Casing Annular Pressure Bleed-Down Generic Procedure

July 2015

Casing Annular Pressure Bleed-Down

Generic Procedure (PM3, PM305/314)

NO DEVIATION FROM THIS PROGRAM SHALL BE MADE WITHOUT AUTHORIZATION.

PLEASE CONTACT THE AUTHOR OR WELLS ENGINEER.

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Table of Contents
1.0  OBJECTIVE .......................................................................................................................... 5 
2.0  DEFINITIONS AND ABBREVIATION ................................................................................... 5 
3.0  OVERVIEW........................................................................................................................... 6 
4.0  CASING ANNULUS PRESSURE MONITORING ............................................................... 11 
5.0  TRIGGER PRESSURE ....................................................................................................... 11 
6.0  BLEED DOWN FREQUENCY ............................................................................................ 12 
7.0  CASING ANNULUS PRESSURE BLEED DOWN CRITERIA ............................................ 13 
8.0  BLEED DOWN GUIDELINES ............................................................................................. 14 
9.0  GENERIC PROCEDURE TO BLEED DOWN ANNULUS PRESSURE ............................. 15 
Attachment 01: Annular Pressure Diagnostic Table .......................................................... 17 
Attachment 02: A-Annulus Pressure Bleed-Down Guideline Flowchart ............................. 18 
Attachment 03: B and C Casing Annulus Pressure Bleed-Down Guideline Flowchart ...... 19 
10.0  Distribution List ................................................................................................................... 20 

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1.0 OBJECTIVE
The objective of casing annular pressure bleed-down is to evaluate whether there is any
down-hole well infra-structure failure that resulted in the presence of the pressure in the
casing annulus.

The need to diagnose is consistent with PPGUA requirement per industry practices (API
RP90).

2.0 DEFINITIONS AND ABBREVIATION

A-Annulus Production Tubing x Immediate Casing Annulus (Production Casing Annulus)

B-Annulus Next annulus exterior to the A-Annulus
C-Annulus Next annulus exterior to the B-Annulus
API American Petroleum Institute
BOL Back On Line
CV Crown Valve
GLM Gas Lift Mandrel
HC Hydrocarbon
LMV Lower Master Valve
MAASP Maximum Allowable Annulus Surface Pressure
MAWOP Maximum Allowable Wellhead Operating Pressure
MOC Management of change
OIM Offshore Installation Manager
PPGUA PETRONAS Procedures & Guidelines for Upstream Activities
PTW Permit to work
SCP Sustained Casing Pressure
SCSSV Surface Controlled Subsurface Valve
SPM Side Pocket Mandrel
SSV Surface Safety Valve
SVLN Safety Valve Landing Nipple
WIM Well Integrity Manual
WV Wing Valve

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3.0 OVERVIEW
Casing Annulus Pressure is defined as the pressure between two strings of concentric
tubulars. Through the monitoring of annular pressures, we can identify potential risks that
may exist in our wellbores, and take appropriate action to effectively manage these risks.

The principal functions of tubulars used in wells are as follows (refer to Figure 1.0 sketch)

1. Structural support of the wellhead and other tubular strings;

2. Pressure and fluid containment (both internally and externally) to prevent contamination
of subsurface zones; and
3. A conduit for produced or injected fluids.

As a result of these requirements, the various tubular strings are designed to withstand
external loads and be compatible with the producing environment.

A well may require from one to several strings of casing and tubing. Well and operating
conditions determine how many strings are required.

For newly drilled and completed wells, the Drilling Supervisors are responsible to ensure
the outlet of all casing valves are equipped with pressure gauges and facilities to bleed
down casing annulus pressure before hand-over to Operations.

The Platform Production Supervisor is responsible in ensuring that adequate facilities are
installed together with the casing head valve to allow casing annulus pressure to be
recorded as well as can be bled off, if required.

CASING PRESSURES CAN BE PRESENT IN CASING ANNULUS DUE TO SEVERAL

FACTORS. DUE TO THE INTEGRITY LIMIT OF THE CASING ANNULUS, ABOVE
WHICH THE WELL INFRASTRUCTURE MAY FAIL (E.G., CASING FAILURE),
HYDROCARBON MAY BE UNCONTROLLABLY RELEASED AND POTENTIALLY
CAUSE HARM TO PEOPLE AND ASSETS. UNLESS THE PRESENCE OF THE
PRESSURE IS UNDERSTOOD, DIAGNOSTIC IS CARRIED OUT TO DETERMINE THE
ACCEPTABILITY OF THE PRESSURE.

As wells with casing annular pressures that failed diagnostic tests may results in unwanted
incidents, MOC or dispensation approvals is required to continue to operate the well and
platform pending intervention by Wells team and/or repair.

A-Annulus pressure (Production casing annular pressure) may be due to the following
(refer to Figure 2.0):

1. Tubing leak
2. SPM or GLM leaks
3. Introduced Pressure e.g., gas lift gas pressure (controlled condition)
4. Casing leak (external) allowing gas from the formation to directly enter the annulus
5. Packer leak
6. Increased pressure due to thermal expansion of annulus fluid due to wellbore
temperature (e.g., during well producing or back-on-line activities)
7. Tubing Hanger leaks

B-Annulus pressure (Surface casing pressure) can be caused by (refer to Figure 3.0):

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1. Cement channeling between production casing and surface casing

2. Inadequate top cement height outside the production casing
3. Casing Hanger leak
4. Production Casing leak
5. Surface Casing leak

While “unwanted pressures” are to be evaluated, the presence of some pressures (say
~150 psi) is beneficial to keep air or oxygen from entering the annulus and potentially
causing internal casing corrosion. In addition, only annulus with pressures that exceeds
acceptable trigger pressures are to be diagnosed.

Detailed information on Casing Annular Pressures is available in WIM.

The requirement for managing casing annular pressures is described in PPGUA (Chapter-
8), and in Oil & Gas industry guidelines, API RP90.

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Figure 1.0 (Typical Wellbore Sketch)

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Figure 2.0 (Potential Causes of A-Annulus Pressure)

POTENTIAL CAUSES OF PRODUCTION CASING PRESSURE

CROWN VALVE 1 - TUBING LEAK

THP

2 - SIDE POCKET MANDREL LEAK

WING VALVE
3 - TUBING HANGER LEAK
SURFACE SAFETY VALVE /
UPPER MASTER VALVE 4 - PRODUCTION CASING LEAK
5 - PACKER OR SEAL ASSEMBLY LEAK
LOWER MASTER VALVE 6 - TEMPERATURE / EXPANSION
PCP A-Annulus Pressure

B-Annulus Pressure SCP

DRIVE PIPE 1
2

CONDUCTOR
CASING
SIDE POCKET 6
MANDREL
SHALLOW FORMATION

SURFACE
CASING

PRODUCTION
TUBING
OIL / GAS FORMATION
4
TOP OF CEMENT

5
OIL / GAS FORMATION
PRODUCTION PACKER

PERFORATION OIL / GAS FORMATION

WATER FORMATION
PRODUCTION
CASING

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Figure 3.0 (Potential Causes of B-Annulus Pressure)

POTENTIAL CAUSES OF SURFACE CASING PRESSURE

CROWN VALVE THP

1. CEMENT CHANNEL
WING VALVE 2. TOP OF CEMENT TOO LOW
SURFACE SAFETY VALVE / 3. CASING HANGER LEAK
UPPER MASTER VALVE
4. PRODUCTION CASING LEAK

LOWER MASTER VALVE 5. SURFACE CASING LEAK

PCP A-Annulus Pressure

B-Annulus Pressure SCP

3
DRIVE PIPE

5
CONDUCTOR
CASING 4

SHALLOW FORMATION

SURFACE
CASING 2

PRODUCTION
TUBING
1
OIL / GAS FORMATION

TOP OF CEMENT

OIL / GAS FORMATION

PRODUCTION PACKER

PERFORATION OIL / GAS FORMATION

WATER FORMATION
PRODUCTION
CASING

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4.0 CASING ANNULUS PRESSURE MONITORING

Casing annular pressure may increase or decrease during the life of the well. Due to the
importance of managing the casing pressures, they must be monitored and reviewed
regularly. While some casing pressures on some platforms/ annulus may be reported on-
line, the individual annulus pressure review and verification is required on a weekly basis.
Verification may include the need to read/compare pressures against that read on the
pressure gauges at the casing head needle pressure. These verified casing pressure
readings are to be forwarded to the Well Integrity Engineers for further evaluation.

5.0 TRIGGER PRESSURE

Trigger pressure is the pressure to initiate technical review to determine whether the
casing annulus pressure bleed-down needs to be initiated or not.

The standardized trigger pressure limits for casing annular pressures is as follows:

Annulus Psi

A. A-Annulus 500

B. B-Annulus 300

C. C-Annulus 300

While the above are the trigger pressures to initiate evaluation of the integrity condition of
the well’s casings, at no time can the casing pressures exceed their respective MAASP
(Maximum Allowable Annular Surface Pressure). This is the recommended allowable
pressure, above which failure is anticipated. Failure modes include:

• Failure of casing, tubing or other equipment constituting the annulus in question

• Fracturing of open hole included in the annulus casing
• Failure modes of the outer annulus

The allowable Maximum Allowable Wellhead Operating Pressure (MAWOP) represents the
upper limit allowable to operate the well which is below the MAASP. The intention of the
MAWOP is to reduce the probability of exceeding MAASP and providing response time to
manage pressures which approach these recommended criteria.

For simplicity and standardization, the MAWOP for the various annuli is as follows:

Annulus Psi
A. A-Annulus 2000
B. B-Annulus 800
C. C-Annulus 800

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The MAWOP is limited to the test pressure documented during drilling or workover or the
burst rating of the casing, whichever is lower, and may be de-rated further to account for
age or corrosion.

Production operations personnel must become familiar with these values and realize that
any well which exhibit casing pressures higher than these limits should be brought
to the attention of the OIM, Wells Engineer and the Wells Integrity Engineer.
However, wells exhibiting casing annulus pressure above the trigger pressure limit and
have been successfully diagnosed with results of casing pressure bleed down within the
acceptable criteria can continue to be utilized. This same acceptable annulus pressure will
again be diagnosed 12 months after its last bled down diagnostic, for verification.

6.0 BLEED DOWN FREQUENCY

Wells Department will issue an Annulus Pressure Bleed-Down schedule once every six (6)
months. The OIM shall be responsible to ensure that the bleed down is performed within 2
months after the schedule is issued. The OIM shall seek the approval from the Wells
Manager for any deferral of the Annulus Pressure Bleed-Down schedule.

The Annulus Pressure Bleed-Down frequency is as follows:

Activity A-Annulus B/C-Annulus Remark

Production Operation to send

Monitoring Weekly data to Well Integrity
Engineer

The bleed down frequency is

aimed at:
Initially if it exceed 300 psi. 1. Ensure bleed down is
Initially, if annulus exceeds
Subsequently subject to carried out when required
500 psi. Subsequent bleed
pressure increase and 2. Minimizing unnecessary
Bleed Down down is every 12 months.
encroachment to MAWOP. bleed down that will only
Frequency
erode barriers
Also refer to flowchart on
Also, refer to flowchart on 3. This applies to all gaslift
Attachment 02
Attachment 03 (GL) wells, and non-GL
wells when A-annulus
exceeds 500psi

A. A-Annulus Pressure (also referred to as Production Casing Pressure) bleed down

flowchart:

A-Annulus Pressure greater than the trigger pressure of 500 psi must be diagnosed by
bleeding down the pressure and observing for build-up once every twelve (12) months.
From the results of the diagnostic, if pressure build-up exceeds acceptable criteria (see
Section on Casing Annulus Pressure Acceptable Criteria), further diagnostic or
remedial actions are required.

When a well A-Annulus Pressure bleed off does not exceed the diagnostic criteria but
will exhibits pressure above 500 psi subsequent to the test, no follow-up is needed until
the following twelve (12) months from the date of the most recent bleed-off test.

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B. B/C-Annulus Pressure (also referred to as Surface Casing Pressure / Conductor

Casing Pressure) bleed down flowchart:

B and C Annulus Casing pressure that is greater than 300 psi must initially be bled off.
Subsequent bleed offs is required only 12 months after the last diagnostic provided
there is an increase in pressure value by at least 150 psi from the recent stabilized
observed reading. However, immediate action must be taken if the annulus pressure is
encroaching its MAWOP value.

Except for the need to manage thermal casing annular pressures when producing a
new well initially or BOL (Back-On-Line) a shut-in well, and observed sudden increase
of casing annular pressures, casing annular pressure will not be bled down unless it
has been scheduled for bleed down or as advised by the Wells Engineer.

Bi-monthly Schedule:

Once a process is in place, a bi-monthly schedule for casing annular pressures due for
bleed down will be issued to the respective OIM by the Wells Department. Bleed down of
each annulus in the schedule (based on the above criteria) are to be completed within two
months windows provided. The OIM is responsible to seek Dispensation approval from the
Wells Manager for any deferral (refer to Attachment 02 and 03 for guidelines).

For this initial Repsol implementation, Wells Engineers are to advice on the annular casing
pressure bleed down strategy / schedule based on their records and priority.

7.0 CASING ANNULUS PRESSURE BLEED DOWN CRITERIA

The results of the casing annulus pressure bleed-down are to be analyzed by the
respective Wells Engineer and Wells Integrity Engineer. Either the Wells Engineer or the
Wells Integrity Engineer will advise the Platform OIM if further action is required.

The following criteria will be used to evaluate and determine if further diagnostic or
remedial action is required:

1. The annulus pressure build-up after 24 hours is greater than 500 psi for A-Annulus
Pressure or 300 psi for B or C annulus pressure.

2. The annulus pressure build-up after 24 hours exceeds 50% of the pressure bled down.

Example:

A well has 400 psi on the B Annulus pressure. The pressure was bled down to 100 psi.
After 24 hours, the pressure builds back up to 280 psi.

• Since the pressure after 24 hours is less than 300 psi, i.e., less than the trigger
pressure (even though the increase is 60% of the pressure bled down), no further
action is required.
• However, should the pressure after 24 hours is 350 psi (83%), this well requires further
work because the build-up is > 50% of the bled-down pressure.

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3. During bleed-down, an adjacent annulus has a significant change in pressure

(indicating potential communication between strings).

4. Continuous Oil or HC is bled from the annulus.

Any well which exhibits one or more of the above four criteria requires immediate action.
The action may include shutting in the well (subject to further well work diagnostics which
may include packer leak tests etc.), repeat bleed downs for confirmation, or to continue to
flow the well with appropriate approved exceptions / MOC approvals.

8.0 BLEED DOWN GUIDELINES

A. All casing annulus pressure should be bled down through a double block and bleed
valve arrangement, with the primary valve being fully open. (A needle valve can be
considered a second valve).

B. Determine the fluid bled.

C. Do not bleed HC to atmosphere continuously except when checking for fluid content
(i.e. to check if bled down fluid is gas, oil or water). Bleed off pressure via the
flowline/venting system.

D. Gas pressure should not be bled off for more than 2 hours through a fully-opened 1/2"
valve. If a longer bleed down duration is anticipated, the Production Supervisor will
obtain the approval of the Platform OIM.

E. With the exception of gas-lifted wells, bleeding-down operations should be discontinued

if pressure does not decrease by 150 psi in 30 minutes.

F. For gas-lifted wells, the duration of bleed off can exceed 2 hours. DO NOT Bleed Off for
more than 24 hours.

G. Bleed off annulus pressure to as low as possible, subject to the following:

• A-Annulus can be bled down to as low as possible or to zero

• B & C Annulus to not less than 150 psi (KEEP SOME PRESSURE IN ANNULUS).

Note: Ensure SCSSV, LMV and SSV are opened (both LS and SS for dual wells) and
Crown Valve (CV) cracked opened to enable monitoring of the Tubing Pressure as the
bleed off is conducted. WV can either be in opened or closed position depending on
prevailing well status (i.e., producing or shut-in). Ensure Gas lift supply to the well is
also isolated and valve is not passing. Close the CV after completing the bleed off.

H. All Annulus Pressure Bleed-Down shall be recorded as per Attachment 01 and send to
Well Integrity Engineer.

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9.0 GENERIC PROCEDURE TO BLEED DOWN ANNULUS PRESSURE

Note: Each site is to develop their own respective “Site Specific Procedure” or SSP for
annular pressure bleed down that should consider their respective unique facilities on-
board.

(This procedure applies to the bleeding off of pressure from any casing annulus, i.e., A, B
and C Annulus).

1. Obtain the appropriate PTW(s).

This procedure will include the bleeding off of hydrocarbons to the platform closed
system or atmosphere (not continuously).

2. Close gas lift supply to the well if any (double block).

3. Close casing head valve completely. Install ½” needle valve manifold system with
outlets connected follows:
a. Connected to a pressure gauge
b. Connected to the platform venting line
c. Closed valve (to be used to check fluid bled)

Note: Ensure that the SCSSV, LMV and SSV are fully opened (both strings if a dual
well) and CV is cracked opened to enable monitoring of the THP as the bleed off is
conducted. WV can either be in opened or closed position depending if the well is
producing or shut-in.

4. With all needle valves closed, fully open the casing head valve completely.
• All pressure bleeding shall be conducted through double valves with the primary
valve fully open. A needle valve can be considered the second valve.
• Never bleed pressure through a partially open casing head valve. This can lead to
the erosion to the valve, causing irreparable damage.

5. Open the needle valve to the pressure gauge and read the casing annulus pressure.

6. Slowly open the needle valve to the vent line and commence bleeding pressure into
closed drain system.
Note:
a. IMMEDIATELY CHECK TYPE OF FLUID BEING BLED WHETHER IT IS GAS or
LIQUID.
b. NEVER LEAVE A PRESSURE BLEEDING OPERATION UNATTENDED. SHUT
NEEDLE VALVES AND THEN CLOSE CASING HEAD VALVE IF IT BECOMES
NECESSARY TO LEAVE THE BLEEDING OPERATION.

7. Do not bleed down pressure to zero but to about 150 psi.

8.
9. Continuously check the type of fluid being bled.
a. If liquid (oil, water, completion fluid, etc.) is being bled, verify after 5 minutes and
again after 10 minutes. If liquid is still being bled after 10 minutes, discontinue
bleed down operation.
i. If an estimation of continuous liquid volume bled is possible, stop bleeding
down after ½ bbls of bled down.
b. Do not bleed gas for more than two hours through a fully opened 1/2" needle valve.

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c. Discontinue bleed-down if casing annulus pressure does not decrease by 150 psi in
30 minutes.
d. Secure any loose piping (if any)

10. Close needle valves. Monitor and record pressure build-up at the following intervals:

0 min, 5 min, 1 hour, 3 hour, 6 hour and 24 hours.

11. If the pressure increase between the third and sixth hour readings is less than 20 psi,
the 24-hour reading is not required. Close casing head valve (for non-gas lift wells) and
CV. Normalize all valves to original positions, i.e., either producing, injecting or shut-in.

12. Fill out the Annulus Pressure Diagnostic Table in Attachment 01 and send to the OIM,
Wells Engineer and Well Integrity Engineer. Keep a copy for the platform well files.

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Attachment 01: Annular Pressure Diagnostic Table

ANNULUS PRESSURE REPORT ( APR )

PLATFORM :
( Tick 'X' against status ) ( Tick 'X' against status )
WELL NO : S/S CURRENT STATUS L/S S/S WELL TYPE L/S

DATE : Shut in Gas Lift

DATE OF Producing Natural Flowing

PREVIOUS :
BLEED-OFF Injecting Injecting ( Water )

Is gaslift line hooked up to the well ? : Yes No Injecting ( Gas )

Is gaslift manifold valve leaking ? : Yes No

Is gaslift manifold valve isolate from : Yes No

PC valve ( double block ) ?

A. BLEED-DOWN FLOW DATA: This section is to determine the duration required to bleed down the annulus pressure.
Note: a - Always bleed pressure through a second valve - do not use annulus valve.
b- DO NOT BLEED DOWN PRESSURE to LOWER THAN 150 PSI.
Pressure before B/Down : ____________ psi.

Time annulus opened : ____________ hr. Date :

Bleed valve opening : ____________ ( turns )

Initial fluid bled ( gas, oil, water, mud ) : ____________

Remarks on fluid bled : _______________________________________________________________________________

Time annulus closed : ____________ hr. Date :

Estimate of the initial liquid volumes bled : Oil ________ bbls Water ________ bbls

B. PRESSURE BUILD-UP DATA (after Step A) :

Note: 1. ALL BLANKS must be filled in regardless of the annulus being bled.
2. SCSSV, LMV and SSV must be opened during the diagnostic; record string pressure on Crown Cap gauge.

Annulus being tested:

A-Annulus

B-Annulus PRESSURE (psi)

C-Annulus PROD. CSG G/L LINE PRESS TUBING PRESS **SURF. CSG **COND CSG
Short Lower **DO NOT bleed Surf & Cond Csg
( Perform ONLY ONE of the above tests ) String String pressure < 100 psi
Pressure before opening annulus

Status of tubing strings during bleed-off ( flow / shut-in )

a. Press after closing annulus ( 0 min )

(Immediately after bleed-down per Section A)

b. Press after closing annulus ( 5 min )

c. Press after closing annulus ( 1 hr )

d. Press after closing annulus ( 3 hrs )

e. Press after closing annulus ( 6 hrs )

f. Press after closing annulus ( 24 hrs )

Note: * If pressure increase between the 3rd and 6th hr is less than 20psi, the 24 hr reading is not required.
g. Status of well at end of bleed off ( flow / shut-in )

Prepared by : Remarks:
( Name & Initial )

Reviewed by OIM :
( Name & Initial )

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Attachment 02: A-Annulus Pressure Bleed-Down Guideline Flowchart

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Attachment 03: B and C Casing Annulus Pressure Bleed-Down Guideline Flowchart

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10.0 Distribution List

Name Title Company Type

Tham Wai Hou Well Integrity Team Lead REP Hard copy
Norkhairani Shamsudin Wells Operation Team Lead REP Hard copy
Mohd Shahrizal Hashim Well Engineering & Performance Team Lead REP Hard copy
Saadon Kairon Senior Well Integrity Engineer REP Hard copy
Zulkiflee Ishak Well Integrity Engineer REP Hard copy
REP WIS Well Intervention/Integrity Supervisor REP Soft copy
Fadzalisham Ahmad Sabki Wells Manager REP Soft copy
Mike Budge PM3 Operations Manager REP Soft copy
Mark Craig PM3 Operations Manager REP Soft copy
Mun Ying PM3S Operations Supt REP Soft copy
Johan Adam Leong PM3N/SAA Operations Supt REP Soft copy
BRA OIM Offshore Installation Manager REP Soft copy
BRA Production Supervisor Production Supervisor REP Soft copy
BOA OIM Offshore Installation Manager REP Soft copy
BOA Production Supervisor Production Supervisor REP Soft copy
SAA OIM Offshore Installation Manager REP Soft copy
SAA Production Supervisor Production Supervisor REP Soft copy

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