HYPERSEAL SOLUTIONS

SERVICE AND PRODUCT

HYPER-SEALANT TECHNOLOGY SHARING

30 November 2023
 Todays Agenda

• Brief Introduction - Company Background / Timeline / Achievements

• Product and Services Portfolio
• Operational Requirement & Case Study
• Q&A

HYPERSEAL SOLUTIONS SDN 5 Jalan Riong

HYPERSEAL
BHD SOLUTIONS SDN BHD WELL
WELL INTEGRITY
INTEGRITY SOLUTIONS
SOLUTIONS EXPERT Bangsar
All Rights Reserved
All Rights Reserved EXPERT 59100 Kuala Lumpur
 2015 - 2018 2019 2020 2021 2022 - 2023
Research Phase Commercialization HP Sealants Well Integrity Diagnostics and Surveillance Total Well Integrity Solutions Provider

Commercialization Commercialization of DAS Technology

HYPERSEAL PLT founded
Pressure Activated Sealant
Research and Development
Collaboration with UTM Time Activated Sealant
Epoxy Resin
HyperWrap – Resin
Vigor HC – HP Valve Sealant
Secured first pilot remote wireless sensors
Repairs completed
Wellhead Leak
2018 - Incorporation of
HYPERSEAL SOLUTIONS SDN Casing Hanger Leak
BHD Tubing Hanger
Packer Leak
Strategic Partnership Collaboration with UTM Research team
SYNERGY on two projects:
INTEGRITAS SDN BHD
Total sand control
Improvise Epoxy Resin technology
MPLT for Cairn Energy, India.
Expand contracts – region / global –
INDONESIA / OMAN / VIETNAM
for well integrity monitoring for
Well Integrity Training
ExxonMobil
Commercialized log processing and Incoming SPE Technical Presentation. Decommissioning
interpretation services. and Abandonement,5-6 Dec 23 Bali, Indonesia
Unconventional Solution to Extend Well Life A Successful
Performed Comprehensive APD , Liquid Level Case History for Surface and Downhole Leaks Repair using
High Performance Sealant.
and Direct Flow Measurement Survey for
Petrofac and Repsol

1st SPE Technical Presentation. Perth, Australia. Best Practices for

Conductor Leak and 13-3/8” Casing Hanger Seals Rectification.

2nd SPE Technical Presentation. P&A Conference. Pullman, Kuala

Lumpur. Best Practices in solving SCP/ Micro-Annulus Channeling
issues due to poor cement

HYPERSEAL SOLUTIONS SDN 5 Jalan Riong

HYPERSEAL
BHD SOLUTIONS SDN BHD WELL
WELL INTEGRITY
INTEGRITY SOLUTIONS
SOLUTIONS EXPERT Bangsar
All Rights Reserved
All Rights Reserved EXPERT 59100 Kuala Lumpur
 HYPERSEAL SOLUTIONS

Products & Services

Diagnose Repair Monitor

Well Diagnostic Well Leak Repair Well Monitoring

Services Services Services
 SURFACE DIAGNOSTIC
Wellhead and Annular Pressure Diagnostics
Annular Fluid Level Measurement
Direct Leak/Flow Rate Measurement
HYPERSEAL Gas Composition LOG
INTERPRETATION
Products & Services Well integrity and MPLT
DOWNHOLE
SURVEILLANCE
Diagnose Leak Detection
Corrosion Evaluation
Cement Bond Evaluation
Multi-finger Imaging Tool
Well Diagnostic Advance Production Logging
Services Distributed Fiber Optic (DFO)

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 Wellhead Pressure Diagnostic (WPD):
What will we know?
• Potential communication within Wellhead and XMT
cavities WPD/APD
• Identify pressure record and build up rate
• Potential communication between Wellhead-XMT cavities/between annuli
SURFACE
• Identify pressure build up pattern
Liquid level measurement:
• Liquid Level change Liquid Level Measurement (Echometer, Sonoecho)
Annular Pressure • SBHP
Corrosion evaluation: • Liquid level movement
• MTD – 3 Layers Diagnostic (APD):
• Potential communication • SBHP
• ePDT – 5 Layers Flowmeter:
• MFC – Inner ID 1st Pipe between annuli
• Direct flow measurement
• Identify pressure record and Flowmeter
• Estimate downhole leak/flow rate
build up rate
• Identify fluid from density reading • Cumulative downhole leakrate/flowrate in mass and volumetric
Cement Evaluation: • Echometer result will perfecting flowmeter findings
• RBL – Radial Bond Log
• Behind 1st pipe evaluation
• ICS – Cement Scanner Leak
• Multiple layer evaluation • Tubing / Casing
• Packer
TOTAL • Accessories
DOWNHOLE WELL INTEGRITY SURVEILLANCE Flow
Shallow gas
PACKAGE • Micro-Annulus Channeling
Leak Detection: • Reservoir Crossflow
• CCL/GR – Correlation • Behind Casing Flow
• ALFA – Noise
• HRTP – Temperature/Pressure
• MCFM – Spinner Behind Casing Flow: Reservoir flow analysis / Temperature Modelling
• CCL/GR – Correlation
• Advanced approached complimenting conventional MPLT Result
• ALFA – Noise
DFO – Distributed Fiber Optic • HRTP – Temperature/Pressure
• DTS – Distributed Temperature Cement
• DAS – Distributed Acoustic System
• Poor cementing
Reservoir Crossflow: • Complimenting noise tool for flow identification
• CCL/GR – Correlation • TOC
Reservoir Flow Analysis: • ALFA – Noise
• CCL/GR – Correlation • HRTP – Temperature/Pressure
• ALFA – Noise Corrosion
• MCFM – Spinner • Multiple layer corrosion identification status
• PTCC – Behind Casing Flow/
Pressure/Temperature/Capacitance
Water cut:
• CCL/GR – Correlation Wellhead and Xmas Tree Integrity
DFO – Distributed Fiber Optic • ALFA – Noise
• DTS – Distributed Temperature Tubing / Casing Integrity
• HRTP – Temperature/Pressure
• DAS – Distributed Acoustic System Cement Quality
Water Aquifer
Temperature Modelling

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HYPERSEAL
BHD SOLUTIONS SDN BHD WELL
WELL INTEGRITY
INTEGRITY SOLUTIONS
SOLUTIONS EXPERT Bangsar
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 HIGH PRESSURE SEALANT
Pressure Activated Sealants
Time Activated Sealants
HYPERSEAL Epoxy Resin
Composite Repair
Pipe Wrapping
Products & Services Gate Valve Sealing Compound

SURFACE DOWNHOLE
Repair Wellhead and Xmas Tree Seals
Downhole Safety Valve
Control Line
Tubing Hanger Seals
Production Packer
Metal to Metal Seals
Tubing / Casing Connection
Tubing Hanger Void
Well Leak Repair Conductor Leak
Seal Assemblies
Liner Hanger
Services Pipeline Leak

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HYPERSEALANTS – Core Products

Pressure Time Activated Pipe Wrapping Gate Valve Sealing

Activated Sealant Sealant Epoxy Resin
Sealant Type System Compound
HYPER-PAS HYPER-TAS HYPER-PLUG
HYPER-WRAP VIGOR-HC

Liquid Liquid Liquid Fibre Cloth, Putty,

Physical State Paste
(1 Part) (2 Parts – Ratio 10:1) (2 Parts) Epoxy
Pressure Rating 10,000psi 10,000psi 10,000psi 1,500psi 8,000psi
Temperature Rating 0 - 260 deg C 0 - 260 deg C 250deg C 280 degC -80 to 260deg C
Standard Density 12ppg (adjustable) 9ppg 9.6ppg (adjustable) n/a 16.6ppg
Standard Viscosity 25cps 15,000cps (mixed) 12,000cps (mixed) n/a 1,000,000cps
Instantaneous
Curing Time 16 to 48 hours 30 min to 3 hours 30 minutes n/a
(in-situ)
Shelf Life 12 months 12 months 12 months 12 months 12 months

Crosslinking Crosslinking Manual application of

Activation Pressure differential Time & temperature Time & temperature steel putty and Injected into cavity
dependent dependent wrapping

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 HYPERSEALANTS – Applications

PAS TAS EX101 Hyper-Wrap VIGOR-HC

Pressure Activated Time Activated Sealant Epoxy Resin Pipe Wrap Isolation Valve Sealing
Sealant Compound
Surface Leaks
Wellhead / Xmas Tree / Conductor X X X X X
Gate Valve X X X X X
MTM (SRL/SBMS) Seals X X
Tubing and Casing Hanger Seals X X X
Packoff Seals X X X X

Downhole Leaks
Control Line X X
Downhole Safety Valve X X
Production Packer X X
Seal Stem / Polished Bore Receptacle X
Tubing / Casing Connection Leak X X X
Sliding Side Door X
Side Pocket Mandrels / Injection Valves X
Umbilical Lines X
SCP – Micro Annular Channeling X X X
Plug & Abandonment (P&A Assurance) X

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Pressure Activated Sealant (PAS)
a) PAS in liquid form

i) Black Seal – 500 cp ii) Standard– 25 cp iii) Miscodified PAS– 200 cp

Pressure
Sealant Type Activated Sealant
(PAS)

Physical State Liquid (1 Part)

Pressure Rating 10,000psi

Temperature Rating 0 - 260 deg C

Standard Density 12ppg (adjustable)

Standard Viscosity 25cps

Curing Time Instantaneous

Shelf Life 12 months

b) Activated PAS c) 20K times SEM micrograph of solidified PAS
Differential pressure (Set condition)
creating shear-force thus
forcing intertwining and
Activation & Sealing
polymerization process to
Principle
form a compacted flexible
polymeric bond across
the leak site.

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Time Activated Sealant (TAS)

Time Activated
Sealant Type Sealant
(TAS)
Liquid
Physical State
(2 Parts – Ratio 10:1)
Pressure Rating 10,000psi
a) TAS in liquid form
Temperature Rating 0 - 260 deg C

Standard Density 9ppg c) 500 times SEM micrograph of solidified TAS

Standard Viscosity 15,000cps (mixed)

Curing Time 16 to 48 hours

Shelf Life 12 months

Crosslinking during
polymerization
Activation & Sealing time allow sealant to
Principle cure under pressure b) Solidified TAS removed from test fixture
(After 24hours of curing time) d) Solidified TAS tend to fill up area (self level)
and blockade the leak and form an energize seal when undergo curing
path. under pressure process.

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Epoxy Resin (Hyper-ER)

Epoxy Resin
Sealant Type
HYPER-ER

Physical State Liquid (2 Parts)

Pressure Rating 10,000psi

Temperature Rating 250deg C

Standard Density 9.6ppg (adjustable) a) HYPER-ER in liquid form

Standard Viscosity 1,000cps (mixed) b) On-site weighted 14.7 ppg slurry

of HYPER-ER.

Curing Time 30 min to 3 hours

Shelf Life 12 months

Exothermic
polymerization
process allow sealant
Activation & Sealing
to create a very high
Principle
compressive strength
plug and blockade the
leak path. c) Weighted Cured Resin Plug
( Different Density)

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Pipe Wrapping System (Hyper-Wrap)

Pipe Wrapping
Sealant Type System
HYPER-WRAP
Fibre Cloth, Putty,
Physical State
Epoxy
Pressure Rating 1,500psi

Temperature Rating 280 degC

Conductor Gas Leak
Standard Density n/a After 1 Year
Gap after Detection
Application
Wrap Post Wrap
Standard Viscosity n/a

Curing Time 30 minutes a) HYPER-WRAP Field Application

Shelf Life 12 months

Composite repair
consisting manual
application of steel
putty (2-part liquid) and
Activation & Sealing
fiberglass wrapping
Principle
thus increase the
b) Application of composite repair system
mechanical strength with diverting line to avoid LOPC
of existing surface
equipment.
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 Back Pressure Manifold (BPM)

• HYPERSEAL additional products for surface control line

leak application • Used for severe leaks, prevent damage to WHCP caused
by pressure reversal in control line.

• Can also be used in the case SCSSV piston seals are

damaged & wellbore fluids (oil and/or gas) vented to
surface when control line is bled down. Set the BPM at
point where SCSSV is close but not fully vent the control
line pressure.

Actual BPM setup at wellhead

Min – 350psi
Max – 2750psi

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 SPE-202404-MS • A Novel and Comprehensive Approach to Fix Conductor and Casing Hanger Leaks • Mohamad Kamil Saharuddin

EXAMPLE RECTIFICATION APPROACH & PROCEDURE

Acceptance
1st Barrier! Criteria:
Contingency TAS
Internal Seal Repair PAS Injection Max. 5% pressure
Injection setup injection
drop & 0 psi PBU

1) Hook up injection line to GIF/Test Port. 1) Perform PAS Injection 1) Perform TAS Injection
2) Pressure Test line 2) Re-evaluate seal 2) Curing Time for 24
3) Perform Diagnostic Procedure performance (in-situ) by hours
Verify potential leak communication pressure drop test 3) Perform Integrity Test
4) Quantify leak severity 3) Curing Time for 24 hours
Leak Rate / Injectivity Rate 4) Perform Integrity Test
Pressure Drop/Built Up Rate
5) Sealant selection
Leak rate <1.2 LPM @ 1500 psi = PAS
Leak rate > 1.2 LPM @ 1500 psi = TAS

2nd Barrier!
Acceptance Criteria:
Gas Seepage Application of
NO visible gas fume
Encapsulation Surface Preparation Metal Repair Putty Fiberglass Wrap

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 16

FIELD TRIAL CASE STUDY (SCP)

SUMMARY RESIN INJECTION VOL. & POST MONITORING PRESSURE
First campaign Initial HAP (psi) First campaign Injectivity Volume (liter)
First campaign Resin Volume Utilize (liter) Second campaign Resin Volume Utilize (liter)
Second campaign Post-Treatment pressure (psi)
650

537

520
410

400
395

320
220
190

184
100

90
78

75

72
70
60
60

55
50
30

25

9
5
0
0

0
0

0
0
D1 D2 D3 D4 D5 D6
SPE-199192-MS • Improved Rectification Procedure for
High Annulus Pressure Issues during Production Phase
• Mohamad Kamil Saharuddin
 HYPERSEAL SURFACE MONITORING
Remote Wireless Monitoring Sensors
Products & Services
Sustained Casing Pressure
P&A
Production
Monitor Operational

Well Monitoring
Services

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Holistic Approach to Fixing Leaks

Our Technical Approach

Analyze / Well Leak Datasheet Plan / WOP Execute / OWP Evaluate / EOJR
• Study the Unique Leak Issue • Treatment Methodology • Diagnostic / Optimize • Monitor
• Data Gathering • Technical Procedure • Mitigate Risk • Actual vs Plan
• Laboratory Testing • Decision Tree • Cost Monitoring • Lessons Learned
• Site Survey • Risk Assessment • Precision in Delivery / Adaptable • Opportunities for Improvement
• Budgetary and Costing • System Integration Test • Proactive communication

Our Cost Saving Initiative

Multi Technology Price Rate
• If several technology utilize to
solve one unique leak issue,
additional discount rate will be
given.
SIT/ Laboratory Cost
• All SIT or laboratory cost will be
absorbed by project cost, only
3rd party laboratory cost will be
charge.
Volumetric Discount
• If leak rectification job perform
in campaign mode, the discount
can be in form of additional
FOC well candidate or further
discount can be given.
Extended Warranty No Cure No Pay
• Optional extended warranty can • Imposed to product fee for
be given depend on well leak surface application.
risk. • Flexibility terms for low-risk trial
• Lifetime warranty can be project.
upgraded throughout the
contract subject to T&C.

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Operational Requirement
 Deployment Equipment Package

Pump down control line / Spot with coil tubing or

chemical injection line Light Weight Triplex Pump Spot with wireline dump bailer
capillary string

Pump down subsea umbilical Pump down tubing, spot via Annulus Intervention
or service line. SSD Services

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 Surface Equipment Package

Pelican Case
#2

• Metalbox Container (4ft)

• 1.5HP Air-Driven Hydraulic Pump (inside Pelican Case
#1, with Measuring Jugs and Tubing bleeder)
• Handtools, Hoses and Consumables (inside Pelican Case
#2)
• Pressure Relief Tools (PRT) – 2ea
• 1.4L Injection Cylinder (with piston)
• Handpump (Enerpac P202)
• Digital Pressure Gauge (Additel) – 2ea

Total weight including chemicals and container is less than

1.8MT

Pelican Case
#1

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Personnel & Equipment Setup On-Site

• Require 2 manpower for Surface Leak Repair operation

• Require air supply pressure of 100-140 psi for air-driven

hydraulic pump unit.

• Equipment setup as per shown are suitable for surface

leak diagnostic and rectification involving:
 Control Line
 Gate Valve
 Tubing Hanger (Void)
 Metal-to-Metal
 BPM Installation on Control Line

• Each leak will need to be properly diagnosed (leak source

identification, leak rate, pressure drop, leak
communication etc) prior to confirm the best sealant to be
selected for rectification.

• The duration required for Leak Diagnostic, Sealant

Injection and Integrity Test varies between 3 to 4 days per
leak.

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Brief Procedure Example – Tubing Hanger Leak

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Brief Procedure Example – Tubing Hanger Leak

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Case History Sharing
(Leak Rectification)
Leak Rectification – Tubing & Casing Hanger Leak

The Problem and Challenges

• Surface leak on several wells before/during P&A
campaign.
• Uncertainty in leak severity and heavily ageing wellhead
components.
• Possible delay & increasing rig cost to remedy leaks.
• Chance of jeopardizing subsequent rig operations.

The Solution
• Diagnostic tests to quantify presence, communication
path, and severity of leak in 11 wells.
• Multiple treatment options on site to cover for
uncertainties utilizing Time Activated Sealants.

Client : Petronas Carigali Sdn Bhd – P&A Team The Results

Location: Pulai-Alpha, Offshore Terengganu • Cured 8 wellhead leaks that is considered severed.
• Sustained operations without interruptions as originally
Project : Tubing & Casing Hanger Leak Repair scheduled.
Year : 2019

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Leak Rectification – Conductor & Casing Hanger Leak
The Problem and Challenges
• Two conductors (A&B) were spotted to have gas
seepage whereby the leak was located at the gap in
between the landing support ring & base plate that
sits above the 36” conductor.
• Suspected channelling from downhole source
possibly passing thru the (i) top or (ii) bottom seals of
the 13-3/8” casing hanger.

The Solution
• Diagnostic tests to quantify presence,
communication path, and severity of leak in all the
casing hanger seal ports of each conductor.
• Combination of sealant treatment using PAS & TAS.
• Hyperwrap was introduced to secure the gap and act
as secondary barrier for the leak.

Client : Petrofac (Malaysia-PM304) The Results

• All leaking casing hanger seal ports were rectified
Location: Cendor Alpha, Offshore Malaysia using sealant.
Project : 36” Conductor, Casing Hanger and Landing Ring • No more gas seen at the section gap after being
Leak wrapped and tested by soapy test.
• SPE-202404-MS : A Novel and Comprehensive
Year : 2019
Approach to Fix Conductor and Casing Hanger Leaks.

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Leak Rectification – Control Line Leak
Leak Diagnostic & Rectification –
Control Line Leak (Insert Valve)
The Problem and Challenges
• The well installed with IV suffer 2-way CL leak communication.
• CL unable to hold pressure and gas ingress into CL (PBU).
• IV sealing element utilizing SwellStack Swellable O-rings
packing system.

The Solution
• Diagnostic test with severe injectivity leak rate (616 ml/min @
3500 psi ) and PBU rate ( 305 psi/ 30min).
• Optimize volumetric deployment of proprietary Pressure
Activated Sealant (PAS) to seal leak in-situ base on leak
severity.
• Continuous sealing performance evaluation throughout the
rectification work.
• Installation of On-site Setting Back Pressure Manifold (BPM) to
resolve gas ingress issues.
Client : EXXON MOBIL Malaysia (EMEPMI)
Location: Tabu Bravo, Offshore Malaysia The Results
• Severe leak in CL (Insert Valve) sealed after several positive
Project : CL Leak Diagnostic and Rectification and negative pressure test.
• No more gas blowing out when bleed off CL.
Year : 2022 • Good indication of flowtube movement and Tubing Inflow test
re-instate the CL and TRSV functionality.

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Leak Rectification – Production Packer Leak
The Problem and Challenges
• 9-5/8” x 3-1/2” Production Packer Leak at 2021ft.
• Leak rate based on Scanwell - 13.5 scf/min (approx.
0.3bpm gas/liquid conversion).
• Crane limitation – Small Pumping Unit (DOS Triplex).

The Solution
• 5 bbl. of pressure activated sealant (PAS) was displaced
into the annulus and squeezed thru leak at packer
• Performed over 50 lab tests (and system integrity test)
that include (i) HiVis vs PAS Compatibility Test (ii) Fall
Rate Test (iii) TAS vs PAS Sealing Test (iv) Pumpability
Test (v) Spacer Viscosity and Breaker Test (vi) Crude vs
Sealant Compatibility in Water Quality

Client : Hibiscus Petroleum The Results

• Packer is holding pressure since leak cured on 11th Oct
Location: Saint Joseph, Offshore Sabah with zero pressure increase in A-annulus.
Project : 9-5/8” x 3-1/2” Dual Production Packer Repair • Well has been put back online since shut in for over 3years

Year : 2019 & 2021

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Leak Rectification – Cement Plug Leak (P&A Assurance)
The Problem Statement
• The wells were temporarily abandoned
• Suffered sustain casing pressure (SCP)
• Suspected to have microchannel leak source from (i) isolation plug leak (ii)
perforation squeezed leak
• Maximum pressure recorded on Section C&D was 1000+ psi.

The Challenges
• Rig-less, small footprint, fit-for-purpose equipment requirement
• Logistic – remote location
• Existing fluid compatibility / density
• Well construction integrity

The Objective
• To seal gas migration / pressure built up on surface cement plug leak using
engineered epoxy resin (weigh up density higher than existing completion fluid)
• Effective sealant placement method via macaroni tubing deployment (mud
circulation out and resin injection on top of cement).

The Solution
• Well leak diagnostic (i) injectivity test (ii) PBU rate (iii) surface integrity pressure test.
• Sealant placement design through macaroni tubing (1~2 bbl.)
Client : Genting Oil Kasuri Pte Ltd • Sealant squeeze and placement resin plug on top of leak area (within MASP)
• Rectification acceptance criteria (i) perform integrity test (ii) PBU rate before & after.
Location: ASAP & BEDIDI, West Papua Indonesia
The Results
Project : Cement Plug Leak Rectification
• Successfully injected 2 bbl. of resin plug via Macaroni String
Year : 2022 • Cured resin under surface pressure (24 hrs)
• No PBU recorded post-sealant treatment
• Fit-for-purpose equipment work as intended
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RESIN APPLICATION (P&A)

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RESIN APPLICATION (P&A)

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RESIN APPLICATION (P&A)

Compressive strength (Psi) Cement Resin

- 8412 + 580 - 11168 + 725

Flexural Strength (Psi)
- 1450 + 145 - 6526 + 435
E-modulus (Psi)
- 536639. + 87022 - 324884 + 10152
Rupture Elongation (%)
- 0.01 - 3.5
Tensile Strength
- 1 - 60
Failure flexural strain (%) - 0.32 + 0.04 - 1.9 + 0.2

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 Clients and Partners
2015 - 2018 2019 2020 2021 2022

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