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This document discusses challenges in solving small tubing leaks, selecting the right sealant, and high repair costs. It notes that leaks under 1 gpm are difficult to detect but need to be identified and repaired cost-effectively. Ultrasonic logging tools can now find such small leaks. The right sealant mechanism depends on temperature, pressure, fluids and leak rates to avoid damage. Case studies show how ultrasonic logging and custom sealants allowed repairs of small leaks without costly rig workovers. High repair costs often make non-rig repairs preferable when assessing tubing string condition and repair viability.
This document discusses challenges in solving small tubing leaks, selecting the right sealant, and high repair costs. It notes that leaks under 1 gpm are difficult to detect but need to be identified and repaired cost-effectively. Ultrasonic logging tools can now find such small leaks. The right sealant mechanism depends on temperature, pressure, fluids and leak rates to avoid damage. Case studies show how ultrasonic logging and custom sealants allowed repairs of small leaks without costly rig workovers. High repair costs often make non-rig repairs preferable when assessing tubing string condition and repair viability.
This document discusses challenges in solving small tubing leaks, selecting the right sealant, and high repair costs. It notes that leaks under 1 gpm are difficult to detect but need to be identified and repaired cost-effectively. Ultrasonic logging tools can now find such small leaks. The right sealant mechanism depends on temperature, pressure, fluids and leak rates to avoid damage. Case studies show how ultrasonic logging and custom sealants allowed repairs of small leaks without costly rig workovers. High repair costs often make non-rig repairs preferable when assessing tubing string condition and repair viability.
– Defines as leaks < 1 gpm – Difficult using conventional logging techniques (spinners and temperature logs) – Below the resolution of logging tools – Need to be identify & remediate, cost efficient (no workover!) – Solution: Ultrasonic tool (New log tool!) – Case Study (North Slope, Alaska) • Well A is an active water and gas injection well completed with 3.5” tubing inside 7” casing. • The “A” annulus failed a mechanical integrity test and the well was shut in due to loss of a barrier. • A calculated leak rate was established between 0.21- 0.39 gpm. • By ultrasonic logging operation, typical leak signature was located at 2574’ measured depth (MD) during a dynamic pass of 30 ft/min. Challenge in Solving Tubing Leak 2. Sealant Selection – Needs to find right sealant mechanism • Particulate Sealant • Catalyzed Sealant • Activated-pressure Sealant – Sealant components is determined by temperature, pressure, system fluids & leak rates – Wrong mechanism may clog or damage critical components in wellbore or hydraulic system – Leaks failed to repair – Case Study (BP, Gulf of Mexico ) • In the late 2002, BP identified a pressure anomaly in one of its subsea tieback wells. • Diagnostics indicates that the leak was in the production tubing between the subsea tree and the subsurface safe safety valve (SCSSV). • A custom blend of sealant then was injected into the annulus. • The increase pressure on the annulus pushes the concentrated sealant from the annulus into and through the leak site. • By creating the differential pressure through the leak site, cause the sealant to polymerize within the leak site. Challenge in Solving Tubing Leak 3. High Repair Cost – Conventional repair method is the rig workover – Expensive (US$ 750,000-1,000,000) – Workover is hazardous (personnel, equipment, environment) – Alternative is non-rig repair – Asses overall tubing string condition (Identify all leak path) – Critical decision; Is the tubing is worth repairing or the well should be worked over? – Case Study 1 (BP, Gulf of Mexico ) • BP identified a production tubing leak on its subsea completion in the Gulf of Mexico. • Due to the high cost and risks associated with a subsea rig intervention, BP considered different repair options decided to evaluate a sealant solution. – Case Study 2 (Shell, Gulf of Mexico ) • On Popeye A-1, a leak developed in repairing its subsea completion (high-pressure hydraulic fluid supply line) • Most conventional option considered by Shell was to kill the well, recover the tree, tighten the fitting and reinstall the tree. • Direct cost >$1mil, not including the risk adjusted costs of potential problems that might arise during the operation.