Flexible Self-Repairing System: A permanent Isolation Solution in The Gulf of Mexico

The Gulf of Mexico plays a pivotal role in the United States’ energy landscape, serving as the primary offshore source of oil and gas. It contributes approximately 97% of all oil and gas production on the US Outer Continental Shelf (OCS). Within this dynamic offshore environment, numerous major operators manage a variety of platforms and systems. Notably, a longstanding pioneer in the Gulf region has been at the forefront of technological advancements in the design, construction, and operation of world-class oil and gas production facilities for over four decades. The prominence of being one of the Gulf’s key operators comes with both advantages and challenges that must be addressed as part of the daily operational landscape. Historically, this operator has adhered to its established best practices and remained loyal to proven strategies, which can pose challenges when introducing new products or technologies. In May 2021, a situation arose when a client contacted a multinational service company, seeking assistance with a well in the production phase located adjacent to the Mississippi Canyon. A case of Sustained Casing Pressure (SCP) emerged in the B-Annulus, necessitating a resolution within an extremely tight timeframe of just 2-3 weeks. In response to this critical situation, our organization was tasked with delivering a solution to remediate the well afflicted by SCP and hydrocarbon (HC) flow issues. Within our extensive technology portfolio, a Flexible Self-Healing Cement (FSHC) system was identified as the ideal solution to ensure well integrity from drilling through abandonment, providing a reliable annular pressure seal and safeguarding against hydrocarbon leaks and SCP at the wellhead. Tailored to meet the client’s unique challenges and specifications, this system was deemed the most suitable choice for the operation. This paper delves into the comprehensive development, execution, evaluation, and post-job analysis of the inaugural application of the Flexible Self-Healing Cement system in the Gulf of Mexico. This innovative system promises to address the pressing challenges posed by SCP and HC flow, further enhancing the operational efficiency and well integrity in this strategically vital region.