Casing Hanger Seal Void Hybrid Isolation with IG & MS-Sealant Malaysia

Challenge

KCI were asked by a Major Oil and Gas Operator in South East Asia to provide an isolation to prevent the B-Annulus pressure entering the 13 3/8” Casing Hanger Void. During KCI’s evaluation process the leak was verified. The BAnnulus pressure was vented from the Casing Hanger Void and it built up to full B-Annulus pressure overnight. This test was carried out twice with the same result verifying the failure.

A standard Sealant deployment operation was not suitable for is application as the Casing Hanger Locking Mechanism must be protected to ensure it can be recovered at a later date. IG was used to safeguard the moving parts as it can be broken back to fluid for a trouble free Hanger recovery operation. The well was shut-in due to this serious well integrity issue.

Solution

Rigged up KCI’s Test Manifold and injected Test Fluid to verify the Leak Rate. Activated, Mixed & Injected 8 Litres of IG. It sinks in oil and fills all available gaps in the Casing Hanger Locking Mechanism.

Allowed the IG to fully cure. Activated, Mixed & Injected 8 Litres of MS-Sealant 02 (low viscosity sealant) above the cured IG. This created a PBU (Pressure Build Up) which compressed and energised the IG.

Allow the MS-Sealant to fully cure under injection pressure. Once the MS-Sealant 02 had fully cured, a Leak Off Test was performed at the Injection Port with full Annulus. Pressure from below – This resulted in a Zero PBU. The Isolation was successful and the Well was safely brought back online.

Result

Operation successfully completed. This Value Adding, Rigless Isolation Operation saved the Well owner from a potentially time consuming and costly Wellhead Workover repair operation.