Strategic Enhancement of Well Integrity in Ultra-Sour HPHT Wells: A Multidimensional Approach to Operational Resilience, Decarbonization, and Sustainable Equipment Efficacy

Abstract The integrity of downhole completion systems is paramount in high-risk wells characterized by Ultra-Sour conditions, extreme temperatures, and elevated pressures. This study proposes a proactive material testing initiative to fortify well integrity management strategies and mitigate the risk of catastrophic well integrity failures. A comprehensive review of tubing materials for high-risk wells was conducted, revealing gaps in industry benchmarks and potential failure mechanisms. The proposed environmental material tests, adhering to NACE and ASTM standards, will assess the performance of the selected alloys in simulated operational conditions. The material testing conducted revealed key findings. For tubing materials, the lab test duration was extended to align with industry standards. This addressed the previously limited duration and incorporated additional tests. The tests also considered higher environmental stress levels and uncertain factors. The study on Elastomers revealed limitations in chemical compatibilities and temperatures, with recommendations for testing due to limited experience in such environments. The proposed minimum requirements include conducting material tests for an extended duration for both environments. Rigorous testing and collaboration among specialists are instrumental in safeguarding the operational integrity of high-risk wells. The proposed testing initiative underscores the significance of a systematic approach to well integrity management, with special focus on high-profile wells and the harsh conditions they will encounter.