Subsea Well Annular Integrity Repair Using Coiled Tubing and Pressure Activated Sealant

Abstract Production from a subsea well was halted due to hurricane activity in the Gulf of Mexico. When the well was returned to production, the annulus experienced a loss of pressure integrity. To achieve regulatory compliance and return the well to production, annular integrity had to be restored in a safe, expeditious manner. This paper will describe the process of operations undertaken to cure this well integrity issue utilizing pressure activated sealant deployed via coiled tubing. Pressure activated sealants have been utilized for a number of years to efficiently cure leaks in a wide variety of applications. One of the first challenges to be addressed when considering a sealant repair is the method of getting the material to the leak site. For the purpose of the subsea well in question, coiled tubing was used to convey the sealant to the sea floor from a service vessel. An ROV then connected the coil to an external tree cap via a flying lead after which the sealant was introduced to the annulus by lube and bleed pressure cycles. The annular integrity issue was analyzed in an effort to determine leak severity and location. Pressure trends noted at annular pressures of 4000 psi indicated a leak ranging from 0.15 – 1.5 lit/min. Gradient analysis indicated that the leak was deep in the completion potentially at a liner lap or the packer. Based on this information a sealant blend approximately 2 ppg heavier than the completion fluid was developed for the purpose of curing the leak. An external tree cap was installed on the well in order to provide access to the annulus of the well via a hot stab connection. About eleven cubic meters of sealant was transferred to the annulus through 2" coiled tubing extended to the sea floor connected to the well via a flying lead. A series of lubricate and bleed cycles were performed to accomplish this without exceeding predetermined pressure limits. After allowing the sealant to settle on the packer, annular pressure was maintained to allow the sealant to cure at the leak site. The pressure differential at the leak caused the liquid sealant to form an elastomeric seal. A positive pressure test was obtained shortly after the process and the well was returned to production. An example of how using pressure activated sealants designed to polymerize only at a leak site affords options to expensive workovers on subsea wells will be provided herein. The use of this technology in concert with coiled tubing deployment represents an expeditious, economic approach to solving complex well integrity issues.