Lube and Bleed Operation KLS-1 Rig Less Feb 2017

Lube & Bleed Operation
KLS-1
KAHLOUCHE SUD 1 (KLS#1)
Annulus B & Annulus C

Casing pressure
Prepared By: Boubenia Authorization: Approval: Version: 1

Date: 01-Mars-17 Engineering SH/B&C WC Specialists Page 1 of 19
KLS-1
Abstract:
Following the Workshop on the wells Integrity in the Southwest Region held at HMD on 25 and 26 January 2017 and in the
framework of the sharing of experience, the Reggane Group invites us to attend the Operation on site prior to lube and bleed the
pressures in B and C annuli of the KLS-1 well. On 23th January of 2017 I arrived on location to assist this operation.
Well Summary:
In continuation with the compromise that Groupement Reggane Nord (GRN) has made to the civil authorities of Algeria,
specifically to the ARH, we plan to intervene in the annulus B and annulus C on the KLS-1 well in order to guarantee the well
integrity of the well, for a longer life span of production, and in anticipation of any possible change out of the casing head
housing that will allow a proper seat of the production string at the wellhead.
KAHLOUCHE SOUTH-1 is a vertical appraisal well drilled in the Algerian Sahara, block 351 C and 352c, of the Reggane basin.
It is situated 60Km W of the previous well Reggane field and closed to Baamor Village. 85 km of land track connected this
village to rig location. The main town Adrar is 125 km away from the location. The well penetrated the primary target Lower
Devonian (Sieginnian – Gedinian). It was drilled by Dalma rig 12 in the year 2007.
During the monitoring campaigns carried out on March of 2015 a pressure of 500 Psi was noted at casing Head spool (Annulus
B). In previous monitoring exercises there was also pressure on annulus C. In May of 2016 the pressure reading was confirmed
to be at 500 Psi, but also the absent pressure in the 2015 on annulus C was confirmed to be at 400 Psi.
Since there was a suspicion of communication between the two annuli (B and C) a bleed off operation was done for the KLS-1
well. The bleed off determinate that the annulus C had „‟Hot Air‟‟ and no presence of gas, which lead us to understand that this
annulus may lack cement and may be affected by the expansion of the inner most annuls (13‟‟3/8 csg to be more specific).
In order to help alleviate the integrity of the annulus C it is also recommended to fill up with Calcium Bromide in order to provide
more “cushion” for any force applied by the expansion of the inner annulus.
The plan for this well is to intervene it, by means of Lubricate and Bleed, and to utilize the Halliburton well testing personnel and
equipment that will be on Rig KCA-D, T-45, Well KL-39 / KL-22 combined with a pumping unit from any available contract. In
addition, a water transport and a Bulk Brine transport from AVA will be recommended.
The primary objective of the operation is to be fully compliant with GRN‟s HSE policy, to make the proper arrangements and
measures for pressure control operations and to ensure that the personnel involved are always in a safe atmosphere and
understand the risks and limitations of the operation. In the same manner, the environmental consequences of the operation
have been quantified and qualified and the expected residues of the fluid existing in the annulus are to be disposed and treated
as needed.

KLS-1
Well KLS-1 MAWOP and Annulus Pressure Data:

The Table below provides the MAWOP (Maximum-Allowable-Well-Operating- Pressure) for the Well Kahlouche South – 1:
The table below shows the recorded pressures on KLS-1 throughout the monitoring campaigns:

KLS-1
LOCATION / FIELD MAP:

KLS-1
CURRENT WELL SCHEMATICS:

KLS-1
BLEED OFF RESULTS FOR ANNULUS B AND C:

KLS-1

KLS-1

KLS-1

KLS-1
INTERPRETATION OF BLEED-OFF RESULTS:
This could also be a reason for having the pressure build up so quickly and for the absence of gas in the bleed-off on Annulus-C.
The idea here is that the outer-most annulus (in this case annulus-C) is pressured up due to two conditions: 1) the lack of hard
material (cement) in the system that basically has the pipe free, and 2) the expansion of the inner casing (in this case the 13 3/8”
CSG) due to the pressure exercised by the formation where the gas is coming from.
KLS-1
SOLUTION:
In any of both cases, it is assumed that the origin from the gas in the Annulus-B and the problem on Annulus-C (either from direct
invasion or from expansion) is due to the gas presence in the Viseans, which has been very evident for GRN up to this point. The
Viseans in the Kahlouche field differ from FP between 500 psi to 750 psi, depending on the area where they are located.
In order to eliminate the pressure of both annuli (Annulus-B and Annulus-C) the ideal aproach will be to kill the source in the
Visean, therefore, perform a Lube & Bleed operation directly to Annulus-B and observe the behavior of Annulus-C while this is
being done in order to determine the closeness of the communication between them.
In any of the two scenarios presented above, a Lube & Bleed in the Annulus-B would in theory solve both problems.
Nevertheless, it is also recommended to “fill up” Annulus-C in any case, in order for the annulus to have some sort of liquid that
would help the integrity of the well by providing more cushion to both casings (13-3/8” and 18-5/8”) in case of any future influx
inside Annulus-B.
If the operation deems that the Annulus-C has an independent source from Annulus-B (very highly unlikely) then a Lube & Bleed
operation shall be performed in this annulus once the operation for Annulus-B has been deemed successful.
CBL ANALYSIS OF 9 5/8” CSG:
As the transit times are fine there is no reason to suggest that the tools were not functioning properly
The CBL and VDL demonstrated that there was a reasonably good bond from the first reading only up to around 3640m. Above
this point until around 2980m there appeared to be predominantly no cement interspersed with rare section with very poor
cement. The couplings on the casing can clearly be seen ringing out on the log.
Above 2980m the bond begins to improve and by around 2945m the log indicates that a moderate to good bond exists. By 2925m
the bond appears to be very good. The good bond continues up the hole with only sporadic isolated sections (less than 30m thick)
where the cement is absent or very poorly bonded to the casing. This continues up to around 2140m.
Above 2980m the bond begins to improve and by around 2945m the log indicates that a moderate to good bond exists. By 2925m
the bond appears to be very good. The good bond continues up the hole with only sporadic isolated sections (less than 30m thick)
where the cement is absent or very poorly bonded to the casing. This continues up to around 2140m.
At 2140m the bond deteriorates markedly. Once again the casing couplings ring out on the log, suggesting that there is little or no
cement behind the casing. This continues to approximately 1975m at which depth the log suggests that a moderate to good bond
exists once more. Once again there are areas within this section that suggest very poor to no cement.
The top of the cement can be seen on the log at around 1560m
It should be noted that this log comes in the wake of a very poor cement job. While pumping the tail cement the batch mixer failed.
This resulted in large fluctuations in the slurry density (1.60 sg to 2.10 sg). The last 10m3 of cement were not pumped, the plug
was not bumped and it has been established that approximately 40m3 of fluids were lost down hole during the displacement. The

KLS-1
pressure during the displacement was also much higher than expected increasing from 1200psi to 3200 psi very quickly. The
expected final pressure was 1500 psi. This is consistent with either a pack off in the annulus or the cement “flash setting” in the
annulus. It is not clear on the log where a restriction causing the pressure increase may have developed but the result could have
been a break down in the formation integrity at some point with fluids being injected into the formation
LUBE & BLEED OPERATIONS:
The principal of a Lubricate and Bleed-off, (Lube & Bleed). Operation is to lubricate in or pump in a fluid, allow the fluid to fall to
the bottom of an air or gas gap, allow the fluid time to “Stack Up” then to bleed off a pressure that is comparable to the pressure
that is created by the hydrostatic stacking of the fluid + pressure rise due to pumping into the annulus.
The usual unknown is the height or length of open space that the fluid has to fall through and the time that it will require for the
fluid to free-fall from the surface to either the top of a standing fluid level or a solid base. Fluid can be lubricated through a gas but
not another fluid. Lubrication is achieved by the higher density fluid dropping through or “Lubricating” through the lower density
gas. This does not occur efficiently with a higher density fluid attempting to lubricate through a lower density fluid.
During the Pressure Bleed off Operation, (Bleed Cycle), only gas is bled from the well. The process works because gas is
compressible and will react following the modified Ideal Gas Law, P1V1 = P2V2. If performed in a closed vessel or at pressures
that are lower than fracture or injection pressure then the Pressure / Volume relationship can be utilized to determine the air or
gas gap volume and thus the hydraulic height that can be achieved.

KLS-1
A general synopsis of the operation on KLS-1is as follows for Annulus-B:

Pressure Test:
1. Hold Pre Job Safety Meeting

2. Install a 3” “T” onto the “B” annulus keeping the Annulus valve closed
3. On one side of the “T” install test iron from the well to the test manifold and on through a flare line.
4. On the opposite side of the 3” “T”, install a crossover to 2”, a 2” “T” with a bleed off valve lying horizontal and a check valve in
the vertical position. Install the check valve so that fluid can be pumped into the well but well fluid / gas cannot flow back to the
pump.
5. Fill the piping with water and pressure test to the choke manifold to 2500 psi.
6. Bleed test water from the system through the 2” Valve at the below the check valve.
7. Record all pressures at the annulus connection.
Lube & Bleed Procedures for Annulus-B:
BLEED-OFF
1. Close the Low Torque Valve going to the Pump Line.
2. Open the Well to the choke manifold in CLOSE position.
3. Record pressure drop behavior at the choke manifold data recorder.
4. OPEN the choke and record pressure drop – make sure it coincides with previous behavior.
5. During bleed off the pressure from section b, closed monitor the pressure in section c.
6. Bleed Off and vent well for as long as it is reasonable according to the bleed-down trend. If the pressure doesn‟t completely
drop, it is recommended to kick-start the lubrication process.
7. Close the Low Torque Valve to the Choke in preparation to Lubricate.
LUBRICATE IN:
Pump the 1.70 sg (Brine) at lowest pump rate into the annulus watching closely the MAWOP at the pump pressure gauge not
exceeding 1,200 psi.
2. Do not exceed pumping an initial volume of 8 bbls in initial circulation.
3. Allow time for the fluid to drop to the bottom of the air/gas gap. (This could be several hours to a full 12 hours depending on the
height or length of the air/gas gap and will depend on lubrication rate.
4. Calculate the annular height of the fluid pumped and the additional hydrostatic pressure that is applied due to the height of fluid
pumped into the annulus.
5. Bleed the hydrostatic pressure built + the pressure increase during pumping, (100 psi recommended)
6. Repeat steps 2 through 5 until a pressure bleed that takes the pressure to 0 psi is performed.

KLS-1
GENERAL CALCULATIONS:
Fluid Stacking Height = Volume Pumped, (liters) /Annulus Capacity, (l/m)

Hydrostatic Stacking, (psi) = SG X 1.4206 X Volume Pumped, (liters) /Annulus Capacity, (L/m)
Annulus Capacity, (l/m) = (OD2 – ID2) /1.9735 OD and ID in inches
Hydraulic Gradient, (psi/m) = SG X 1.4206
Required Fluid Column, (m) = Annulus Pressure, (psi) /Hydraulic Gradient, (psi/m)
Boyle’s Law for a constant mass of gas P1V1 = P2V2
Pressure is in Absolute Pressure, (psi + 14.7)
Volume, V1 and V2 must be in the same units
Specific Calculations for KLS-1 Annulus-B
 Annular Capacity: between 9-5/8” 53.5# and 13-3/8” 72# is 40.33 lit/meter
 Annular Volume to TOC: Unknown
 Volumes Available on KL39 location:
 1.70 SG Brine x 4m3 = 239.4 psi and 99 m column height
 Expected TOC: Shows of Cement @ 1580
 Volumes for Performing Kill (500 psi): 1.70 SG Brine x 8.34 m3 = 500 psi and 207 meters column.
Sequence of operations done on rig:
On 21 feb 2017:
 Move the Well Test equipment to KLS-1, unload, spot and R/U the surface lines of cement unit and WT equipment.
 R/U the flare line from choke manifold to pit, and pressure test the lines.
On 22 feb 2017:
 Meeting held at KLS-1 to show roles and responsibilities and HSE importance, GRN HSE, GRN Well Integrity Engineer,
discussed spotting equipment, rigging up equipment and confined space entry. *Roles & Responsibilities
 Start Unloading first loads on KLS-1 and spotting equipment and started R/U equipment,
- Connected adapter flange to well head.
- Commenced rigging up well test equipment; upstream line, Choke manifold.
- Commenced rigging up Cementing lines and completed cementing unit and lines

KLS-1
On 23 feb 2017:
 Held a Prejob safety meeting, GRN HSE, discussed unloading the equipment, rigging up equipment.
 Waiting for flare lines from T212, was delay because of bad road conditions-
 Arrived to KLS-1 with visitors and GRN team, attend the HSE induction and short briefing about Lube and Bleed.
 R/U the flare lines 85% done.
On 24 feb 2017:
 Finalized R/U of the flare lines and installed the ignition system on end of flare line,
 Installed the gauges on choke manifold upstream and downstream.
 Connected the Halliburton chart data recorder.
 Installed the simple point for mud density.
 Pressure tested of cement lines, diverter, choke manifold and iron lines against wellhead annulus "B" SOV to 830/3,700 psi
for 5/10 min - OK.
 Check the gauge to make sure the gauges on choke manifold, chart recorder show the same pressures as on cement unit.
 Bled off the lines to 0 psi, closed in the diverter manifold valve to the cement unit line and closed the choke manifold valves.
Opened the SOV on annulus C and record the annulus C pressure 300 psi, opened the Annulus A SOV an recorded the
pressure 0 psi and last opened the Annulus B SOV and recorded the annulus B pressure on choke manifold to 350 psi on
(manifold gauge and Chart data recorder),
 Started opening the gate valve on choke manifold observed the gas on cutting pit, immediately closed the valve on manifold,
wait for a while to vent the lines from gas.
 Open the LTV to flare pit and CLOSED the LTV to the cutting pit.
 Wait for while and first brine on the end of flare line by halliburton well testing system and then started opening the valves on
choke manifold then burnt the gas.

KLS-1
 Flare line was burning for 5 min, stopped the flow of gas from well, vent for 10 min the well.
 Closed on choke manifold the valves of bleed line closed the valve on diverter and open the valve of diverter to annulus b.
 Started Lubricating 1.70sg CaBr2, as follows:
1.5bbl / 0.3bpm / 17psi

2.0bbl / 0.3bpm / 22psi
2.5bbl / 0.3bpm / 29psi
3.0bbl / 0.6bpm / 52psi
3.5bbl / 0.6bpm / 80psi
4.0bbl / 0.6bpm / 163psi
4.5bbl / 0.6bpm / 444psi
5.0bbl / 0.4bpm / 698psi
5.5bbl / 0.4bpm / 1,044psi
5.7bbl / 0.4bpm / 1,178psi
 Stopped pumping and shut the well in by closing the SOV of annulus "B".
 Bleed off pressure of SLB cement line down to the 15Kpsi Check Valve. Opened Diverter and Choke Manifold valves and
bleed off the pressure to the flare line. Secured the well by closing the SOV's on well head, Diverter and Choke Manifold
valves.
Note:
No pressure change noticed on annulus "C" gauge while lubing or bleeding the annulus "B". Pressure stable at 300psi
Well Shut-in for brine settlement, Annulus "B" pressure: 1,178psi and Annulus "C" pressure: 300psi.
On 25 feb 2017:
 GRN expat personnel and visitors left KL-39 location and arrived to KLS-1 @ 09:00, held the HSE induction and Lube
and Bleed operation briefing for visitors.
 Opened the SOV on annulus C and recorded annulus pressure at 300 psi. Opened annulus A SOV and recorded 0 psi.
Finally opened the annulus B SOV and recorded the annulus B pressure on choke manifold at 850 psi on manifold gauge
and Chart data recorder. (Pressure decline from original 1,178psi due to line compressibility). Monitored annulus B
pressure for 15min on choke manifold gauges, OK, stable reading.
 Opened gate valve on choke manifold and sent annulus B fluid to flare pit. Observed small increase on igniter flame
due to gas presence on flare pit (2min). Stopped the flow of gas from well, vent annulus B through flare line for 30
min. With Diverter valves open, closed choke manifold valves down to the flare line. Checked line up from SLB pumping
unit to annulus B and chart data recorder on choke manifold.
 Lubricated 1.70sg CaBr2 at 0.3bpm constant rate, as follows:
 0.5bbl / 155psi
 1.0bbl / 555psi
 1.5bbl / 924psi
 1.8bbl / 1,203 psi
 Stopped pumping, closed LTV on SLB pumping line and upstream valve on HAL diverter. Bled off pressure back to SLB
pumping unit (minor Brine volume returned). Monitored pressure on choke manifold gauges for 30 minutes, stable
pressure at 1,220 psi.
 Closed the well in on SOV of annulus "B".
 Bled off pressure of pumping line via choke manifold to waste pit.
 Closed the diverter and choke manifold valves.

KLS-1
 Well Shut-in for brine settlement

 Annulus "B" pressure: 1,220psi
 Annulus "C" pressure: 300psi
On 26 feb 2017:
 GRN expat personnel and visitors left KL-39 location and arrived to KLS-1 @ 13:30, held the HSE induction and Lube and
Bleed operation briefing for visitors.
and Chart data recorder (pressure decline from original 1,220 psi due to line compressibility). Monitored annulus B pressure
for 15min on choke manifold gauges, OK, stable reading.
 Opened gate valve on choke manifold and sent annulus B fluid to flare pit. Observed small increase on igniter flame due to
gas presence on flare pit. Stopped the flow of gas from well and divert the flow to cutting pit + 20 liters with density 1.26 -
1.28 SG very small flow was observed. With Diverter valves open, closed choke manifold valves down to the flare line.
Checked line up from SLB pumping unit to annulus B and chart data recorder on choke manifold.
 Lubricated 1.70sg CaBr2 at 0.3bpm constant rate, as follows:
 0.1bbl / 8 Psi
 0.2 bbl / 14 Psi
 0.5bbl / 173 Psi
 1.0bbl / 563 Psi
 1.5bbl / 907 Psi
 1.9bbl / 1,225 Psi

KLS-1
 Stopped pumping, closed LTV on SLB pumping line and upstream valve on HAL diverter. Bled off pressure back to SLB
pumping unit (minor Brine volume returned). Monitored pressure on choke manifold gauges for 15 minutes, stable pressure
at 1,225 psi.
 Closed the well in on SOV of annulus "B".
 Bled off pressure of pumping line via choke manifold to waste pit.
 Closed the diverter and choke manifold valves.
 Well Shut-in for brine settlement
 Annulus "B" pressure: 1,225psi
 Annulus "C" pressure: 300psi
On 27 feb 2017:
 GRN expat personnel and visitors left KL-39 location and arrived to KLS-1 @ 8:30, held the HSE induction and Lube and
Bleed operation briefing for visitors.
and Chart data recorder (pressure decline from original 1,220 psi due to line compressibility). Monitored annulus B
pressure for 15min on choke manifold gauges, OK, stable reading.
 Opened gate valve on choke manifold and sent annulus B fluid to flare pit. Observed small flame due to gas presence on
flare pit. Stopped the flow of gas from well and divert the flow to cutting pit +/- 25 liters with density 1.23 - 1.26 SG very
small flow was observed. Closed the SOV on well head and flash the surface lines with fresh water to cutting pit and flare
line pit.
Mud coming
from annulus B
while bleeding
MW=1.23 - 1.26sg
 R/D the line and put the flange on section B and put the gauge and open the SOV on section B (on gauge shows 0 psi
after 45 mints).
 R/D Halliburton well testing equipment KLS-1 and loaded to the trucks moves it to KL-2 location.
NOTE: @ 16:00 the annulus pressure in B was 100 psi.
@ 19:00 the annulus pressure in B was 150 psi.

KLS-1
Conclusion and recommendations:
It was a good experience for me to attend this operations but it was not completed for the following reasons:
 The operation on paper appears easier but in reality, it was difficult to realize it.
 To pump theoretical volume (8.34m3) to kill the annulus B pressure (500 Psi) will take more than month. So it‟s
very costly and unrealizable.
 The operation was bothered by rigging up T 212 rig.
 Since the majority of the participant is expatriates, it was difficult to leave the rig site earlier and to come back late,
problem of escort.
It is important to understand that once cement is placed in the annulus, and set, it cannot be removed then replaced with more
desirable cement regardless of its "compressive strength". In order to avoid these problems of annular pressures in the future; we
need a good cementation that will go through the following things:
 Adequate cement design.

 Adequate circulation and cleaning of the hole prior to cementing,
 Centralization of the casing in the hole,
 Casing movement during circulation and cementing,
 Use of a cement slurry that exhibits no free water separation or solids segregation, and
 Placement of the cement in the entire annulus without losing circulation. Unfortunately, the high quality cement we
mix at the surface does not always yield what is perceived as correspondingly high quality cement in the annulus.


Lube and Bleed Operation KLS-1 Rig Less Feb 2017

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Lube & Bleed Operation

KAHLOUCHE SUD 1 (KLS#1)

Annulus B & Annulus C

Lube & Bleed Operation

Prepared By: Boubenia Authorization: Approval: Version: 1

Prepared By: Boubenia Authorization: Approval: Version: 1

Well KLS-1 MAWOP and Annulus Pressure Data:

Prepared By: Boubenia Authorization: Approval: Version: 1

LOCATION / FIELD MAP:

Prepared By: Boubenia Authorization: Approval: Version: 1

CURRENT WELL SCHEMATICS:

Prepared By: Boubenia Authorization: Approval: Version: 1

BLEED OFF RESULTS FOR ANNULUS B AND C:

Prepared By: Boubenia Authorization: Approval: Version: 1

Prepared By: Boubenia Authorization: Approval: Version: 1

Prepared By: Boubenia Authorization: Approval: Version: 1

Prepared By: Boubenia Authorization: Approval: Version: 1

INTERPRETATION OF BLEED-OFF RESULTS:

CBL ANALYSIS OF 9 5/8” CSG:

Prepared By: Boubenia Authorization: Approval: Version: 1

LUBE & BLEED OPERATIONS:

Prepared By: Boubenia Authorization: Approval: Version: 1

A general synopsis of the operation on KLS-1is as follows for Annulus-B:

1. Hold Pre Job Safety Meeting

Prepared By: Boubenia Authorization: Approval: Version: 1

Fluid Stacking Height = Volume Pumped, (liters) /Annulus Capacity, (l/m)

Specific Calculations for KLS-1 Annulus-B

Sequence of operations done on rig:

Prepared By: Boubenia Authorization: Approval: Version: 1

Prepared By: Boubenia Authorization: Approval: Version: 1

1.5bbl / 0.3bpm / 17psi

Prepared By: Boubenia Authorization: Approval: Version: 1

 Well Shut-in for brine settlement

Prepared By: Boubenia Authorization: Approval: Version: 1

Prepared By: Boubenia Authorization: Approval: Version: 1

Conclusion and recommendations:

 Adequate cement design.

Prepared By: Boubenia Authorization: Approval: Version: 1

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