Resin Sealant System Solved Liner Hanger Assembly Leakage and Restored Well Integrity: Case History from Western Desert

Abstract

Abstract Resin is a solid-free fluid that can penetrate tight narrow annuli, cracks, or fissures previously inaccessible to conventional or fine cement slurries. Furthermore, this resin system can transition from a liquid to a solid phase through crosslinking reactions consisting of stages of low-viscosity liquid, high-viscosity liquid, viscoelastic solid, and finally forming a solid crosslinked three-dimensional (3D) polymer network. The resin continues to transmit hydrostatic pressure to the formation until an impermeable barrier of cured resin creates a highly ductile material that provides resistance to liquid or gas penetration. During the completion of a well in Western Desert, Egypt, pressure tests revealed a leak with a 1-bbl/min leakoff rate at 1,600 psi in the 4.5-in. liner hanger assembly, which was caused by liner top packer failure. This issue required fast remediation to maintain the economic value of the well. After careful evaluation, the resin sealant system was determined to be the best solution. The resin was tailored to meet the well requirements for placement across the leakage area by applying a squeeze method, successfully stopping the leak. A 4,000-psi pressure test proved the integrity of the well after the resin placement. This paper discusses other solutions considered during this case study and provides details about the process of elimination of each, as compared to resin. The resin sealant system provided a dependable barrier and enabled operations to continue without issue. This intervention enabled the well to successfully meet its original objective