs are capable of performing drilling operations
while resting on the seafloor as well as being in a floating position. In other words,
the drilling rig is on a barge similar to submersible rigs. Compared to submersible rigs
(known also as bottle-type semisubmersible rig), the semisubmersible rigs (known
as column-stabilized semisubmersible rigs) are designed with good stability and
seakeeping characteristics. These types of rigs are usually used at larger water
depths where a rig cannot rest on the seafloor. When the semisubmersible rig cannot

Fig. 5.3 A semisubmersible

drilling rig towed to location.
(Courtesy of Seadrill)
5.2 Offshore Units 141

rest on the seafloor, the unit is either anchored onto the position or kept on loca-
tion with dynamic positioning systems. The construction and operational cost of
semisubmersible rigs are higher than for submersible rigs.

5.2.3 Drillship

A drillship is a type of floating vessel where the drilling rig is mounted on a merchant
ship (see Fig. 5.4). The drillship is usually used for offshore exploration and equipped
with advanced dynamic positioning systems. As drillships benefit from the dynamic
positioning systems, they are usually much more costly compared to semisubmersible
rigs. In recent years, drillships have been used for operation in deepwater and ultra-
deepwater areas. There are some generations of drillships, which are equipped with
only mooring systems or general dynamic positioning systems that have lower cost
compared to semisubmersible rigs. Another challenge for using a drillship is its
susceptibility to severe waves, wind and currents. A benefit of using drillships is
their efficient mobilization and high speed between drilling locations.
Recently, riserless well intervention vessels have been used for small activities
such as coring [4]. These types of vessels are small sized drillships which have
the capability to be equipped with well intervention equipment such as coiled tubing
units. The cost of these vessels is much lower than cost of other types of rigs; however,

Fig. 5.4 Drillship on location (Courtesy of Seadrill)

142 5 Different Categories of Working Units

Fig. 5.5 A jackup rig on

location. (Courtesy of
Seadrill)

time spent waiting on weather is higher compared to other types of drilling rigs. The
vessels will be reviewed later in this chapter.

5.2.4 Jackup Rig

Jackups are the most common bottom-supported rigs. The rig consists of a barge-
type hull (triangular barge form) and three legs, Fig. 5.5. When the rig is in place,
legs are lowered to adjust to a given clearance. Jackups are self-contained rigs that
can be mobilized and demobilized easily. Depending on their size, they can operate
in water depths up to 500 (ft) [5].

5.2.5 Platform Rigs

Platform rigs are usually employed during development phase where an economi-
cally viable offshore field is exploited. Many directional wells can be drilled from
a platform. Large platforms are capable of accommodating drilling rigs or modular
5.2 Offshore Units 143

Fig. 5.6 A platform rig in operation. (AkerBP)

rigs and therefore are known as self-contained (see Fig. 5.6). Rig-up time of plat-
form rigs are usually less compared to most of the MODUs as no mooring system
nor dynamic positioning system is required. But there are some circumstances when
the rig-up time can increase due to waiting on weather.

5.2.6 Tendered Rigs

There are circumstances where the platform is small and not capable of accommo-
dating all the components of a drilling rig or storage facilities. In this situation, a
floating vessel is anchored next to the platform (see Fig. 5.7). The floating vessel is
known as the rig tender. The rig tender can contain storage facilities, many of the
rig components and the living quarters.

5.2.7 Vessels

Vessels are small sized merchant ships which offer some basic operations such as
well intervention activities and anchor handling. Compared to drillships, the day
rate of vessels are much lower. These types of vessels are categorized as light well
intervention vessel and anchor handing vessels.
144 5 Different Categories of Working Units

Fig. 5.7 A tender rig in operation while the anchored vessel is in service. (Courtesy of Seadrill)

5.2.7.1 Light Well Intervention Vessels

Light Well Intervention Vessels (LWIVs) have been used for over 25 years in the
North Sea. LWIVs are typically monohull, flexible and extremely cost efficient and
can be used for a single or multi-well (a campaign) of subsea wells. They can
accommodate a wireline unit and coiled tubing unit, Fig. 5.8.
Well integrity and suspension operations including mechanical plug setting,
mechanical repair or well maintenance, perforating and setting cement plugs, well-
head cutting and removal, logging, Remotely Operating Vehicle (ROV) services, and
pumping operations are typical activities which are conducted by use of LWIVs [6].
The future approach for the use of LWIVs is to perform the complete permanent
P&A operations. However, there are some limitations to be solved before reaching
to the goal, see Table 5.1.

5.2.7.2 Anchor Handler Vessels (AHVs)

Anchor handling operations may contribute 10–20% of the total well costs of off-
shore exploration drilling [8]. In a conventional anchor handling operation, the rig’s
winches are used to tension the anchors. AHV transports and deploys the anchors,
connects the required chains, wires and polyester ropes. AHV can pre-lay the anchors
before the rig arrives, and more time can be dedicated to drilling or P&A operations.
5.3 Types of Offshore Wells 145

Fig. 5.8 Light well intervention vessel. (Courtesy of Helix Energy Solutions Group)

Table 5.1 Advantages and

Advantages Possible limitations
possible limitations of LWIVs
for use in permanent P&A • Equipped with well control • Limited pulling capacity
operations [7] package • Waiting on weather is high
• Wireline operations due to the small size
• Coiled tubing operations • Unable to work full bore
• Wellhead cut and removal 7-in.
• Activities for establishment • Limited deck space
of temporary abandonment • High motions add more risk
• Pipe handling
• Cementing adaptor tool
• Flexible and cost efficient

5.3 Types of Offshore Wells

Depending on the field development planning, offshore wells can be completed as

either subsea wells or platform wells. Depending on well type, subsea or platform,
the plug and abandonment operation will be different. Therefore, it is important to
review the major differences between subsea and platform wells.
146 5 Different Categories of Working Units

5.3.1 Subsea Wells

In a subsea well, the wellhead, XMT, and production-control equipment are located
on the seabed. Subsea wells may be drilled and completed individually, in clusters,
or on a template.
Individual subsea wells—An individual subsea well is a well which is drilled
and completed as a single well. Every time a well is completed, the drilling unit is
demobilized and mobilized to the next well and consequently, associated costs are
increased.
Clustered subsea satellite wells—The concept of clustered subsea satellite wells
is that individual wells are drilled but they are connected to a manifold, Fig. 5.9, and
then the manifold is connected to a production unit. In this case, some costs associated
with field development are saved because of flow line and control umbilical savings.
Multiwell template subsea wells—The multi-well template is another subsea field
development concept where wells are drilled from one location by utilization of
a drilling template. In this concept, the drilling unit stays in place while drilling
several wells through the template. Therefore, costs associated with demobilization
and mobilization will be minimized.
Subsea wells are equipped with templates, a large supportive structure which
is made of steel. The template is used as a temporary guide base and serves as the
anchor for guidelines for a permanent guide base. The template has opening(s) which
the bit passes through and drilling can be performed, Fig. 5.10. A subsea permanent

Fig. 5.9 Clustered subsea satellite wells connected to a manifold. (Courtesy of TechnipFMC)
5.3 Types of Offshore Wells 147

Fig. 5.10 Subsea multi-well template below a moon pool. (Courtesy of Claxton)

guide base is initially used for drilling, hanging off and supporting conductor, well-
head, and subsea tree. In addition, templates provide a base for protective structures.
The permanent guide base is a steel structure which seats in and is attached to the
temporary guide base, Fig. 5.11.

Fig. 5.11 Single-well temporary and permanent guide bases. (Taken from Encyclopedia of
Hydrocarbons Eni)
148 5 Different Categories of Working Units

5.3.2 Platform Wells

For a platform well, the wellhead, Christmas tree, and production-control equipment
are located on the production platform. Platform size depends on number of wells,
water depth, and facilities to be installed on top side such as the drilling rig, living
quarters, Helipad, etc.

5.4 Types of Offshore Production Units

Offshore production units can be divided into two main categories: bottom supported
and vertically moored structures, and floating production systems. Figure 5.12 shows
different categories of offshore platforms.

5.4.1 Bottom Supported and Vertically Moored Structures

This category of offshore platforms can be divided into four major types (see
Fig. 5.13):
• Fixed platform
• Compliant tower
• Tension leg platform
• Mini-Tension leg platform
Fixed platform—These platform types are, built on concrete or steel legs, or both,
and directly anchored to the seabed. They are designed and built for long-term use
in moderate water depths up to 400 m. Steel jacket, concrete caisson, floating steel,
and floating concrete are various types of fixed platforms. Steel jackets are vertical
sections made of tubular steel members, which provides a protective layer around
pipes, and are usually piled into the seabed. Fixed platforms typically have a main
deck, a cellar deck, and a Helideck which comprise the deck structure. The deck

Fig. 5.12 Different categories of offshore platforms

5.4 Types of Offshore Production Units 149

Fig. 5.13 Various types of bottom supported and vertically moored offshore platforms. (Courtesy
of BOEM)

structure is standing on deck legs which are connected to the top of the piles. The
piles, which are located inside the legs of a jacket, penetrate into soil and are extended
above the mean sea level.
Compliant towers—This type of platform is capable of moving along with the
external forces acting on the structure. Therefore, a flexibility is given to the structure
and it responds to the applied external forces [9]. A compliant tower platform consists
of a narrow and flexible (compliant) tower which is supported by piled foundations.
The pilled foundations (connected to the sea floor and allowing the structure to move
freely with current, waves, and wind) support the deck which accommodates the
drilling rig and production facility. However, they are not usually designed for drilling
operations but exceptions may exist. The compliant tower platforms are designed and
built for deep water depths ranging from 1400 to 3000 (ft). Guyed towers (either piled
or spud can foundation), articulated towers, and tension leg platforms are different
types of compliant tower platforms.
Tension leg platforms—These type of platforms, known as TLPs, may also be
noted as a subcategory of compliant towers as they can move horizontally (see
Fig. 5.14). A TLP is a 4-column design whereas each column is moored perma-
nently to the seabed by tethers or tendons. A tether is a vertical steel tube. A group of
tethers is called a tension leg, and are designed in such a way that vertical movement
of the platform is eliminated. In other words, all the tethers are in pre-tension. This
feature allows the wellhead to be placed on deck and connected to the subsea well
by use of a rigid riser. As the legs are in tension, the platform is sensitive to topside
load variations.
150 5 Different Categories of Working Units

Fig. 5.14 A tension leg platform which is restrained in vertical direction but highly flexible in
horizontal plane

Mini-Tension leg platforms—These type of platforms combine the simplicity of

a SPAR platform (a floating platform) and favorable features of a TLP [10]. The
platform consists of decks, tower, hull, horizontal pontoons, and tethers. Typically,
a mini TLP has a low water plane and subsequently experiences less environmental
loads and has good response characteristics.

5.4.2 Floating Production Systems

This category of offshore platforms can be divided into three major types (see
Fig. 5.15):
• Spar platforms
• Floating production systems
• Floating, production, storage and offloading (FPSO) vessels
Spar platforms—A Spar platform is a type of floating production facility made
of a large-diameter, single vertical cylinder (hard tank), which supports a deck on
5.4 Types of Offshore Production Units 151

Fig. 5.15 Overview of floating production systems (Courtesy of BOEM)

top. Spar platforms are permanently anchored to the seabed, vertically, by a spread
moored system. There are four different types of Spar platforms: classic Spar, truss
Spar, cell Spar, and mini-DOC Spar (see Fig. 5.16). One of the major differences of
these types is related to size and design of the hard tank. Among these, types, the
truss Spar platforms are the most common.

Fig. 5.16 Four different types of Spar platforms

152 5 Different Categories of Working Units

It provides accommodation, crane facilities and usually a drilling rig. The

Christmas tree can be either on the seabed (wet tree) or on the platform (dry tree).
Floating production systems (FPSs)—FPSs consist of monohull structures and
are equipped with processing facilities. FPSs are moored and can be mobilized and
reused after the abandonment of wells. The FPSs are usually used for subsea wells.
There are different types of systems and floating, production, storage and offloading
systems are a variant.
Floating, production, storage and offloading vessels (FPSO)—FPSOs are a gen-
eration of the FPSs. These vessels are ship shaped floaters and do not provide rig or
intervention units [11]. The FPSOs are used for subsea wells.

5.5 Manned and Unmanned Platforms

Fixed platforms can be categorized in two types: manned platforms and normally
unmanned platforms.

5.5.1 Manned Platforms

All the offshore construction facilities, which accommodate at least one person rou-
tinely for more than 12 h for 24 h periods, are known as manned platforms. Such
facilities provide an area for a well intervention unit or supporting drilling rig.

5.5.2 Unmanned Platforms

Unmanned platforms are a type of automated offshore platform which primarily

operate remotely and without the continuous presence of personnel. Such platforms
are operated remotely from onshore bases. They can be categorized into five different
types by considering the number of available wells, helideck availability, fire water
system, and crane availability (see Table 5.2).
These types of platforms are small in size and may provide a helipad on top but they
do not possess accommodation, except for shelters to address personnel emergencies.
If a crane is available, they are usually light-weight and not rated for lifting heavy
units such as coiled tubing units. As such platforms are small, when the platform
is manned to carry out routine activities such as maintenance and well intervention
activities, a supply vessel or jackup unit stands by the platform. The standby unit
provides enough deck space and accommodation for personnel on board (POB).
When an unmanned platform is manned for activities which require more POB,
additional safety measures are necessary as the platform may not provide enough
rescue boats or fixed fire water systems.
5.5 Manned and Unmanned Platforms 153

Table 5.2 Five different types of unmanned platform [12]

Type Specifications
Type 0: Complex platform with helideck • Equipped with fixed fire water
system
• Equipped with various process
equipment including crane
(lifting capacity of 50–60
tonnes)
• Automated
• Allows remote operation for
typically 1–5 weeks
• Designed for both coiled
tubing and wireline operations
Type 1: Simple platform with helideck • Supports typically 2–12 wells
• Crane is available (lifting
capacity of 10–50 tonnes)
• No fire water system
• Equipped with test separator or
multiphase metering
• Allows remote operation for
typically 2–3 weeks
• May be designed for coiled
tubing and wireline operations
or only wireline operations
Type 2: Simple platform without • Supports typically 2–10 wells
helideck • Small crane is available (lifting
capacity of 1–2 tonnes)
• No fire water system
• No process facility
• Allows remote operation for
typically 3–5 weeks

Type 3: Minimalistic platform • Supports typically 2–12 wells

• No crane
• No fire water system
• No process facility
• Allows remote operation for
typically 6 months up to
2 years
• All well intervention
operations require an offshore
support rig
Type 4: Super minimalistic platform • Supports typically 1 well
• One small deck
• Well is connected directly
connected to pipeline
• All well intervention
operations require an offshore
support rig
154 5 Different Categories of Working Units

It is a common practice to design and construct simplified offshore installations

to keep the initial costs low. Consequently, when considering operational activities
for unmanned platforms, some major factors should be considered including: safety-
critical systems, deck space, POB, and weather. Due to the design of unmanned
platforms, they are not equipped with all of the safety-critical systems such as fixed
firewater pumps and larger capacity life boats. The deck space is also very limited
due to the compact design of the platforms. Consequently, during operations, a min-
imum of personnel are permitted to work on unmanned platforms due to safety and
emergency response, unless the operation is carried out from a standby working
unit. Weather is another major factor to be considered for executing operations on
unmanned platforms. Due to constraints including deck space, lifting capacity, etc.,
an offshore support rig (working unit) is employed to perform the operations. If the
employed working unit is not a bottom supported unit, bad weather could cause dis-
astrous consequences such as a collision between the platform and working unit or
compromising pressure control procedures. When employing floating working units
for intervention and P&A activities, a weather downtime of up to 50% is reported
for unmanned platforms in North Sea. However, this depends on the season.
Challenges associated with unmanned platforms can be listed as personnel accom-
modation, equipment limitations (such as number, size, and weight), and fast crew
transfer. Most of these challenges can be overcome by proper selection of a supple-
mentary working unit. Normal anchor handler tug (AHT) vessels, supply vessels,
and dynamic positioning vessels are some options besides offshore drilling units
[12, 13].

5.6 Mooring Systems for Floating Units

When considering offshore activities, unit motion becomes a critical subject which
increases the operation cost and risk. For floating platforms and floating working
units, motion means weather downtime and subsequently, weather downtime means
increased operation cost. In other words, the primary task of mooring is to reduce the
motion of platform or working unit. Fixed platforms and fixed working units do not
require mooring system. Studies show that mooring operations can contribute up to
25% of drilling cost. Therefore, an efficient mooring system needs to be considered
during P&A of subsea wells or platform wells that may require a complementary
floating unit. A mooring system consists of: mooring chain (chain cable) and fiber
ropes, windlass, anchors, and mooring winches.
Mooring systems can be either temporary or permanent. A temporary mooring
system provides service for relatively short periods of time. The periods can be
weeks or months at a time. Most mobile units employed to carry out P&A operations
benefit from a temporary mooring system. However, permanent mooring systems
provide station-keeping for several years. Typically, permanent mooring systems are
utilized to tether floating production facilities. The differences between permanent
and temporary mooring systems can be referred to as criteria considered in the design
5.6 Mooring Systems for Floating Units 155

Fig. 5.17 Three main categories of mooring systems

process of the system, type and size of mooring components, type of system anal-
ysis, installation methods, and inspection and maintenance philosophy. Generally,
mooring systems are categorized into three main categories (see Fig. 5.17): spread
mooring systems (Fig. 5.18a), turret mooring systems (Fig. 5.18b), and conventional
buoy mooring system (Fig. 5.18c).

5.6.1 Spread Mooring Systems

In this system, mooring lines are spread over multiple points and the system maintains
the working unit or platform on location with a fixed heading. In spread mooring sys-
tems, two different configurations of mooring line are distinguishable (see Fig. 5.19):
catenary system, and taut leg mooring system.
In a catenary system, a parabolic geometry of cables are anchored to the seabed
(see Fig. 5.19a). In this configuration, lines are laid down on the seabed and then
leave the seabed to the connectors on the unit. Usually, lines are steel chains which
subsequently occupy a large space and their transportation is a challenging task.
Corrosion of chains is another issue to be considered when utilizing steel lines.
In taut system, lines are stretched between two points; one point on the seabed and
another point to the connectors of the unit (see Fig. 5.19b). The lines are polyester
ropes which have several advantageous over steel chains. Advantageous include:
polyester ropes are lighter and less challenging with regards to accommodation
and transportation, they give a softer mooring system, better vortex induced motion
response to loop currents, lower product cost, no concerns associated with corrosion,
and reduction in mooring pre-tension [14].
156 5 Different Categories of Working Units

Fig. 5.18 a Spread mooring system, b Internal turret mooring system, and c Buoy mooring system.
(Courtesy of Offshore Magazine)

Fig. 5.19 Mooring line configuration used in spread mooring systems; a Catenary system, b Taut
leg mooring system. (Courtesy of Offshore Magazine)
5.6 Mooring Systems for Floating Units 157

Fig. 5.20 External turret

with dry mooring table.
(Courtesy of Offshore
Magazine)

5.6.2 Turret Mooring Systems

Turret mooring systems are divided into two main categories: internal turret and
external turret (Fig. 5.20). Internal turret mooring systems are the most common for
extreme design conditions. The internal turret mooring system is positioned inside
the hull (see Fig. 5.18b) and it is either permanent or disconnectable [15–17]. Per-
manent internal turret mooring systems are located in a moonpool. Internal turret
mooring systems are designed for moderate to deep water depths and locations where
a large number of flexible risers are required. External turret mooring systems are
also categorized as permanent or disconnectable. Turret mooring system are usually
used for Floating, Production, Storage, and Offloading (FPSO) floating systems and
drillships.

5.6.3 Conventional Buoy Mooring System

A conventional buoy mooring (CBM) system (see Fig. 5.18c) typically consists of
buoys, mooring legs, and anchor points. A typical CBM consists of 3 to 4 buoys
which are moored to the seabed by chain legs, high holding power anchors, or piles.
158 5 Different Categories of Working Units

5.6.4 Offshore Mooring Patterns

There are different types of offshore mooring patterns for temporary and permanent
mooring systems, Fig. 5.21. Depending on the intended use of the floating offshore
unit, type of operation, and location, different configurations are available.
A mooring line is made of different components (see Fig. 5.22). Manufacturing
and selection of the components depends on duration of tethering, size of floating
offshore unit, location, water depth, etc. Weight and space allocation for mooring
lines is important during the designing process which may influence the mooring
configuration.

Fig. 5.21 Temporary and permanent offshore mooring configurations. (Courtesy of Offshore
Magazine)
5.6 Mooring Systems for Floating Units 159

Fig. 5.22 Mooring line components. (Courtesy of Offshore Magazine)

5.6.5 Dynamic Positioning

When thrusters, standalone or in combination with mooring systems, are simultane-

ously applied to keep the unit in place, it is called “Dynamic Positioning” system or
DP system. Such a system provides a highly versatile anchoring system for floating
units at deep and ultra-deep locations [18].

5.7 Anchoring Types

Mooring systems need to be anchored to the seabed. The marine ground-anchors

are designed based on their capacity for withstanding uplift force and horizontal
drag force. There are different anchor types including clump weight, driven pile,
drag anchor, suction pile, torpedo pile (drop anchor), and vertical load anchor (see
Fig. 5.23).
160 5 Different Categories of Working Units

Fig. 5.23 Different anchor types. (Courtesy of Offshore Magazine)

Pre-laid mooring system

In traditional mooring systems, the mooring system is established while the working
unit is in place. However, due to the day-rate hire cost of the rig, this is not of interest.
Pre-laid mooring system is a cost efficient alternative scenario. In this approach, prior
to mobilizing the working unit, a vessel spreads and establishes the mooring system.

5.8 Moonpool

The moonpool is an open space located in the hull of a vessel or a drillship, which
provides access to water entry. The moonpool can have different configurations vary-
ing from rectangular to an inverted funnel-like shape, Fig. 5.24. Size, configuration
and number of available moonpool can impact the efficiency of a P&A operation as
the number of operations which can run simultaneously and crew numbers depend on
such factors. When a working unit is in operating mode, at zero speed, the moonpool
is opened and a large volume of water known as entrained water enters into it. The
entrained water has motion which appears as two modes, oscillation and sloshing.
5.8 Moonpool 161

Fig. 5.24 Some types of moonpool configurations. (After Hammargren and Tornblom) [19]

The oscillation mode is when there is a vertical motion of water column. The sloshing
mode is when water moves in a longitudinal direction. There are situations where
the water motion inside the moonpool can be so strong that the water level reaches
the deck and can cause harm to personnel.
162 5 Different Categories of Working Units

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Chapter 6
Work Classification and Selection
of Working Units

As reviewed in the previous chapter, there are different types of working units
employed for permanent P&A operations depending on the well location and type of
production facility. When considering onshore wells, the site space is not a concern,
except for mountainous areas and swamps. However, site space for offshore wells
may be a concern. Selection of working units for offshore wells is a concern as the
daily rate of working units highly affect the final cost of permanent P&A operation.
Generally speaking, there are some critical factors to be considered for the selection
of the optimal working unit for the P&A job including: well location (either onshore
or offshore), depth of operation/hole, required horsepower, availability of working
unit, type of production facility, type of well completion, unit capacity (offshore
wells) and availability of space (offshore wells). Unit capacity is the maximum load
which a unit, production facility or platform, can support without collapsing.
When considering offshore wells, more than one type of working unit may be
employed when performing different phases of P&A operation, depending on the
type of production facility and availability of units. Generally, if a working unit is
supposed to fully conduct the permanent P&A operation, the following systems are
necessary: power system, fluid-circulating system, hoisting system, rotary system,
well control system, well-monitoring system, and special marine equipment. At first
glance, the required systems may suggest a drilling rig to be convenient, however,
this might not be correct. A drilling rig is designed for the purpose of drilling. It
has a high daily rates and needs to have all the mentioned systems at the same time.
A P&A working unit may not need all the available systems at the drilling rig. For
example: a multipurpose modular working unit could be an example of such a unit
whereby different systems can be integrated at the required time. A modular rig may
be used when either the existing drilling rig is not properly maintained or when there
is no existing drilling rig onboard the platform. A P&A unit requires much lower
drilling fluid pit volume compared to a drilling rig. However, it should be mentioned
that a modular rig has a significant mobilization and demobilization cost and relies
on existing infrastructure such as cementing system, mud system, utility, etc. to a
large extent.
© The Author(s) 2020 165
M. Khalifeh and A. Saasen, Introduction to Permanent Plug
and Abandonment of Wells, Ocean Engineering & Oceanography 12,
https://doi.org/10.1007/978-3-030-39970-2_6
166 6 Work Classification and Selection of Working Units

6.1 P&A Code System

Consider a situation where you wish to briefly explain the complexity of permanent
abandonment of a well or several wells. Perhaps, it would be time consuming to
explain the well location and complexity of each abandonment phase. A P&A code
system can address their challenge. A P&A code system aims to classify wells for
abandonment cost estimation. The P&A code system classifies wells according to
three factors [1]:
• Well location
• Abandonment phases
• Abandonment complexity.
The well location is presented by two letters and followed by three digits, where
each digit represents the complexity of abandonment operation for each abandonment
phases.

6.1.1 Well Location

The Well location defines the physical location of well; land, platform, or subsea.
So, the first two letters are as following:
• LA—Land well,
• PL—Platform well,
• SS—Subsea well.

6.1.2 Abandonment Phases

A P&A operation, can be divided into three different phases: Phase 1—reservoir
abandonment, Phase 2—intermediate abandonment, and Phase 3—wellhead and
conductor cut and removal. These phases are regardless of well location. The main
goal in P&A is to perform the full operation as possible without a rig and removing as
little steel as possible. The footprint should also be kept small. Therefore, experienced
personnel should be involved with a good knowledge of what is required.

6.1.2.1 Phase 1—Reservoir Abandonment

This phase includes the following activities: wellhead is checked, waste handling
system is prepared, wireline investigations are conducted and if possible, cement is
squeezed into the reservoir perforations. If the squeezed cement is extended across
6.1 P&A Code System 167

the cap rock and is qualified, it is counted as a primary permanent barrier. So far,
these activities are performed with XMT in place and it is a rigless operation. If
the squeezed cement is not qualified, the primary and secondary permanent barriers
shall be established to secure the reservoir. This step may be carried out rigless or
using a rig. When a rig is required, the well control system needs to be established.
There are circumstances which require the use of a rig during the operation of Phase
1. These circumstances include: restricted access through the tubing to the barrier
depth, lack of technology to log casing cement through the production tubing, poor
cement or no cement behind the production casing, retrieval of production tubing
due to presence of control lines at the barrier depth, a permanent packer set above
cap rock, presence of an Annulus Safety Valve (ASV), and experiencing SCP due to
hydrocarbon or overpressures.

6.1.2.2 Phase 2—Intermediate Abandonment

In this phase, all the identified zones with flow potential in the overburden need to be
isolated. All the hydrocarbon flow potentials are secured by primary and secondary
permanent barriers. Hydrocarbon zones with no flow potential and water bearing
zones are isolated by establishing one permanent barrier. If the water bearing zone is
a pressurized zone, then two permanent barriers, primary and secondary, are required.
In the last part of Phase 2, a top plug often called and environmental plug, is installed.
This phase may be carried out with a rig or rigless. The circumstances which dictate
the use of a rig, in Phase 2, include: SCP due to hydrocarbons or overpressure at
barrier depth which originates from the reservoir, restricted access to the casing, no
isolated fresh water aquifers or zones, and non-isolated shallow gas. In addition,
poor cement or uncemented casing at barrier depth, lack of technology to log casing
cement behind the second casing string, and the presence of control lines (if not
retrieved during Phase 1) can dictate the use of rig.

6.1.2.3 Phase 3—Wellhead and Conductor Cut and Removal

This phase is the last stage of a permanent P&A operation whereby the well control
system is dismantled and wellhead and conductor are cut and pulled. When the
wellhead is removed, re-entry to the wellbore would be almost impossible as the
well control system cannot be installed. The cut and removal can be performed by
use of a rig, conductor jack, vessel (subsea wells), or heavy lift vessel (offshore wells).
The circumstances which may require the use of a rig, in Phase 3, may include: poor
conductor integrity, platform may not be able to support the conductor load during
pulling (offshore wells), water depth is beyond the limitation for cutting by anchor
handling vessels or LWIV for subsea wells. Poor integrity of conductor may be
caused by corrosion, weak connectors or shallow damage.
168 6 Work Classification and Selection of Working Units

6.1.3 Abandonment Complexity

The well abandonment complexity is shown by a digit from 0 to 4, which is

distinguished for each abandonment phases.
Complexity 0: No work is required. The abandonment phase has already been
accomplished and no further work is required.
Complexity 1: Simple rig-less operation. A wireline unit, pumping, crane and jacks
are utilized for the operation. Riser-less LWIV will be employed for subsea wells.
Complexity 2: Complex rig-less operation. Wireline unit, coiled tubing unit,
hydraulic work-over unit (HWU), crane, and jacks are utilized during the operation.
A heavy duty well intervention vessel with riser may be used for subsea wells.
Complexity 3: Simple rig-based operation. Operation requires retrieval of tubing
and casing.
Complexity 4: Complex rig-based operation. Due to limited access to barrier
depth, poor casing cement, or no casing cement, tubing and casing are required to
be retrieved, and section milling and cement repair are necessary.
To figure out the complexity of each phase, it is recommended to consider some
criteria, which are based on experience. These criteria are presented in Tables 6.1,
6.2 and 6.3. Sustained casing pressure related to hydrocarbons or overpressure is an
indication of a well integrity issue associated with failure of the primary cement.
The cement failure needs to be mitigated at cap rock level and there are risks associ-
ated with well control. Therefore, the operation is highly complex and well control
equipment is required. Uncemented casing or poor casing cement means that the
annulus needs to be accessed and a new annular barrier needs to be established. In a
conventional P&A operation, section milling or an alternative technique is required.
Therefore, the operation is of high complexity and HSE issues are associated with
it. One of the main concerns, especially at the first stage of the P&A operation, is
access downhole to below the estimated minimum setting depth where permanent
barriers are required to be established. Drift diameter can be limited due to collapse or
deposits of downhole minerals or chemicals. Such circumstances may be mitigated
by injecting chemicals or it may require retrieval of the production tubing, either by a
cut and pull operation or milling. There are situations where due to restricted access,
the production tubing is milled from near surface to all the way down to the required
depth of barriers. High torque and circulation gives the operation a complexity level
of 4. The production tubing can also create a challenge if it is leaking, as the circu-
lation of fluid or cement cannot be done. If a coiled tubing unit cannot be utilized
for circulating or pumping cement, then the production tubing needs to be retrieved.
Even though tests have shown that zonal isolation is possible, most authorities do not
accept the presence of control lines and downhole gauges as a part of the permanent
barrier. Because the control lines are attached to the production tubing, the tubing
needs to be retrieved which requires a high pulling capacity. It should be noted that
retrieval of production tubing means a higher cost of pipe pulling and handling, HSE
issues for personnel and transportation to a location for disposal.
6.1 P&A Code System 169

Table 6.1 The considered criteria for classifying complexity of Phase 1 of a permanent P&A
operation [1]
√
×: Not feasible, : Well abandonment complexity
Required, O: Type 1 Type 2 Type 3 Type 4
Optional
Simple rigless Complex Simple Complex
rigless rig-based rig-based
√
1 Sustained × × ×
Casing
Pressure (SCP)
due to
hydrocarbons
or overpressure
√
2 Uncemented × × ×
casing or liner
at barrier depth
(cap rock)
√
3 Restricted × × O
access to tubing
√
4 Deep electrical × × O
or hydraulic
lines present at
barrier depth
√
5 Annular Safety × × O
Valve (ASV)
present
√
6 Packer set × × O
above cap rock
√
7 Site does not × × O
allow
CT/HWU
pumping
operations
√
8 Multiple × O O
reservoirs to be
isolated
√
9 Tubing leak × O O
(e.g. corrosion,
accessories)
√
10 Inclination × O O
>60° above
packer
(wireline
access)
√
11 Well with good O O O
integrity, no
limitations
170 6 Work Classification and Selection of Working Units

Table 6.2 The criteria considered for classifying the complexity of Phase 2 of a permanent P&A
operation [1]
√
×: Not feasible, : Well abandonment complexity
Required, O: Type 1 Type 2 Type 3 Type 4
Optional
Simple rigless Complex Simple Complex
rigless rig-based rig-based
√
1 Sustained × × ×
Casing
Pressure due to
hydrocarbons
or overpressure
√
2 Restricted × × ×
access to tubing
√
3 No isolated × × ×
fresh water
aquifers/zones
√
4 Uncemented × × ×
casing or liner
at barrier depth
(cap rock)
√
5 No isolated × × ×
shallow gas
√
6 Site does not × × O
allow
CT/HWU
pumping
operations
√
7 Poor primary × × O
casing cement
√
8 No tubing in × O O
well
√
9 Inclination × O O
>60° above
barrier depth
(wireline
access)
√
10 Well with good O O O
integrity, no
obstacles,
tubing in place

An annulus safety valve may represent a restriction and limit the maximum
flowrate required when circulating fluids or cement through tubing, which may
demand retrieval of the production tubing. When the permanent packer is above
the estimated minimum setting depth, and the workstring cannot pass through it
6.1 P&A Code System 171

Table 6.3 The criteria considered for classifying the complexity of Phase 3 of a permanent P&A
operation [1]
√
×: Not feasible, : Well abandonment complexity
Required, O: Type 1 Type 2 Type 3 Type 4
Optional
Simple rigless Complex Simple Complex
rigless rig-based rig-based
√
1 Poor conductor × × ×
integrity
√
2 Platform unable × × O
to manage
conductor load
during retrieval
√
3 Water depth × × O
beyond
limitation for
cutting by
LWIV (Subsea
well)
√
4 Conductor O O O
cutting/rigless
retrieval

to establish the primary and secondary permanent barriers, the packer needs to be
milled.
As discussed in Chap. 5, that actual offshore facilities may not be able to accom-
modate crews, store equipment, use cranes or withstand load capacity. A support
vessel may therefore be required. A typical situation is the need to isolate multiple
reservoirs or multiple high pressure zones which may require a rig to remove the
downhole completion and packers. Permanent plug and abandonment of multiple
reservoirs or flow potential sections means a higher complexity of the operation.
When the permanent barriers are to be installed in depths with inclinations greater
than 60°, a tractor is necessary for conducting wireline operation such as setting
wireline plugs. Even at high inclinations, punching casing or running a wireline
operation can be almost impossible. Therefore, high inclination at the barrier depth
introduces multiple challenges.
Permanent P&A operation of wells with good integrity can be done rigless as
internal plugs only need to be installed across the qualified annular barrier. Such
operations can be done utilizing a coiled tubing unit.
Fresh water zones, abnormally pressured water bearing zones, and shallow gas
zones need to be isolated by installing cross-sectional barriers. If such zones are
poorly isolated or the corresponding annular space is uncemented, access to the
formation should be achieved to establish permanent barriers. Such an operation
may require section milling and well control systems.
Poor integrity of the conductor caused by corrosion, weak connectors, leaking
connectors, etc. requires program with contingency plans. There are circumstances
172 6 Work Classification and Selection of Working Units

where a platform or mobile offshore unit is not able to manage the conductor load dur-
ing conductor removal. The situation is amplified when the inner casing is cemented.
For subsea wells, the wellhead and conductor are usually cut and retrieved using an
anchor handling vessel or LWIV. However, if the water depth is beyond the opera-
tional water depth for the LWIV, a heavy offshore unit may be required. Water depth
can create challenges for the cut and removal of the wellhead. As an example, cur-
rently 500 m water depth is the limit for abrasive cutting of the wellhead or conductor
due to the limit for compressor capacity.

Example 6.1 A subsea well, which is located in an ultra-deep water area, is going
to be permanently plugged and abandoned. The well suffers from sustained casing
pressure in A- and B-annulus. Logging data shows a shallow gas zone, which has
not been isolated properly. What is the P&A code for the well.

Solution As the well is a subsea well, the first two letters are SS. The well suf-
fers from SCP which means well integrity issue at cap rock level. By refereeing to
Table 6.1, the P&A complexity of operation for Phase 1 is 4. The shallow gas zone
needs to be secured and as there is uncemented casing at the depth of the gas zone,
by referring to Table 6.2, the complexity of operation for Phase 2 is 4. The well is
located in ultra-deep water area which is beyond conventional vessels. By referring
to Table 6.3, the operation complexity is 4. Therefore, the P&A code system for the
well is: SS-4-4-4.

6.2 Time and Cost Estimation of a P&A Operation

As a candidate well for permanent P&A is not going to be profitable, and all the P&A
cost associated with it are not going to be recovered, cost estimation is an important
process. To understand necessary time and cost of a P&A operation, it is necessary to
identify the factors affecting the operation and to quantify their interaction. However,
it is impractical to identify all the characteristics of a P&A operation. Therefore,
in practice it is important to consider those factors that adequately represent the
P&A operation. The contributing factors can be classified as either observable or
unobservable factors. Observable factors are measured and quantified directly such
as well characteristics, or may need to be represented by a proxy variable, such
as operator experience. Unobservable factors are those kinds of factors which also
affect the P&A operation, but are impossible to quantify, such as project management
skills, communication skills, and readiness level of personnel. The observable and
unobservable factors can be either dependent variables or independent variables.
When time for a P&A operation is estimated, then cost of operation is consequently
estimated.
6.2 Time and Cost Estimation of a P&A Operation 173

6.2.1 Description of Factors

There are many factors and events that impact time and cost associated with P&A
operations. The factors can include well characteristics, well complexity, site char-
acteristics, working unit, operator philosophy, local regulations, exogenous events,
dependent variables, and unobservable variables.

6.2.1.1 Well Characteristics

In P&A operations, characteristics of the well such as well length, hole diameter, and
well inclination contribute to time, cost, and HSE risk. For example, hole diameter
and length of the required plug determine the P&A material volume, and the material
to be removed from the well.

6.2.1.2 Well Complexity

The well complexity can be increased because of different reasons, including but
not limited to: limited access to the desired interval, type of completion, high-
pressure and high-temperature condition, and well integrity issues. Consequently,
increase of well complexity can increase the duration and cost of P&A operation.
Well complexity can also directly influence the type of required working unit.

6.2.1.3 Site Characteristics

Geographical location, distance from the well to the nearest service station, and water
depth at the site for offshore well are some of the main site characteristics.

6.2.1.4 Working Unit

Type of working unit and personnel on board, directly contribute to a large part of the
total P&A cost. Selection of the working unit depends on other factors such as well
complexity, site characteristics, vessel availability for offshore wells, environmental
criteria, etc. Therefore, this factor is a dependent factor.

6.2.1.5 Operator Philosophy

The operator decides when to permanently P&A a well, what type of contract is
necessary, and how to carry out the operation. In addition, duration, P&A design, job
174 6 Work Classification and Selection of Working Units

specification (single well or campaign P&A), and strategies are the main parameters,
which are based on operator preferences, for determining time and cost of P&A.

6.2.1.6 Local Regulations

As discussed in Chap. 1, different authorities have their own requirements with

respect to permanent P&A of wells. Local regulations may impact the time and cost
of the operation. Consider the North Sea where the UK regulation requires 30 (m)
of a continuous qualified plug whereby the Norwegian regulation requires 50 (m) of
a continuous qualified plug.

6.2.1.7 Exogenous Events

There are situations where the P&A operation may be subject to delays. Equipment
failure is an example of such circumstances. If a spare part is not available, then
activities are delayed. Sometimes, equipment or equipment’s parts may be lost in
the well. Fishing or a multiple fishing operation may be necessary to retrieve these
elements. For offshore P&A, activities may be significantly delayed due to weather.
Weather downtime can become an important factor in the total time and cost of an
operation. Severe weather conditions can cause delays for supply boats to deliver
equipment or material which are of a critical stock level. Weather can also impact
anchoring and moving time of floating working units. In some geographical locations,
such as the North Sea, the weather can be too severe and cause the operation to be
suspended. Therefore, weather conditions and waiting on weather time needs to be
considered for P&A.

6.2.1.8 Dependent Variables

The number of days spent to accomplish Phase 1 to Phase 3, is defined as time to

P&A a well. It includes, mooring and demooring (if applicable), time to survey the
well condition, tripping, time spent on barrier installation and its verification, weather
time, and cut and removal of the wellhead.

6.2.1.9 Unobservable Variable

There are many factors known to be difficult to quantify and incorporate directly into
time and cost analysis. Of these one can refer to unique P&A design, incidents during
preparation, project management and leadership skills, availability of technology and
technique, and personnel skills.
P&A design and preparation—Evaluation of well condition and careful planning
is required to complete a P&A project successfully. The first step in P&A design is
6.2 Time and Cost Estimation of a P&A Operation 175

to identify the different permeable zones that needs to be isolated. There are two
different approaches with respect to the number of plugs to be installed: traditional
approach or risk-based approach. In a traditional approach, each hydrocarbon zone
requires its permanent barriers. However, in a risk-based approach, the consequence
of combining formations which contain fluid is carefully studied. If the risk of any
harm to environment or failure of barrier is low, the two or more formations are
grouped and a barrier is installed for them. The installed barrier consists of a primary
and a secondary permanent barrier. Each approach has its impact on time and cost.
In addition, a multidisciplinary team should design the P&A efficiently to deal with
objectives of the operation.
Project management and leadership skills—Appropriate project management
and leadership has to have comprehensive and integrated engineering planning, with
coordinated skills and well defined contingencies. The project is to be executed in
the shortest possible time in collaboration with all team members.
Technology and technique—The impact of technology and technique on perfor-
mance of a P&A operation is extensive. New technology can be enabling or enhancing
or both, and will shift from enabling to enhancing over time, due to learning effects.
Generally, new technology is expensive, but if the performance of the operation and
safety is improved, then costs will decline. It is difficult to find out the impact of new
technologies on estimation of time and costs of an operation. A kind of such tool is
perforate, wash and cement technique which reduces the time of P&A operation by
eliminating section milling (see Chap. 8).
Personnel skill—Another factor which is part of unobservable variables is skill
and experience. During P&A design, experienced engineers can include their learn-
ings from other operations which can significantly influence the time and cost. During
the operation, experienced personnel, crossed trained, can implement their experi-
ences to solve the challenges on site instead of awaiting personnel to arrive from
another site. Hence, the cost can be significantly reduced by suing properly trained
personnel.

6.2.2 Traditional Method for Time Estimation

Traditionally time of a P&A operation is estimated using deterministic values. This

statistical approach, also known as the deterministic method, uses a mathematical
model to estimate the outcomes precisely. In deterministic methods, a deterministic
model governs the outcomes through known relationships among the factors, observ-
able and quantifiable factors, Fig. 6.1. However, there is no room for unobservable
and variable factors. In this method, a given input will always produce the same out-
put which means that the model defines an exact relationship between the variables.
This defined relationship allows prediction of the impact of one variable on the other.
The traditional method assumes certainty in its solution.
The deterministic approach has its advantages and limitations. The advantages
include simplicity of approach, clear assumptions, and transparent communication
176 6 Work Classification and Selection of Working Units

Fig. 6.1 A deterministic

model precisely estimates
the outcome based on the
input factors

of results [2]. The limitations are the prediction’s optimistic bias on good results,
not presenting the full range of possible outcomes. Uncertainty associated with sub-
operations are not included in the final results [2].

6.2.3 Probabilistic Method for Time Estimation

The probabilistic approach, also known as the stochastic method, uses a mathemat-
ical model which presents probability of a random phenomenon. In this method,
the probability of an event occurring again is estimated based on historical data and
governing statistical analysis models. The probabilistic model is likely to produce
different outcomes even with the same initial conditions. So, variation and uncer-
tainty of data on each event are considered in the probabilistic model, Fig. 6.2. In
fact, a probabilistic model includes both deterministic components and random error
components.
The advantages of the probabilistic approach are addressed as: reflecting uncer-
tainties, presenting a range of possible outcomes, including unexpected events, pro-
viding the opportunity to apply sensitivity analysis, possible to include learning
effects, the interaction between sub-operations can be analyzed, and decision mak-
ing process of the operation can be improved [2]. Although the probabilistic approach
introduces advantageous features, there are also limitations and subjectivity associ-
ated with it. A probabilistic model will not and should not be expected to identify and

Fig. 6.2 A probabilistic model includes uncertainty of input data and includes uncertainty in the
outcome values
6.2 Time and Cost Estimation of a P&A Operation 177

capture all risks as the presence of unknowns are always part of the story. Considering
the results of a probabilistic approach without the accompanying philosophy behind
them has limited value. Defining the relationship of inputs is not straight forward
[3].

6.2.3.1 Refreshing Statistics

It is important to avoid any misinterpretation or misconstruction of results obtained

by probabilistic estimates. Therefore, there are terms which need to be elaborated
and be properly used. The most common terms are percentiles, mode, mean and
median [4].
Percentiles (also known as the “P” number)—In probabilistic methods, the range
of outcomes produced by models are divided into 100 parts and presented by 99
percentiles, P1 –P99 . Each percentile contains 1% probability of the outcomes. Of
these percentiles, three percentiles are the most common to be used when discussing
the results. These include P10 , P50 , and P90 (see Fig. 6.3). P10 is the percentile whereby
10% or less of outcomes have the probability to fall in the range of P1 –P10 . P90 is the
percentile whereby 10% or less of outcomes have the probability to fall in the range of
P90 –P99 . In other words, P1 –P10 and P90 –P99 are less likely outcomes. P50 , also known
as median, is the probability of having 50% of the outcomes equal to or exceeding the
best estimate. Similarly, 50% of the outcomes equal or less than the best estimate. The
distribution curve of outcomes can be symmetric or asymmetric (skewed), Fig. 6.4.
For an asymmetric distribution, the P50 and mean value are unequal.

Fig. 6.3 Distribution outcome with statistical terms used in probabilistic method of estimation
178 6 Work Classification and Selection of Working Units

Fig. 6.4 Symmetric and a symmetric distribution with mode, median and mean values

Mode (also known as the Most Likely Value)—This is the most frequent value in
the data set which occurs during thousands of iterations of time or cost estimation.
On a probability frequency chart, the mode is the value at the highest point, see
Fig. 6.4.
Mean (also known as the Expected Value)—This is the arithmetic average, sum
of values of a data set divided by number of values, of all the outcomes of simulation
iterations. If mean values are summed up together, a meaningful result is obtained
which is commonly used for Authority for Expenditure (AFE) or analysis of a single
well.
Median (also known as the “P50 ”)—This is the middle value which separates the
greater and lesser outcomes of a data set.

6.2.3.2 Probability Distributions

In the probability approach, an offset data is a value which indicates the distance
between the beginning of the value and a given point. Probability distributions are
used to characterize the behavior of random variables. To fit offset data, there are
several probability distributions to choose: normal, triangular, lognormal, and uni-
form [5]. Of these, the two widely accepted probability distributions are uniform
distributions and triangular distributions (the two lower left distributions shown in
Fig. 6.2). The uniform distributions are the simplest of all and are described by a
minimum and a maximum value. The triangular distributions are an extended form
of uniform distributions by adding the mode, the most likely value.
When considering probability distributions three terms are distinguished: Proba-
bility Mass Function (PMF), Probability Distribution1 Function (PDF) and Cumu-
lative Distribution Function (CDF). To clarify the difference between these terms, it
is necessary to understand two main types of random variable distribution: discrete
or continuous. A continuous random variable distribution is a curve with an infinite
number of values on it which characterizes the distribution of a random variable.

1 Distribution is also noted as Density in some references.

6.2 Time and Cost Estimation of a P&A Operation 179

Fig. 6.5 Random variable distributions: a continuous, b discrete

To specify a local location on a continuous distribution, probability, one exact value

cannot be given but an interval is presented. So to specify the interval on a continuous
distribution, a PDF represents the interval (see Fig. 6.5a). Examples of continuous
random variables are distance, time and asset returns in finance. A discrete ran-
dom variable distribution is obtained by counting and is a finite measurement (see
Fig. 6.5b). So the probability of a random variable is an exact value. Therefore, a PMF
presents the outcome. Briefly, continuous random variables are measured, however,
discrete distribution random variables are counted.
When considering a continuous distribution of a random variable, to present the
probability of outcomes, approximately equally, of an input value, PDF is used. But
to present the outcome probability of an input value, CDF is used.

Example 6.2 Figure 6.6 shows Monte Carlo simulation results of time estimation
for a subsea single well which is going to plugged and abandoned. In one scenario,
the entire operation is supposed to be carried out by a semisubmersible rig while in
another scenario the operation is carried out partly by a semisubmersible unit and
partly by a vessel.
(a) What will be the most likely value, the mode, for time of this operation when
performing the operation entirely by deploying a semisubmersible unit and what
will be the occurrence probability of the most likely value?

Fig. 6.6 Time distribution for P&A of a single well: a PDF, b CDF [2]
180 6 Work Classification and Selection of Working Units

(b) What will be the most likely value, the mode, for time of this operation when
performing the operation by deploying a combination of a semisubmersible
unit and a vessel and what will be the occurrence probability of the most likely
value?
(c) Interpret the outcomes of PDF and CDF of having 42 days when using a
combination of a submersible and a vessel.

Solution The probability is presented by a value from 0 to 1.0 or in percentage, from

0 to 100%.
(a) By referring to the PDF curve, semisubmersible rig, the occurrence proba-
bility of the mode is approximately 85.7% and the associated time will be
approximately 39 days.
(b) By referring to the PDF curve, semisubmersible rig and vessel, the occurrence
probability of the mode is approximately 83% and the associated time will be
approximately 42 days.
(c) By considering the probability of having the time of operation 42 days, when
combination of semisubmersible and vessel are employed, the CFD is approx-
imately 55%. In other words, having the expected time of the P&A operation
being less or equal to 42 days is 55%.

Offset data analysis includes data gathering and analyzing the offset data.
Although this planning procedure is time consuming it should be carried out prop-
erly as more accurate input results in a better quality of outcomes. Therefore, during
data gathering, team members need to discuss and analyze the data. Non-Productive
Time (NPT) should be split into predicted and unpredicted offset data and analyzed
separately. It is important to document the analysis of offset data.
Considering time estimation of P&A operations, limited or poor offset data
requires predominantly expert judgement. However, this might become a challenge
as biased positive and negative experiences of experts may lead to an unrealistic
understanding of their ability to assess uncertainties. In addition, poor handling of
uncertainty may also be rooted in outdated methodology and poorly quantitative
ideas about it.

6.2.3.3 Central Limit Theorem

When building a model for time estimation, the Central Limit Theorem (CLT) can
be used. According to the CLT, when independent random distributions, of any
distribution shape, are added, the sum of probability distribution tends toward a
normal distribution.
To reduce the impact of the CLT and avoid unrealistically narrow results of estima-
tions, three main ways have been suggested and addressed. These includes: restricting
the number of input variables, avoid using too narrow input ranges and not underes-
timating uncertainty, and dependencies between input variables to be addressed by
use of correlation [4].
6.2 Time and Cost Estimation of a P&A Operation 181

Fig. 6.7 Five general steps of Monte Carlo simulation

6.2.3.4 Monte Carlo Simulation of Time Estimation

The concept of the Monte Carlo was developed by a Polish-American mathematician,

Stanislaw Ulam, in the late 1940s. Before Monte Carlo simulation was developed,
statistical sampling was used to estimate uncertainties of deterministic simulations.
Monte Carlo simulation is a method of estimating the value of an unknown quantity
by deploying the principles of inferential statistics. The inferential statistics make
inferences and predictions about population (a set of examples) and samples (a proper
subset of a population). In other words, Monte Carlo is a numerical technique to
forecast the outcomes based on the available evidences [6]. The predicted outcome
depends on the size of input variables and the variance. Since the introduction of
the Monte Carlo method and with advancement of computers, application of the
technique has been adapted in different fields, including a wide variety of problems
in the petroleum industry [2, 4, 7–11].
The Monte Carlo simulation method can be divided into five steps (see Fig. 6.7):
defining the model, data gathering, defining input distributions, sampling input
distributions, and interpreting and using the results.
Defining the model—A Monte Carlo simulation begins with a model. The fore-
caster needs to clarify the scope of the analysis including the contingencies and
possibilities, to be determined. Once done, appropriate input parameters are speci-
fied to the model. Then, the output values are calculated. Each of these parameters
are viewed as random parameters [5].
Data gathering—In a P&A operation, the assumption is that the exact values of
the model inputs are unknown, so offset data are used which means uncertainty in
modeling. Data gathering is necessary to quantify this uncertainty. Offset data is the
key step in Monte Carlo forecasting.
Defining input distributions—When offset data are ready, the probability dis-
tributions are defined and sampling of each uncertain input value to the model is
accomplished. This process can be subdivided into two steps: selection of distribu-
tion shape (e.g. uniform, normal, lognormal, etc.) and distribution parameters (e.g.
minimum, standard, deviation, P90 percentile, etc.).
Sampling input distributions—Monte Carlo simulation performs random sam-
pling from input distributions and conducts a large number of trials. A trial is the
process of selecting one value for each input and calculating the output or possible
results. A simulation is a series of hundreds or thousands of repeated trials for which
the outputs are stored. The selection of random numbers from the input distributions
can have a significant effect on the outcomes.
182 6 Work Classification and Selection of Working Units

A major driver of the final range of outcomes is correlation. A correlation is

defined as any relationship or dependency between two input quantities which moti-
vates their joint distribution to deviate from statistical independency [4, 11]. Corre-
lation is part of physical reality and as the relationships between input quantities are
often not amendable to quantification, correlations are quite subjective and amor-
phous [12]. Spearman’s rank order, Pearson, and Kendall Tau are some common
correlations to consider the dependency [13]. The dependency between inputs is
assigned with a value between –1 and +1 whereas full independency is shown by
–1 and full dependency by +1. Spearman’s rank order correlation, also known as
Spearman’s rho, is a measure of statistical dependency between the rankings of two
variables. For two data sets of X and Y, Spearman’s rank order correlation coefficient
is given by [13].
  2
r6×
ρ =1−   (6.1)
n× n −1
2

r = x − y (6.2)

where n is the number of correlated data pairs between the data sets, and x and y
correspond to ranks of the data sets. It should be noted that the Spearman’s rank
order correlation is independent of distribution of data.
Pearson correlation coefficient for two data sets is given by:
n   
X i − X  Yi − Y 
i=1
P =   (6.3)
n  2 n  2
i=1 (X i − X ) i=1 (Yi − Y )

 
where Xi and Yi are a pair of the correlated data sets, X and Y are their mean
values, and n is the number of correlated data pairs between the data sets. One of the
main drawbacks of this correlation is that a non-linear transformation between two
variables is not preserved. In addition, this correlation does not capture a non-linear
relationship between the two variables.
Unlike the Spearman’s rank order and the Pearson’s correlations, the Kendall Tau
rank correlation coefficient captures the dependency pattern between two variables.
The Kendall Tau rank correlation coefficient is given by:

(number o f concor dant pair s) − (number o f discor dant pair s)

τ= n(n−1)
(6.4)
2

where n is the size of samples, concordant pairs are the pairs that are moving in the
same direction, and discordant pairs are the ones that are moving in the opposite
direction. When the correlations are generated, they will be included in the model.
Interpreting and using the results—PDF and CDF are the basic outcomes of a
Monte Carlo simulation, for each quantity [2]. In order to avoid any false outcome or
misinterpretation, these must pass some quality-assurance or a sensitivity analysis
6.2 Time and Cost Estimation of a P&A Operation 183

prior to being used. When the process is successfully completed, the distribution
curves are ready to be used in a variety of processes of a P&A operation, including
risk analysis and decision making, budget allocation, setting targets and expectations
[4, 11].

6.2.4 Regression Method for Time Estimation

A regression approach uses a model in which deterministic and probabilistic models

are applied. The contribution of the deterministic part in the regression model pro-
vides the opportunity that output results depend on input values. But the contribution
of the probabilistic part in the regression model does not allow to produce an exact
value for output values.

References

1. Oil and Gas UK. 2011. Guideline on well abandonment cost estimation. The United Kingdom
Offshore Oil and Gas Industry Association: United Kingdom.
2. Moeinikia, F., K.K. Fjelde, A. Saasen, et al. 2015. A probabilistic methodology to evaluate the
cost efficiency of rigless technology for subsea multiwell abandonment. SPE Production and
Operations 30 (04): 270–282. https://doi.org/10.2118/167923-PA.
3. Moeinikia, F., E.P. Ford, H.P. Lohne, et al. 2018. Leakage calculator for plugged-and-abandoned
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Chapter 7
Fundamentals of Plug Placement

The best practice of permanent plug and abandonment requires a cross sectional
barrier, which is known as rock-to-rock barrier. The barrier is placed at the right
depth where formation is capable to hold the maximum anticipated pressure. To
fulfill the requirement, two general situations could be encountered: openhole plug
placement or cased hole plug placement.

7.1 Openhole Plug Placement

To place a permanent cement plug in an openhole, the fluid in the well needs to
be replaced with cement. As the compositions and properties of drilling (or milling)
fluids and cement slurries vary widely, severe contamination can occur at the interface
of drilling fluid and cement slurries due to incompatibility. Therefore, fluid removal
during cement plug placement is a crucial task.

7.1.1 Fluid Removal

Fluid removal has been an interest for cement engineers for many years. To achieve
the objectives, drilling fluid and pre-flushes must be fully removed from the open-
hole interval and be exchanged fully with cement or any plugging material. The fluid
removal process is a function of borehole quality, circulation and displacement effi-
ciency, fluid conditioning and properties of drilling fluids, spacers and washes [1–6].
Fluid removal process can be carried out in two main different ways: hydraulically or
mechanically. In the hydraulic process, spacer fluids with specific viscous behavior
are pumped ahead of cement slurry to displace drilling or milling fluid. The contam-
ination effect of these spacer fluids on cement is less compared to drilling or milling
fluids.
© The Author(s) 2020 185
M. Khalifeh and A. Saasen, Introduction to Permanent Plug
and Abandonment of Wells, Ocean Engineering & Oceanography 12,
https://doi.org/10.1007/978-3-030-39970-2_7
186 7 Fundamentals of Plug Placement

One major difference, when considering milling operation during permanent

P&A, is that a window of casing is milled to reach the formation and therefore,
milling fluid is used instead of drilling fluid. So, compatibility of cement and milling
fluid is strongly dependent on the chemistry and properties of milling fluid; therefore,
milling fluids will be reviewed briefly.

7.1.2 Milling Fluid

When casing is milled away, the generated debris known as swarf (Fig. 7.1) needs to
be transported to surface or left behind in the bottom of the well as will be discussed
in Chap. 8. As drilling fluids do not have the transportation capacity of swarf, spe-
cial fluids known as milling fluids are used. Milling fluids are usually water based.
Of milling fluids one can list: bentonite/bicarbonate mud, bentonite/MMH (Mixed
Metal Hydroxide) mud, xanthan gum/sea water mud, and potassium formate milling
fluid [7–9]. Considering the geometry of the circulation system and non-Newtonian
behavior of milling fluids, the hydrodynamics of swarf transportation and hole clean-
ing are identical to cutting transportation and hole cleaning during drilling. However,
given the fact that swarf are much larger (see Fig. 7.1), having higher density com-
pared to rocks and having irregular shapes, the problems are different [7]. A desired
milling fluid should have high transportation capacity with low shear rate viscosity.
When considering the transportation of swarf by milling fluid, settling velocity of
swarf in static and dynamic fluids and transportation velocity of debris are important.
Experimental studies show that in static fluids the gel strength and effective viscosity
of milling fluid are critical factors besides, the shape, surface area and the settlement
orientation of swarf. The gel strength causes suspension of swarf but when the swarf
is sharp, the gel strength can be overcome.

Fig. 7.1 Swarf from a milling operation in the North Sea (Courtesy of equinor)
7.1 Openhole Plug Placement 187

When swarf is in dynamic conditions, flowing fluid, the mean circulating velocity
required to prevent the swarf from settling is significantly higher. In dynamic condi-
tions, there are areas close to the wall where the flow velocity is near zero and large
volumes of swarf will be located in an un-sheared zone [7].

7.1.3 Hydraulic Mud Removal

Spacer or displacement fluids are type of fluids which minimize the cement con-
tamination and improve the fluid removal efficiency. Any liquid which physically
separates a special liquid from another is known as spacer fluid. In most practical
operations, a cement slurry should have turbulent flow conditions to displace drilling
fluid. But the flow regime cannot be achieved because of operational restrictions.
So, spacer fluid needs to be selected to reach a turbulent or pseudo-laminar flow to
remove the left fluids. Displacement fluid is usually used to force a cement slurry
out of the workstring or into the annulus behind casing.
A spacer should have the following characteristics: compatible with a given type
of drilling fluid or milling fluid, including bentonite muds and polymer based muds.
The spacer properties should not affect the cement slurry viscosity nor changing the
pumping time; to tolerate high solids and mud cake; to tolerate addition of wetting
agents, dispersants, friction reducers, and retarders; low-fluid-loss properties; and
permitting turbulence flow regime at low pumping rates for efficient mud removal
[10–14]. Although spacers are used to remove drilling fluid and mud cake but it is
unlikely to remove the mud cake without using mechanical aids.

7.1.4 Mechanical Filter Cake Removal

To clean the formation interface for achieving better bonding between the plugging
material and formation, mechanical devices known as wall cleaners can be utilized.
Mud cleaners or scratchers (sometimes called mud stirrers) are mechanical devices
used to remove the mud or condition the drilling fluid filter cakes off of openhole wall
for achievement of a better shear bond strength and hydraulic bond strength. The wall
cleaning operation is different from reaming and under-reaming. Reaming operation
is for enlarging wellbore by utilization of a mechanical device. However, enlarging
hole is avoided during plug placement as it creates challenges during cement place-
ment. Mechanical cleaners are fastened on the outside of workstring to agitate the
mud and make it easier to displace it. The introduced motion breaks the gel strength
of the mud filtercake and with help of wash fluid, the drilling fluid is displaced easier.
The rotational type and the reciprocation type scratchers are the two commonly used
types, see Fig. 7.2.
The rotational type scratcher cleans the formation when workstring is rotated. A
continues length of scratcher is fastened on the workstring, Fig. 7.2a. The steel spike
188 7 Fundamentals of Plug Placement

Fig. 7.2 Two commonly used scratchers: a rotational type scratcher, b reciprocation type scratcher

or steel cable sets are installed on workstring with different phasing to improve the
cleaning efficiency.
The reciprocation type scratcher cleans the formation has either steel spikes or
steel cables. Depending on the length of zone to be cleaned, one or more scratchers
are attached to outside of workstring. Each scratcher is limited by two rings or clamps
in the desired interval: one above and one below, Fig. 7.2b. These types of scratchers
clean the formation when workstring is moved upwards and downwards.
During the mechanical cleaning operation, a wash fluid is pumped to displace and
wash the mud and filter cakes. If the plug is off-bottom plug, when the interval is
clean, a viscous reactive pill is pumped to create a base for cement plug and keeping
plug in position, Fig. 7.3. Viscous reactive pill is a special blend of drilling fluid
containing silicate component, which has higher density than cement slurry. When
the calcium in the cement reacts with the reactive pill, a gel forms that prevents flow
between cement and the pill. The reactive viscous pill is compatible with cement
slurry and its high yield stress provides base functionality while cement sets. When
the reactive viscous pill is in place, the cement slurry is placed on top of it which is
across the cleaned formation.
If the drilling fluid present in bore is an oil-base mud, a viscous spacer is necessary
before and after pill to minimize slurry contamination. The failure roots of plugs in
openholes have been investigated by different authors and include the following [16]:
7.1 Openhole Plug Placement 189

Fig. 7.3 Cement plug is placed in an openhole on a viscous pill, a ideal cement set, b unsatisfactory
results for a cement plug placed on a lighter fluid (Taken from well cementing) [15]

• Poor mud removal

• Poorly designed slurry properties
• Incorrect estimation of slurry volume
• Poor downhole temperature estimation
• Poor job execution and placement
• Instability of the interfaces and swapping.
When cement plug is placed, it is left undisturbed until it develops high enough
strength. When cement plug solidified sufficiently, top of cement is dressed off (top
of cement is drilled out until hard cement is reached). As the plug is in an openhole,
pressure testing is meaningless. Therefore, the TOC is tagged and a certain weight is
applied on cement. If position of cement did not change, the cement plug is regarded
as qualified. However, if the plug is not capable to hold the weight or the tagged
TOC is not at the right depth, the plug is regarded as disqualified and a new cement
plug needs to be established. In case of wireline and coiled tubing utilization, the
maximum weight availability is limited compared to use of drillpipe.

7.2 Cased Hole Plug Placement

When considering plug placement for a cased hole, two different scenarios can be
considered: either qualified annular barrier is proven or annular barrier is disqualified.
Each case can dictate different operations.
190 7 Fundamentals of Plug Placement

7.2.1 Qualified Annular Barrier

If the annular barrier behind casing is qualified, then a mechanical plug is installed
to create a foundation for cement plug. The mechanical foundation is not a part
of permanent well barrier envelope but has the following advantages: avoiding gas
invasion of cement while it sets, avoiding dispositioning of cement while it sets,
and minimizing the cement contamination. When the mechanical plug is installed,
it is pressure tested. If it successfully passes the pressure test, then cement plug
is poured on top of it and left undisturbed until it develops high enough strength.
When cement is solidified, cement is dressed off and tagged. As the mechanical
plug has already passed the pressure test, the pressure testing of the cement plug
is meaningless. However, if mechanical plug has not tested or did not successfully
pass the pressure test, the cement plug is pressure tested and documented. Pressure
test failure of cement plug means that another cement plug needs to be established.
Different authorities require different plug length and different rate of pressure test.

7.2.2 Disqualified Annular Barrier

Wherever the quality of casing cement is not qualified or there is no annular cement,
access to the annular space behind casing should be established to place a qualified
barrier both inside and outside the casing. The conventional approach is section
milling. The operation of removing a part of casing by milling or machining the
casing is called section milling. To mill out casing steel, special knives are employed.
Section milling is explained in Chap. 8. New methods exist called Perforate, Wash
and Cement (PWC). PWC is described in the next chapter.

7.3 Plug Placement Techniques

7.3.1 Balanced-Plug Method

This is the most common plug placement technique used for placing permanent
plugs. A work string is run into the hole to the desired depth for the plug base. As
the work string is surrounded by mud, spacer and chemical wash are pumped ahead
and behind the slurry to avoid mud contamination and ensure wetting of the surface
of casing or formation. Cement slurry is pumped down through the work string and
up in the annulus between the work string and casing or formation. The volumes of
spacer ahead and behind the slurry are calculated so that the spacer height inside and
outside the work string end up at the same level, Fig. 7.4.
7.3 Plug Placement Techniques 191

Fig. 7.4 Balanced-plug placement technique, a common work string, b deploying a stinger to
minimize the agitation of slurry during pulling out of slurry

Example 7.1 You are asked to install a balanced plug across a suitable formation
whereby the plug base is supposed to be at 10,000 ft measured depth. For this job,
a 4½-in. drillpipe will be used as a workstring in an openhole with 8¾-in. diameter.
The plug length is expected to be 200 ft and 24 bbl of fresh water will be pumped
ahead of cement as spacer. Additional information: string capacity = 0.01422 bbl/ft,
annular capacity = 0.0547 bbl/ft. Assume the wellbore is vertical.
(a) Calculate the required volume of cement.
(b) Calculate the height of cement plug with workstring in.
(c) Calculate the required volume of spacer behind slurry.
(d) Calculate the volume of displacement fluid.

Solution The goal of balanced plug placement technique is to have an equal drillpipe
pressure and annular pressure, at the plug base (see Fig. 7.5). It can be written as:

PC D + PW D + PM D = PC A + PW A + PM A

PD = PA (7.1)

whereas ΔPCD is the hydrostatic pressure exerted by cement inside workstring, ΔPWD
is the hydrostatic pressure exerted by spacer inside workstring, ΔPMD is the hydro-
static pressure exerted by mud inside workstring, ΔPCA is the hydrostatic pressure
exerted by annular cement, ΔPMA is the hydrostatic pressure exerted by annular
spacer, and ΔPMA is the hydrostatic pressure exerted by annular mud.
In this example, the spacer ahead and behind the slurry are the same type with
the same characteristics. However, there are circumstances where spacer ahead and
behind the slurry are different. The latter case is given as problem, at the end of this
chapter.
(a) Volume of cement assuming no washout:
192 7 Fundamentals of Plug Placement

Fig. 7.5 A balanced plug

whereas the spacer inside
and outside workstring are in
the same level and the same
chemistry

π D2
V = ∗h (7.2)
4
where D is wellbore diameter (ft), and h is plug length with no workstring inside
plug.

π × 8.752 (1 ft)2  
V = × 200 × = 83.517 ft3
4 (12 in.) 2

(b) Height of cement plug when workstring is inside plug is given by equation [15]:

V
H= (7.3)
C+S

where C is annular capacity (bbl/ft), S is workstring capacity (bbl/ft), V is

volume of slurry (bbl), and H is height of plug with pipe in place (ft).
 
83.517 ft3 × 1 bbl
5.615 ft3
H= = 215.814 ft
(0.01422 + 0.0547) bblft

(c) The required volume of spacer behind slurry is supposed to be at the same height
as spacer ahead of slurry. It means:
7.3 Plug Placement Techniques 193

L sp2 = L sp1 (7.4)

Then, it can be written as:

Vsp2 Vsp1
= (7.5)
S C
where V sp1 is the spacer volume ahead of slurry (bbl) and V sp2 is the spacer
volume behind slurry (bbl).

Vsp2 24
=
0.01422 0.0547
Vsp2 = 6.24 (bbl)

(d) Volume of displacement fluid is the amount of fluid which needs to be pumped
behind spacer to level the heights and keep the pressure equal, at the base of
plug. The displacement volume in bbl is given by Eq. (7.6):
  
Vdis = S × L dis − H + L sp2 (7.6)

whereas Ldis is length to be displaced which is measured depth (ft), and Lsp2 is
length of spacer behind slurry.

Vdis = 0.01422 × [10,000 − (215.814 + 438.7)] = 132.89 bbl

Cement plug contamination is one of the main challenges associated with the
balanced plugs and can occur in three different ways: mud contamination during
pumping, contamination caused by cement agitation while pulling the work string
out of the plug, and plug displacement while it sets. Contamination during pumping
the slurry may occur in the slurry-spacer interface and due to poor mud removal from
formation or casing surface. The best practice to minimize the effect is to properly
design the type, volume and flowrate of spacer and chemical wash or use a two-plug
method.

7.3.2 Two-Plug Method

To minimize the contamination of the cement plug with the fluid ahead and behind,
the two-plug method is used (see Fig. 7.6). In this technique, a wiper dart is run
ahead of the cement plug (between the lead cement slurry and spacer) and another
wiper dart behind the slurry (between the tail cement slurry and spacer). Thus, from
surface down to a depth close to the tailpipe or stinger, the slurry is fully separated
from the spacer and consequently, the risk of contamination is decreased. Each wiper
dart has a diaphragm which holds pressure up to a certain point and ruptures at a
194 7 Fundamentals of Plug Placement

Fig. 7.6 Two-plug method; a first wiper dart separates cement from spacer until it lands on the
locator sub, b second wiper dart separates cement from spacer behind cement, c the diaphragm of
the first wiper dart is sheared due to the increased pressure and cement slurry passes through it,
d second wiper dart seats on the first wiper dart and its diaphragm is sheared due to the increased
pressure and the spacer passes through it [15]

higher pressure. The work string is equipped with a locator sub close to the stinger
or tailpipe. When the first wiper dart seats on the locator sub, the pressure increases
until the diaphragm ruptures, and the cement passes through the first wiper dart.
Afterwards, the second wiper dart seats on the first wiper dart and causes a pressure
increase. Due to the increased pressure, its diaphragm is ruptured and spacer passes
through.

7.3.3 Dump Bailer Method

It is a wireline tool for placing small volumes of slurries at the desired depth with a
minimal contamination. It is normally used only for onshore wells. The bailer is filled
with cement and run into the wellbore. When it reaches the desired depth, the bailer
cap is opened electronically via a signal or mechanically via touching a mechanical
foundation. It is a common practice to use a mechanical foundation when a dump
bailer is going to be used, Fig. 7.7. Some of its advantages are: minimizing the effect
of contamination, it is inexpensive, drilling rig is not necessary for the operation,
plug depth is easily controlled and operational time is significantly less compared
to other methods. Low capacity of bailers and multi runs may be necessary, cement
7.3 Plug Placement Techniques 195

Fig. 7.7 Dump bailer

method for plug placement

may set inside the bailer due to static conditions inside the bailer while running it
down to the desired depth, and uncertainties associated with mud or spacer removal
are some of the limitations for this method. It should be noted that slurry gelation or
instability must be avoided to ensure that the slurry can exit the dump bailer.

7.3.4 Coiled Tubing Method

Coiled tubing is a long continuous pipe wound on a spool. The pipe is straightened
prior to being pushed into the wellbore and rewound to recoil the pipe back onto
the transport and storage spool. Depending on the pipe diameter and the spool size,
coiled tubing can range from 2000 to 15,000 ft or greater lengths. Table 7.1 presents
typical coiled tubing sizes.
Utilization of coiled tubing for remedial cementing began in the early 80’s. Since
then, the technique has received considerable attention. This technique has proved
to be very economical to place small volumes of cement slurries required in curing
channeling behind tubulars, blocking off perforations, squeezing cement into perfo-
rations, curing lost circulation zones during drilling, and placing cement whipstocks
[17]. As the pipe is continuous, challenges associated with making connections and
the need for a conventional rig are minimized which means it is a cost effective
technique. However, there are some concerns limiting the use of coiled tubing for
cement plug placement including fatigue problems, hole cleaning, special cement
slurry design, unit space and capacity, crane capacity, and local regulations.
 196

Table 7.1 Industry coiled tubing sizes available to date for material grades GT-80 (courtesy of global-tubing)
Specified dimensions Axial load capacity Pressure capacity Torsional strength External Internal
displacement capacity
per 1000
ft
Outside Wall Inside Nominal Yield Tensile Yield Hydrotest Yield Ultimate Barrels Barrels
diameter thickness diameter weight load (lb) load (lb) pressure pressure (ft/lb) (ft/lb) tmin
(in.) (in.) d (in.) (lb/ft) tnom tnom (psi) 90% (psi) tmin
1.250 0.190 0.870 2.16 50,620 55,680 23,040 15,000 1,097 1,206 1.52 0.74
1.500 0.087 1.326 1.32 30,900 33,990 8,850 7,970 955 1,051 2.19 1.71
1.750 0.109 1.532 1.91 44,950 49,950 9,510 8,560 1,609 1,770 2.97 2.28
2.000 0.109 1.782 2.21 51,800 56,980 8,320 7,490 2,149 2,364 3.89 3.08
2.375 0.125 2.125 3.01 70,690 77,750 7,950 7,160 3,463 3,809 5.48 4.39
2.625 0.134 2.357 3.57 83,890 92, 280 7, 740 6,970 4,571 5,028 6.69 5.40
2.875 0.156 2.563 4.54 106,600 117,260 8,240 7,420 6,330 6,963 8.03 6.38
3.250 0.156 2.938 5.17 121,310 133,440 7,290 6,560 8,236 9,060 10.26 8.39
3.500 0.175 3.150 6.23 146,240 160,870 7,630 6,870 10,708 11,778 11.90 9.64
4.500 0.224 4.052 10.25 240,730 264,800 7,610 6,850 22,639 24,962 19.67 15.95
5.000 0.276 4.448 13.96 327,690 360,460 8,510 7,660 34,231 37,654 24.29 19.22
7 Fundamentals of Plug Placement
7.3 Plug Placement Techniques 197

Fatigue problems—Coiled tubing fatigue life is a major area of concern as the

coiled tubing diameter increases for cementing applications. Each time that coiled
tubing is spooled on and off the reel and over the gooseneck of the coiled tubing unit,
it is stressed. This concern is greater in coiled tubing with larger diameters. Another
cause is the internal pressure in the coiled tubing during bending and straightening
[18]. As there is no practical non-destructive means of measuring the amount of
damage accumulation, coiled tubing lifetime prediction models have been developed
to predict the coiled tubing properties.
Hole cleaning—Limited flow capacity due to the size of the coiled tubing and
lack of mechanical agitation effects through pipe rotation reduces the hole cleaning
efficiency in large hole sizes [19].
Unit space and capacity—When considering the feasibility of coiled tubing for
cementing, the unit deck area for placing the coiled tubing equipment such as reel,
injector, pumping equipment, cementing equipment, and testing equipment need to
be studied. In addition, the unit structure should have the capacity to hold the weight
of equipment without introducing a risk of failure. For onshore wells the soil and the
area should be able to hold the weight and also for offshore wells platform, drillship,
vessel, semi-submersible or other working units the weight must be considered.
As cementing utilizing a coiled tubing unit requires larger pipe diameters, the size
and capacity of pipe handling equipment (e.g. injector heads, reels, well control
equipment, etc.) have to be increased. Therefore, the unit space and capacity need
particular consideration.
Crane capacity—In case of offshore activities, platform cranes must be able to
lift up equipment from a supply boat to platform or any other offshore working unit
[20]. The increase in weight and dimensions created by larger pipe diameters require
higher crane capacity and introduces additional hazards.
Local regulations—Regulations aim for performing a safe coiled tubing operation
which requires quality control of coiled tubing, wellsite safety standards, and safe
deployment of tools in and out of the well. Well control equipment (e.g. BOPs),
pressure rating of coiled tubing, fatigue prediction, unit capacity, and crane capacity
are some of the main concerns focused on by local regulators. However, different
regulatory authorities have different criteria.
Cement slurry design—As coiled tubing has a lower flow capacity compared to
drillpipe, a standard coiled tubing cement recipe is not the same as a standard primary
cement recipe. Due to the mixing energy introduced by coiled tubing on the cement
slurry, a mechanical acceleration result. Therefore, a typical cement slurry designed
for placement with coiled tubing has a longer thickening time, and lower viscosity
and yield stress [21].
198 7 Fundamentals of Plug Placement

7.4 Mud Displacement During Cementing

The replacement of drilling fluids with cement to establish a barrier and to seal for-
mation pressures hydraulically is the main task to be achieved during plug placement,
besides the prime physical properties of the cured cement. Several parameters influ-
encing mud displacement efficiency during plug placement include: hole geometry
and inclination, flow rate, degree of turbulence, ECD, cement or mud and spacer
design, hole conditioning, rheological behavior, buoyancy and plug stability, pulling
out of plug, size of work string, and centralization of work string [3, 22–26]. Obvi-
ously, no single technique, will magically make mud displacement and cementing a
success.
Hole geometry and inclination—The geometry of openhole where the cement plug
is to be placed is very important for mud displacement and pumping of the correct
volume of cement. When the milled section (openhole) has a constant diameter, it
is referred to as in-gauge. An in-gauge hole has a round cross section but as the
cross section starts to deviate from the round shape, it is referred to as an oval hole,
Fig. 7.8. If the milled section has variations in diameter, it is called an irregular
wellbore geometry, and has resulted from washouts.
When washouts exist, the annular flow velocity is less than for in-gauge portions
of the hole. If the annular velocity is low enough, the mud will be left in the washout
in a gelled state and the mud removal by cement becomes very difficult. Another
challenge introduced by washouts is that if there is a large uncertainty in hole size, the
cement volume will be underestimated and the plug length will be less than required.
Therefore, the hole is usually callipered to better describe the wellbore geometry.
In deviated holes, unstable fluid interfaces with regards to gravitational forces,
and fluid contamination introduce complications to balance the fluids during plug
placement. A properly designed plug can be contaminated during pulling the tailpipe
of the work string out of the cement plug, especially in deviated sections [27]. In
addition, deviated boreholes intensify challenges related to free fluid and particle
segregation [28].
Flow rate—Another major parameter which affects the displacement process is
the flow rate. As drilling fluids and cement slurries are non-Newtonian fluids, they

Fig. 7.8 Caliper log may not be able to read the oval-hole diameter
7.4 Mud Displacement During Cementing 199

Fig. 7.9 Different flow regimes in which a non-Newtonian may exist (balanced-plug placement
technique)

require a certain pressure drop to establish a significant flowrate. There are two
possible flow regimes that a non-Newtonian fluid may have (see Fig. 7.9); laminar
flow and turbulent flow. Sometimes plug flow regime is also defined as another flow
regime but it is a pattern of laminar flow. As shown in Fig. 7.9, the bulk annular
velocity profile (dashed lines) and the actual velocity profile (solid lines) are not
equal, and the axial velocity (arrows) in the laminar flow regime is not as uniform
across the annulus as in the turbulent flow regime. Axial velocity distribution is a
maximum in the center of each flow regime and higher than the axial velocity of fluid
adjacent to the boundaries [29]. Therefore, mud removal from boundaries might be
complex and ineffective.
Cement contamination by drilling fluid is more prone when the drilling fluid
removal is inefficient. Haut and Crook [29] showed that the contamination is due
to instabilities occurring at the cement-mud interface where the velocities are not
strictly axial. The formation of instabilities are a result of nonlinear coupling of
changes in shear rate and shear stress at the interface of the fluids, and lead to mud
channeling.
Degree of turbulence—In order to achieve a turbulent flow regime for cement, a
high flow rate is required; however, it may be unachievable if the slurry has a high
viscosity. When a shear force is applied on a non-Newtonian fluid, the fluid resists
to flow and undergoes an elastic deformation until the elastic structure breaks down
(yields) at some point and the material begins to flow [30]. In practice, turbulent flow
of cement during plug placement is less likely to be achieved because of operational
200 7 Fundamentals of Plug Placement

limitations. Nevertheless, from a practical point of view, it is important that the

frictional pressure drop of cement to be higher than the frictional pressure drop of
drilling fluid.
Equivalent circulating density—Long-term zonal isolation requires effective mud
displacement which requires the use of high pumping rates during cementing. How-
ever, when considering a depleted formation or a subsided field, the formation fracture
pressure is lower than the original formation fracture pressure and consequently a
narrow pressure window should be expected and tight ECD management is a prior-
ity. Therefore, pumping rates during cementing operations are limited. High flowrate
results in high frictional pressure, which may exceed the fracture pressure of the for-
mation. This scenario gets even more complex in depleted long horizontal wells.
Modifying the rheological behavior of cement and optimizing the pumping rates are
to be considered for maintaining low ECDs and to help ensure effective cementing
operations [31].
Cement/mud and spacer design—There are several types of spacer systems avail-
able including: flushes, gels, water based, oil based, and emulsions (water in oil emul-
sion and oil in water emulsion). Among these, flushes are mainly used to achieve tur-
bulent flow for improved mud removal [32]. Spacers are designed to improve cement
bonds by water-wetting the cement-pipe or cement-formation interfaces while not
destabilizing any sensitive zones and not adversely affecting the mud or cement prop-
erties [33]. In order to obtain an improved mud removal, studies show that density
of displacing fluid should be at least 10% heavier than the displaced fluid, and the
friction pressure of the displacing fluid should be greater by at least 20% than the
displaced fluid [13]. The maximum mud removal occurs when the viscosity profile
of spacer systems is higher than the viscosity profile of the drilling fluid and lower
than the cement slurry.
The analysis of removing drilling fluid and replacing it with cement can be per-
formed properly by simulating multiphase flow. In a multiphase flow simulation,
interfaces between cement and space fluid, and spacer fluid and drilling mud are
presented by solutions of the governing equations [2, 34–37].
In order to minimize the poor mud displacement, a cementing checklist is prepared
as guideline [24, 38]:
1. Determine the displacement rates for cement plug on the basis of the mixing and
pump capabilities, and ECDs during cementing for typical spacer rheology.
2. Select the spacer and check its compatibility with the mud system.
3. Once the spacer has been selected, determine its viscous properties at bottomhole
circulating temperature (BHCT) and bottomhole pressure.
4. Recalculate ECDs during cementing by using viscosity to select the mix, pump,
and displacement rate.
5. Calculate cement volumes and annular velocities on the basis of a multi-finger
caliper log.
6. Condition the drilling fluid to obtain lower viscosity.
7. Keep solids loading down, especially in high-angle holes.
7.4 Mud Displacement During Cementing 201

8. Calculate the surge pressures while running the work string, and run at a speed
slow enough to minimize the risk of breaking the formation.
9. Once the work string is at the desired depth, start circulation at the calculated
flowrate.
Hole conditioning—Due to high viscosity and gel strength, drilling fluids are not
suitable for cement plug operations. Hence mud and hole are conditioned prior to
placing cement plugs in open holes. Proper hole conditioning means to establish a
hole free of swarf, cuttings, gels, etc., whereas the hole has a mud in a fully displace-
able or circulatable condition. This allows the spacer and cement slurry to effectively
displace the mud in the desired hole interval. The circulatable hole condition should
be established before the first barrel of cement-mud spacer is pumped down [39].
In addition, hole conditioning results in mud conditioning which reduces the yield
point of mud and consequently enables more efficient mud removal during cement
placement.
Rheological behavior—In order to improve the mud removal efficiency and avoid
fracturing formations, modification of cement slurries may be required (role of
sophisticated tools and techniques and skilled personnel are inseparable); density
changes or rheological behavior modification may be necessary. If pore pressure
restrictions do not allow density changes, then modification of slurry rheological
behavior is recommended. As an example, rheology of cement slurry can be modified
by improving its thixotropic behavior for a better mud displacement [40]. Thixotropy
is the characteristic of fluids which have time-dependent shear thinning properties.
In other words, when the fluid is in stationary conditions, it forms a gelled structure.
But when the fluid is under constant shear rate, the viscosity is decreased over time
until it reaches an equilibrium condition. A thixotropic slurry can create a plug flow
regime during placement and improve the mud displacement efficiency [41]. How-
ever, thixotropic behavior may challenge the plug stability when cement slurry is
placed on a pill and while pulling the work string out of the plug.
Buoyancy forces and plug stability—When a cement slurry is placed at the
required depth on a less dense drilling fluid, it should resist falling down while setting.
Studies performed on the physics of buoyancy driven failure modes of cement plugs
placed on drilling fluids, show that a minimum yield stress is required to achieve
plug stability. The stability of the interface between drilling fluid and cement is gov-
erned by well inclination from vertical, fluids yield stress, the density differences
between drilling fluid and cement, the gravity force, and hole diameter [42, 43]. The
instability occurring at the interface between two fluids with different densities is
known as the Rayleigh-Taylor instability. When a cement slurry is placed on a fluid
with lower density than the cement in an inclined hole, instabilities in the interface
between cement and fluid creates three distinct zones (see Fig. 7.10b); transition
zone intruding the mud, exchange flow zone, and the transition zone in the base of
cement. The movement of fluids which resulted by the instabilities in the interfaces
of cement and slurry caused by buoyancy force is termed slumping motion. In the
slumping motion of a cement plug, it is assumed that the bulk of the two fluids moves
axially at a slow rate, but in the transition zone, a three-dimensional flow exists.
202 7 Fundamentals of Plug Placement

Fig. 7.10 Schematic of stratified axial exchange flow; a cement plug placed on a drilling fluid with
lower density than cement, b buoyancy force is compromising the plug stability and creates three
distinct zones [16]

There are some recommendations to minimize the contamination introduced by

buoyancy and to achieve a stable plug, including reducing the density differences
between cement and drilling fluid (viscous pill), increasing the yield stress or gel
strength of the drilling fluid below the intended cement plug, placing a reactive
gelled pill between cement and drilling fluid, and avoiding thixotropic cement slur-
ries for balanced plugs [38, 44, 45]. If the induced agitation passes the YP of slurry,
the buoyancy and gravity forces will be activated and the contamination effect will
be intensified at the interface between the slurry and the drilling fluid and subse-
quently, the plug stability. It is believed that during balanced-plug placement when a
thixotropic slurry is used, the slurry tends to stay in the end of the tailpipe when the
intended cement plug is placed. Pulling the tailpipe out of the static thixotropic slurry
creates a drag force on the drilling fluid below the cement, and leads to intrusion of
the drilling fluid into the slurry, therefore the slurry is contaminated [45]. However,
use of a thixotropic cement slurry, which develops gel strength rapidly, improves the
plug stability while cement sets [44].
One solution to minimize the effect of buoyancy forces while cement sets is
to install a mechanical foundation and place the slurry on top of it [46]. Then,
plug stability is provided while cement sets and the gas invasion is minimized. One
limitation for the utilization of mechanical foundations is that they cannot be used
in openhole sections.
Centralization of work string—An eccentric annulus between work string and for-
mation or casing can channel the displacing fluid to the wide side of the annulus and
leave remaining drilling fluid on the narrow side, Fig. 7.11. However, the difference
between the density of displacing fluid and displaced fluid creates a hydrostatic pres-
sure imbalance between the narrow side and wide side. On the one hand, the created
imbalance pushes the heavier fluid to the narrow side and displacement efficiency is
increased. On the other hand, this phenomenon may intensify mud contamination.
7.4 Mud Displacement During Cementing 203

Fig. 7.11 Improper

centralization of stinger
guides the cement through
the large space (1), and
gravitational force replaces
mud and slurry (2) and (3)

Tehrani et al. [47] studied the effect of eccentricity of pipe on displacement effi-
ciency of mud in inclined wells. Their assumptions included a laminar displacement
in the annulus for non-Newtonian fluids in a three-dimensional wellbore. According
to their work, good pipe centralization, a high density contrast between drilling fluid
and slurry, and positive rheological hierarchy are important factors which improve
mud displacement.
Jakobsen et al. [23] considered displacement of fluids with different densities,
in eccentric annulus. They concluded that when the displacing fluid is 5% heavier
than the fluid to be displaced, the lighter fluid in the narrower part moves to the
upper part which is wider. This mechanism, buoyancy-induced, strongly improves
the displacement efficiency. This process is recommended when turbulent flow or
effective laminar displacement is difficult [48].
Pulling out of plug—The assumption behind the balanced-plug calculation
method is that the fluid is going to remain in place while the work string is pulled
out of plug with minimal falling of the fluid due to the void caused by metal dis-
placement. However, this assumption is correct only when neglecting the role of
drag forces between fluids and work string and the volumes attached to the work
string surface, and where a mechanical foundation is used as a base. In order to
minimize the agitation effect, a tailpipe or stinger1 with a smaller diameter and wall
thickness is deployed. Because of a thinner wall thickness and a smaller diameter,
the fluid volumes involved are smaller and consequently contamination is supposed
to be minimized [49]. However, Roye and Pickett [50] showed that the initially bal-
anced plug becomes unbalanced as a dynamic condition is imposed when pulling

1 The stingers are usually made of fiberglass or aluminum pipe.

204 7 Fundamentals of Plug Placement

the work string out of the plug with a pill as a base. When pulling the work string
out of hole, a volume of fluid inside the near surface pipe is displaced, as the same
volume should be displaced inside the stinger (with a smaller diameter compared to
near surface work string pipe), the height of the displaced fluid inside the stinger is
higher. Therefore after pulling a few work string joints out of the hole, the cement
inside the stinger is fully displaced with spacer while cement slurry still is left in the
annulus. This phenomenon is shown step by step in Fig. 7.12.
Some alternatives are suggested to minimize the effect of dynamic conditions
imposed by pulling out of the hole: using a model to correctly calculate the volume
of spacer ahead and behind the cement slurry, eliminating the use of stinger, and/or
using mechanical devices in the drillpipe just above the stinger [50]. To minimize
the plug contamination due to its movement while it sets, it is recommended to use
a gelled fluid pill or a mechanical foundation.
Cement job monitoring—The recording of pressure, slurry rate, density, and inte-
grated volume (e.g. mud return rate compared with pump rate) in real time gives a
better understanding of the job execution [51, 52]. These data can be analyzed and
used for other jobs especially in a campaign plug placement. Figure 7.13 shows the
framework of a process control loop for eliminating future plug failures.

7.5 Verification of Placement Operation

Position verification—When a cement plug is placed at the desired interval, its depth
and sealability need to be verified. When cement is set, it is dressed off and the top of
cement is identified by tagging. Cement plugs placed on a mechanical foundations
are not tagged when the depth of plug has been verified.
Sealing verification—The evaluation of plug sealing capability is conducted by
either pressure testing, or weight testing based on the elements of the well barrier
envelope.
Pressure testing—Plugs installed inside casing are placed on either mechanical
plugs or viscous pills, Fig. 7.14. When the mechanical plug is used as foundation
and it passes the pressure test, usually the cement installed on top of it is not pressure
tested. However, if the mechanical plug is not pressure tested or fails to pass the
pressure test, the installed plug is pressure tested.
When a cement plug is installed on a viscous pill, its sealability is evaluated by
performing either positive or negative pressure testing. In a positive pressure test the
well is subjected to a given pressure and the pressure changes are recorded. The given
pressure is higher than the pressure below the plug, Fig. 7.15a. When considering a
positive test, the primary cement (cement behind casing), cement-pipe bonding, and
casing should not be damaged. To avoid this issue, the test pressure is selected to not
exceed the casing strength minus wear allowance. Another factor to be considered
during positive pressure testing is the effect of ballooning uncemented casing. It
happens when the test pressure exceeds the casing mechanical limit and casing is
expanded in the intervals where liquid fills the annulus behind the casing. In this case
7.5 Verification of Placement Operation 205

Fig. 7.12 An unbalanced condition during pulling the work string equipped with stinger out of
hole: a Balanced-plug is established while workstring is inside plug, b workstring is removed slowly
from the plug but due to the removed volume of workstring, the height of spacer inside and outside
is not in the same level, c the more the workstring is run out of hole, the higher the differences of
the fluid levels d spacer reaches the tailpipe while the annular cement slurry is still left [50]
206 7 Fundamentals of Plug Placement

Fig. 7.13 Process control loop for a plug placement operation [53]

Fig. 7.14 Pressure testing of a cement plug placed inside casing; a plug placed on a mechanical
foundation, b plug placed on a viscous pill

as the test-pressure increases, a portion of injected fluid fills the volume created due
to ballooning however, it may be misinterpreted and lead to disqualifying the plug.
Pressure testing of cement plug is reviewed in Chap. 9.
In a negative pressure test, the well pressure is dropped and the pressure build-
up is recorded. In other words, pressure below the installed plug is higher than the
pressure above the plug, Fig. 7.15b. The negative pressure test is also known by other
names such as inflow test or drawdown test. Table 7.2 summarizes requirements for
pressure testing of different regulatory authorities.
Weight testing—This method is used for plugs installed in open holes as pressure
testing in open holes is meaningless. In this method, top of cement is dressed off
7.5 Verification of Placement Operation 207

Fig. 7.15 Pressure testing of an installed plug inside casing; a positive pressure testing, b negative
pressure testing

Table 7.2 Requirements for pressure testing and weight testing variation for some countries
Country Pressure testing requirement Weight testing requirement
Norway [54] • The positive pressure test • Cement plug installed in an
requirement is 1000 psi above openhole should be weight
the estimated leak off pressure tested
(below casing/potential leak
path)
• The positive pressure test
requirement for a surface
casing plug is 500 psi above the
estimated leak off pressure
• Cement plug installed on a
pressure tested foundation need
not to be pressure tested
United Kingdom [55] • The positive pressure test • Cement plug installed in open
requirement is minimum 500 hole is weight tested by
psi above the source pressure drillpipe with typically 10–15
• Inflow test requirement at least klbs
the maximum pressure • When cement plug installed in
differential which barrier will open hole is weight tested by
experience after permanent wireline, coiled tubing or
abandonment stinger then the weight is
limited by tools and geometry
208 7 Fundamentals of Plug Placement

Fig. 7.16 Weight testing of

a plug installed in an
openhole

and a weight is applied on the plug, Fig. 7.16. Drillpipe, coiled tubing, stinger,
and wireline can be used for weight testing however, the application of stinger,
wireline, and coiled tubing is limited by weight of the tools or geometry. Different
regulators have different weight requirements. Table 7.2 summarizes some specific
requirements for weight testing of different regulatory authorities.
The cement plug installed inside tubing is usually verified by pressure testing and
tagging. If the plug is installed on a pressure tested bridge plug, then it is not pressure
tested. As the plug is installed on a tested bridge plug, its position verification and
pressure testing are not possible. Sealing capability of cement plugs installed between
tubing and production casing is verified by pressure testing and position verification
is done by bond logging.

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212 7 Fundamentals of Plug Placement

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Chapter 8
Tools and Techniques for Plug
and Abandonment

8.1 Casing Cut and Removal Techniques

In permanent P&A, establishment of a rock-to-rock barrier is a requirement. There

are situations where the annular barrier behind casing is not qualified or there is no
annular barrier. Therefore, full access to the formation shall be obtained. Different
techniques have been utilized by the petroleum industry such as cut-and-pull, casing
milling, and section milling. Some new techniques have been suggested some of
which are in use and others are in development. Such techniques include perforate-
wash-cement, upward section milling, melting downhole completion, and plasma-
based milling. This chapter will present these techniques, briefly.

8.1.1 Cut-and-Pull Casing

In permanent P&A operations, there are situations where there is only a poor annular
barrier or no annular barrier at all. When there is a long length of uncemented
casing, a cut-and-pull operation can be the necessary option. In this operation, a
circumferential cut is made of the casing, above a casing coupling, and then a spear
is engaged inside the casing to pull the casing out of hole. The spear can be engaged
hydraulically. For the traditional method, the pulling force is provided by the working
unit through the workstring to the bottom hole assembly. However, the advancement
of cut-and-pull techniques provides a new generation of tools, downhole hydraulic
pulling tool anchors, to create large amounts of pulling force without fully engaging
the working unit pulling capacity. As an example, by use of 1 psi hydraulic power,
300 psi is generated by the downhole hydraulic pulling tool anchors [1].

© The Author(s) 2020 213

M. Khalifeh and A. Saasen, Introduction to Permanent Plug
and Abandonment of Wells, Ocean Engineering & Oceanography 12,
https://doi.org/10.1007/978-3-030-39970-2_8
214 8 Tools and Techniques for Plug and Abandonment

Ideally, the cut-and-pull operation is a single trip. However, there are challenges
associated with it, which may require multiple trips. Such challenges are settled barite
behind casing, scale depositions, collapsed formation, or unknown bond strength of
the poor casing cement. Therefore, pipe retrieval requires high pulling capacity. The
pulling capacity can be beyond the working unit or workstring capacity. It can also
compromise the stability of the facility (i.e. working unit or platform). Therefore,
multiple trip are performed by cutting the casing into short lengths. During casing
pulling operations when the casing is moving, debris may fall down around the casing
causing it to get stuck and even be irretrievable. Multiple trips expose personnel to
several cut-and-pull operations and increases the risk of HSE issues. In addition, the
retrieved pipe needs to be handled safely and disposed off properly.
The casing cut can be done using explosives, chemicals, mechanical cutters or
using abrasive cutters. Regardless of which type of cutting technique is used, usually
the cut is performed when the casing is under tension. Some of the challenges asso-
ciated with explosive cutters are transportation, handling and storage, uncertainties
related to eccentricity or stand-off of the device and damage of the outer casing,
dispersion of force from the device, and shape of the resulting cut. Radial cutting
torches, which use thermite derivatives to melt casing radially, can cut the casing
partially or cut the pipe behind casing. Chemical cutters utilize chemicals which
react with steel. Bromine triflouride is an example of such a chemical which is
extremely hazardous for surrounding and personnel with irreversible health effects.
The efficiency of chemical cutters can be affected by the presence of scale, poor
spray pattern, or eccentricity of casing. Mechanical cutters are either electrical pipe
cutters (see Fig. 8.1) or hydraulic pipe cutters (see Fig. 8.2). One of the advantages
of mechanical cutters is the centralizer which holds the cutter in the pipe center and
the risk of damaging the outer casing due to eccentricity is reduced.
For abrasive cutting techniques, abrasive cutting particles are injected into a water
jet and wear away the production tubing, casing, drill pipe or drill collar. As this
technique has advantages for cut and removal, especially wellhead cut and removal,
the subject is covered in more detail, later in this chapter.

Fig. 8.1 Mechanical pipe

cutter which is powered
electrically. (Courtesy of
Baker Hughes)
8.1 Casing Cut and Removal Techniques 215

Fig. 8.2 Mechanical pipe

cutter which is powered
hydraulically. (Courtesy of
Schlumberger)

8.1.2 Casing Milling

In this operation, casing is milled when a length of casing needs to be removed. Such
circumstances may include slot recovery or sidetracking. The process of opening a
window is typically done by a mill, however, milling with the use of an abrasive fluid
jet has been studied [2]. In a P&A operation the required length is usually longer than
required for sidetracking. Therefore, typically a section casing milling operation is
carried out.

8.1.3 Casing Section Milling

One of the main reasons limiting the use of rigless P&A operations is poor casing
cement or uncemented casing. For conventional practice, a window is section milled
and the operation is called section milling. The aim of section milling is to grind
away a portion of casing and cement. While section milling the casing, the hole
needs to be kept clean by removal of produced swarf and other debris. The term
swarf is used for metal fillings or shavings created by the milling tool during the
casing removal process. The opened window needs to be under-reamed to expose
new formation. Then, a cement plug is placed. Section milling is a time consuming
operation and difficult to execute safely and efficiently. The current rate of milling
216 8 Tools and Techniques for Plug and Abandonment

Table 8.1 Section milling data gathered during P&A operation of a well on the NCS
Casing Milling Length of Type of Number of Milling Weight of
size fluid window cutters runs rate removed
metal
13 3/8-in. KCl based 164 ft Tungsten 1–2 8.5 ft/h 72 lbm/ft
polymer carbide
fluids or
MMH
based
fluids

operations for 7-in. casing is typically around 7–9 (ft/h), with additional time taken
for tripping, hole cleaning and cleaning of BOP cleaning. The operation increases
risk and introduces different challenges. The fluids designed for section milling
must have sufficient weight and viscosity to suspend and transport swarf to surface
while keeping the opened hole stable. Sometimes, the required viscous profile of
the designed fluids increases the ECD to exceed the fracture gradient, resulting in
breaking the formation. This phenomenon may lead to fluid loss and subsequently
swabbing and loss of well control. Presence of fluid loss also causes poor hole
cleaning and risk of packing off the Bottom Hole Assembly (BHA) which can lead
to sticking of the milling or under-reaming BHAs. Section milling is also affected
by the location of casing couplings and casing accessories such as centralizers and
scratchers. With current milling tools, there is a risk of splitting and buckling the
casing, which effects performance and the ability to successfully mill the required
interval. Swarf and skimmed casing, and debris can also damage the BOP and effect
its functionality. At surface, the transported swarf must be separated and captured
by use of handling equipment. Swarf needs to be handled and disposed off properly
and as it has sharp angular surfaces, it introduces HSE challenges. Swarf therefore
requires a special handling system with trained personnel who need to be equipped
with protective equipment. The milling operation requires the use of a drilling rig
which is costly. As the cutting tool is worn out after only some feet of milling,
frequent trip out and in is often required, which is time consuming. An additional
limitation of section milling is generated vibrations. Table 8.1 shows the milling data
gathered from a well on the NCS. Due to challenges associated with conventional
milling operations, some techniques or methods have been suggested as alternative
solutions. These techniques include upward milling, PWC, melting the downhole
completion and plasma-based milling.

8.1.4 Upward Milling

Section milling is a proven technique which gives full access to the original formation
for creating a rock-to-rock barrier. However, swarf transportation to surface and swarf
8.1 Casing Cut and Removal Techniques 217

handling on surface are time consuming and costly operations which are associated
with HSE risks. If swarf could be left behind in the wellbore, section milling without
swarf to surface, the section milling technique could be more efficient. Upward
milling is a new form of section milling technique where the milling operation is
performed while moving upward, cutting the swarf into small bits, where the swarf
falls down into the wellbore. This system consists of a taper mill, auger section,
section mill, emergency release disconnect, jet sub, left-hand rotating mud motor,
drill collars, torque isolation assembly, spring loaded pads, spiral stabilizer, and
intensifier [3, 4]. Figure 8.3 shows the main tools of upward milling bottom-hole
assembly, from top (component 1) to bottom (component 11).
The key components of the upward section mill assembly are shown in Fig. 8.3. At
the bottom of the planned milled window, the assembly opens its knives and creates
the cut through the casing. Then, it mills upward to the desired depth, and finally
retracts the knives at the top of the window. In conventional milling, the knives are
retracted when pulling the workstring upward. However, the retraction mechanism
for knives in the upward milling method is challenging as the knives cannot retract
through upward movement.
Emergency release disconnect—This is a designed weak link in the system to
release the assembly if the knives do not retract or the BHA becomes stuck. By
over-pulling the workstring, the designed weak link is activated and the BHA is

Fig. 8.3 Main components of an upward milling BHA without swarf to surface; (1) intensifier, (2)
spiral stabilizer, (3) spring loaded pads, (4) torque isolator, (5) drill collars, (6) left-hand mud motor
(7) jet sub, (8) disconnect, (9) section mill, (10) auger section, and (11) taper mill [3]
218 8 Tools and Techniques for Plug and Abandonment

Table 8.2 Advantages and

Advantages Possible limitations
possible limitations of
upward milling technique • No HSE issues related to • High inclination can affect
swarf handling the swarf movement to the
• Time and cost efficient well leg
• No steel as part of
permanent barrier

released. However, this is a last option to release the BHA. Other scenarios such as
reciprocating the workstring to retract knives and pushing the knives to the bottom
of window are tested prior to activation of the release disconnect feature.
Drill collars—As reaming is a part of the operation, it is important to ensure
that the torque isolation assembly remains inside casing. Therefore, drill collars are
installed above the left-hand mud motor.
Intensifier—This is a hydraulic spring to increase the impact force while enabling
smooth load transition from the applied over-pull, at surface, to the knives, downhole,
when milling upwards.
Left-hand mud motor—Right-hand rotation upward milling increases the risk and
chance of unscrewing casing collars, especially at intervals where uncemented casing
exists. Therefore a left-hand motor provides the downhole left-hand rotation and the
required torque for the section mill and auger. A design feature for such a motor is
high-torque and low-speed. This type of motor may be used in combination with
coiled tubing to carry out rigless P&A operations.
Jet sub—To divert the flow of mud to the annulus while allowing swarf and
cuttings to fall down the well, a jet sub is used below the left-hand mud motor. The
main function of the jet sub is to avoid circulating fluid along the knives, if it is out of
control and the swarf and cuttings might move upward and cause serious challenges
and risks. The nozzle design and nozzle configuration are important to open the
knives and generate enough force for milling. The nozzles are designed for different
flowrates and fluid densities.
Torque isolator assembly—This is used to minimize the heavy vibration which
occurs during section milling, especially upward section milling. By using such a
component, axial movement and a continuous torsional constraint are provided.
Auger—In order to improve the process of swarf movement into the rat hole and
prevent bridging, auger sections are used (see Fig. 8.3). Casing inside diameter, auger
outside diameter, fluid flowrate, density of fluid and system operational procedures
are some of the parameters considered during the design process of the auger and
which affect the efficiency of it.
Taper mill—Swarf and cuttings can bridge across the cut-out and block the path
for other swarf to fall down the wellbore. A taper mill is installed below the section
mill to clean out such swarf bridges.
When milling upwards, to prevent backing-off of casing collars, a left-hand rota-
tion is necessary. It can be facilitated either by a left hand mud motor or by left-hand
workstring to surface. An alternative flow path is also a requirement as swarf or cut-
tings need to be deposited below the milled section. Table 8.2 presents advantages
and possible limitations of the upward milling technique.
8.2 Perforate, Wash and Cement Technique 219

8.2 Perforate, Wash and Cement Technique

8.2.1 Concept Behind the Technique

Generally speaking, this technique was first taken into use in the 70’s to establish
annular barrier whereby casing is perforated, washed and cemented [5]. Briefly, a
perforation gun is run to the barrier depth where there no cement or poor cement
behind casing. The casing is perforated, Fig. 8.4, and the gun is either left in hole
or retrieved. In the next step, a washing tool is Run in Hole (RIH) and washes
the annular space behind the perforated casing to remove the debris, settled mud
and mud film [6, 7]. The washing process is carried out downward and a several
times to obtain fresh formation. At surface, removed metal and debris can be seen
and monitored on shakers which gives better control of the washing process. When
washing is completed, an integrity test is performed to check the quality of washed
and removed zone. If the integrity test is successful, the washing tool may either be
left below the bottom perforations to function as a mechanical foundation for the

Fig. 8.4 Perforate and wash part of PWC technique; a casing is perforated, b washing tool is RIH
and washes the annular space behind the perforated interval, downward, c BHA is placed below the
bottom perforations, d spacer is pumped and work string is pulled, upward, e spacer is extended
above the top perforations. (Courtesy of Archer Oiltools)
220 8 Tools and Techniques for Plug and Abandonment

Fig. 8.5 Perforation gun and washing tool are RIH in single trip. (Courtesy of Archer Oiltools)

cement plug, which is placed in the next step, or it is used as BHA for the cementing
stage. For the washing tool to serve as a foundation, a packer is incorporated in the
tool and once activated, stays in place. For the next step, spacer is pumped through
the perforations. To do so, a new BHA may be used if the wash tool has already been
released after the washing process. While pumping spacer, the work string is pulled
out of hole. The process is known as pump-and-pull. The spacer is placed below the
bottom perforations and extended to above the top perforations.
Nowadays, the perforation gun and washing tool are run in a single trip and when
perforating is completed, an activation mechanism is engaged and drops the gun into
the well rat hole. The single trip method saves time (Fig. 8.5).
For the next step of the operation, the BHA is placed below the bottom perforations
and cement slurry is pumped, Fig. 8.6. After pumping some volumes to remove the
spacer around the BHA, work string is pulled out of hole while pumping cement.
The pumping of cement is continued with the calculated rate while pulling the work
string with an optimal speed until cement and BHA reach above the top perforations.
The BHA needs to be pulled out of the cement plug, to at least two stands above the
top of cement. Then the well must be circulated to get clean.
One of the challenging parts of the PWC technique is the washing operation. The
goal of washing is to remove any materials present behind the perforated casing.
Wash fluid, which is a modified water-based fluid, should be pushed through the
created perforations, and transport any materials presents out from the annular space.
Currently, there are two different methods of washing: swab cup tool and jet tool. In
the swab cup method, rubber plastic cups are installed below and above the injection
nozzle present on the BHA, Fig. 8.7. Cups create a seal between casing and the work
string and prevent the washing fluid traveling in the annular space between the casing
and tool, Fig. 8.8a. In this way, wash fluid penetrates through the perforations into
the annulus behind the casing and moves upward.
The jet tool method uses a jetting tool to wash and clean out debris by spraying
wash fluid, Fig. 8.8b. The angle of jet nozzles and the exit velocity of wash fluid
play an important role in the success rate of the washing technique. Centralization of
the jet tool while washing could be a concern while for the swab cup tool, the cups
partly act as a centralizer. Table 8.3 presents field data from a P&A operation where
the PWC technique was used.
8.2 Perforate, Wash and Cement Technique 221

Fig. 8.6 Cementing part of PWC technique; a BHA is placed below the bottom perforations,
pumping few volumes of cement, b pump-and-pull while cementing, c pump cement and circulate
out the cement in BHA, pull the BHA out of cement, at least 2 stands above top of cement. (Courtesy
of Archer Oiltools)

Fig. 8.7 Swab cup tool used in PWC technique. (Courtesy of Archer Oiltools)

When pumping cement slurry through the perforations, the cement should fill
the annular space behind the perforations. Displacement efficiency of spacer and
placement of cement is a strong function of exit velocity and inclination of the
casing, Fig. 8.9. The displacement efficiency, during washing and cementing, is a
222 8 Tools and Techniques for Plug and Abandonment

Fig. 8.8 Washing tools for PWC technique; a swab cups create a seal inside casing and force the
wash fluid into perforations, b jet tool sprays the wash fluid through perforations. (Courtesy of
Hydrawell AS)

Table 8.3 Field data obtained from a P&A operation on the NCS where PWC technique has been
used
Casing Length Wash Number Perforation Perforation Weight Inclination Used
size of tool of trip size phasing of time
window in removed
metal
9 164 ft Swab Single >1-in. NA 2% 63° 36 h
5/8-in. cups trip

concern and matter of research. More theoretical and experimental work should be
performed to understand the mechanisms involved. To improve the cement place-
ment and force cement through the perforations, different tools have been designed.
Creating a cyclone effect is one of the suggested methods, Fig. 8.10.
There are advantages and possible limitations for the PWC technique, Table 8.4.
Lack of qualification methods are the most challenging limitations. With current
technologies, to qualify a PWC job, the cement inside the casing is drilled out and
casing cement placed during the PWC job is logged by employing sonic logs. How-
ever, holes created during perforating challenge the reliability of logging data, in
addition to uncertainties associated with sonic logs and the interpretation of logging
data in general. If the annular barrier is qualified, cement is placed inside the casing
and when the cement has set, it is pressure tested and tagged.

8.3 Explosives to Establish Annular Barrier

In P&A, establishing the annular barrier is one of the main challenges. In order
to overcome the challenge, it has been suggested to use explosives for expanding
the casing to create a seal or foundation for the annular barrier to be placed on.
The amount of explosive to be used, is selected in such a way that the casing will be
ballooned but not ruptured. The challenge is to select the correct amount of explosive
8.3 Explosives to Establish Annular Barrier 223

Fig. 8.9 Cementing of perforated casing in PWC technique; a cement is pumped through perfo-
rations, b the ideal cement job to be expected, c due to inefficient displacement and inclination
cement slurry may not be able to fully displace spacer

Fig. 8.10 Creating a cyclone effect for a better cement placement for PWC technique. (Courtesy
of Hydrawell AS)

required as the casing string may not have its original thickness due to corrosion.
This technique has been lab and yard tested but today has not been applied in the
field.
224 8 Tools and Techniques for Plug and Abandonment

Table 8.4 Advantages and possible limitations of PWC technique

Advantages Possible limitations
• Time and cost effective technique • Effectiveness of washing must be verified
• No milling is required • No convenient qualification tool or technique to verify
• Metal is left in place established annular barrier
• Effective perforation size and phasing need more
theoretical and practical investigation
• Casing eccentricity during washing and cementing

8.4 Melting Downhole Completion

One of the challenges associated with P&A of wells is removal of the downhole
completion to create a rock-to-rock barrier, also known as a cross-sectional barrier.
Retrieval of downhole completion exposes personnel to HSE risks, increases the
operational time, and carries cost associated with proper handling and disposal of
the retrieved equipment. Therefore, a possible solution is to leave as much metal
as possible downhole. But the presence of downhole completion at the required
depth for the barrier is another challenge to be considered. One possible solution
that may solve the issue and create a permanent barrier could be to melt all of
the downhole completion and create a rock-to-rock barrier. For this method, the
downhole completion and surrounding formation are melted in a controlled manner
by use of thermite. In a thermite reaction, aluminum alloys and iron oxide (rusted
steel) react and extreme amount of heat is generated. The oxygen required for the
reaction is provided by the iron oxide [8]. Consider the reaction of thermite and the
reaction mechanisms in Chap. 4.
The use of thermite for cutting tubing, drillpipe and bottomhole assemblies has
already been employed in the field [9]. When considering melting the downhole com-
pletion and creating a barrier by modifying in situ materials, the barrier verification
might be a challenge as discussed in Chap. 9.

8.5 Plasma-Based Milling

8.5.1 Concept Behind the Technology

During permanent plug and abandonment of Oil and Gas wells, the presence of the
production tubing introduces challenges associated with logging cement behind the
production casing, and cutting and pulling or section milling part of the production
casing. Therefore, in conventional P&A methods, the production tubing needs to be
retrieved, which is time consuming, costly and associated with risk. The limitations
with cutting and pulling casing revolve around two main issues, the ability to effec-
tively cut and retrieve casing and the manual handling of pipe at the surface. Current
8.5 Plasma-Based Milling 225

technology generally requires at least two BHA runs, one with a cutting assembly
to cut the pipe at the required depth, then an additional run to retrieve (fish) the pipe
above the cut. There are tools available that allow cutting and pulling in one run but a
significant time reduction is not yet achieved. Many situations exist which make the
pipe unrecoverable, even if the cut is fully successful. In such cases, section milling
may be necessary. Challenges introduced by section milling have already been dis-
cussed in this chapter. The challenges related to section milling are proliferated by
the type of production facility and working unit used for P&A. For offshore P&A
activities, rigless P&A utilizing LWIV is a goal. The reason is a significant reduction
of daily rental cost. Plasma-based technology may address some of these challenges.
The development of plasma-based milling technology for through tubing well aban-
donment might be a potential solution. Generally speaking, plasma-based milling
technology aims to disintegrate steel into small particles and transport the particles
to surface [10].

8.5.2 Scientific Background of the Technology

In 1920’s, Irving Langmuir described a fundamental state of matter which, unlike

the other three fundamental states of matter, does not freely exist, where an ionized
gaseous substance becomes highly electrically conductive. In this state, the behavior
of matter is dominated by long-range electric and magnetic fields. In 1928, Irving
coined the term “plasma” for the new matter state. Lightning and fire are exam-
ples of plasma. Plasma can be produced artificially by subjecting some gases to a
strong magnetic field or by heating them [11, 12]. The most common gases used for
generation of plasma include: air, argon, nitrogen, hydrogen and carbon dioxide. A
Plasma jet can be used for different processes such as plasma cutting, plasma arc
welding, plasma spraying, etc. Plasma cutting is a process of cutting an electrically
conductive material utilizing an accelerated jet of superheated electrically ionized
gas, plasma, having a large kinetic energy [12]. Figure 8.11 shows a schematic of a
thermal plasma DC torch based on a cathode ionizing a gas stream.
Downhole conditions and materials imply that, the plasma-based milling technol-
ogy cannot utilize state-of-the-art conventional plasma torch technology. The most
important difference compared to conventional plasma torch technology is that the
electrical arc with temperatures of tens of thousands of degrees Kelvin heats the
surface of target material directly. In addition, its radiation component is also more
efficient, with minimalized heating of intermediate gas. The intermediate gas flow
in conventional plasma torches reduces the efficiency of heat transfer into the rock.
Moreover, the arc creates area-wide, relatively homogeneous heat flow from a spiral
arc on the whole surface for a high-intensity disintegration process.
226 8 Tools and Techniques for Plug and Abandonment

Fig. 8.11 A non-transferred plasma cutter based on hot cathode

Figure 8.12 shows a process of tubing and casing section milling using plasma-
based tools. The tool is deployed through the tubing to the target zone where the
plug is to be set (Fig. 8.12a). The electric arc is ignited, plasma is created and the
tool moves upwards while milling the tubing (Fig. 8.12b). After tubing milling, the
tool is moved back to its starting position and then removes casing and cement layers
(Fig. 8.12c). After the removal of both tubing and casing, the tool is pulled out of
hole (Fig. 8.12d). The section is then ready for cement plug placement (Fig. 8.12e).
The combination of a high temperature large cross-section plasma torch and rotat-
ing electric arc is another generation of plasma generators, which might be an effec-
tive tool for casing milling. The process using plasma technology is based on a
mixture of hybridized plasma, chemical and thermochemical processes resulting in
fast metal degradation and removal. The main process responsible for the rate and
effectivity of steel degradation and removal is high temperature oxidation supported
by melting and evaporation. Nowadays, several studies and techniques deal with the
effect of water steam and temperature on the steel removal rate for a wide range of
input parameters. One can conclude that temperature and heat transfer were found
to be the key factors in increasing the constant rate needed for the required thermo-
chemical and thermo-physical processes. The proportional contribution of the pro-
cesses results in a steel removal effect, which varies with changing temperature and
brings the following basic features [10]:
• The oxidative part of the targeted steels’ structural degradation is an exothermic
process - i.e. it supplies additional energy for all steel removal sub-processes.
• Oxidation and evaporation rate of steel raises with increasing plasma tempera-
ture, power density through the unit area at the plasma-steel interface and plasma
enthalpy.
• Oxidation and evaporation rate of steel is most efficient in water steam and air-
steam mixtures from an energetic point of view (in comparison with other industrial
gases).
• There is a narrow temperature window in the range of 3055–3390 °C where
enthalpy liberated from oxidative processes raises by a factor of 3. It means that
8.5 Plasma-Based Milling 227

Fig. 8.12 Casing section milling of tubing and casing with plasma-based tool. (Courtesy of GA
Drilling)

three times more energy is supplied to the steel removal processes without increas-
ing external power of the plasma generator. This window should be valid for all
types of steel alloys since at such high temperatures all the compounds are in
gaseous phase.
• Above a steel surface temperature of 6100 °F, a total dissociation and evaporation
occurs. Plasma particles impact on the steel surface in the form of active ionic
atoms resulting in metal etching effect. It is important not to forget that oxidation
is still active during melting and evaporation processes.
Because of steel oxidative processes, a large amount of energy is released dur-
ing oxidation reactions and recycled to the steel removal processes. In closed vessel
conditions, the total energy consumed for steel removal is at least by 30–40% lower
than the theoretical value needed for steel melting. Penetration rate is a strong func-
tion of total power put into the steel degradation processes and the environment
[10, 13]. Theoretically, by increasing input power the steel removal rate should be
increased slightly linearly up to its saturation point, which can be obtained only by
experimentation.
228 8 Tools and Techniques for Plug and Abandonment

Fig. 8.13 a Plasma-based tool entering a multistring casing sample; b upper view on the sample
after the experiment; c sample after diagonal section in order to reveal obtained steel-cement removal
[14]

Figure 8.13 shows a plasma-based tool, which is acting on a mono-structure

multistring casing sample whereas casing cements support the casings. As shown in
Fig. 8.13, the inner casing and cement layer have been completely removed on the
chosen section. Experiments have proved that a 3.5-in. tool is capable of milling a
wide range of casing sizes including 4½-in., 5½-in. and 7-in. [14].
Scaled testing in pressures up to 1450 psi has been reported. Based on the chal-
lenges associated with section milling challenges, several parameters like ROP, steel
types and cuttings types from plasma milling processes have been analyzed. Experi-
ments carried out at different boundary conditions show that the efficiency of cutting
steel can be characterized, empirically, by one special parameter. This parameter, ε,
describes the energy needed for total removal of a mass of steel under the physical
conditions. The parameter, ε, has a statistical character as it summarizes the liberated
energy coming from exothermic iron oxidation processes and the real electric energy
supplied to the plasma generator. Therefore, it is evident that ε is always lower than
the consumed electric energy. It was also found that ε is dependent on the degree
or type of steel oxidation and hydrodynamic circumstances [14]. In order to deter-
mine the ROP, testing with a plasma generator has been carried out on two types of
steels: carbon steel S355 and alloy steel with 20% Cr and 12% Ni. The value of ε is
calculated from [14]:

U × I ×t
ε= (8.1)
m
where U × I is the electrical power to plasma generator, m is the mass of the removed
steel from the sample plate, and t is the time of the process.
8.5 Plasma-Based Milling 229

A functional correlation has been reported between the steel removal rate (SRR
[kg/h]) and plasma voltage U [V], current intensity I [A], plasma torch efficiency h
[0–1] and net energy requirement per unit mass of removed steel ε [MJ/kg]:

U × I × 3.6 × 10−3
SRR = ×h (8.2)
ε
In real casing conditions, in a water environment at low pressures, the value of ε
is found to be in the range of 3–4 MJ/kg. When considering power output 250 kW,
plasma torch efficiency 70% and net energy requirement per unit mass of removed
steel 3 MJ/kg, the value of SRR is 210 kg/h [14]. This value means ROP 2.0–4.5 m/h
for 9 5/8-in. casing section milling (depending on the wall thickness). This ROP is
comparable to present-day section milling techniques, however the real difference
is the fact that the plasma-based tool is able to mill various casing dimensions (as
well as multiple strings) using one tool. This means a reduction in tripping and a
significant increase in overall productivity.
For S355 steel, scanning electron microscopy (SEM) analysis clearly indicates
the dominant presence of iron (II) oxide in the cuttings, Fig. 8.14. Structural analysis
proved a heterogeneity between the formed oxidized and diffusive metallic layers
in the cuttings. This resulted in differences in the thermal expansion coefficients of
metal-oxide systems at the border of metallic and oxide layers. Therefore, hydrody-
namic removal of such weakened multilayers could be realized relatively easily. In the

Fig. 8.14 Samples of SEM image and EDX analysis of cuttings’ material formed during plasma-
based steel removal process of S355. (Courtesy of GA Drilling)
230 8 Tools and Techniques for Plug and Abandonment

case of alloy steel, the aforementioned differences in thermal expansion properties

of metal-oxide multilayers are significantly higher due to a higher grade of chemical
heterogeneity in the microstructure. Figure 8.14 shows samples of SEM image and
Energy-dispersive X-ray spectroscopy (EDX) analysis of cuttings´ material formed
during plasma-based steel removal process of S355 steel.
Apparently, the plasma-based technology is capable of removing carbon steel
as well as steel alloys without significant obstacles. Recently, plasma milling in a
high-pressure environment has been presented. Subsequently, the following topics
associated with the plasma-based milling process of production tubing and/or casing
were researched [15]:
• Radial reach of plasma to cement in a high pressure (HP) environment up to 6000
psi
• Effect of the water-based fluids on the milling process in HP of 3600 psi
• Effect of the Oil-Based Mud (OBM) on the milling process in HP of 3600 psi
• Tests of possible damage to casing when milling eccentric tubing in HP of 3600
psi.
Cement removal at pressures of up to 42 MPa using electrical plasma has been
tested at laboratory scale. In the case of implementation for either water-based or
oil-based fluids, no interference effects on the milling process are reported but due to
the presence of drilling fluid contaminating the cement, the removal process seems
to be enhanced. The degradation is increased due to different thermal conductivity
of present materials. Likely, chemical reactions with a plasma-forming medium are
more significant and drilling fluid degradation is stronger or drilling fluid is flushed
by the dynamics of implementation of the plasma forming medium into the process.
In addition, it is possible to retrieve data of increased electrolysis when the process
takes place in a “muddy” environment. The electrolysis level increase is different
for WBM and OBM. This gives an important input to the knowledge regarding the
structure of the milled casing.
Experimentally it has been shown that plasma-based milling technology can
remove production tubing with control line and clamps. Since control line removal
is a challenge using conventional technologies, this ability is another advantage.
A well documented advantage is related to the production of small particles instead
of swarf. Figure 8.15a shows a typical example of cuttings collected from the casings
after the milling processes. Using a sieve analysis, the size distribution of cuttings
after drying was evaluated, Fig. 8.15b.
8.5 Plasma-Based Milling 231

Fig. 8.15 a Cuttings generated during plasma milling processes in water environment (scale in
mm); b cuttings size distribution [16]

The smaller particles are formed from small fragments of oxidized particles with
an irregular shape. A fraction of bigger particles contains a larger number of globular
particles having smooth surfaces. The ratio of cement particles is approximately
the same for each size group. SEM-EDX analysis has been carried out for each
size groups and it has been concluded that oxidation processes penetrate the steel
volume. Figure 8.16a shows spherical particles identified as a ferrite material with
small amounts of oxygen in the structure. Higher content of oxide is shown in the
dark parts on the particles. Figure 8.16b, c show a visible inner structure of the oxide
fragment. Advantages and possible limitations of plasma-based milling technology
are listed in Table 8.5.

Fig. 8.16 a Spherical cutting particle having feritic structure; b and c SEM photo of oxidized
cuttings surface. (Courtesy of GA Drilling)
232 8 Tools and Techniques for Plug and Abandonment

Table 8.5 Advantages and possible limitations of plasma-based milling technology

Advantages Possible limitations
• Rigless operation as the system is designed • Not field proven yet and therefore, not
as a coiled tubing deployed solution commercially available
• High milling ROP and subsequently cost • The Plasma Bit requires a purpose-built
effective CT-reel conveyed umbilical
• No swarf generation • Ability to deliver sufficient electric power
• Non-contact approach which improves with transfer lines
reliability by minimizing the wear and tear
of the tool or challenges associated with
sticking
• Fully automated coiled tubing milling
process goes hand in hand with the
enhanced safety of operational staff
• No need to remove Christmas tree

8.6 Wellhead Cut and Removal

For a P&A operation, in Phase 3, the wellhead needs to be handled safely and effi-
ciently. Depending on the well location and the corresponding authority regulations,
the wellhead can be cut and removed or left in place with a cover protection. Consid-
ering deep or ultra-deep subsea wells, wellhead cut and removal may not be necessary
as there might be no other activities (e.g. the fishing industry) in the area. However,
it is a common practice to cut, below the baseline, and remove wellhead of land and
platform wells.
Wellhead cut and removal can become a complex and costly operation, especially
for subsea wells as a mobile offshore drilling unit, not necessarily a drilling rig,
needs to be employed. Experience shows that the total time spent on mechanical
wellhead removal of a subsea well can take between 6 and up to 40 h though a
typical operation may take approximately 19 h. Therefore, it is necessary to consider
wellhead cut and removal and its impact on the AFE. Different types of wellhead
cutting are available including explosive cutting, hot cutting, mechanical methods,
abrasive methods, and laser cutting. Some of these techniques are already in use
whereas others are a relatively young state of the art technology. These technologies
are explained in this section.

8.6.1 Explosive Cutting

Explosive technology has been used for control of blowing wells, removal of conduc-
tors for well abandonment, removal of platform piling for salvage, and the removal
of debris which may present a hazard to navigation and the fishing industry [17]. In
this technique, shaped charge cutters are used to produce slot type cuts rather than
producing holes in a classical manner. In the classical manner, conical lined shaped
8.6 Wellhead Cut and Removal 233

Fig. 8.17 Drawing of a shaped charge cutter and the provided cut in the steel target [17]

charges are used to produce perforations when completing oil and gas wells. The
principal of charge cutters and conical shaped charges are the same but the charge
cutters provide a linear cutting action (see Fig. 8.17). To create a cut in circular
geometries (such as pipes and wellheads) circular cutters, which consist of two 180°
hermetically sealed charges, are used (see Fig. 8.18). The circular charges can be
used inside or outside circular geometries.
Generally, an explosive cutter system consists of three main parts: command unit,
detonator, and charge. The command unit sends a signal via a shielded electrical
cable to a detonator, and the detonator initiates the charge directly or via a cortex
link. There are some advantages and possible limitations associated with use of
explosive cutting for wellhead cut and removal, Table 8.6 (Fig. 8.19).

Fig. 8.18 Inside circular

cutter [17]
234 8 Tools and Techniques for Plug and Abandonment

Table 8.6 Advantages and possible limitations associated with use explosive cutting for wellhead
cut and removal
Advantages Possible limitations
• Easy to handle and install • No guarantee of the completion of the cut
• No limitation in size of cut • No control on cutting stages
• Fast cutting performance • Restrictions imposed by some authorities for wellhead
cutting (environmental concerns)
• Due to unclean cut, the removal process of wellhead could be
difficult
• Associated safety issues

Fig. 8.19 Schematic

presentations of unclean cut
created by explosives.
(Courtesy of Blast Design)
8.6 Wellhead Cut and Removal 235

8.6.2 Hot Cutting

The petroleum industry is familiar with different hot cutting methods including
oxygen-gas cutting, oxygen-arc cutting, thermic lance, plasma arc cutting, pyrotech-
nic cutting, and flame jet cutting. The hot cutting technique for land-based and
underwater (wet) cutting is almost the same. However, due to presence of water, a
gas pocket needs to be created between the torch and target. One main reason to cre-
ate the gas pocket is that water dissipates the heat more than air and the cut efficiency
is dramatically reduced. General advantages and possible limitations of hot cutting
are listed in Table 8.7.
In the flame cut process, an oxygen-fuel flame burns in the gas pocket and heats
a spot on metal. A jet of pure oxygen, which is located in the center of the heating
flame, blows against the spot on the metal to oxidize it with pure oxygen. As the
torch is moved, the cut is formed [18]. Hydrogen is the prime fuel gas used for
underwater cutting. The oxygen-acetylene flame is another type of flame which
generates more heat compared to the oxygen-hydrogen flame. The flame equipment
is bulky and requires added skills. In addition, it will only cut through steel and cannot
cut through stainless steel nor nonferrous metals such as aluminum, and bronze. This
lack of cutting ability is due to the low degree of oxidation of such materials. The
flames cut efficiency is a function of water depth. Therefore, the technique is not
used as it was used in the old days. The advancement of arc cutting technology has
resulted in reduced use of flame cutting.
The arc cutting technique is almost similar to the flame cut but instead of a flame,
a plasma arc is the source of heat. The arc heats the metal and oxygen is blown
through the electrode to oxidize the metal. Compared to the flame cutting technique,
arc cutting is faster and easier to handle and use. However, it can only cut through
carbon or alloy steel. A variation of arc cutting is plasma-arc cutting.
The plasma-arc cutter generates a large amount of heat which acts on a spot on
the steel surface. A gas flow blows away the molten metal, Fig. 8.20. The plasma-arc
is able to cut through thick metal devices with high speed. It can cut through steel,
aluminum, copper, and stainless steel alloys, cement and multiple casings.

Table 8.7 Advantages and possible limitations of hot cutting

Advantages Possible limitations
• Easy to handle and install • Requires diver or ROV
• Full control at all cutting stages • Restrictions imposed by some authorities for wellhead
• No limitation in size of cut cutting (environmental concerns)
• Guarantee of the complete cut • Poor cutting performance
• Associated safety issues with regards to explosion of
fuels and gases
236 8 Tools and Techniques for Plug and Abandonment

Fig. 8.20 Plasma-arc

cutting of steel [18]

8.6.3 Mechanical Methods

Generally speaking, mechanical cutting methods have limitations specially when

there is no cement in the annular space between conductor and casing string. The lat-
eral movement of one string creates a challenge for cutting the next string. Mechanical
cutting is divided into different categories including diamond wire cutting system,
milling cutter, sawing (guillotine saw), and grinding.

8.6.3.1 Diamond Wire Cutting System

The system utilizes a series of machines, which are operated remotely, to create
external cuts. The system uses a diamond embedded wire (e.g. a chain saw-like
mechanism) to cut. The cutting operation can be done on steel, concrete or composite
materials. A diamond wire cutting system consists of a clamping frame, cutting frame
with wire driving pulleys and motor, wire feeding system, wire tensioning system,
umbilical assembly, and diamond wire cable. As the cutting operation is mechanical,
there is no operational limit concerning water depth. In addition, environmental-
friendly, full control of the cutting operation, no limitation in size of cut, and fast
cutting performance are other advantages of the system. One of the main limitations
of this system is that only external cuts can be performed (see Fig. 8.21) [19]. In
addition, the wire can get stuck when unstable structures are cut. These types of
cutter make the cut above the baseline, seabed or ground, which is less of interest.

8.6.3.2 Milling Cutter

In milling cutting, a hydraulically actuated cutter is activated to create the cut while
rotating (see Fig. 8.2). The mechanical cutter is equipped with carbide-tipped tung-
sten blades. When attempting multiple cemented casing strings, the blades may be
worn out and trips in and out are required. Eccentricity of the inner string can result
8.6 Wellhead Cut and Removal 237

Fig. 8.21 Diamond wire saw. (Courtesy of Mirage Machines)

in an incomplete cut. This method is easy to handle, with fast cutting performance.
However, a large amount of swarf is generated which needs to be handled. Replacing
the blades can be time consuming, and the risk of over-torque may result in a tool
stuck in the well.

8.6.3.3 Sawing (Guillotine Saw)

Guillotine pipe saws are designed for cold cutting and the most common type is
reciprocating hydraulic driven saws with automatic feeding (see Fig. 8.22). This
type of cutters can perform both on dry and wet environments and the operation can
be controlled remotely [20]. Guillotine saws perform external cuts and their blade
can get stuck when unstable constructions are subjected to cutting. These type of
cutters are fast in cutting but they cut the pipe above the baseline, seabed or ground.

Fig. 8.22 Guillotine saw

performing surface
sectioning. (Courtesy of
Oceaneering)
238 8 Tools and Techniques for Plug and Abandonment

8.6.3.4 Grinding

Grinding is a type of mechanical machining where a cutting tool removes layers of

the target material. The cutting tool is significantly harder than the target material.
The electrochemical grinding cutting system is one type of grinding system. An
electrochemical grinding cutting system consists of pumps, Direct Current (DC)
generators, drive unit and manipulator, umbilical, and the cutting tool. Grinding
cutters are environment friendly, safe and reliable with no limitation in size of cut. In
addition, the cutting stages are under full control. However, it is a hot work method,
slow process and vulnerable to casing compression.

8.6.4 Abrasive Methods

Abrasive methods have long been used in industrial and manufacturing processes to
create cuts through rock, steel, and reinforced concrete [21]. Abrasive methods used
in the petroleum industry to create cuts are categorized as sand cutting and abrasive
water jet cutting. This categorization is based on the pressure used to create the cut.
In a sand cutting technique, a high volume of particles are pumped at low pressure;
however in abrasive water jet cutting, a low volume of solid particles are pumped at
high pressure [22].

8.6.4.1 Sand Cutting

The process of tubing erosion caused by high-velocity sand has been a known well
integrity issue. Development of mobile, high-pressure, high-horsepower pumping
equipment, and controlling the rheological behavior of sand slurry resulted in sand
cutting techniques in the 1960’s [23]. In this technique, a fluid which contains abra-
sive solids is pumped through a set of nozzles with high differential pressure. The
differential pressure is typically between 14 and 28 (MPa) with a flowrate between
350 and 450 (l/min). When the abrasive solids pass the nozzles, pressure is con-
verted to kinetic energy and consequently high velocity is imparted to the solids.
The solids with high velocities impact on casing, cement or formation and erode
the target material in an organized pattern. Figure 8.23 shows the principle of sand
cutting equipment. The equipment includes a high-pressure pump, blender unit with
sand catch tank, hydroblast tool, and cutter heads with nozzles. The cut performance
depends on nozzle differential pressure, sand concentration, nozzle stand-off distance
and back-pressure.
The theoretical power available in the jet stream at the exist of nozzle may be
expressed as [24]:

Power = QW h (8.3)
8.6 Wellhead Cut and Removal 239

Fig. 8.23 Principle of a sand

cutting unit

where Q is the flowrate of the sand-fluid mixture in ft3 /s, W is the specific weight
of the sand-fluid mixture in lb/ft3 , and h is the drop in pressure head across the jet
nozzle in ft.
Setting the weight of sand-fluid mixture consists of weight of sand and fluid:

W = Ws + W f (8.4)

where W s is the weight of sand per ft3 of sand-fluid mixture and W f is the weight of
carrier fluid per ft3 of sand-fluid mixture.
By substituting Eq. (8.4) in Eq. (8.3) gives:
 
Power = Q Ws + W f h (8.5)

It can be assumed that during sand cutting, the energy imparted to casing and
cement by jet stream is due to presence of sand and the energy of carrier fluid is
negligible. So, W f can be set at zero. Therefore, energy per unit of time or power
imparted by sand in the jet stream is given by:

Power = QWs h (8.6)

The flowrate, Q, of the nozzle can be expressed as:

Q = AV (8.7)

2
√ of jet stream in ft/s and A is the area of nozzle orifice in ft .
where V is the velocity
By substituting V = 2gh, then Eq. (8.7) can be written as:

Q = A 2gh (8.8)

Substituting Eq. (8.8) in Eq. (8.6), the power can be given as:
240 8 Tools and Techniques for Plug and Abandonment

Power = A 2ghWs h (8.9)

Or
  
Power = AWs 2g h 3/2 (8.10)

The pressure head can be expressed in term of pressure drop and weight of the
sand-fluid mixture as:
P
h= (8.11)
W

where P is the pressure drop in lb/ft2 . Therefore, substituting Eq. (8.11) in Eq. (8.10)
gives:
 3/2
P
Power = Ws A 2g (8.12)
W

Example 8.1 Assume that a sand cutter, with single nozzle, is used to cut a casing.
The pressure drop across the nozzle increased from 1,000 to 2,000 psi. Calculated
the theoretical cutting power of the sand-fluid stream.

Solution The theoretical cutting power varies with the 3/2 power of the pressure
drop across the jet nozzle. Therefore, for constant values of A, Ws and W, increasing
the pressure drop across the jet nozzle from 1,000 to 2,000 psi increases the cutting
power of the sand-fluid stream by 23/2 = 2.83 times.

Sand cutting is an environmentally friendly technique, which is economical, fast

and powerful. But it is difficult to monitor the progress and requires large volumes
of sand or slag. Cutting multistring casing is also challenging. Therefore, abrasive
water jet cutting has been developed.

8.6.4.2 Abrasive Water Jet Cutting

Abrasive Water-Jet Cutting (AWJC) technique uses high pressure at the nozzle but
low volume of sand-fluid. The pressure at the nozzle ranges from 48 to 250 (MPa)
and the flowrate ranges from 40 to 100 (l/min). The principle of AWJC technique
is the same as sand-cutting, which means utilizing the kinetic energy of abrasive
particles carried by a carrier fluid in a high velocity jet to erode the target material.
Velocity of particles and distribution of abrasive particles within the carrier fluid are
important parameters for the efficiency of the cutting process. One of the challenges
associated with abrasive cutting is blockage of the nozzle by oversized grit particles.
To minimize the risk, a certain flow is kept at all times to prevent blockage of the
nozzle. In addition, Polymeric additives are optionally used to suspend the particles
8.6 Wellhead Cut and Removal 241

Fig. 8.24 Principle of an

AWJC

in the carrier fluid and minimize the grit segregation rate if surface equipment fails
and the pumping operation is halted.
A conventional AWJC unit consists of a cutting tool, manipulator, abrasive mixing
or dispensing unit, high pressure water pumps, air compressors, hydraulic power unit,
control panels, and cut monitoring systems (Fig. 8.24). The manipulator controls the
positioning and movement of the nozzle. Presence of water in the interval of nozzle
and target material reduces the efficiency of cutting by taking the kinetic energy of
particles. Therefore, air compressors are used to blow air and create an atmosphere
around the jet. Creating the atmosphere around the nozzle is more challenging where
the cut depth increases.
During wellhead retrieval operation, the cutting tool is lowered into the well,
centralized and anchored at the required depth. The AWJC unit can be placed on a
vessel or MODU for offshore activities. The abrasive fluid is pumped to the nozzle
by a water pump which is usually diesel engine driven. The cutting progresses as the
manipulator rotates the nozzle. The AWJC technique offers a cold cutting solution,
shock free cutting action, no torque between tool and target material, and proven
remote operation. However, the size of topside support equipment, limited control
over the reach,1 volume of abrasive require on board, and the required number of
crew to operate are some of the limitations of AWJC technique.
When considering the rate of penetration of abrasive cutters, power and velocity
of the jet stream are the contributing parameters. Therefore, power equations and
velocity equations are reviewed as follows.
Power Equations—In AWJC technique, the rate of penetration of hydraulic jet
is proportional to power or energy of the jet at the interface of abrasive fluid and
the target. The energy of jet stream is decreased with distance from the nozzle exit.
As the distance between the nozzle exit and point in question increases, the energy
diminishes to a value equal to the threshold cutting power. So the phenomenon can
be expressed as:

1 Reach is the cut length.

242 8 Tools and Techniques for Plug and Abandonment
 
dL ft
= K p (PL − Pth − Plosses ) (8.13)
dt s

where dL is the distance between the nozzle exit to point in question in [ft/s], PL is
the power contained in the jet stream at the point L in [(ft-lbf )/s] or [hp], Pth is the
threshold cutting power in [(ft-lbf )/s] or [hp], Plosses is the hydraulic losses caused
by casing, cutting restriction, and back-pressure in [(ft-lbf )/s] or [hp], and K p is
the constant of proportionality for power equation in [1/lbf ] which is obtained from
experimental data.
The power contained in the jet stream at point L distance from the nozzle exit is
expressed as:
 
1 2 ft − lbf
PL = m̄ L V L (8.14)
2 s

where m̄ L is the mass rate of jet stream in [lbm /s] and V L is the jet velocity at
the distance L in [ft/s]. Due to diffusion of the jet stream with distance, the mass
rate is proportional to the initial mass rate at the nozzle exit. The mass rate is also
proportional to the ratio of nozzle diameter to distance of point in question from the
nozzle exit. Therefore, the mass rate is expressed as:
 
D lbm
m̄ L = Cm m̄ 0 (8.15)
L s

where m̄ 0 is the initial mass rate at zero distance in [lbm /s], D is the nozzle opening
diameter in ft, or in., L is the distance from nozzle exit to the point of question in
ft., or in., and C m is an empirical dimensionless constant (C m = 5.2). The jet stream
velocity at distance L is proportional to initial velocity of the stream at the nozzle exit
and to the ratio of nozzle diameter to distance of point in question from the nozzle
exit. Therefore, the velocity equation is expressed as:
 
Cv V 0 D ft
VL = (8.16)
L s

where V 0 is the initial velocity of the jet at the nozzle exit in [ft/s], and C v is an
empirical dimensionless constant (C v = 6.4). Substituting Eqs. (8.16) and (8.15) in
Eq. (8.14) gives:
2
Cm Cv2 m̄ 0 V 0 D 3
PL = (8.17)
2gL 3

lbm −ft
where g is the conversion constant in lb f −s2
. From continuity equation, it can be
written:
8.6 Wellhead Cut and Removal 243

m̄ 0 = ρ AV0 (8.18)

where A is the area of nozzle and can be written as:

π D2
A=
4
and

P
V0 = 2g 144 (8.19)
ρ

By substituting Eqs. (8.18) and (8.19) into Eq. (8.17), it gives:

3
B D 5 (P0 ) 2 1
PL = B = 3πCm Cv2 (2g) 2 (8.20)
L 3 ρ 1/2

where P0 is the pressure differential across the nozzle in [psi], and ρ is the sand-fluid
density in [lbm /ft3 ]. Combining Eqs. (8.20) and (8.13) will result:
 3
 
dL B D 5 (P0 ) 2 ft
= Kp − Pth − Plosses (8.21)
dt L ρ
3 1/2 s

Velocity Equations—The rate of penetration dL/dt, of the hydraulic jet is pro-

portional to the velocity of abrasive fluid at the interface of the fluid and the target
material. So, the rate of penetration in terms of velocity can be expressed as:
 
dL   ft
= kv VL − Vth − Vbp (8.22)
dt s

where V L is the velocity of abrasive fluid at the interface of the fluid and target
material in (ft/s), V th is the threshold velocity or the minimum velocity required to
create the cut in (ft/s), V bp is the velocity of loss of the jet resulting from the return
flow of the abrasive in (ft/s), and k ’v is the constant of proportionality for the velocity
equation and is obtained experimentally
By substituting Eq. (8.16) into (8.22):

dL C v V D
= kv
0
− Vth − Vbp (8.23)
dt L

By rearranging Eq. (8.23) and solving for dt:

kv Ld L
dt = [s] (8.24)
Cv V 0 D − L Vth − LVbp
244 8 Tools and Techniques for Plug and Abandonment

Fig. 8.25 Abrasive cut process for a cemented casing

where k v is reciprocal of k ’v So, the integration of Eq. (8.24) yields [23] (Fig. 8.25):
  
Cv V 0 D Cv V 0 D L
t = kv ln e   − 
(Vth + Vbp )2 Cv V 0 D − Vth + Vbp L Vth + Vbp
(8.25)

The research work conducted by researchers shows that the threshold cutting
velocity is directly proportional to the hardness of target material:

Vth = cH (8.26)

and
1
H∝ (8.27)
L max

whereas

Cv DV 0 Cv DV 0
L max = = (8.28)
Vth + Vbp cH + Vbp

where c is the proportionality constant, V 0 average fluid velocity of the jet at the
nozzle exit in (ft/s), L max is the maximum penetration in (ft), H is the relative abrasion
hardness of material and is proportional to the reciprocal of the maximum penetration.
When considering AWJC, although casing back-pressure and size of opening
created by the jet cutter have a significant effect on the cut efficiency, the effect of
hydraulic jet stand-off, effect of sand concentration, and communication effect of
materials by induced fractures or formation permeability are important parameters.
Advantages of AWJC includes but are not limited to fast cutting performance
compared to the other cutting methods, environmentally friendly and no special
permission is required to conduct it, and no torque between the tool and target. How-
ever, the drawbacks are limited control on the reach (cut length), cutting efficiency
8.6 Wellhead Cut and Removal 245

decreases with water depth, large volume of abrasive fluid is required on board, large
topside spread compared to the other cutting methods, and number of crew to carry
out the operation.

8.6.5 Laser Cutting

Light Amplification by Stimulated Emission of Radiation, broadly known as Laser,

was coined by Gordon Gould in 1957. Generally speaking, lasers are devices which
convert different kinds of energy to electromagnetic beams of monochromatic and
coherent waves. Monochromatic means the output electromagnetic waves have a
single output wavelength or in other words it means one color output. Coherent means
that all the waves are in phase with one another. The generated waves span through
the different regions including gamma, X-ray, ultraviolet, visible light, infra-red,
microwave, and radio waves.
If the generated stream of electromagnetic beams have high enough energy, then
they can create a cut on steel and rock samples. However, high-powered laser tech-
nology is required for such operations. The intensity of a laser beam depends on the
wavelength of the beam. Common components of a laser are active medium, energy
input (known as pump source), and feedback (laser cavity). An electron is pumped
into a highly excited state and transit to a metastable region. As the electron loses its
energy to return to its initial conditions, it generates photons in different directions.
This process is known as spontaneous emission.
The efficiency of a laser cutter depends on several laser properties including
discharge type, peak power, wavelength, average power, intensity, repetition rate,
and pulse with the discharge type [25–27]. The laser discharge can be pulsed or
continuous. In pulsed discharge type, the optical power appears in pulses for a certain
period of time at some repetition rate. However, in continuous type of discharge, the
optical power appears continuously.
The main challenge associated with the utilization of laser cutters at downhole
conditions is the presence of wellbore fluids. Downhole fluids are opaque, near-
opaque, or even dark which are not conducive to laser cutting.

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Chapter 9
Barrier Verification

The main goal of a P&A operation is to restore the cap rock functionality by estab-
lishing competent barriers. When a barrier is established, its functionality needs to be
verified. There are different test procedures to verify integrity of permanent barriers.
Some include verification of annular barrier (barrier between casing and formation),
some include verification of permanent plug inside casing, and some others include
verification of barriers in open holes. The main challenge for barrier verification is
the lack of direct relationship between laboratory verification and field performance
testing. In the laboratory testing of cement, the following parameters are evaluated:
mechanical properties (e.g. compressive strength, tensile strength, Young’s modulus,
etc.), shear bond strength, hydraulic bond strength and tensile bond strength, fluid
migration analysis, static gel strength analysis, etc. In addition, most of laboratory
experiments replicate best case scenario with respect to contamination of cement
slurry. However, there is no simple way of accurately testing these parameters at
expected downhole conditions. In fact, the only tests available to verify cement plugs
in the field are hydraulic pressure testing, weight testing and tagging with workstring.
The annular barrier is tested indirectly by logging. This chapter will review these
field test methods.

9.1 Annular Barrier Verification

The concept of cross-sectional barrier has already been defined in previous chap-
ters. In order to verify the cross-sectional barrier, barrier behind casing needs to be
verified where casing exist. There are different methods to qualify the integrity of
annular barrier. Acoustic logging of annular barrier, passive noise logging, tempera-
ture logging, and hydraulic pressure testing are the most commonly used verification
method which will be reviewed in this chapter.

© The Author(s) 2020 249

M. Khalifeh and A. Saasen, Introduction to Permanent Plug
and Abandonment of Wells, Ocean Engineering & Oceanography 12,
https://doi.org/10.1007/978-3-030-39970-2_9
250 9 Barrier Verification

9.1.1 Acoustic Logging of Annular Barrier

Acoustic logging of annular barrier technique is the prime method used in petroleum
industry for verification of casing cement but also may be used for other types of
barrier materials. Therefore, this technique will be discussed more in detail.
In acoustic logging method, an acoustic signal is emitted by a transducer, the
emitted signal goes to a journey through casing fluid, casing steel, barrier behind
casing, adjacent formation and all the way back to two receivers, Fig. 9.1. The
receivers pick up the reflected acoustic signal and engineers process the collected
data to check the quality of annular barrier.
The history of sonic logging goes back to 1950s when during formation evaluation
by sonic logs the occurrence of skipped cycles were noticed where openhole and
cased hole were evaluated [1]. Since then, the technology has advanced whereas
ultrasonic tools have been developed and are in use. Nowadays, cement bond logs
are run to determine cement to casing bonding, cement to formation bonding, and

Fig. 9.1 A cement bond log

(CBL) and variable density
log (VDL) tool
9.1 Annular Barrier Verification 251

evaluate cement conditions. The evaluation of cement conditions include detection

of channeling, compromised cement (by gas cut, dehydration, etc.), top of cement,
and micro-annuli.
Acoustic logging is a process of recording of some acoustic property of formation
and wellbore. The result of process is displayed on an acoustic log which presents
traveling time of acoustic waves versus depth in a wellbore. The acoustic logging of
annular barrier can be through sonic, and ultrasonic (pulse-echo) measurements.

9.1.1.1 Sonic Measurements

Sonic tools are working in a frequency range of 10–30 kHz. An electrical signal is
sent to a piezoelectric transducer, and the transducer generates an omnidirectional
acoustic signal. Piezoelectric transducers are capable to receive electricity and con-
vert it to acoustic signal and vice versa. Acoustic signals are sound waves which
are categorized into compressional wave (P-wave), shear wave (S-wave), and plate
wave, Fig. 9.2. Compressional wave (sometimes called longitudinal wave) is a wave
that the motion occurs in the same direction or opposite direction to wave propa-
gation. Compressional waves can travel through solid, liquid and gas. Shear wave
(sometimes called an elastic S-wave) is a wave that the motion is perpendicular to
the wave propagation. Large amplitude shear waves can travel only through solid
phases. Plate wave (sometimes called Lamb wave) propagates in solid plates but
slightly slower than compressional wave in steel plates.

Fig. 9.2 Wave propagation modes [2]

252 9 Barrier Verification

Piezoelectric transmitter fires acoustic signal, compressional wave, and the wave
propagates through casing fluid, casing steel, barrier material behind casing, and for-
mation. The wave is reflected back through all of these medium toward the receivers
(two piezoelectric receivers). Two receivers, placed 3 and 5 ft away from transmit-
ter pick up the reflected signal, Fig. 9.1. The 3 ft receiver picks up the signal from
casing arrival and casing fluid and the 5 ft receiver picks up the formation arrival.
The recorded data are presented on a log which consists of a log heading, main log
and repeat section, determination of logging pressure, before and after survey cali-
brations and parameter box, and log tail. A log heading is composed of four parts:
API heading, remark box, well schematic, and tool schematic with sensor distances,
Fig. 9.3.
The main log presentation consists of three tracks: Track 1 for quality control,
Track 2 show the quality of bonding between cement and casing, and Track 3 which
shows formation arrival (see Fig. 9.4). Depending on the logging tool used for logging
annular barrier, more tracks may be distinguished, Fig. 9.4.
A repeat section is to examine the logging operation and the recorded length is
usually 100 m which covers the zone where good sealing is expected. Sonic logs are
always run under pressure in order to differentiate microannulus from channeling.
As the pressure affects the amplitude of sound, the logging pressure is determined
and presented on the log. The parameter box and sonic summary, before and after
calibration, are presented on the log. The last section on a log presentation is a log
tail which repeats the top part of the heading.
When transmitter emits an acoustic signal, an elapsed time is passed until the
receiver can detect the first part of the wave arrival, which is exceeding a preset
amplitude threshold. The elapsed time is known as transit time. Amplitude is the
strength of the first arrival wave. When time passes, the amplitude recorded by
receiver increases up to a level and then decreases. Time taken by an emitted signal
to travel from transmitter to receiver is called travel time. Figure 9.5 shows the above-
mentioned terminologies. When the emitted signal travels through different medium
(e.g. casing fluid, casing, material behind casing), it loses the energy. The loss of
sound energy, strength, is called attenuation. So, the higher the attenuation the lower
the amplitude.
An acoustic logging tool may be configured with some complementary logging
tools. The most common complementary logs include casing collar locator (CCL) and
Gamma ray logs. Figure 9.6 shows two sonic logs equipped with CCL, GR detector
and centralizers; however, tool centralization is valid in wells with inclination less
than 50°. CCL is used to locate casing collar for depth calibration. GR detector is
also used for depth and formation calibration. In fact, Track 1 does not provide any
information regarding the cement quality but it is used for quality control.
A transmitter fires a compressional wave and it propagates spherically. A part of
the compressional wave travels downwards along casing fluid along casing steel and
a part reaches the casing and travels downward along the casing. Another portion of
the wave which entered to casing steel travels further toward material behind casing
and formation. If there is solid material behind casing, at the interface of casing
and the solid material shear waves is generated. So, the generated shear wave and
9.1 Annular Barrier Verification 253

Fig. 9.3 A log heading

254 9 Barrier Verification

Fig. 9.4 A CBL-VDL log with radial mapping which includes five tracks

Fig. 9.5 Recorded amplitude of an acoustic signal

compressional wave continue to travel through the solid material behind casing and
formation, and also downwards. But if there is no solid material behind casing, shear
wave is not produced and only the compressional wave will travel through annulus
behind casing to formation and downwards. In order to get the wave propagation
inside the casing plate, the waves are emitted in a predetermined critical angel.

Example 9.1 In order to understand the concept behind acoustic logging of casing,
you are asked to run an experiment. Pick up a pozzolan or steel coffee cup with a
9.1 Annular Barrier Verification 255

Fig. 9.6 A cement logging

tool assembly [3]

teaspoon. Ask an assistant to hold the cup from its handle part with no hands around
it, and hit the cup with teaspoon from inside and listen to the noise, Fig. 9.7a. For the
second time, ask the assistant to hold the cup between his/her hand tightly. Again,
try to hit the cup with the teaspoon from inside and listen to the noise, Fig. 9.7b.

Fig. 9.7 Simulating reflected noise from an uncemented and cemented casing: a cup has no barrier
behind it, b hand acts as barrier behind cup and absorbs the noise energy
256 9 Barrier Verification

Now assume that the cup is casing, teaspoon is transmitter, and hands around the
cup is cement behind casing. Based on the experiments explain and interpret your
observations.
Solution When holding the cup form its handle and hitting the cup wall with tea-
spoon, the sound energy is high. In other words, the reflected sound has high energy
which is known as ringing. The same phenomenon happens when there is free casing,
the casing rings.
When holding the cup tightly between hands, the emitted sound is absorbed by the
hand and lower sound energy is reflected. When there is solid barrier behind casing,
the emitted sound travels further and less energy is reflected back.
As described earlier, the transmitted acoustic signal is picked up by two receivers:
3 and 5 ft. 3 ft receiver picks up the reflected sound from casing and presented on
Track 2, which is known as CBL log. The CBL log shows the quality of bonding
between casing and the material behind it. When CBL log shows high amplitude
(high energy), then the casing reflects back most of the transmitted sound because of
poor bonding. In other words, the casing is ringing because of poor bonding between
solid material adjacent to casing, whereas sound is not absorbed. But if there is
good bonding between solid material in annulus behind casing and casing, the sound
travels further to formation and it is picked up by the 5 ft receiver. The recorded data
are presented on Track 3, which is known as VDL log. The VDL log records the
amplitude of transmitted sound though casing fluid, casing, barrier behind casing,
and formation (Fig. 9.8). When VDL log shows formation arrival, then there is a
solid material in the annulus behind casing up to formation.
Information of the compressional wave velocity allows engineers to measure com-
pressional acoustic impedance (Z) of materials. Every material has its natural acoustic
impedance property and by estimating the acoustic impedance of an unknown mate-
rial, the material might be distinguished. This is the main driver of sonic logs for veri-
fication of annular barrier. The acoustic impedance of a homogenous, non-dissipative

Fig. 9.8 Signal arrivals from casing fluids is the latest as sound travels slower in liquid phases,
casing arrival is the first to arrive. Composite amplitude is presented on VDL log
9.1 Annular Barrier Verification 257

medium, is given by:

Z = ρv P (9.1)

where ρ is the material density (kg/m3 ) and ν Pis compressional

 wave velocity
6 kg s
(m/s). The acoustic impedance is expressed in 10 m2 which known also as mega-
Rayleigh (MRayl).
When designing, executing and interpreting sonic logs, there are well parame-
ters, organizational and operational factors, and human factors, which can affect the
final result. The well parameters include, but are not limited to: temperature and
pressure, wellbore-fluid properties, casing size and thickness, cement thickness, and
surrounding formation. Organizational and operational factors may include selection
of service provider, pre-job meeting and discussions, surface pressure (equipment
and procedure used), detection setting, and log quality control procedures. All of
these factors affect the reliability of the final logs and their interpretation.
Considering utilization of sonic logging tools in P&A, for verification of annular
barrier, their reliability may be questioned if the logging tool is calibrated according to
well conditions for primary cementing. This is due to change in properties of annular
barrier over time, casing thickness changes, and formation subsidence. Therefore,
calibration and re-evaluation of logs based on current well condition are expected.
Advances of sonic logging tools has been in progress since their development and
utilization. Re-evaluation of annular barrier, in place from primary cementing, with
recently modified sonic logging tools could give a better understanding of annular
barrier condition.

Example 9.2 In recent years, PWC technique has been developed and employed to
avoid section milling. After barrier establishment with PWC, the internal cement is
drilled out and annular barrier is logged with sonic tools. How can the perforated
casing create difficulties and uncertainty in sonic logging?

Solution When casing is perforated, plate waves cannot effectively travel through
casing unless they have very low shot density. In addition, generation of shear waves
at the interface between casing and cement is disrupted. Therefore, increased atten-
uation of sound waves is expected which is caused by the holes created during per-
foration. One possible solution is to remove the effect of holes during Fast Fourier
Transform processing.

Sonic logs have their advantages including: wireline operation, non-destructive

technique, and safe operation. However, there are some limitations associated with
utilization of sonic tools. Sonic logging provides a qualitative evaluation of cement
quality and it does not show the direction of anomaly. In other words, the CBL-
VDL graphs show an average of circumferential measurements. These tools are
also sensitive to liquid-filled micro-annulus. Therefore, ultrasonic tools have been
developed and are employed more often than sonic tools.
258 9 Barrier Verification

9.1.1.2 Ultrasonic Measurements

Ultrasonic pulse-echo (PE) techniques were introduced to the industry for cement
evaluation in the early 1980s. These cement-mapping tools operate at much higher
frequencies than acoustic tools, typically between 200 and 700 kHz [2, 4, 5]. The
principle of the ultrasonic technique is to cause a small area of the casing to resonate
across its thickness. In pulse-echo techniques, a transducer, acting as both a transmit-
ter and a receiver, mounted in a rotating head, sends out a short pulse of ultrasound
and picks up the echo containing resonance, Fig. 9.9 [6]. As ultrasonic tools provide
peripheral rotation, a radial map (Track 4 in Fig. 9.4) is generated as result and defect
location can be distinguished. In order to apply real time corrections for impedance
calculations, ultrasonic tools provide real time measurements of fluid impedance in
a built-in mud cell. The rate of decay of the resonance will be lower if there is fluid
behind the casing whereas cement will damp the resonance faster [7].
A limitation with PE measurements is that they are only able to investigate the
presence of cement behind a single casing string. Another known weakness of this
ultrasonic sonic measurement technique is its sensitivity to the presence of small gas
bubbles [8].
Viggen et al. [9] attempted to model ultrasonic pitch-catch measurements in a
through-tubing logging configuration. In pitch-catch techniques, there is one trans-
mitting transducer and one or more receiving transducers. They used a finite element
model of a double-casing geometry with a two-receiver pitch-catch setup. In their
study, they found that a cascade of leaky flexural Lamb wave packets appears on
both casings caused by leaked wave fronts. Their study shows that the received pulse

Fig. 9.9 Ultrasonic

measurement, pulse-eco
technology
9.1 Annular Barrier Verification 259

from the second wave packet contains information about the bonded material in the
outer annulus as well as the interface between cement and formation.
Viggen et al. [10] attempted to analyze outer casing echoes through simulations
of ultrasonic pulse-echo measurements through-tubing. Their work examined the
hypothesis that anomalies behind a second casing string can cause significant varia-
tions of pulse-echo. Their finding shows that variations of the outer casing interface
echo with the outer casing thickness and the B-annulus material may be too subtle
to be reliably applied to through-tubing logging. In addition, they found that eccen-
tricity of the casing and transducer angle influence the travel time of the interface
echo.
A recent development targets the utilization of electro-magnetic acoustic trans-
ducers (EMAT) for the generation of guided acoustic waves in the casing [11]. For this
technology, a Lorentz force1 is used to generate and measure acoustic waves directly.
EMAT operate with a coil, a magnet and a conductive casing, and it can function
both as transmitter and receiver. EMAT generate two fundamental wave modes; shear
horizontal and lamb flexural (plate). In the shear horizontal wave mode, the particle
motion is perpendicular to the direction of wave propagation; however in the lamb
flexural mode, the particle motion is normal to the casing surface. The study of these
wave modes is a direct measurement of the shear modulus of the solid material behind
casing with a higher resolution compared to conventional acoustic techniques whilst
eliminating sensitivity to the wellbore fluid or the need for physical contact of the
transducers with the casing [12].

9.1.2 Noise Logging Measurements

When a leak occurs through cement defect, noise may be generated which depends
on the defect size and geometry, leakage rate, and surrounding materials. If the
generated noise is above a threshold level, it can be detected and analyzed; either by
passive noise logging or active noise logging.

9.1.2.1 Passive Noise Logging

Fluid flow through a leakage pathway generates noise with two measureable param-
eters; intensity and frequency. Noise intensity, also known as acoustic intensity, is
defined as the energy carried by the sound wave per unit area. In the context of
leakage, noise intensity depends on fluid flowrate and differential pressure driving
it, while noise frequency depends on the geometry of leakage pathway. As a rule
of thumb, when fluid flows with ease through a large area, a low frequency noise is
generated whereas fluid flowing with difficulty through a narrow space generates a

1 Itis an electromagnetic force that acts on a charged particle which is moving with a velocity
through and electric magnetic field.
260 9 Barrier Verification

high frequency noise. There are a variety of tools able to record noise generated by
leaks over a wide frequency range with a high resolution and high sensitivity.

9.1.2.2 Active Noise Listening

Active listening is an acoustic technique whereby a very short acoustic pulse is fired
at the region being examined and the reflected signal is thereafter recorded. After a
short waiting time, the same region is examined again by an identical signal and the
reflected signals are thereafter subtracted from each other. If there is no difference in
the reflected signals, it means that there is no motion or other changes in the material
behind the casing. In other words, motion in the material during emitting the first
signal and the second signal will result in an incoherence in the signals at the same
depth. The strengths of this technique compared to conventional noise logging is
that it is sensitive to a wider range of flowrates, provides a quantitative estimate of
flow velocity, the distance to channels can be estimated and gas migration through a
column of liquid in the channel can be detected.

9.1.3 Temperature Logging

Temperature logs are used to detect the temperature anomalies behind casing caused
by cement hydration or leakage of fluids. Of temperature logs, cement hydration
detection, communication indicator, radial differential temperature, active temper-
ature logging and distributed temperature sensing are the most known temperature
logging techniques [8].

9.1.3.1 Cement Hydration Detection

Temperature logs are used to detect the temperature anomalies behind casing caused
by cement hydration or leakage of fluids. Cement hydration occurs over a period
of six to twelve hours after initial mixing of cement and is an exothermic chemical
reaction which generates considerable heat. It is the temperature rise inside the well
due to the heat conducted by the casing from the cement that is readily detected by
temperature logs. Temperature logs recorded at a suitable point in time can be used
to detect the TOC, however, complete verification of the seal quality of a primary
cementing operation is challenging. Detecting cement hydration must be performed
before the temperature increase due to hydration has dissipated and this technique is
not therefore suitable for inspecting the casing cement later in the well life.
9.1 Annular Barrier Verification 261

9.1.3.2 Communication Indicator

When fluids leak through a defect, the temperature of the surroundings is affected.
In thermodynamics, the Joule–Thomson effect describes the temperature change
of a real gas or liquid when it is forced through a restriction. A condition of the
Joule–Thomson effect is that the enthalpy, H, remains constant:

H = U + PV (9.2)

where U is internal energy, P is pressure and V is volume. According to the Joule–

Thomson effect, the change in PV shows the work done by the fluid. When a fluid
passes through a defect, the PV is increased and to keep the H constant, U is
decreased. This means that cooling due to expansion is expected if gas flow occurs.
A conventional temperature log measures the fluid temperature inside the well and
the recorded data is plotted versus depth. By comparing the obtained data with
the geothermal temperature gradient the depth of anomalies can be identified that
might be related to fluid leakage through defects in the cement. Temperature gradient
differences can also be created by injected fluid flowing in the channels.

9.1.3.3 Radial Differential Temperature

Radial Differential Temperature (RDT) logging is a modified version of conventional

temperature log for detecting channels. This method utilizes two sensors (in addition
to a sensor in the center of well) to measure the pipe wall surface temperature around
its circumference. The difference in temperature between casing wall and sensor
in the center of pipe is measured and plotted versus depth. Deviation of recorded
temperatures from geothermal temperature can be used to locate channels near to
the casing.

9.1.3.4 Active Temperature Logging

Active temperature logging uses short-term local inductive heating of the metal in
the casing to give the reservoir fluid a thermal signature that can be detected during
production. As a result of inductive heating of the casing, a thermal anomaly is
induced both inside the well and in the fluid moving behind the casing which can
be detected by sensors once the fluid is produced into the well. Figure 9.10 shows
an active temperature logging tool equipped with inductor, distributed temperature
sensors; T1, T2 and T3, collar locator, gamma ray detector and water resistivity
recorder.
262 9 Barrier Verification

Fig. 9.10 Active temperature logging tool with its inductive heater

9.1.3.5 Distributed Temperature Sensing—Fiber-Optic Sensing

Pulses of light generated by a laser sent through an optical fiber are reflected repeat-
edly from the fiber walls. The fiber and its coating form a wave guide with total
internal reflection such that light is not lost through the fiber walls. A sensor or
combination of sensors can be placed along the fiber and record measurands such
as; pressure, temperature, seismic, mechanical stresses, chemicals, and flow [13,
14]. Figure 9.11 shows three main types of fiber-optic sensor arrangements; single
point sensor, multi-point sensors, and distributed sensors. The single point sensor
measures the parameter of interest at a single point in space typically at the end
of the fiber. The multi-point sensor measures the measurand at a number of fixed,
discrete points along a single fiber-optic cable. The distributed sensor measures the
measurand with a certain spatial resolution at any point along the fiber-optic cable.
In the latter case, the fiber cable itself is the sensor and backscattered light carries
information. Distributed sensing has the potential to identify leakage pathways and
thereby cement defects. Two different distributed sensing systems are Distributed
Temperature Sensing (DTS) and Distributed Acoustic Sensing (DAS).

Fig. 9.11 Different modes fiber-optic sensing

9.1 Annular Barrier Verification 263

Fig. 9.12 Graphical schematic of DTS system

In the DTS system, a short pulse of light is launched into the fiber. The forward
propagating light generates Raman backscattered light at two distinct wavelengths,
from all points along the fiber, Fig. 9.12. These two wavelengths are named “Stokes
light” and “anti-Stokes light” and are generated due to inelastic scattering of a pho-
ton. Anti-Stokes light is temperature-dependent, while the Stokes light is weakly
temperature-dependent. The local temperature of the optical fiber is calculated from
the ratio between the amplitude of the Stokes and the anti-Stokes detected light.
One of the challenges for temperature logging tools is high-temperature wells
where the generated temperature during cement hydration or temperature anomaly
caused by leakage is difficult to identify from the high geothermal temperature.

9.1.4 Hydraulic Pressure Testing

Inability to log annulus behind the second steel string, Fig. 9.13a, is one of the main
challenges associated with the current acoustic logging technologies. So, utiliza-
tion of rig might be inevitable to examine the annular barriers, red boxes shown
in Fig. 9.13a. Therefore, rig is required to retrieve the production tubing to log the
annular barrier behind the production casing, the solid red boxes in Fig. 9.13b. But
264 9 Barrier Verification

Fig. 9.13 Acoustic logging tools are not capable to log through two strings of steel; a rigless
operations is not possible due to technology deficit of acoustic logging tools, b rig is required to
retrieve the production tubing and only logging the red box marked with solid line. The dotted-line-
box area cannot be verified even after removal of production tubing

logging the annular barrier behind the production casing, across the liner (the dotted
red box in Fig. 9.13b), still remains unsolved due to technology deficit.
When utilization of acoustic logging tools for verification of annular barrier is
impossible or may create extra work, hydraulic pressure testing (known as communi-
cation testing) might be an option [15]. Such circumstances may include, verification
of casing cement when production tubing is in place, verification of annular barriers
behind the second casing string, or when PWC technique is used to establish both
internal and external barriers [16], Fig. 9.13a.
In hydraulic pressure testing method, a bridge plug is installed at the base, where
base of annular barrier is supposed to be. The installed bridge plug is pressure tested
and when it passed the pressure testing, above the bridge plug a small window is
perforated. Another bridge plug which is equipped with a wireless pressure gauge
is installed away above the created perforations. This bridge plug also needs to pass
pressure testing. A new window needs to be perforated above the second bridge plug,
Fig. 9.14. The distance between the windows of perforations depends on the required
9.1 Annular Barrier Verification 265

Fig. 9.14 Hydraulic testing,

communication testing, of
annular barrier behind
second casing string

length of annular barrier to be verified. A workstring, equipped with a packer is run

and the packer is engaged above the second perforations. A fluid is pumped through
the workstring and pressure changes are monitored. If the downhole pressure gauge
and surface gauge do not record any changes, the annular barrier is qualified.
The pressure testing is a cycle of extended leak-off and drawdown tests, Fig. 9.15.
The pressure test data can be used for both investigating the hydraulic communication
between the perforations, and corresponding the pressure data to expected formation
strength.
Hydraulic communication test—When fluid is pumped through middle perfora-
tions, any pressure changes above the packer attached on workstring or between the
bridge plugs means failure of annular barriers. However, no pressure changes means
intact and subsequently verified annular barriers.
Extended leak-off test—The extended leak-off tests are conducted to make sure
that perforations reached to the adjacent formation. This can be examined by increas-
ing the injection pressure until leak-off occurs. If the leak-off and breakdown pres-
sures are corresponding to expected formation strength, it means perforations pene-
trated to formation. In addition, extended leak-off test is conducted to make sure that
annular barriers can hold the maximum anticipated pressure.
266 9 Barrier Verification

Fig. 9.15 Extended leak-off test and drawdown test to verify annular barriers, shown in Fig. 9.14,
by hydraulic testing

9.2 Internal Barrier Verification/Plug Inside Openhole

or Casing

9.2.1 Hydraulic Pressure Testing

Pressure testing is applied to plugs installed inside casing, openhole plugs which
are extended to casing or plugs installed entirely in openhole, Fig. 9.16. Pressure

Fig. 9.16 Cement plug installed in wellbore; a cement plug is installed inside casing across a
qualified annular barrier, b cement plug installed in an openhole but extended to casing, c cement
plug entirely installed in an openhole
9.2 Internal Barrier Verification/Plug Inside Openhole or Casing 267

testing has other names such as pump pressure testing and hydraulic testing. Where
mechanical plug is used as foundation for cement plug and the foundation passed
the pressure testing, pressure testing of plug is meaningless.
There is a misunderstanding about information obtained by carrying out pres-
sure testing. Pressure testing gives an insight about sealability of cement plug and
sealing capability at the interface of cement plug and adjacent element [17]. But it
does not necessary provide information about the hydraulic bond strength (for more
information regarding hydraulic bond strength refer to Chap. 3) of entire plug length.
Depending on the direction of applied hydraulic pressure, positive pressure testing
or negative pressure testing can be distinguished.

9.2.1.1 Positive Pressure Testing

In positive pressure testing, fluid is injected by surface pump whereas pressure above
the plug is higher than the pressure below, P1 is higher than P2 (see Fig. 9.1) [18].
When the P across fulfills the requirement asked by local authority, the pressure is
monitored for some minutes and if a stable pressure is reading, the plug is a qualified
plug. The positive pressure testing is carried out on plugs installed inside casing and
across a qualified annular barrier, and plugs installed inside openhole but extended
to casing string (see Fig. 9.16a, b). Pressure testing of plugs installed entirely in
openhole is meaningless (see Fig. 9.16c). The reason is that when subjecting the
openhole plug to the injected fluid, the fluid can penetrate the surrounding formation,
Fig. 9.17.
There are some concerns associate with the positive pressure testing technique
including, but not limited to uncertainty associated with sealing capability of cas-
ing connections, casing corrosion, and ballooning effect of casing. When hydraulic
pressure is applied, the injected fluid can leak thorough casing connections and sta-
ble pressure reading may not be reached (Fig. 9.18). In this case, it is difficult to

Fig. 9.17 Positive pressure

testing of the plug installed
entirely in openhole is
meaningless
268 9 Barrier Verification

Fig. 9.18 Potential leak path

through threads in positive
pressure testing

identify the source of leak; casing connections or a failed plug. Where casing experi-
ences small holes cause by corrosion or caused by mechanical wearing, the applied
hydraulic pressure leaks through the casing and pressure monitoring does not show
a stable reading. Ballooning effect is susceptible when there is liquid in the annular
space behind casing and casing thickness has been affected over years. In this sce-
nario, the casing can expand if the applied pressure exceeds the casing design criteria
such as its elasticity (Fig. 9.19).
Positive pressure testing can also be used to estimate the shear bond strength
between plug and the adjacent material by following equation:

Pp × A p
Shear bond str ength ≥ (9.3)
π × Di × L p

where Pp is the pump pressure, Ap is the surface area of plug, Di is the inner diameter
of the geometry plug placed inside, and L p is the plug length. However, this is valid
when the material sealability and the material mechanical strength is higher than the
shear bond strength of the entire plug.
9.2 Internal Barrier Verification/Plug Inside Openhole or Casing 269

Fig. 9.19 Ballooning of

casing while carrying out the
positive pressure testing, D0
is the origin casing diameter
and D1 is the diameter after
ballooning

9.2.1.2 Negative Pressure Testing

In negative pressure testing (also known as inflow testing), the hydrostatic pressure
above the plug is decreased so that pressure below the plug (P2 ) will be higher than
pressure above the plug (P1 ), see Fig. 9.16. Then, the changes in pressure is recorded.
A stable pressure means a sealed plug. If a transparent fluid is placed on top of plug,
possible leak can be seen directly by use of downhole camera. Negative pressure
testing is used where integrity of connections or casing string above the plug is
questioned and positive pressure testing cannot be performed. In addition, when plug
is entirely placed in openhole, which positive pressure testing is not feasible, negative
pressure testing may be performed. The challenge associated with this method is that
the current pressure, below the plug, might be lower than the expected final pressure.
Therefore, plug is not qualified based on the estimated future pressure but the current
pressure.

9.2.2 Weight Testing

When plug is installed, it is necessary that the plug keeps its position and does not
move due to increase of pressure below it. Weight testing is a method to measure the
positioning, bond strength to adjacent element, and also measures the plug location.
Where cement plug is entirely placed inside openhole, it is not possible to positive
pressure test it or even sometimes negative pressure test it. Thus, weight testing is
270 9 Barrier Verification

carried out to check the positioning of the plug; however, weight testing does not
provide any information about the hydraulic sealability of plug.
Weight testing measures the shear bond strength of plug to adjacent material.
So, the required shear bond strength measured by drillpipe during weight testing is
defined as drillpipe tag weight, W dp , divided by circumferential area of cement plug
and is given by:

Wdp
Shear bond str ength ≥ (9.4)
π × Di × L p

The main challenge to estimate the shear bond strength is the plug length, as the
theoretical plug length is different from plug length retained from contamination.
Studies show that much larger amount of shear bond strength is achieved for short
cement plugs when placed inside small diameter geometries. Studies also show that
by increasing the plug length placed inside a constant diameter geometry, the required
shear bond strength decreases.
Weight testing is operationally feasible in rig-based operations by use of drillpipe
but it might be feasible to carry it out in rig-less operations by use of coiled tubing
or wireline.

9.2.2.1 Drillpipe

It is a normal practice to weight test the plug when drillpipe is available on site.
To avoid any challenge introduced by contaminated cement on top of plug, top of
cement is drilled to reach hard cement. This operation is known as cement dress-off.
The required weight is calculated carefully to avoid any damage to the cement plug.
By using a part of drillpipe weight, the pre-determined weight, positioning of plug
is tested (see Fig. 9.20a). In fact, weight testing provides the shear bond strength
between plug and adjacent material. If the plug can hold the applied weight without
being displaced, its positioning is qualified.

9.2.2.2 Coiled Tubing

Coiled tubing can be used for weight testing where drillpipe is not available. To
dress-off cement plug, a downhole motor is used. One of the main limitations of
coiled tubing to be used in weight testing is the maximum weight that can be cre-
ated. In addition, coiled tubing may be susceptible to helical ramp or tortuosity (see
Fig. 9.20b) and difficult to apply more weight.
9.2 Internal Barrier Verification/Plug Inside Openhole or Casing 271

Fig. 9.20 Weight testing of cement plug placed inside casing; a drillpipe, b a heavy weight may
be used with coiled tubing but coiled tubing may experience helical shape due to its design factors,
c limited weight can be used for wireline

9.2.2.3 Wireline

Wireline may also be used for weight testing where there is no drillpipe nor coiled
tubing unit. A downhole motor is used to dress-off the plug and then a limited weight
is applied on the plug with no chance to apply additional weight (see Fig. 9.20c).
Compared to drillpipe and coiled tubing, the use of wireline for weight testing is
not accepted by many regulators due to the limitations of exerted weight. However,
wireline can be used to confirm the depth of top of cement.

9.3 Hydraulic Pressure Equivalent to Drillpipe Tag Weight

As mentioned earlier, in some cases is difficult to perform positive pressure testing

and weight testing needs to be carried out instead. In fact, weight testing and positive
pressure testing impose the force on top of plug; weight testing is a mechanical
way and positive pressure testing in a hydraulic way of doing it. So, it is possible
to estimate the equivalent hydraulic pressure to drillpipe tag weight, Eqs. (9.3) and
(9.4) can be equal:

Pp × A p Wdp
= (9.5)
π × Di × L p π × Di × L p

and simplification of the equation gives:

272 9 Barrier Verification

Wdp
Pp = π × Di2
(9.6)
4

Equation (9.6) shows that the required pump pressure to estimate the tag weight
and the equivalent pump pressure is independent of plug length.

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