Ala. Admin. Code r. 400-1-4-.09

Current through Register Vol. 43, No. 1, October 31, 2024

Section 400-1-4-.09 - Casing, Cementing, And Test Pressure Requirements

(1) The operator shall case and cement all wells with a sufficient number of strings in a manner necessary to:

(a) prevent communication between separate hydrocarbon-bearing strata (except such strata approved for commingling) and between hydrocarbon and water-bearing strata;

(b) prevent contamination of freshwater-bearing strata;

(c) support unconsolidated sediments; and

(d) otherwise provide a means of controlling formation pressures and fluids.

(2) The operator shall install casing that meets American Petroleum Institute (API) standards. Cement shall meet API standards and shall be mixed with water of adequate quality so as not to degrade the setting properties. Safety factors in casing program design shall be of sufficient magnitude to provide optimum well control while drilling and to assure safe operations for the life of the well.

(a) Surface Casing. The minimum amount of surface or first intermediate casing to be set below ground level, the cement requirements, and the test pressure requirements shall be determined from Table 1. However, if the operator does not set surface or first intermediate casing below the base of the underground source of drinking water (USDW) containing fluids of less than ten thousand (10,000) milligrams per liter total dissolved solids, the operator may not be allowed to dispose of pit fluids in the well. See Rule 400-1-4-.11(1), relating to Disposal of Pit Fluids.

TABLE 1

Proposed true vertical depth (TVD) (ft) Minimum casing required (ft) Cement required Surface test-pressure (psi)

0 - 4,000 300 Circulate to surface 600

4,001 - 5,000 400 Circulate to surface 600

5,001 - 6,000 600 Circulate to surface 800

6,001 - 7,000 800 Circulate to surface 1,000

7,001 - 8,000 1,000 Circulate to surface 1,000

8,001 - 9,000 1,400 Circulate to surface 1,000

Greater than 9,000 1,800 Circulate to surface 1,500

The Supervisor may specify surface or first intermediate casing requirements other than those set forth in Table 1 if such requirements are needed to provide for increased protection of freshwater resources.

(b) Intermediate Casing. Intermediate or protective casing shall be set when required by abnormal pressure, mud weights, sediments, and other well conditions. A quantity of cement sufficient to cover and isolate all hydrocarbon zones and to isolate abnormal pressure intervals from normal pressure intervals shall be used. If a liner is used as an intermediate string, the cement shall be tested by a fluid entry or pressure test to determine whether a seal between the liner top and next larger casing string has been achieved. The test shall be recorded in the driller's log. When such liner is used as production casing, it shall be extended to the surface and cemented to avoid surface casing being used as production casing.

(c) Production Casing. Production casing shall be set before completing the well for production. It shall be cemented in a manner necessary to cover or isolate all zones which contain hydrocarbons. A calculated volume of cement sufficient to fill the annular space at least five hundred (500) feet above the top of the uppermost hydrocarbon zone shall be used. When a liner is used as production casing, the testing of the seal between the liner top and next larger string shall be conducted as in the case of intermediate liners.

(d) The Supervisor may approve an alternative casing program upon written justification by the operator.

(3) If there are indications of inadequate primary cementing (such as lost returns, cement channeling, or mechanical failure of equipment) of the surface, intermediate, or production casing strings, the operator shall evaluate the adequacy of the cementing operations by pressure testing the casing shoe, running a cement bond log or a cement evaluation tool log, running a temperature survey, or a combination thereof before continuing operations. If the evaluation indicates inadequate cementing, the operator shall re-cement or take other actions as approved by the Supervisor. The operator shall verify the adequacy of the remedial cementing operations as described above.

(4) Pressure Testing. An operator shall give notice to the Supervisor prior to pressure testing.

(a) After primary cementing of surface casing and intermediate or protective casing, drilling shall not be resumed until a time lapse of twelve (12) hours under pressure. Cement is considered under pressure when one or more float valves are employed and are shown to be holding the cement in place or when other means of holding pressure are used. After cementing and prior to drilling the plug, surface casing and intermediate or protective casing shall be pressure tested as set forth in Table 1 above. All pressure tests are to be held for thirty (30) minutes. If during this test period the pressure declines more than ten percent (10%) of the initial test pressure, then such corrective measures shall be taken to insure that the casing string is so set and cemented that it will hold the test pressure for thirty (30) minutes without a drop of more than ten percent (10%).

(b) Upon conclusion of the drilling of the well, or prior to the setting of either intermediate or protective, or production casing strings, the surface casing shall be re-tested in accordance with Rule 400-1-4-.09(2)(a) in order to verify the integrity of the casing string. This requirement will not apply if the well is permitted to be drilled to a total depth of less than six thousand (6,000) feet and no problems are encountered during the drilling of such well that would require a retest to verify the mechanical integrity of its surface casing string.

(c) After primary cementing of production casing, drilling shall not resume until a time lapse of twelve (12) hours under pressure. Cement is considered under pressure when one or more float valves are employed and are shown to be holding the cement in place or when other means of holding pressure are used. After cementing and prior to drilling the plug, production casing shall be pressure tested at a pressure in pounds per square inch (psi) calculated by multiplying the vertical depth of the producing string by two-tenths (2/10) or any other pressure required by the Board or Supervisor. All pressure tests are to be held for thirty (30) minutes and the maximum test pressure required shall not exceed fifteen hundred (1,500) psi. If during this test period the pressure declines more than ten percent (10%) of the initial test pressure, then corrective measures shall be taken to insure that the casing string is so set and cemented that it will hold the test pressure for thirty (30) minutes without a drop of more than ten percent (10%).

(d) In the event of prolonged drill-pipe rotation within a casing string run to surface or of extended operations such as milling, fishing, jarring, washing over, working over, or other operations which could damage the casing, such casing string shall be pressure tested, and if required by the Supervisor, evaluated by a logging technique such as a caliper or casing inspection log every thirty (30) days. The evaluation results shall be submitted to the Supervisor with a determination of the integrity of casing for continued service during both drilling and workover operations, and over the producing life of the well. If the integrity of the casing in the well is deteriorated to a potentially unsafe level, remedial operations shall be conducted with a plan approved by the Supervisor prior to continuing operations.

(5) Recording Test Pressures.

(a) Proper documentation of pressure tests, including beginning and ending pressures and the duration of each test, shall be recorded in a daily drilling report.

(b) Unless witnessed by an agent of the Board, all pressure tests and re-tests shall be documented with a properly calibrated continuous pressure recorder or other pressure recording device acceptable to the Supervisor. A representative of the operator shall sign the pressure test record(s) following completion of each pressure test.

(c) The operator shall maintain all pressure test records at the well site during drilling operations. Such records shall be made available for inspection upon request.

(d) The operator shall maintain all pressure test records for a minimum of three (3) years from the date such pressure tests were conducted.

(6) Reporting Test Pressures. The operator shall report pressure tests on Form OGB-7.

Author: State Oil and Gas Board

Ala. Admin. Code r. 400-1-4-.09

Filed September 30, 1982. Repealed and New Rule: Filed April 11, 2000; effective May 16, 2000.

Statutory Authority:Code of Ala. 1975, §§ 9-17-1, etseq.