While developing an offshore well in Brazil, the integrity of a well under construction became compromised resulting from channel communication after cementing the production liner. Leaks in producing wells can cause formation damage, loss of production, and increase tubular corrosion. This paper discusses the application of a new resin for a casing-leakage problem caused by a channel after the primary cementing operation.

Conventional cements and slurries are commonly used to repair this challenge; however, these solutions are limited, at best. Depending on the channel size, well integrity can be restored with cement, but only if the channel is large enough to allow a sufficient volume of slurry to enter. The new epoxy resin exhibits exceptional resistance to contamination, including oil-based and water-based fluids, tailored mechanical properties, very-low yield point, as well availability of solids-free designs, making the resin an ideal candidate for a wide range of remedial operations throughout the life of the well.

When the challenge is outside the capabilities of either conventional solution (Portland cement/microfine cement), another method is necessary to squeeze off the leak. Recent developments have shown that resins are an excellent alternative for these types of challenges. A new resin design has overcome this limitation and is helping ensure wellbore integrity, thereby contributing to environmental sustainability and social responsibility, while acting as an annular barricade against water and gas leaks. The liner-hanger leak was repaired in one attempt using the new epoxy resin and squeeze techniques. Well integrity was restored, and the operator was able to perform the completion operation without any signs of leakage.

The new epoxy resin has become the primary solution and offers three primary benefits for restoring wellbore-integrity applications, including solids-free liquid with high-penetration capabilities and tailored mechanical properties to withstand a variety of wellbore challenges and enable customization and optimization for specific pumping operations.

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