Challenge in Solving Tubing Leak

1. Detecting Very Small Leak

– 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.