SPE-182978-MS

Thermal Activated Resin to Repair Casing Leaks in the Middle East

A. E. Sanabria, K. Knudsen, and G. A. Leon, WellCem AS

Copyright 2016, Society of Petroleum Engineers

This paper was prepared for presentation at the Abu Dhabi International Petroleum Exhibition & Conference held in Abu Dhabi, UAE, 7-10 November 2016.

This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents
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Abstract
The challenge was with wells where the casing had lost its barrier/integrity because of casing leakage.
There the result was that production wells were closed in. These problems are often caused by cementing
failure when the well was drilled and cemented, lost zone, experienced corrosive formation fluid from the
formation, treads leakage or other reasons for this integrity failure. There have been tried out serial methods
for how this casing leakage can be repaired safely and in a cost-effective manner.
Casing damage/leakage with low or non-injectivity have been squeezed and repaired with Thermal
activated resin. Thermal activated resin is a nonreactive polymer with qualities that are resistant to all
formation corrosives/hazard fluids. Thermal activated resin will reinstall a good well barrier and integrity to
protect casing from future corrosion. Thermal activated resin has been used in serial wells in Saudi Arabia
in both onshore and offshore fields. In a small volume, with a controlled setting and short operation time,
a high success rate has been achieved.
The solution to these challenges was developed by designing thermal activated resin casing repair liquid
plug with a density equal from 64 pcf to 152 pcf. The setting time can also be adjusted accurately. This
new treatment slurry was able to be bullheaded and displaced with polymer mud/brine at 64 pcf to 152 pcf.
The slurry was easily able to be pumped through the drill pipe. This novel product possesses low elastic
modulus and high flexibility in density, viscosity and fast setting time according to requirements. The well
barrier elements made of this product have no risk of shrinking, cracking, gas channeling or deterioration
upon exposure to harsh reservoir environments.
This paper presents a case history and field application of this novel polymer based casing repair material
for successful treatment of full losses or when there is no/low injectivity in formations in most of the
critical oil and gas fields in Saudi Arabia. Also, the paper includes a discussion of the methodology, material
properties and applications.

Introduction
When a well has been drilled and all casings have been cemented, it is difficult to accurately estimate the
problems that will occur throughout the productive life of the well. However, if a well remains in service
long enough, for sure the casing will leak, especially when corrosion is present.
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Repairing casing/liner leaks is one of the most challenging problems that operators and service companies
face in mature oil and gas fields. Wells with casing leaks usually do not meet well operating criteria so they
must be shut-in, causing a loss in valuable production even in the best case scenario.
Cementing the leak with squeezing techniques often becomes the method of repair. While many casing
leaks have been repaired successfully in this manner, the casing leak sometimes is so limited to fluid
injection that it does not lend itself to repair by conventional cementing methods. This type of casing leak
may be too small to allow penetration of cement particles and, in many cases, requires several cementing
operations for a successful repair. Even worse, many of these small leaks cannot be repaired at all with
cementing techniques and result in well abandonment.
In response to this problem, a thermal polymer-based resin material was developed, that can deeply
penetrate formations or cement, and provide a full seal off micro cracks and channels. In this manner,
small leaks previously inaccessible to conventional cement slurries have now been repaired by this particle
free and multicomponent polymer resin based liquid plugging material with a curing process activated by
temperature.

Well Integrity
Well Integrity is defined in Norsok D-010 as: "application of technical, operational and organizational
solutions to reduce risk of uncontrolled release of formation fluids throughout the life cycle of a well". The
personnel planning of the drilling and completion of wells will have to identify the possible solutions that
will give the well a safe life cycle and designs that meets the minimum requirements of the correspondent
standard.
Norsok D-010 specifies that: "there shall be two well barriers available during all well activities and
operations, including suspended or abandoned wells, where a pressure differential exists that may cause
uncontrolled outflow from the borehole/well to the external environment".
Well Integrity can in its simplest description be defined as a condition of a well in operation that has full
functionality and two qualified well barrier envelopes. Any deviation from this state is a minor or major
well integrity issue. Common integrity issues are often related to leaks in tubular or valves, but can also be
related to reservoir issues as loss of zonal control. Any factor that leads to a functional failure is a loss of
well integrity. The challenge is of course to define all possible scenarios (H. E. Bensnes, H. Brandanger, S.
Sangesland, B. Sigve, J. Sæby, S. Johnsen, M. Rausand and M. A Lundeteigen. 2012).
Many different types of failures can lead to loss of well integrity. The degree of severity is also varying.
A generic list of failure mechanisms for wells can be as follow. Some of these are illustrated in Figure 1
(Celia, M.A., Bachu, S., Nordbotten, J.M., Kavetski, D., Gasda, S. E. 2005):
a. between cement and outside of casing;
b. between cement and inside of casing;
c. through the cement;
d. through the casing,
e. through fractures in cement,
f. between cement and formation,
SPE-182978-MS 3

Figure 1—Types of failures responsible of loss of well integrity

The obvious consequences of the loss of well integrity are blowouts or leaks that can cause material
damage, personnel injuries, loss of production and environmental damages resulting in costly and risky
repairs. Often these losses exceed the cost of the well's repair.

Casing Leaks
Whenever leakage downhole occurs because of pinhole-sized breaks in the casing caused by pitting or
corrosion, repairs are vital. Such repairs are necessary on injection wells to satisfy regulatory requirements,
and on producing wells to avoid unwanted water production. Casing leaks can occur in designated
freshwater zones, across intervals with poor primary cement jobs, or in regions characterized by a high
influx of water.
The undesirable migration of water can cause formation damage, loss of production, and an increase
in the corrosion of tubular and surface equipment. Finding a remedy to the leakage problem helps avoid
subsequent costs associated with drillouts, repeated cement squeezes, and workovers.
Operators and Services Companies are encouraged to investigate casing repair options when a casing
leak is discovered. Casing repair options depend on the size and condition of the casing, the depth and extent
of the leak, and the productivity of the well. In Saudi Arabia, they have used a number of different casing
repair techniques with varying degrees of success. These techniques include cement squeezing (typically
more than one squeeze is required to achieve shut-off), running a casing liner or patch, polymer water
shut-off jobs, and for holes in the casing above the surface casing shoe, removal and replacement of the
casing. However, since 2013 the thermal activated resin have been used to seal off these casing leaks with
a considerable high level of success in many of the offshore and onshore wells across the Kingdom.
These leaks are often too tight even for the small particle cements to be placed outside the casing.
Therefore, this type of cements cannot provide a barrier to the water influx or allow zonal isolation. The
occurrence of small pressure drops presents additional difficulties in placing fine grind cements. Filtrate
4 SPE-182978-MS

from fine grind cements are squeezed through the leaks, causing a node of cement particles to build up on
the casing face where the leaks occur. Upon drillout, pressure tests may fail and the leaks may reoccur.
Conventional cement slurries have proven to be less effective in squeezing casing leaks and generally
require casing perforations for slurry. Fine grind cement jobs can be successful if casing leaks are large
enough to allow sufficient slurry to enter the annulus (P. Creel, R. Crook: Gels. 1997).
If the casing leaks are small, the cementitious material is not protected from dissolution and deterioration
caused by water influx. Also, the success of conventional slurries depends largely on the severity of the
casing leak, as indicated by pressure leakoff rates, and the maximum injection rate achievable below
maximum pressure restrictions.
If these conditions are outside the capabilities of conventional cement slurries, different methods, such
as thermal activated resin, may be necessary to squeeze off the leaks.

Thermal Activated Resin (K. Knudsen, G. A. Leon, A. E. Sanabria, A. Ansari

and R. M. Pino. 2014)
Definition
The thermal activated resin is a particle free, multicomponent polymer resin based liquid plugging material
with a curing process activated by temperature. The initiation of curing process and curing time can be
adjusted in a way to suit the predetermined temperatures of formation or the location of the plug to be placed
in the well. Due to its adjustable density and viscosity, it is easily pumpable and can be placed with precision
in the well. Figure 2 shows the liquid and color appearance of the thermal activated resin.

Figure 2—Physical and color appearance of the thermal activated resin

The thermal activated resin is a low viscosity resin system, which by far exceeds the compressive and
tensile strengths found in traditional cement systems. The ageing test concludes that unlike cement, the
mechanical properties are not diminished over time.
SPE-182978-MS 5

Properties
Thermal activated resin is a new cementing technology that has overcome a lot of the traditional cement
problems. It acts as a fluid, has a variety in weight and viscosity and can be adjusted to determined formation
temperatures between 20 – 150 °C. The viscosity range can be from 10 to 2000 cP and the density range
can be from 0.75 to 2.5 SG (Figure 3). Some of the most important properties of the thermal activated resin
are displayed in Table 1.

Figure 3—Variety in weight of thermal activated resin plugs

Table 1—Thermal activated resin properties

Property Range

Specific gravity (SG) 1.03-1.05

Density 0.75-2.5 g/cc (44-156 pcf)

Viscosity 10-2000 cP

Setting time 3 min to as long as required

Right angle set Yes

Miscible with water or well fluids No

Pumpable through tubing/drill pipe/ BHA/bit Yes

Target temperature 9-135°C (48-275°F)

Resistant up to (temperature) 480°C (896°F)

Technical Description
Thermal activated resin is a particle free fluid that can deeply penetrate formations, and provide a full seal
off micro cracks and channels, whether in formation or cement, or even narrow control lines. It also can
enhance the strength of the treated area in the process. Thermal activated resin may provide one of the best
solutions for lasting well integrity (SINTEF NORWAY Test report number: 31.697.00/01/11: "Long Term
Integrity of ThermaSet as a permanent P&A Well Barrier Material". May 2011), and is recommended to be
taken into consideration from the planning stage of the well, and therefore used in the early stages of well
construction as tail cement to provide crucial strength at the shoe area while drilling the next sections.
Other notable properties are good bonding to steel (International Research Institute of Stavanger, test
report number: IRIS 2010/095 "ISO 14310 V3". June 2010), compatibility with most fluids and cements and
extreme tolerability to contamination. Thermal activated resin cures into a strong and flexible material that
can resist the thermal expansion of the casing without cracking. The curing is temperature based, allowing
6 SPE-182978-MS

material placement and curing to be accurate and therefore regulated according to customer requirements
for each and every well.
When density is regulated, it maintains its homogeneous structure and consistency; it could contain and
hold heavy or lighter weight additives. Besides regulating the density of the thermal activated resin, it could
also reduce the exothermic peak encountered in the right angle setting (Figure 4).

Figure 4—Exothermic reaction of thermal activated resin. Gel time: total time taken from the agreed testing temperature to the
starting of exothermic peak. Setting time: the time from start of the reaction until the exothermic peak returned to the baseline

Additives Materials
The following is a definition and description of the thermal activated resin additive materials that needed
to be used in thermal activated resin plugs, each of them are added for a specific purpose:
1. Curing Initiator: a liquid material added to thermal activated resin with a specific percentage per
weight to give a certain curing time. Curing initiator is a catalyst that reacts with polymer resin to
accelerate the reaction at relatively low temperature.
2. Accelerators: a liquid chemical added to thermal activated resin plug by percentile per weight to speed
the curing process. Accelerators are used when the temperature is low.
3. Inhibitors: a liquid chemical added to thermal activated resin plug to slow the curing process time.
Inhibitors are used when the temperature is high.
4. Viscosifier: chemical added to thermal activated resin plug to increase the viscosity and therefore
facilitate the lifting of the heavy weight material added to the plug. Also used to provide rheological
properties needed to suspend filler.
5. Weight Fillers: solid materials added to thermal activated resin plug to reach a specific weight, they
could be added either to decrease the weight, or to increase it.
6. Thermal Activated Resin Cleaner: a chemical used to wash and remove thermal activated resin plug
from batch mixer, pumps, lines and all equipment involved in the mixing and pumping procedures.
7. Thermal Activated Resin Solvent: used to dissolve and remove undesirable thermal activated resin
plugs after its hardened, could be used on the surface, or down the well.

Thermal Activated Resin vs. Traditional Cement

As mentioned before, thermal activated resin is a new cementing technology that overcame a lot of the
traditional cement problems, such as inherited weakness of cement and time produced deterioration; like
shrinkage, ductility and the formation of micro channels that could produce communication between
reservoir and well or other permeable formations. Also the high density and viscosity of cement restricts
its application in most of the phases.
SPE-182978-MS 7

Table 2 shows a comparison of mechanical properties between thermal activated resin and traditional
cement (SINTEF NORWAY Test report number: 31.697.00/01/11: "Long Term Integrity of ThermaSet as
a permanent P&A Well Barrier Material". May 2011).

Table 2—Thermal activated resin vs. traditional cement

Properties Thermal Activated Resin Traditional Cement

Water permeability, mD < 0.5 1,600

Compressive strength, Mpa 77 58

Flexural strength, Mpa 43 10

Failure flexural strain, % 1.9 0.32

E-modulus, Mpa 2,240 3,700

Tensile strength, Mpa 60 1

Density, S.G. 0.75-2.5 1.5 +

Right angle setting Yes No

Common Applications
Thermal activated resin has the ability to be designed in a range of densities and viscosities, pumpable
through narrow channels and holding mechanical properties that exceed those found in traditional cement.
So that it has a wide range of applications such as:
– Lost circulation material – treat and drill
– Casings leak repairs, well integrity
– Elimination of the pressure build up in casing-casing annulus (CCA).
– Plugs for P&A, squeeze jobs to seal off leaks/unwanted zones, plugging of control/transmittal lines
– Fast setting kick off plug – pumped through bit
– Zonal isolation/water and gas shut-offs
– Casing cementing, especially where extra security in the shoe area is needed, or where low density
systems are required, i.e., foam cement, top jobs
– Control line plug off, and packer inflatable material, for permanent setting of packers
– Sand consolidation
– Sand plugging
– Multilateral strengthening

Case History
The objective of this paper is to present a case history of this novel polymer-based material, for a successful
casing leak treatment in a 7" liner in onshore oil/gas well in Uthmaniyah field in the Kingdom of Saudi
Arabia.

Well History
UTMN well was drilled and completed as a vertical open hole observation well to a total depth of 7335'
MD. The 18-5/8" casing was set and cemented with 0% circulation and no cement returns to surface. The
13-3/8" casing shoe was cemented with 0% circulation with estimated top of cement at 2490' (LCZ), second
stage thru DV tool had cement to surface. The 9-5/8" casing shoe was cemented with 100% circulation with
cements returns to surface. The 7" liner was set and cemented with 100% circulation at 6948'. Drilled 6-1/4"
hole with 71 pcf mud to 7335' MD TD. A 4-1/2" liner was set and cemented with 100% circulation at 7333'
MD. The well was completed with 4-1/2" tubing and no packer. Figure 5 shows the well cross section plot.
8 SPE-182978-MS

Figure 5—Well cross section plot

Casing Leak Problem

The top of the leak was detected at +/- 6750' after ran a corrosion and cement bond evaluation log across
the 7" liner. The leakage length was around 120'. A retrievable packer was set at 6920' and the injection rate
was established in 0.3 BPM with a maximum pressure of 500 psi.
Several conventional cement plugs were pumped and squeezed without much success on securing the
well integrity or seal off the leak. The decision was then taken to pump and squeeze a thermal activated
resin slurry for the casing leak application.
The objective of the thermal activated resin slurry as a balanced plug is to seal off the liner leak, secure
the well and restore its integrity, allowing the well to be returned to production as soon as possible.
Table 3 indicates the parameters and conditions of the casing leak problem presented in the onshore well
in Uthmaniyah Field.
SPE-182978-MS 9

Table 3—Casing leak problem parameters

Parameters Value or Range

Casing OD 7"

Casing ID 6.184'

Depth of Casing shoe 6948'

Top of the leak +/− 6750'

Leakage area 120'

Injection rate 0.3 BPM

Mud weight inside the well Brine 87 pcf

Temperature at 6750' 175 F

Job Execution
A temperature log (Figure 6) was used in the design of the slurry to confirm the temperature profile needed
to achieve a successful casing leak job. This figure is crucial for an accurate thermal activate resin design.

Figure 6—Temperature log

10 SPE-182978-MS

Before starting any procedure, it is always mandatory to run an onsite pre-test. This test will be used as a
guide for mixing the thermal activated resin. Table 4 shows the testing results for a slow thermal activated
resin setting time used in this case.

Table 4—Pre-testing results for a slow thermal activated resin setting time

Temperature Curing Time when Overall

Start Time Gel Time Gel Time
(F) Initiator (%) reached Temp. Setting Time

175 2 16:22 16:39 18:14 1h35m 1h46m

175 1.75 8:24 8:41 10:34 1h53m 2h05m

17 1.5 8:24 8:41 11:37 2h56m 3h14m

A total of 20 bbl of thermal activated resin slurry was prepared according to the recipe showed in Table
5, with a setting time of 3 hours at 175°F. After testing the surface lines, the batch mixer and once the well
was ready, the rest of the operations were carried out in the following way:
1. Mixing Procedure:
– Transfer the required volume of thermal activated resin from drums into a batch mixer in a
convenient safe way.
– Agitate and circulate.
– Add viscosifier into the batch mixer through the hopper system.
– Shear for at least 10 minutes.
– Stop circulation and agitate only.
– Add weighting material in a convenient way until the correct weight has been reached. Agitate
for 5-15 minutes.
– Add the right amount of accelerator. Run agitator for maximum 5 minutes.
– Measure temperature in a batch mixer and take a sample of mixed thermal activated resin slurry
and run a curing/setting simulation test.
2. Spotting and Squeezing Procedure:
– Injectivity rate test should have been established before performing the job.
– Set a retrievable barrier plug around 50' below the bottom of the leak.
– Spot ahead a Hi-Vis spacer plug to have it as a cushion.
– Place OEDP to top of Hi-Vis pill.
– Spot 20 bbls of thermal activated resin slurry.
– POOH the numbers of stands necessary to have at least 200 ft above the theoretical thermal
activated resin slurry top.
– Circulate to ensure the string is free of thermal activated resin slurry.
– Close BOP pipe rams.
– Gently squeeze of the thermal activated resin slurry, as per pre-established maximum pressure
according to casing burst and injectivity parameters.
– Once the thermal activated resin slurry has been injected into casing, hold constant pressure.
– Let the thermal activated resin slurry fully set for at least 6 hours after the pill has been spotted /
squeezed.
– Run back in to confirm the top of the plug and pressure test as per standards.
– Drill out the thermal activated resin plug with 50-80 ft/hr and pressure test as per standards.
3. Equipment Cleaning Procedure:
– Transfer the thermal activated resin cleaner from a drum into batch mixer in a convenient way.
SPE-182978-MS 11

– Run the agitator and circulation at high speed. Wait for 30 minutes.
– Empty the batch mixer into a slops tank.
– Put water into a batch mixer.
– Run the agitator and circulation at high speed. Wait for 10 minutes.
– Empty the mixer into the slops tank.

Table 5—Recipe for the thermal activated resin slurry

Additives Volume/Weight

Thermal activated resin 3,000 liters

Weight filler 4,000 Kg

Viscosifier 30 Kg

Curing initiator 180 liters

Thermal activated resin cleaner 1,000 liters

After the BOP pipe rams were closed, around 5 bbls were able to be squeezed into the casing leak.
Following the 6 hours, the top of the plug was confirmed at 6515'. The pressure test was holding at 500 psi
for 10 minutes and after drilling out the thermal activated resin plug, the pressure was still holding at 500 psi.

Conclusions
• One of the most time-consuming and costly failure of well integrity is the casing leaks that can
cause material damage, personnel injuries, loss of production and environmental damages.
• Thermal activated resin provides the best solution for well integrity and loss of circulation in the
oil and gas well drilling and workover industry.
• Using thermal activated resin for small casing leaks may be necessary to squeeze off the leaks. In
the other hand, conventional and fine grind cement slurries have proven less effective in squeezing
small casing leaks.
• Temperature profile is crucial for an accurate thermal activate resin design.

• The 7" casing leak was successfully sealed off and the well integrity was restored in an onshore
well located in Uthmaniyah Field in the Middle East.
• Top of the cured thermal activated resin plug was tagged at 6515', which means that around 5 bbls
were successfully squeezed into the 7" casing leak.
• Successful final pressure tests were done in order to verify the well integrity. It held at 500 psi for
10 minutes before and after the thermal activated resin plug was drilled out.

References
1. James W. Styler, Suliman S. Al-Suwailem, Ramez L. Akhnoukh and James R. Leighton: A
Unique Rigless Casing Leak Repair, Ghawar Field, Saudi Arabia. SPE-68129-MS. 2001.
2. R.W. Chivvis, Robert W. Chivvis, Jennifer Yvonne Julian, J.Y. Julian, David Neil Cary and D.N.
Cary: Pressure-Activated Sealant Economically Repairs Casing Leaks on Prudhoe Bay Wells.
SPE-120978-MS. 2009.
3. K.F. Lizak, T.A. Zeltmann and R.J. Crook: Permian Basin Operators Seal Casing Leaks With
Small-Particle Cement. SPE-23985-MS. 1992.
4. J.W. Meek and Kirk Harris: Repairing Casing Leaks Using Small-Particle-Size Cement.
SPE-21972-PA. 1993.
12 SPE-182978-MS

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Corrosion Logs To Investigate Casing Leaks. SPE-93184-MS. 2005.
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A Lundeteigen: An Introduction to Well Integrity. 2012.
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