Permian Basin operators who need to seal casing leaks to pass Texas Railroad Commission mechanical integrity tests have successfully applied small particle-sized cements, which penetrate casing cracks and very small channels to effect a seal.

Small casing leaks plague injection operations when integrity testing results in pressure bleedoff, which indicates presence of leaks. A batch-mixed volume of 25 to 75 sacks of fine particle cement is the typical application used to seal these leaks. There are some critical steps that must be taken to help ensure job success; these are discussed. The paper also presents a discussion of small particle-size cements, including accounts of laboratory testing. Case histories describing techniques of casing leak repair with small particle cements are recounted.

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