Gate Valve Leak Repair with Mac-Pac – Middle East

The Client

Industry: Oil & Gas
Location: Middle East
Operator: Confidential Middle East Operator

 

The Results

The successful isolation of the leak allowed the operator to proceed with the planned well intervention activities without delay, ensuring safety and operational continuity. Following our intervention, there were no further leaks from the stem seals.

The client was extremely satisfied with KCI's rapid, safe, and efficient solution. The Mac-Pac technology proved to be both effective and reliable, addressing the challenge without disrupting the ongoing project.

 

The Challenge

A major Middle East oil and gas operator faced a critical issue with one of its flow wing valves (FWV) on a well site. Although the valve had passed all integrity tests, a persistent leak to the atmosphere through the stem seals was discovered. This posed a potential risk to safety and ongoing well intervention operations, requiring immediate intervention.

KCI was engaged to design an isolation solution that would safely seal the leak without halting ongoing well operations. The operator needed a solution that eliminated the leak and allowed further well intervention work to proceed without downtime or delays.

Key challenges:

  • Leaking stem seals on the FWV despite the valve passing integrity tests.

  • An urgent need to prevent any further leakage to ensure safety during subsequent well intervention tasks.

  • The need for an effective, quick solution to minimise disruption to operations.

 

The Solution

KCI proposed using its innovative Mac-Pac isolation technology to address the leak. The process involved deploying two litres of Mac-Pac into the cavity of the FWV. This specialised product was designed to effectively isolate and seal the leaking area within the stem seals.

Steps taken:

  1. KCI’s team injected two litres of Mac-Pac into the FWV cavity.

  2. After deployment, the FWV was functioned and monitored for leaks.

  3. The Mac-Pac successfully sealed the leak, preventing further leakage to the atmosphere and restoring the valve's integrity.

This intervention ensured the well site remained safe for ongoing operations.

Conclusion

KCI's application of Mac-Pac technology enabled a Middle East oil and gas operator to resolve a critical valve leak swiftly and effectively. By sealing the leak, the operator avoided potential safety hazards and ensured the well intervention operations could continue smoothly. This case demonstrates KCI's expertise in delivering fast, effective solutions to complex well intervention challenges, ensuring operational safety and customer satisfaction.