A New Direction For Wellhead Inspection

from Oilfield Technology September 2022

Innovations For Emissions Management

Bhavesh Ranka and John Hatteberg, Cudd Well Control,

USA, describe the advantages of automated cloud-based audit programs over more traditional manual methods of wellhead inspection.

The oil and gas inspection industry operates according to stringent standards that strive to keep equipment running efficiently while maintaining workplace safety. Oil and gas companies demand a low failure rate to stay profitable. Their assets, however, are subject to heavy use and are constantly exposed to the elements. Therefore, one of the most important steps a well owner can take is to visually check the wellhead and the surrounding area to detect potential issues before they become problems. Typically, trained technicians conduct these wellhead inspections to detect welding flaws, corrosion development, and cracks. However, previously they have had to rely on spreadsheets to note any findings, then write a report, and send it to the operator. This approach has proven to be time-consuming and can easily lead to human errors, both of which can negatively impact operations. To help address this challenge and aid operators in increasing the efficiency, traceability, and accuracy of their wellhead audits, Cudd Well Control has launched a fully automated wellhead audit tool that can help save operators time and money. The new wellhead audit platform is an efficient tool that allows operators to inspect the surface of a wellhead faster than traditional pen and paper methods while helping to identify any problems with corrosion, valve functionality and pressure. As a cloud-based solution, the tool can provide customers with advantages when conducting wellhead audits.

Streamlined software

The wellhead audit tool is a streamlined system that enables users to inspect and write wellhead audit reports in under an

hour as opposed to what used to take several days to complete. Engineers can conduct these audits onsite with an iPad or tablet, enter the data, and the program will create customised, immediate reports. For customers with wells in remote locations, the platform allows them to complete more audits in a day and access that information immediately. Since the size and scope of each operator’s assets can vary, the platform was created to be flexible in order to meet customer needs based on their data/well count. Inspectors see the well condition immediately on one platform instead of having to go to multiple resources or sources. This new solution is based on API standards with all findings uploaded and shown on a customer’s wellhead audit dashboard that is accessible 24 hours a day. As security of information is always a critical issue, the platform features a private and secure portal where users access the information via a login name and password protected interface. The site administrator can add or delete user access as needed.

Figure 1. Wellhead images taken during an audit and a schematic drawing to the right, displaying that all components of the wellhead have passed the audit and are in good condition.

Figure 2. Map view of wells and API number on the right hand table.

Figure 3. A closer view of the map with the well icon defining the well type, such as production or storage.

Digital solutions: a new chapter for the oilfield

With the industry adopting more digital solutions, wellhead audit tools are the next step at the oilfield. Customers can go online via a private portal and review all the data, results, maps, recommendations, print reports and more. Currently, this is done by hand and with an excel spreadsheet. Using the platform, users can pull up every inspected well in their region and see the visual inspection data and status. The interface graphically displays what is nearby the wells, such as schools, residences, pipelines or rivers – anything that needs to be considered when taking steps to conduct remedial activities on the well. Users are provided with a map view of the wells, which are identified with their status coloured coded in green for ‘all good,’ yellow for ‘caution,’ and red for ‘requires immediate attention.’

Users of the platform can also look at the history of the wells and see how they have been treated over time. This advantage also extends to companies considering buying a well or a series of wells, as it confirms what condition the wells are actually in. The tool features pop up details of the wellhead including its overall condition and details on any potential issues or problems that need to be addressed, such as corrosion or a valve not functioning. To provide comprehensive information, the software provides historic data from previous audits. These findings are further supported by photos as well as comments from the auditor. When the audit report is completed, an email is sent to the customer with a link to the portal.

Identifying which wells to address first

Operators must constantly work according to budgets and schedules. With this tool, problem wells go to the top of the risk matrix, allowing operators to deduce which wells to take care of first, so they can keep production flowing. The condition of the wellhead dictates what takes priority – repairs or remedial work. As a result, operators can quickly

take preventative measures to avoid further issues and possible catastrophic events, preventing injuries whilst also saving time and money.

Assurance for the insurance industry

Older wells represent the biggest liability insurance companies can face when underwriting wells. Often, these companies do not have the accurate information needed to make the decision on which wells to underwrite and which wells to pass by. To address this, the wellhead audit tool has access to the API 10 numbers database. So, if an underwriter has wells to underwrite, they input the wells’ 10 API numbers and the tool goes to that database to see the age of the wells, how deep they are, the types of wellheads used, the well types, and much more. With this vital information, insurance providers can make the right decision on which wells to underwrite. Figure 4. Problem wells go to the top of the risk matrix, allowing operators to know which wells to focus on first.

Asset protection

Oil and gas wellheads provide the structural and pressure-containing interface for drilling and production equipment. Ensuring all equipment at the wellhead is in working order is key to remaining online and productive. When wellhead equipment fails, the cost can be incredibly high both from an environmental perspective and from the time and expense it takes to remediate any failure. For those reasons, operators need to be consistently proactive about conducting wellhead inspections.

Wellhead audit tools help operators ensure that assets, equipment, and related componentry at the wellhead remain free of defects and damage. Users benefit from a combination of software development expertise and asset protection. Whether operating 10 wells, 100 wells, or more, this automated solution allows operators to inspect larger quantities of wells faster and more accurately, so they can strengthen their well control barriers, avoid incidents, and enjoy safer and more reliable operations.