Metal-to-Metal D Seal Isolation with MS-Sealant
The client
A major North Sea operator faced a critical wellhead integrity issue involving a failure in the original wellhead sealing structure.
The operator had brine leaking from the metal-to-metal (M2M) seal, which resulted in annulus fluids leaking into the environment.
The results
We applied our unique solution, MS-Sealant, to fill the cavity, providing a complete isolation that prevented pressure buildup and further fluid loss. The isolation was successfully tested, confirming that no further fluids leaked past the M2M seal and that the C-annulus pressure was fully contained.
The original wellhead pressure-retaining envelope was regained, allowing the well to be safely returned to operational status. The leaking annulus fluids were contained, preventing any further environmental impact.
The solution not only resolved the leak but also reinforced the original wellhead sealing structure, enhancing the wellhead's overall integrity.
The challenge
The D Seal test cavity showed pressure from the C-annulus, indicating a loss of the wellhead barrier. This failure resulted in brine leaking from the M2M seal, allowing annulus fluids to leak into the environment, posing both environmental risks and operational hazards.
The operator needed an immediate solution to reinstate the integrity of the wellhead sealing structure, eliminate the C-annulus pressure passing the D Seal, and prevent further environmental leakage and loss of wellhead fluids.
The solution
We provided an engineered solution tailored to the wellhead issue's specific requirements. The process involved using our specialised MS-Sealant, bespoke tooling, and technical service expertise to create effective isolation in the D Seal test cavity.
Our expert team injected MS-Sealant into the D Seal test cavity to create a barrier between the M2M seal and the D Seal.
Our solution enabled the North Sea operator to restore wellhead integrity, protect the environment, and safely return the well to operation.
“We are very happy with the successful outcome of the job and the support provided by KCI during design and work prep. Will certainly add your technology application to our toolbox for future consideration!”