EXPLORATION • DRILLING • FIELD SERVICES OPERATIONS & MAINTENANCE
LIMITING LEAKS
Graham Steele introduces new developments to reliably address leaks and pressure loss in DHSV and production packers
cases, unreliable; occasionally blocking the control line entirely where the sealant is squeezed through a restriction that it may unhelpfully plug in the same way as a leak. Similarly, isolating and repairing leaks in deep-set production packers has historically posed huge challenges, despite leaks being almost inevitable when the packer element becomes brittle, cracked or perished over time. KCI Engineering has developed solutions to both issues, having evolved and tested new technologies in response to customer demand. Te Isolation Gel-Fluid Piston (IG- FP) is designed to isolate leaks in DHSV control line compression fittings where hydraulic fluid is leaking out of the system (which is the most common instance of control line leaks). A well may have to be shut in and taken offline if hydraulic leaks are excessive, or if the DHSV cannot be kept open. Te hydraulic control panel will
S
ome traditional solutions used to repair leaks within downhole safety valve (DHSV) control lines are only partially effective and, in some
try to keep up with any leak, but the hydraulic fluid reservoir will become depleted quite quickly if not constantly topped up with expensive hydraulic fluids.
IG-FP offers a genuine alternative to
pressure-activated sealants. Te product has been extensively tested by KCI (Kinetics, Controls & Innovation) at different leak rates, variable bore sizes and at pressures up to 10,000psi. Te sealant has also been tested at temperatures up to 175°C and continued to work well. Kevin Watt, managing director at KCI,
says, “In response to customer feedback, we sought to develop a simpler yet more robust product that would create long-lasting and reliable isolations in DHSV control lines while retaining full functionality. “Our solution is a pre-cured, tough gel with microfilaments that can be pumped into the control line at surface level, and which continues to move along the control line until it reaches the leak path. Te chemically engineered gel then creates an initial block and starts to raise the system pressure.”
IG-FP is a smart alternative to pressure- activated sealants
Detailing how the solution works,
The IG-FP has been designed to isolate leaks, enabling the operator to keep the downhole safety valve open rather than needing to shut the well
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Watt explains that, “As the gel is forced through the leak path, the microfilaments are pulled through and start to build up and fill all the spaces in and around the leaking compression fitting. With pressure slowly increasing, more sealant gel is squeezed into the leak path until it is fully blocked and isolated. “Any remaining IG-FP remains at the leak path, shuttling back and forth as the
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