Technology Project Final Report

General Information & Responsibilities

Annular intervention with capillary

Project Name injection tube for displacing fluids, aiming
to cure leaks
ROPEP21520512/ Please select:
Project Number Cooperation form
EI.005209.P.12 ☐Academic ☒Industry ☐No
External project/ JIP
Project Manager Felicia Cirstian No
leader
Participating academic No
Project Owner Alexandru Dragomir
institution

Planned 0.150 mn EUR Project start 02 2021

Costs
Planned 12 2021
Actual 0.150 mn EUR Project end
Actual 12 2021

Technology classification

Theme Other Domain Workover & well integrity

Production Technology -
Area Completion Technology Owner
Reinhard Pongratz

Technology Readiness level (TRL) TRL 5 - TRL 6 -

TRL TRL
(project start)
System (project end)
System
Refer to the end of this document for details
tested installed

Project summary

Scope of project is to Run capillary into the C-ann of well 4540 Totea (SCP of 160bar) with the following targets:
• Circulate fluid into the annulus, break the emulsion pelicula, inject higher density fluid as deep as possible
• Facilitate fluid exchange, replacing light fluid 1.1 sg with heavier fluid (CaCl2 – 1,35 sg)
• Resolve gas leak / lower the annulus pressure

Business objectives

Well integrity objectives into this New Technology project are to confirm the possibility of annular intervention with capillary
tube injecting fluid in an annulus to cure or reduce annular sustained pressure. Criteria for success are:
• Depth of circulating the fluid (as deep as possible)
• Ability to perform fluid exchange (Density differential with heavier fluid left in the annulus)
• Pressure reduction in C annulus.
The pilot is well 4540 Totea, gas well with sustained pressure (SCP) in C annulus of
Potential pilot assets
165bar

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Other gas wells with annular sustained pressure, mainly in Asset Oltenia, Moldova;
Potential deployment assets
also wells during drilling / WO where sustained annuls pressure occurs.

Time until deployment (TRL 7) 10 months

Please tick
Benefit estimation Project specific Global deployment
if yes
150 kUSD per well/ 14 days
Decrease of costs ☒ operation
<x kEUR>

Increase of production ☐ <x boe> <x boe>

Increase of reserves ☐ <x boe> <x boe>

Increase exploration
☐ <%> <%>
success rate

Proposal of next steps

Please select:
☐Develop ☒Pilot ☐Deploy ☐Already deployed ☐Waiting for follow up ☐Stop

Can be used in special cases, when is required to enforce circulation into an annulus with sustained pressure

Comments Technology Owner

Project details

1. Initial situation

Introduction
Casing and tubing leaks or casing cement failure are the root cause of annuli pressure, hydrocarbon spills in the
environment and “lost oil” underground through tubular’s failure, channeling, leakage and cross flow.

A particular type of sustained casing pressure are the outer annuli SCP, mainly caused by external sources of pressure,
which found path to enter trough failed cementations of the casings or even through casing connection sometimes.

OMV Petrom confronted with such cases of outer annuli sustained pressure and uses as mitigation classic method of
lubricating the annuli with heavier fluid. One particular well did not responded to lubrication solution, continuing to build
up annular pressure up to 165 bar, requiring to investigate further options to solve the case.

EXPRO NORTH SEA LTD, who is a partner of OMV Petrom for other Well Integrity solutions, presented the method of
annular intervention, developed recently for such cases and New Technology 2021 program accepted the trail project
proposed by Well Integrity team.

Partners

EXPRO NORTH SEA LTD, a company incorporated and functioning under the laws of England and Wales,
having registered headquarters located in Davidson House, Forbury Square, Reading, Berkshire, United

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Kingdom. Expro has been selected by OMV Petrom based on its bid and that has the necessary expertise
and the specific knowledge to perform such Services performed using their specific equipment named
Octopoda - Annular Intervention

Procurement process description

OMV Petrom and EXPRO North Sea LTD signed a contract based on Single Source procedure, for one time
trail operation in the selected well.
Lump Sum Contract per well included standard operation of 14 Days, inclusive of 1 run of Annular Intervention
Well Spring. This is also inclusive of 2 set of crew to run 24 Hours Operations. Any additional charges after 14
days or > 1 run was not part of the contract and would require Additional Addendum to the contract.

2. Technical description of the operation

2.1 Tools and equipment used by this technology

The Wellspring System has been designed to ensure that at no point during the operation the Integrity of the
Annulus is compromised in any way.
The Wellspring System is pressure and function tested before shipment to the location. Once the equipment
arrives at the location the pressure and function tests are repeated before the equipment can be installed on
the Wellhead.
Expro Annulus Intervention has contingency procedures in place should any one of the Annulus Integrity barriers
become compromised.
The drawing below indicates the primary and secondary barriers in place during the operation

1 Well Spring Hose (Reeler)

2 Stripper
3 Spring Container
4 Well Spring tool (including tube)
5 Annulus gate valve body
6 Ball isolation valve (with optional hose cutter)

One complete Wellspring package shall be supplied for the proposed operation. The standard Wellspring
package consists of the following:
 Dual Stripper with remote control panel
 Hose Reeler with measuring head, Strain gauge and remote control panel
 Hose Crimping machine
 High Pressure circulating pump (quantity 2)
 Pressure test pump
 Densitometer

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 Wellspring tool (including conversion parts for 1 or 2 Gate Valves)

 Ener-Pac pump
 Injector
 Dual Stripper
 Electronic Pressure Recorder (quantity 3)
 Spring Container
 Spring BHA
 High Pressure Pump Manifold
 Low Pressure Filter Assembly
 PDA Pump Skid (contains 2 PDA Pumps)
 Spares Package
 Hose Package

2.1.1 Wellspring Tool

 The Wellspring tool configured for connection to the C-Annulus inlet – 2-1/6” 5000psi Flange

2.1.2 Spring and Spring Connection

The spring is crimped to the Hose using a dedicated crimping machine. The crimp is designed to release at 50kg
tension allowing the spring to be left in the Annulus in an emergency.
The two WellSpring Hose dimensions available are the small version having a 6.9 mm OD and the large version
having a 11.5 mm OD. The difference in OD requires two different set-up of most main components such as the
Injector, the Dual Stripper, the Spring Container and the core components of the WellSpring Tool.

2.1.3 Injector and Dual Stripper

-Dual Stripper containing one static element and one Dynamic element
-Injector table
-Remote control panel

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 Footprint 2m x 0.5m x 1m
 Weight Injector 45kg
Stripper 25kg
Assembly 90kg
 Stripper Working

2.1.4 Hose Reeler

• Depth and tension monitoring system

• Remote control panel
• Hydraulic wheel jacks for manual handling

 Footprint: 1.75m x 1.54m x 1.64m

 Weight - including water filled hose 1750kg
 Working Pressure: 10000psi
 Certification: DNV 2.7-1, ATEX Zone 1, Gas Group 11B, Temp Class T4

2.1.5 Personnel

The Annulus Intervention Wellspring system requires a minimum of two people to operate.
 • Wellspring Supervisor- one per 12hour shift
 • Wellspring Operator - one per 12hour shift

 Two shifts working, with client agreement, is recommended.

2.1.6 The following services were provided by OMV Petrom:

1 Remove and pressure testing the C-annulus valve.

2 Annulus fluid return system on the passive side of wellhead.
3 Fluid to be circulated into C-annulus, CaCl2, stored into a haba .

2.2 Operation steps proposed by the contractor EXPRO North Sea LTD

1. Onsite annulus lubricator be disconnected from well head assembly 1 week before commencing of AI operations to
allow segregation of fluid in annulus
2. Second valve on C annulus to be removed from passive side to allow commencement of well spring system
3. The Wellspring system maybe rigged up as per the Scope of Supply drawing. The exact Rig up may vary due to
space restrictions on the installation.
4. Ensure the work area is secure, clean, and other is sufficient space for the system.
5. Complete pressure and function tests as per Expro procedures.
6. Install the Wellspring tool onto the Annulus gate valve and pressure test as per Expro procedures.
7. Equalise pressure across the gate valve.

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8. Slowly RIH with intervention hose & spring to confirm access through the upper part of the annular space inside of
the Annulus Gate Valve
9. If access is confirmed RIH to 5m and stop.
10. Line up to pump fluid (TBD) into the intervention hose and commence pumping fluid at minimum rate. Do not exceed
maximum allowed annulus pressure.
11. Once the fluid has been observed at the sample point, continue RIH slowly whilst pumping at the minimum rate.
Continuously monitor return fluid sg, if lower than pumped fluid, continue RIH. If returned fluid sg is same as pumped
fluid stop RIH and observe until sg drops.
12. Take regular samples to monitor sg of returns, record results.
13. Continue RIH until target depth (approx. 950m for 1000m hose)
14. In case of losing string weight, pull back 3m, circulate 15min and recommence RIH with lower speed
15. With intervention hose at maximum possible depth (approx. 950m), stop RIH.
16. Increase pump rate until maximum pump pressure has been achieved, while maintaining within the allowed annulus
pressure.
17. Displace annulus to fluid from hose depth to surface. Note: Ensure returns are regularly checked for sg and returned
volumes measured, record results.
18. When fluid weight of returns is consistent over 30 minutes, POOH to surface.
19. Retract the guide head into the Wellspring tool.
20. Close in and perform inflow testing of Annulus Gate Valve attached to the Wellspring tool.
21. Close in and perform inflow testing of Annulus Gate Valve with return line.
22. Continuously/closely monitor the annulus pressure for any pressure build-up. Note: The results of the well monitoring
will decide further operations (rig-down/continue pumping)
23. Commence rigging down Wellspring annulus intervention system and fluid pumping equipment and prepare for back
loading.

3. Results and Observation- Annular Intervention in C annulus of well 4540 Totea

3.1 General data of the Well

Well 4540 Totea is a gas well and was drilled in 2015

Production casing 7” -3460m - cemented to 500m
Intermediate casing 9 5/8” -3140m - cemented to 2800m
Surface Casing 13 ¾” -2850m- cemented to surface
Well bottom Cement plug at 3520 m;
Tubing 31/2" at 3260 m (24.03.2015)
Intermittent Production 3 days per month: Qg=35.000 Nm3/d, Qt=1.8t/d
Well Pressures: WHP=31bar / 81bar static, A-ann=53bar, B-ann=0bar, C-ann=165bar

3.2 Recent well history

4540 Totea, well selected for this trail is a well with C annulus sustained pressure of up to 165 bar, since
2015 immediately after well drilling and putting in production, most probable the leak coming from an
external layer other than the productive reservoir and is infiltrated via casing (threats) or via casing cement
into the C-annulus.

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C annulus is defined as the annular space between 9 5/8” casing and 13 ¾” casing with a ToC of 2800m,
having an approximate non cemented volume of 87m3, originally filled with drilling fluid 1.8 sg.
Since 2015 the C-annulus pressure was present and demonstrated to be sustained, starting from 40 bar and
slowly increasing after repeated bleed offs up to 140 bar stabilized. After the well was put on an intermittent
production due to depletion, C-annulus pressure increased up to MAWOP of C-ann=172bar, during the
productive periods, on a thermal basis, following that after cooling down during shut down phase, Ca-nn
pressure to drop to cca 165bar.
In 2017 was performed a casing leak detection using a Sonic Noise Log technology, suspected leak area was
established to be located between 1600 – 2440m, with 2 possible sources:
1. Reservoir, leaking through damaged cement barrier (9 5/8 TOC at 2800m)
2. An upper layer, saturated with gas/condensate fluid, leaking through casing joint
OMV Petrom tried to mitigate the sustained pressure with lubrication since 2020, using CaCl2 of 1,35 sg
considering that the fluid resulted from C-annulus was lighter 1,1sg, consisting of a mixture between drilling
mud, condensate and gas

Lubrication started Aug 2020, from a C-ann pressure of 165bar stabilized. Initially C-ann pressure was slightly
reduced needing frequent bleed off. After several months was noted the fluid exchange is not good, observing
that the lubricator tower was still filled with initial density CaCl2 while C-ann having light fluid on top
The possible reasons why Lubrication did not work and the fluid exchange happened only at surface are:
 high gas influx from the leak source;
 high fluid emulsion pelicula, not allowing CaCl2 fluid to penetrate and move below
 lubrication fluid of 1,35 sg not heavy enough;

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 lubrication manifold not enough sloped

This classic methods to remediate Sustainable Pressure in outer annuli did not responded in this case, so we
looked for a solution to facilitate fluid exchange deeper into the annulus

3.3 Objectives

Run capillary hose into C-annulus as deep as possible, having as limit hose maximum length of 1000m
Obtain circulation of fluids in C-ann, displace exiting light fluid cca 1,1 sg with CaCal2 of 1,35sg
Displace as much lighter fluid as possible with the purpose to reduce annular stabilized pressure or stop the
leak

3.4 Preliminary preparation for the operation

EXPRO NorthSea Team arrived on location with a crew of 2 operators and 2 engineers, on 18 November and started
with the following preparation jobs:
 Installed Octapoda equipment near well 4540 Totea
 Tested all the equipment as per procedure, inspected system barriers, connected to the C-annulus of the Well
which was prepare by OMV Petrom crew.
 Prepared monitoring tools for operation parameters: circulation fluids volumes, densities, pressure
 Before commencing Annulus Intervention operations, well was shut in for 7 days and isolated from
lubrication system. As a result, pressure built up to 165 bar and fluid level dropped in
 Measured the fluid level in C-annulus, observed 167m

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3.5 Description of the operation

Step 1: 19 Nov, 21.00 until 21 Nov, 12.30 -40 hours

 Bleed off C-ann from 165bar to 50bar

 Run in capillary hose through C-ann at 567m
o Best depth achieved by Octapoda ever,
o depending also on the level of fluid in C-ann, fluid in the annulus providing portance for the hose
o Difficult advancement also due to casing centralizers Restrictions at each 9m
 Pumped 13,7m3 fluid CaCl2 1.2sg
 Returned 10,9m3 fluid 1.05 sg
 Observed the fluid pumped was of low density than planned

21 Nov, 13.00 until 22 Nov, 8.30 -20 hours

 Continued pumping 4,3m3 new fluid CaCl 2 1,34 sg- contamined

 Returned 2,9m3 fluid 1.05sg
 Pumping rate dropped to 3,6 l/min – indicating circulation difficulties
 After 20hours the hose was blocked

Conclusion Step 1
► Reaching 567m depth was a record for Octapoda injection depth
► Usually the injector doesn’t advance due to centralizers
► The advance is favorized if the anulus is empty, no portance
► The hose penetrated the pelicula and was able to allow fluid exchange
► Second part of circulation to 567m was done with not filtered CaCl2
► Were noted precipitates on the hose which created blockage: possible salts of cryohydrates due to the
temperature variations; also possible un-cleaned/ unfiltered fluid or impurities present in the fluid tank

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► The hose required replacement, with a stand by of 4 days

Step 2: 27 Nov, 00.00 until 29 Nov, 13.30 -61 hours

► Run in hose through C-ann at 170-121m

► Due to the level of fluid in C-ann
► Restrictions due to centralizers a teach 9m
► Pumped 13m3 fluid CaCl2 1,34 sg -clean
► Returned 10,3m3 fluid 1.22sg
► Observed the fluid pumped was of low density than planned

Conclusion Step 2
 Not able to advance more than 120-170m
 Pumped clean almost 2m3 CaCl2 of 1,34 sg
 The fluid returned slowly increased density from 1,15 to 1,24 sg
 The hose plugged again and required to cut and re run the hose

Step 3. 29 Nov, 15.00 until 3 Dec, 12.30 - 61 hours

 Run in hose through C-ann at only 17m
o Due to the level of fluid in C-ann
o Restrictions due to centralizers a teach 9m
 Pumped 6m3 fluid CaCl2 1,34 sg -clean
 Returned 5,4m3 fluid 1.324 sg

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 Observed the returned fluid density is the same of pumped fluid,

 Stopped pumping

Conclusion Step 3 final

 Total pumped 30m3 fluid high density and returned 24,5 m3 low density fluid
 Delta 5,1m3 CaCl2 of 1,34 sg remained in the annulus C
 This created a reduction of 30 bar pressure in C-ann
 After EXPRO job the pressure reduced form 160bar stabilized to 130 bar stabilized
 Emulsion pellicula prevent gravitational lubrication efficiency
 Capillary hose was able to penetrate emulsion and facilitate fluid exchange

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3.6 Challenges

 Capillary hose has difficulties to run into the annuls due to:
o Presence of casing centralizers
o Any fluid in the annulus that create portance of the hose
 Liquid pumped into the Capillary hose requires perfect homogeneity:
o Any impurity in the fluid can block the flow in capillary
o Higher density fluids results in lower pumping speeds and may have the same effect of hindering
the flow

4 Conclusions & Recommendations

 Annular Intervention in C annulus of well 4540 Totea, conducted by EXPRO was finalized with no HSSE
incident
 Expro operation managed to inject lubrication fluid below the emulsion pelicula
 Managed to place in the C-ann additional 5,1m3 heavier fluid CaCl2 of 1.35 sg
 Reduced stabilized pressure in C-ann by 30bar
 Facilitated fluid exchange in the C-ann, making possible continuation with gravitational lubrication

5 Final Conclusions and recommendations

5.1 Benefits of the method

The method can be an alternative to solve annular pressure by circulating fluid into the annular space,
providing the annulus is free and accessible
The method is suitable for annuli space where the fluid cannot be displaced by direct lubrication or pumping,
due to different reasons

5.2 Economic considerations

Although the method seems to be expensive, 150.000 USD per well for 14 days circulation, without the cost of
circulation fluid, compared with the alternative solution such as an workover of the well, can be economical
attractive.

5.3 Recommendations

 Apply to wells during drilling / WO where sustained annuls pressure occurs as ultimate solution
 This method is suitable for annuli where the fluid cannot be displaced by direct lubrication or pumping, due to
different reasons
 Avoid using the method in case of annular obstruction with centralizers, emulsion pellicular etc
 Avoid using the method in case is required to circulate heavier, un-homogeneous fluids that may block the
hose

Appendix 1. Date Time Event Description

18/11/2021
18/11/21 08:00:00 Arrived on wellsite, received site induction, made permit ready.
18/11/21 09:00:00 Hold TBT to offload trucks.
18/11/21 11:00:00 Spotted equipment and start rigging up.
18/11/21 14:00:00 Commenced pressure test equipment against annulus gate valve.
18/11/21 19:00:00 Completed pressure testing.
19/11/2021
19/11/21 08:00:00 Waiting on OMV Echometer.
19/11/21 09:45:00 Echometer shows liquid level at 167 meters.

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19/11/21 10:00:00 Held TBT prior to bleeding down annulus.

19/11/21 10:01:00 Commenced bleeding down annulus.
19/11/21 10:22:00 Annulus pressure is 50 bar. Equalized pressure against gate valve, and opened gate valve.
19/11/21 10:28:00 Commenced stroking tool IN.
19/11/21 13:50:00 Tool is not stroking completely.
19/11/21 14:00:00 Found out after investigation that tool is too short. Start rebuilding tool.
19/11/21 17:00:00 Commenced rigging up longer tool on gate valve, pressure test and start run in hole.
19/11/21 20:00:00 Hose at 170 meter. Commenced pumping with 1.23 SG Brine.
20/11/2021
20/11/21 00:15:00 Tagged 574 meter. Continue pumping with 1.23 SG Brine. SG of the returned fluid is 1.05.
Annulus pressure maintained between 25 and 35 bar.
20/11/21 20:45:00 Pulled back hose to ensure hose is not stuck. New hose depth is 567 meter. Continue
pumping.
21/11/2021
21/11/21 12:45:00 Stopped pumping. Switched to new brine tank. SG of new brine is 1.37. Total brine with
1.23
SG pumped = 12575 liters.
21/11/21 13:00:00 Commenced pumping brine with 1.37 SG.
22/11/2021
22/11/21 09:00:00 Stopped pumping due to plugged WellSpring System.
22/11/21 09:50:00 Pull out of hole to surface.
22/11/21 14:45:00 Hose at surface. Closed gate valve.
22/11/21 17:00:00 Investigation found out that WellSpring Hose is plugged most likely from the salt in the
brine.
New hose mobilized.
23/11/2021
23/11/21 07:00:00 Commenced maintenance on WellSpring Equipment.
23/11/21 17:00:00 Completed maintenance.
24/11/2021
24/11/21 17:00:00 Commenced spooling off plugged WellSpring Hose.
24/11/21 20:00:00 Completed spooling off.
26/11/2021
26/11/21 17:00:00 Hose arrived. Commenced spooling on WellSpring Hose.
26/11/21 19:00:00 Completed spooling.
26/11/21 20:00:00 Commenced rigging up tool on gate valve and pressure test.
26/11/21 22:00:00 Completed rigging up tool and pressure tested. Commenced running in hole.
27/11/2021
27/11/21 00:00:00 Commenced pumping brine while running in hole.
27/11/21 04:45:00 Tagged 120 meter.
27/11/21 15:00:00 Commenced running in hole.
27/11/21 16:00:00 Stopped pumping due to running in hole.
27/11/21 19:00:00 Tagged 100 meter. WellSpring Hose held up at 102, 107 and 110m."
27/11/21 21:25:00 Continue running in hole. Tagged 172 meter.
27/11/21 21:30:00 Commenced pumping brine with 1.37 SG.
28/11/2021
Events
Page 2
Date Time Event Description
28/11/21 11:00:00 Stopped pumping due to running in hole.
28/11/21 11:15:00 Commenced running in hole.
28/11/21 12:00:00 WellSpring hose held up 168 and 164 meter. Tagged 161 meter.
28/11/21 12:30:00 Commenced pumping brine.
28/11/21 23:00:00 Stopped pumping to monitor pressure in Annulus.
29/11/2021

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29/11/21 04:00:00 Commenced pumping brine.

29/11/21 13:30:00 Stopped pumping due to running in hole.
29/11/21 19:00:00 WellSpring Hose held up at 66 meter.
29/11/21 20:30:00 Commenced pulling out WellSpring Hose with different pump and annulus pressures.
30/11/2021
30/11/21 06:00:00 No success with pulling out.
30/11/21 13:30:00 Successfully cut the WellSpring Hose.
30/11/21 13:45:00 Commenced maintenance on WellSpring Equipment.
30/11/21 18:00:00 Completed maintenance.
30/11/21 18:15:00 "Commenced rigging up tool on gate valve, pressure test and start run in hole."
30/11/21 20:50:00 Commenced running in hole.
01/12/2021
01/12/21 05:00:00 Hose held up at 16 meter.
01/12/21 10:30:00 Commenced pumping up annulus to 40 bar.
01/12/21 11:45:00 Completed pumping. Volume pumped = 210L.
01/12/21 12:00:00 Commenced monitoring annulus pressure.
02/12/2021
02/12/21 03:00:00 Bled off gas in annulus. Commenced pumping up annulus to 40 bar again.
02/12/21 03:25:00 Completed pumping. Volume pumped = 87L.
02/12/21 03:30:00 Commenced monitoring annulus pressure.
02/12/21 08:33:00 Bled off gas in annulus. Commenced pumping up annulus to 40 bar again.
02/12/21 09:33:00 Completed pumping. Volume pumped = 30L.
02/12/21 09:35:00 Commenced monitoring annulus pressure.
02/12/21 15:42:00 Bled off annulus. No gas present. Commenced pumping up annulus to 120 bar, in steps of 10
bar."
02/12/21 15:53:00 Completed pumping to 50 bar. Volume pumped = 31L.
02/12/21 16:03:00 Commenced pumping to 60 bar.
02/12/21 16:35:00 Completed pumping to 60 bar. Volume pumped = 83L.
02/12/21 17:00:00 Commenced monitoring annulus pressure at 60 bar.
03/12/2021
03/12/21 08:00:00 Completed monitoring annulus pressure.
03/12/21 08:15:00 Successfully cut the WellSpring Hose.
03/12/21 08:30:00 Commenced rig down WellSpring Equipment.
03/12/21 17:00:00 Completed rig down.

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Appendix 2. Pressure plots during the operation

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