SPE 156048

HSE Challenges While Testing and Completion of Sour HPHT Exploratory

Wells in the State of Kuwait
S. Packirisamy, D. Vidya Sagar, A. Manimaran, Yousef Zaid Al-Salali, Abdullah R. Al-Ibrahim, Anwar Ibrahim,
Abdulrazzaq Al-Nabhan, KOC

Copyright 2012, SPE/APPEA International Conferenceon Health, Safety, and Environment in Oil and Gas Exploration and Production

This paper was prepared for presentation at the SPE/APPEA International Conference on Health, Safety, and Environment in Oil an d Gas Exploration and Production held in Perth, Australia,
11–13 September 2012.

This paper was selected for presentation by an SPE/APPEA program committee following review of information contained in an abst ract submitted by the author(s). Contents of the paper have
not been reviewed by the Society of Petroleum Engineers or the Australian Petroleum Production & Exploration Association Limited and are subject to correction by the a uthor(s). The material
does not necessarily reflect any position of the Society of Petroleum Engineers or the Australian Petroleum Production & Exploration Association Limited, its officers, or members. Electronic
reproduction, distribution, or storage of any part of this paper without the written consent of the Society of Petroleum Engineers or the Australian Petroleum Production & Exploration Association
Limited is p rohibited. Permission to reproduce in print is re stricted to an abstract of not more than 300 words; illustrations may not be co pied. The abstract must contain conspicuous
acknowledgment of SPEcopyright.

Abstract
Kuwait Oil Company (KOC) is fully committed to protect the health and safety of its people and the environment. Strict
adherence to the KOC HSE policies and procedures helped safe execution of critical well testing and completion operations
of sour High Pressure High Temperature (HPHT) exploratory wells.

This paper describes safety challenges, H2S related risks, and methodology adopted to achieve safe and successful well-
testing operations with deep drilling rigs in extreme sour HPHT environmental conditions. Critical operational equipment and
safety precautions to be followed prior to and during well testing will also be discussed in detail.

Deep HPHT wells with sour environment continue to challenge the execution of well testing and completion operations,
especially when wells are of exploratory nature. Wells drilled in deep Jurassic section (14,000’-17,500’) having bottom hole
pressure more than 10,000 psi, bottom hole temperature higher than 280ºF and high sour content(up to 30% H2S) are
considered for this case study. Almost 30 exploratory wells under similar environmental conditions have been drilled and
tested with deep drilling rigs in different fields in the state of Kuwait. Drill Stem Testing (DST) technique is being used to
test the targeted formations.

Well related production testing operations like Perforation, Coiled Tubing, and acid stimulation warrant high HSE standards
and technical precautions. Every HPHT well is unique and demands special attention when it comes to the selection of
critical safety equipment and other safety requirements such as Personal Protective Equipment (PPE), H2S monitors,
wellhead equipment, sealing material, flow control equipment and surface safety valves (SSV) with emergency shutdown
switches.

Even in such hostile environment, with meticulous planning and testing strategies, KOC could overcome all the challenges
and all HPHT sour wells were safely tested without any incident. Commitment to HSE was given the highest priority during
testing of sour HPHT wells with great emphasis on personnel safety.

Introduction
In the state of Kuwait, exploratory wells were drilled and tested with deep drilling rigs to explore deep Jurassic reservoir.
Drill Stem Testing (DST) technique is being used to test the targeted formations. Depth, Pressure and temperature of deep
reservoirs ranging from 13,000 to 17,000 ft, 10,500 psi to 14,500 psi and 255 to 290 0F respectively. High Pressure High
Temperature (HPHT) and high H2S content was encountered during production testing of deep reservoirs. Testing an
exploratory well combined with HPHT and extreme sour environment warrant high HSE preparedness.
2 SPE 156048

KOC is committed to manage the impacts and the risks associated with its activities exploration, drilling, and production of
oil and gas within the State of Kuwait. This commitment is fulfilled through the implementation of a Health, Safety and
Environment (HSE) policy and management system. Kuwait Oil Company, with their many years of experience in petroleum
industry has developed guidelines, standards and operating procedures for safe operations under harsh environment like
Hydrogen Sulfide (H2S), High Pressure, High Temperature, etc. These guidelines and standards were implemented
successfully in HPHT well testing.

Well testing objectives

1. To complete the operations safely, without harm to personnel and / or damage to the environment.
2. To measure liquid and gas flow rate through a separator/Multiphase Flow Meter (MPFM)
3. To obtain representative fluid samples and reservoir data.
4. To determine the production potential of the target zone.

HPHT and High Sour Well testing

Performing well testing in HPHT conditions necessitates minimizing tool joints and cross-overs, in order to have high
reliability in harsh environments. Maximum anticipated values like pressure, temperature, flow rate, H2S, etc. are used to
select field proven equipment with the necessary operating capabilities. Due to the extreme conditions, planning and selection
of equipment have to be meticulous. Metal to metal sealing is highly desirable for HPHT conditions. Tubings with premium
connections and high differential pressure packers are required for service.

15,000 psi sour service wellhead is used to test & complete all deeper formations. The current standard wellhead consists of
annular valves, two master valves, wing valves - two on each side, two surface safety valves (SSV) and a swab valve. Well
testing operations include various activities related to perforation, coiled tubing, acid pumping and separator operations. Safe
operating Procedures are already established for key operations like perforation, activation, stimulation, pressure testing, well
testing and collecting of surface samples, etc.

All applicable safety equipments are installed onsite prior to starting the job and tested along with operational equipment.
Surface and sub-surface testing equipment hookup along with safety device is shown in Fig-1. Some of the Safety
equipments required during well testing are listed below:
1. Surface Safety Valve(SSV)
2. Emergency Shut-Down (ESD) valves
3. Green burner
4. H2S detectors
5. High Pressure pumping equipment
6. Wind sock
7. Fire extinguisher
8. Eye wash/Shower
9. Breathing Apparatus

ESD valves are connected with remote control equipment and additional remote control switches are provided to operate
them from far-off places. One High pressure pump is connected to the production tubing to kill the well in case of
emergency.

Prior to commencing every major well test operation, all personnel on the well site are required to attend a Pre job safety
meeting (PJSM). PJSM is held at the workplace to discuss the HSE hazards that may be encountered during the work and the
procedures that are in place to successfully manage these hazards. The operation in-charge outlines job procedure to be
followed and it is a part of process of continual awareness on HSE matters. Specific hazards like H2S, HPHT conditions,
Perforation, Acid, etc. Will be discussed during safety meeting. All personnel involved in testing operations shall be
primarily responsible for ensuring that the well testing operations are carried out in compliance with the KOC Policy &
Procedures.

KOC HSE Management system

KOC’s Health Safety Environment Management System (HSEMS) provides the frame work for managing all aspects of the
activities. KOC has developed detailed emergency and operational contingency plan procedure that will be followed during
emergency cases. The management system is designed to ensure compliance with law, demonstrate that all hazards are
adequately managed and achieve continuous improvement in HSE performance. KOC’s HSE business models of plan, do,
check and act along with related procedure mentioned below identifies the relationship of the 13 KOC HSEMS System
Elements to the business improvement model.
SPE 156048 3

The following safety policy/procedure exists with KOC for carrying out safe well testing operations with deep drilling rig:
1. Corporate Health, Safety, Environment Management System (HSEMS).
2. Work over/Completions Policies and Procedure
3. HSE Procedure for Exploration, Drilling & Work over Operations
4. HSE Procedure for Well Surveillance Operations
5. Kuwait Oil Company Standards and Recommended Practices
6. Contractor HSE Process and Procedures

In order to ensure high standards of HSE protection, the use of performance measures comprise both proactive and reactive
measures.
Proactive or Leading Performance Indicators
The proactive initiatives taken by the company is to establish a positive HSE culture within the company, for example,
inspections, meetings, audits, certifications etc. Proactive measures of performance that monitors inputs such as
conducting risk assessments; completing training programmes; carrying out inspections and audits. These provide
feedback on the efficiency of the existing systems before an accident or incident occurs. Proactive measures designed in
KOC are:
ƒ Safety observation and conversation (SOC)
ƒ Job safety analysis(JSA)
ƒ Permit to work(PTW)
ƒ Lockout – Tag out(LoTo)
ƒ Site Verification Visit (SVV)
ƒ Leadership visit
ƒ Audits & inspections
ƒ Stop work authority
ƒ Safety alerts
ƒ Safety meetings
ƒ HSE training

Reactive or Lagging Performance Indicators

Reactive or Lagging Performance Indicators are designed for monitoring and measuring of management system failures
or deviations from planned, expected or intended management system results. Examples include the monitoring of
accidents, injuries, environmental excursions and near misses. Reactive monitoring arrangements include systems to
identify and report. KOC follows the following reactive monitoring system:
ƒ Incident reporting
ƒ Near miss reporting
ƒ Incident investigation
ƒ Corrective actions tracking
ƒ Emergency response
4 SPE 156048

H2S Safety
Hydrogen sulfide (H2S) is an extremely toxic gas responsible for numerous deaths in the oil industry. H2S is the second
leading cause of toxin related death (after carbon monoxide) in the workplace. All sour oil and gas produced during
testing shall be flared to the atmosphere through a flare/burner. Many deaths are caused by a lack of awareness, improper
or shortcut procedures, lack of respiratory protection, and/or poor rescue techniques. Work areas where there is a risk of
H2S presence or release should be designated H2S prone / Hazardous Areas.

The following gas detection/monitoring and breathing equipment are available in test location during short term testing
of a well at a drilling rig.
Gas Detection/Monitoring System
• Personal H2S/ Multi-Gas Gas Detectors
• Fixed (Light and Alarm) Monitoring system
• Sampling H2S detector tubes

Breathing Air System

• Self-Contained Breathing Apparatus (SCBA)- 15 and 30 minutes duration
• Air Breathing Apparatus
• Emergency Life Saving Apparatus (ELSA) – 10 min duration
• Breathing Air Cascade System (6-Cylinder Rack) with manifold and hoses

The crew shall be thoroughly trained in H2S & SO2 hazards. Skilled safety persons will be available all the time to
handle any emergency during sour well testing operations.

Safety measures during well testing job execution

All KOC HSE procedures and safe practices guidelines for drilling, testing, perforation, stimulation operations are to be
followed during testing and completion of exploratory wells for the safety of personnel working on location. Well Production
Testing involves:
• Hermetical testing of Casing Head, Casing, Well Head & X-Mas Tree assembly.
• Perforation of Casing
• Activation of Well
• Pay Zone Testing to ascertain reservoir pottential
• Well completion/Abandonment

Hermetical Test:
Hydraulic pressure test of production casing/liner is to verify the integrity of the well from bottom to top. Negative and
positive tests are carried out to confirm the integrity of casing before perforation. Leakages may result in channeling
behind casing & may cause uncontrolled flow.

Perforation: Selected intervals are perforated using High Shot Density (HSD) guns in order to achieve reservoir to
wellbore communication and thereby flow of reservoir fluid to surface.
Safety Measures:
• All sources of ignition to the operation shall be shut off until the explosive device has been lowered into the well
depth of 200 feet or more.
• Radio silence and radar frequency units shut off shall be observed within hazardous distances of explosive
operations.
• During radio silence, radio transmitters are shut off and radio beacons are turned off.
• Mobile phones within the hazardous distance of explosive operations are switched off.
• A lubricator and wire-line blowout preventer are provided at the wellhead while perforating through tubing;
• All well head equipment including the blowout preventer assembly is pressure and function tested to the maximum
working pressure.

Coiled Tubing operation

Since all HPHT exploratory wells are tested and completed with packer system, coiled tubing operation is required
mainly for well displacement, stimulation and for killing if needed. Hookup of safety equipment during CT operation is
placed at Fig-3.
• Any operation with Coil Tubing in a potentially live well shall be treated in the same way as any conventional well
control requirement along with its associated BOP equipment.
SPE 156048 5

• Surface facilities, BOPs, lines and Christmas tree shall be tested to at least the maximum operating pressure prior to
commencing operations.
• In case of HPHT and sour well, H2S service CT equipment shall be used according to NACE MR-0175 and API
standard for conducting safe operation.
• Suitable well kill fluid should be available on location whenever there is an important CT operation in a live high
sour well.
• A check valve assembly should be attached to CT connector at the bottom of the CT to prevent wellbore fluids from
entering the coiled tubing string in the event of treatment fluids are not being pumped.
• Circulation to be established throughout CT operation.

Stimulation: Acid is used in carbonates to create a flow channel which eases the flow of oil from the formation and
increase permeability. Two main types of acids are used, namely hydrochloric acid and hydrofluoric acid. Acid
concentration depends on well conditions, but most of the time 15-28% HCL mixed with water and additives is used to
stimulate carbonate formations. Acidizing operations are done either by bull heading or coiled tubing, where the
treatment is pumped at high pressure.
Safety Measures:
• All personnel should know quantity, type, concentration of acid and hazards.
• All personnel should wear safety gloves and goggles during acid pumping.
• Eye-wash/shower should be available during acid pumping operation.
• Pressure testing the equipment against the wellhead to either 1.5 maximum expected SIWHP during the job or
maximum of well head stack rating (whichever is lower) without exceeding the CT pressure rating.
• Lines from the pumping unit to the well head shall have a non-return valve installed in them as near to the well head
as practicable. Safety meeting should explain the right safe procedure in case of a spill.
• Wind sock, SCBA, escape masks

Drill Stem Testing (DST)

DST technique is generally employed to carryout short term testing of formations with drilling rig. The DST Bottom
Hole Assembly (BHA) and tubing string give the ability to carry out the following operations and functions:
• Two down-hole circulating valve: To circulate the well during Well Killing operations.
• Memory Gauges: Provide down-hole pressure and temperature measurement.
• Production Packer and Seal Assembly: Provide a barrier between the reservoir and annulus.
• Tubing: Premium Connection Tubing run from packer seal assembly to surface.
• TCP: Tubing Conveyed Perforating Guns to perforate at the required depths.
DST schematic with down-hole safety equipment is placed at Fig-2.

Surface Equipment
The surface well test equipment provides the means to carry out the following functions during short term testing of an
exploratory well:
• 15K/20K psi WP X- Tree: Isolate the tubing string from the well test process equipment and provide a means of
pumping down the tubing string through the kill wing valves.
• 15K/20K psi WP SSV’s: To mitigate risks during production operation, two hydraulic activated SSV’s are installed
in all 15K/20K wellheads (One between two master valves and another one in the wing side).
• 15K/20K psi WP Hydraulic Isolation Valve: Isolate the well test process equipment via the ESD system.
• 15K/20K psi WP Choke Manifold: Flow the well as required through a fixed orifice (Choke Bean) and provide a
means to close in the well at surface for a build-up period.
• High Pressure well test separator: Measures both Gas and Liquid flow rates and provide a means of flowing the
separated oil and gas to the respective disposal systems
• Oil and Gas Diverter Manifolds: Divert the produced gas and liquids to the relevant flare pit for disposal
• Surge Tank: Provide a means of cross checking the flow rate of produced liquids as required and calibrate the
separator liquid meters prior to the well test operation.
Surface and subsurface safety well test equipment hook up schematic is placed at Fig-1.

Safety Measures during testing with DST:

• Fluid volume in the casing should be monitored while going in and coming out of the hole to assure that the well
remains under hydrostatic control.
• One or more reverse circulating valves should be incorporated in the test string assembly.
• ESD should be fitted into test line and function tested for emergency shutdown.
• Wellhead and all lines shall be pressure tested up to maximum working pressure;
6 SPE 156048

• No engine shall be operated within 100 feet (30.5 m) without a spark arrestor fitted to its exhaust.
• Initial opening of exploratory well should be opened in daylight.
• The DST tool should not be pulled out of hole after dark unless all test fluids have been pumped out of the test
string.
• Annulus pressure and the fluid level in the annulus should be checked regularly throughout the test to ensure the
packer is holding and gas is not leaking into the annulus from test string.
• In case the fluid produced cannot be delivered to production facility, the fluid produced during a DST shall be burnt
through a flare-line/burner.
• The separator safety valve should be in good working order and properly adjusted;
• During well testing of a sour well, in case the wind direction is towards well head/equipment side from the flare
point, the well should be closed immediately for the safety of personnel working in well site or diverted to other
flare pit.

Conclusions:-
• KOC ensure that Sour HPHT well testing safety and technical objectives are effectively met.
• High H2S concentrations up to 30% was encountered during testing of deep exploratory wells and are effectively
handled without any incident.
• All KOC HSE procedures and safe guidelines for drilling, testing, perforation, stimulation operations are followed
for the safety of personnel working on location.
• Highest focus on safety is given for the testing of deep sour wells and all safety aspects are followed meticulously.
• Proper Planning, selection of right equipment and materials, operating and emergency procedures, on-site
supervision and H2S emergency drills have contributed to successful and safe operations.

Acknowledgements
The authors wish to acknowledge Kuwait Oil Company (KOC) and Ministry of Oil, Government of Kuwait for granting
permission to publish this paper. The authors also would like to extend their appreciation to Discovery Promotion Team, HSE
coordinator and Deep Drilling Group for providing valuable input/support.

Nomenclature
API American Petroleum Institute
BOP Blowout Preventer
BHA Bottom Hole Assembly
ESD Emergency Shut-Down
DST Drill Stem Testing
HCL Hydrochloric Acid
HPHT High Pressure High Temperature
H2S Hydrogen Sulfide
HSE Health Safety Environment
HSEMS Health, Safety and Environment Management System
JSA Job safety analysis
NACE National Association of Corrosion Engineers
PPE Personal Protective Equipment
PTW Permit to work
SIWHP Shut-In Well Head Pressure
SOC Safety observation and conversation
SSV Surface Safety Valve
SVV Site Verification Visit
TCP Tubing Conveyed Perforation
WP Working Pressure
HSD High Shot Density
SPE 156048 7

Fig-1 Surface and sub-surface well test equipment hook-up

15K Well Head 15K ESD Valve ESD Panel H2S sensor Wind sock

15K SSV 15K Choke Manifold Alternate Flare 

15K SSV

H2S sensor

Well fluid By-Pass Line

Remote ESD MPFM

Vent Line

Liquid Line

Gas Line

Circulating Valve Relief Line

DH Gauge HP Seperator Oil & Gas Burner

Circulating Valve

Packer

Jurassic
Formation

Containerized  H2S Services  System  Remote ESD Lab cum Testing control Cabin H2S sensor Wind sock

8 SPE 156048

Fig-2 DST assembly with downhole safety system

TEST STRING WITH SLIM DST ASSEMBLY

30”, 196.1 ppf, “B”

24”, 171.3 ppf, K-55

18.5/8”, 139ppf, P-110,

14”, 113 ppf, P-110

10-3/4” 73.2ppf, Q-125

Liner:

5" liner top

7-5/8” Production Casing Circulating Valve

Tieback: 63.2 ppf, T-95
Liner: 63.2ppf, P-110 Down hole shut in valve

DH Gauge Carrier

Packer

TCP Gun

Landing Collar
5”, 21.4 ppf,Q-125 / HYD 513

SC H EM A TIC NO T TO SCA L E
SPE 156048 9

Fig-3 CT on WH with safty equipment during well testing

Injector

15KSide door stripper

15KSidewinder

15K Risers

15K BOP

15K BOP