Repair of Production Packer Leaks Riglessly Using Thermosetting Resin

Abstract

Abstract Leaks through the production packer, which serves as a primary barrier can compromise well integrity. Traditional methods to restore packer integrity typically entail costly workover operations, necessitating the deployment of a rig to replace the upper completion. This paper presents a cost-effective solution utilizing thermosetting resin, offering an economically viable alternative for remediating packer leaks without the need for heavy workover rigs. The method employs gravity-feeding of thermosetting resin through the annular fluids to seal leaks located often thousands of meters deep. Resin is pumped into the annulus from the surface and descends by gravity to the packer, its cohesive nature allows it to sink through the annular fluids and settle on the packer. Some of the resin is then squeezed into the leak paths to seal the leak. The key characteristics of the thermosetting resin that facilitates gravity feeding includes its immiscibility in water-based fluids, low viscosity, adjustable density and setting time, and its ability to establish a permanent seal in an oil and gas well environment. The methodology, successfully sealing packer leaks across multiple wells, utilizes simple equipment setups. By presenting various case histories, this paper explores the design and implementation of the innovative solution in diverse wells with varying configurations and conditions. The resin operations require only simple mixing and pumping equipment that is both lightweight and has very small footprint to mix, pump and place the thermosetting resin plug. It offers significant advantages in terms of time and operational simplicity. The cases presented demonstrate how this rigless repair method to reduce operational time and costs while effectively addressing production packer leaks in the oil and gas industry. This solution not only showcases practical applications but also aligns with industry demands for economically viable and at the same time environmentally responsible and safer methods, making it a valuable contribution to the existing body of knowledge.