Novel Application of Epoxy Resin to Eliminate Sustained Casing Pressure Without Costly Downhole Well Intervention - Case History from East Kalimantan, Indonesia

An operator recorded 1100 psi of sustained casing pressure between a 9-5/8" casing and a 3.5" production tubing annulus seven days after the cementing operation was completed for the 3.5" production tubing. A production logging run was performed, and results indicated gas was flowing from a zone 86 feet below the 9-5/8" casing shoe. As per the operator's standard, such a situation suggests subsequent well completion operations cannot be processed and must be remediated. The most common solution for such situations is to perforate and squeeze to ensure zonal isolation in the zone from which the gas is flowing. Due to the slim tubing size this operation can be difficult, and there exists a high risk of leaving set cement inside the 3.5" tubing. Furthermore, drilling would require extensive time with a coil tubing unit and in the worst case could lead to the loss of the well. To provide a dependable barrier for long term well integrity, a novel approach consisting of epoxy resin was discussed. A highly ductile, solids-free resin was designed and tailored to seal off communication from the gas source to surface. The void space in the annulus was estimated to be less than 5 bbl. An equipment package was prepared to mix and pump the resin into the annulus. Resin was pumped through the wellhead casing valve using a hesitation squeeze technique with the maximum surface pressure limited to 3000 psi. Once all resin was pumped, the casing valve was closed to allow enough time for the resin to build compressive strength. The job was planned to be performed in multiple stages consisting of smaller volumes. The job was completed in two stages, and the annular pressure was reduced. On the first job, 1 bbl of resin was mixed and injected into the annulus. The pressure build up was decreased from 550 psi per day to 27 psi per day. To lower the annular pressure further, a second resin job was performed using 0.35 bbl resin volume, which further reduced the annular pressure build up to 25 psi within 3 days. No further stages were performed as this was considered a safe working pressure for the well owner. After 2 months no annular pressure was observed. The application of this tailored resin helped to improve the wells integrity under these circumstances in this high-pressure gas well. Epoxy resin with its solid-free nature and deep penetration capabilities helped to seal off a very tight flow path. This application of pumping resin through the wellhead to overcome annular gas pressure can be an option when the flow path is strictly limited, or downhole well intervention is very difficult and risky.