How reliable are sealant solutions?
There can be a general feeling that plugging a leak with sealant is a short-term solution and will ultimately lead to further damage to your asset a few years down the line.
With ageing equipment, damage will inevitably occur, and this can often be costly due to operational downtime. Operators might not want to approach the option of using a sealant, as they may think that the solution will only last a couple of years before wear and tear will cause the leak to open up again, potentially with worse damage than before.
So, what is the effective life of sealant?
After application, KCI’s sealant can last as long as the operator needs it to (based on the sealant properties, as long as 25 years). The sealant will remain in the same robust and sturdy state, maintaining the integrity of the equipment and allowing operations to continue as normal.
When a leak occurs, the sealant can be deployed quickly and safely with minimal to no operational stoppage. Meaning, depending on the leak location (DHSV for example), the operator does not have to worry about expensive downtime and operations can continue as normal whilst the sealant is being deployed and cured.
Due to the reliability of the sealant, the life of operational assets can be extended and will save the operator money in the long run as mature equipment will not need to be replaced.
Which sealant solution should I go for and why?
Wellhead Isolations and Control Line Plugging
As one of the most common well integrity failures, hard plastic packaging is often pumped into the void however, historically, this has been unreliable.
KCI’s Mac-Seal and MS-Sealant solutions are time-activated and deployed in a liquid state converting to a resilient, self-bonding and pressure-energised solid material once in its desired location.
Gate Valve Isolations
Isolations of this nature might be required due to damaged seats or gates, failed pressure tests, or leaking stem seals. Using standard grease is less reliable as it often gets washed out allowing fluids and debris to enter the cavity, increasing the chances of scores and scratches. Potentially causing more damage to the valve.
KCI’s Mac-Pac compound is more viscous than grease and stays in the cavity whilst the valve is opening, preventing the entry of debris, and coating scores and scratches on the internal components. It is ideal for isolation maintenance tasks for tree cap removal, choke change outs, and flow line and production plant work.
Control Line Leak Repair
The control panel regulates the hydraulic pressure which operates and functions the DHSV. The DHSV has a large spring which allows it to close quickly in an emergency, however, it must remain open during operation to allow the well to flow and continue to maintain production efficiency. In extreme cases, the well may have to be taken offline if the hydraulics leak or the DHSV cannot be kept open.
IG-FP, engineered by KCI, is a pre-cured tough gel that is pumped into the control line at surface and moves along until it reaches the leak path. It creates an initial block and starts to raise the system pressure. As the gel is forced through the leak path, it fills the spaces in and around the leaking compression fitting. As the pressure is slowly increased, more gel is squeezed into the leak path until it is fully blocked and isolated. IG-FP can also be used to isolate piston seals and wireline insert valves with damaged seals or bores.
Packer and Casing Shoe Isolations
Over time, the packer element could become brittle, crack or perish and therefore start to leak. This allows pressure to build up in the a-annulus leading to sustained annulus pressure, potentially creating additional stress with the well barrier envelope, and causing further issues. Unless the issue is managed, the well may have to be shut in and plugged.
KCI’s specially engineered IG-H solution is designed to isolate leaks in deep-set production packers where the integrity has been lost and well pressure or fluids are building. It is easy to deploy with a very high success rate and a low risk of creating any damage or operational issues to the well. The solution is engineered onshore and approved by the customer before moving onshore.
Get in touch!
All our products can be tailored to the individual requirements of our customers, get in touch to discuss your leak sealing solution needs.