IG-FP (Isolation Gel - Fluid Piston)
One part non-curing sealant product designed to isolate hydraulic control line leaks in downhole safety valve (DHSV) Control Line compression fittings where the hydraulic fluid is leaking out of the system.
This is all while maintaining the functionality of a downhole safety valve (DHSV).
A solution that provides oil & gas well integrity teams with a genuine alternative to pressure-activated sealants used for this purpose.
Benefits of IG-FP
Pre-cured, tough gel that can be pumped into the Control Line at surface
Neutrally buoyant and will remain in a suspended position with no pressure
Can be modified to be compatible with specific Control Line Fluid
What are the most common causes of Control Line Leaks?
Leaks from DHSV Piston
Leaks from Compression Fittings
Why is it important to repair Control Line Leaks?
The Control Panel regulates the hydraulic pressure which operates and functions the DHSV
The DHSV has a large spring installed which is always wanting to close the valve
This makes the DHSV a Fail-Safe Close, Safety Critical Element in the Well Integrity Barrier Envelope
The spring in the DHSV should allow it to close quickly when the hydraulic pressure is vented off in an emergency situation
However, the DHSV must remain open to allow the Well to flow and continue to keep production efficiency up
This can create issues by building up hydraulic pressure in the Tubing Hanger Void or the A-Annulus.
The Well may have to be shut in and taken offline if hydraulic leaks are excessive or if the DHSV cannot be kept open
How does IG-FP work?
The gel is pumped into the Control Line at surface and moves along until it reaches leak path
It creates an initial block and starts to raise the system pressure
As the gel is forced through the leak path it fills the spaces in and around the leaking compression fitting
As the pressure is slowly increased more gel is squeezed into the leak path until it is fully blocked and isolated
See our animation of a Control Line Leak Repair:
IG-FP FAQs
Click each question below to reveal the answer:
- What’s the suitable leak rate for IG-FP and Xtra? if the test fluid is hydraulic oil.
As a guide, we would always start with the “Standard” version as it can stop quite big leaks. If the “Standard” version failed to totally cure the leak for any reason we would then deploy the “Xtra” version as a contingency and that should cure even high rate leaks. • IG-FP Standard cures leaks from very low rates up to 300mls/min. • IG-FP Xtra cures leaks up to 400mls/min. • Our tests were measured using an air-driven hydraulic pump with the compression fitting backed off to various levels. • A ¼” Compression fitting backed off 1 full turn over 60 seconds = 400ml. • Just for information, the Compression fitting would totally disconnect at 2 turns backed off so we were testing with a very high leak rate.
- What’s the maximum leak rate recommended to trial the sealant? if the test fluid is hydraulic oil.
We have tested leaks up to 400mls/min (24 litres per hour) (288 litres per 12hr day).
- To remove IG-FP in control line, client must recover the DHSV, then displace to remove the sealant?
Once the IG-FP is in place it should remain for the life of the Well. • If the Safety Valve was a Wireline Retrievable version then the DHSV could be pulled then flushed down the Control Line to remove the sealant. • If the Safety Valve was a Tubing Retrievable version then cannot be removed unless it was locked open and the flow tube was punched open to gain a leak path, but this is very extreme.
- Storage temperature is 20 ℃. Does that mean room temperature or does it have to be maintained at about 20 ℃？
This is the approximate temperature of the storage room temperature. We selected that temp as it is the average for our base in Scotland. This is just a guide for this product so there is an acceptable variation.
- Does IG-FP have to be mixed onsite?
IG-FP is formulated and mixed in KCI’s lab and is shipped ready to use. There is no mixing or preparation required onsite. Simply remove the IG-FP from its container, place it into the Deployment Tool and inject it into the Control Line to repair the leak. It's that simple.
- How is it ensured that all IG-FP will not be pumped through the leak point?
A leak rate evaluation will be carried out on-site to verify the customer's report. This will indicate the level of damage within the system. The IG-FP will then be pumped down the line while recording the volume of fluid used to push the sealant into position. This will indicate where the damage is, either at the Hanger or further downhole.
When the system pressure starts to rise that indicates that the IG-FP has located the leak and started to seal it. The “Standard” version of IG-FP should create an isolation but if for some reason, it fails to totally block the leak (it may be a very large leak) we also supply the “Xtra” version that is a heavy-duty/contingency formulation that can be deployed into the system if the leak persists. The leak should be isolated after deploying either of the IG-FP sealants.
- How is the IG-FP volume to be pumped confirmed?
We need to know the operating volume of the DHSV i.e. how much fluid is required to fully open the DHSV piston. Once we know that and the size of the Control Line we then know how much IG-FP to introduce into the system to block the leak with the nose of the sealant pig but still have the tail end of the sealant pig over the leak area. This way the leak path is always covered with sealant to replenish the initial isolation if required.
- Since the cured IG-FP will be left in the control line, how much friction will be caused by moving IG-FP down when the DHSV is opened?
IG-FP is formulated with a high percentage of lubricant material so it is very slippery. It is self-lubricating. When deployed into an oil filled Control Line it moves along very easily. As the DHSV opens and closes the IG-FP simply glides back and forth with the operating fluid.
We have looked into this a lot on our test fixture. If a very high volume of IG-FP is used in the system, it can create a bit of friction which may delay the DHSV from closing slightly. We have seen a 10-20 second delay in closing times using our own Safety Valve but it depends on how strong the DHSV spring is to push the Control Line contents back up to close the flapper.
We tested the closing times on our test fixture through 2 needle valves and a crimp in the line so we have a good understanding of how it will work.
- What’s the biggest risk of pumping IG-FP to repair a control line.
If the leak path is too large and the operating pressure is too high, there is a chance that the isolation will fail if the sealant is extruded through the leap path.
There are no guarantees when it comes to repairing damaged Wellhead systems as we are going into the unknown to a certain degree even with all the data supplied.
In this case, there is the added complication of Seal-Tite having been tried already. They may have left some of their liquid or polymerized sealant (polymerized sealant has turned into small solid rubber scabs) in the system which may block the path if there any restrictions so that should be kept in mind.
IG-FP will not solidify so it is very unlikely it would create any blockages.
As you’ll know, KCI will only go ahead with a project if we expect a high level of success. This goes for Control Line repairs also.
- Can IG-FP be used to seal a leak on a control line?
IG-FP was created and developed to repair loose compression fittings. It is not intended to repair holes or splits on Control Lines. We developed the sealant based on the most common type of leak in the sector which is loose fittings.
It is very unusual to have leaks in a straight section of Control Line as they are generally encapsulated in protective plastic and securely clamped to the tubing string therefore there is nothing to create the damage.
If the issue is corrosion eating away at the Control Line creating perforations then we wouldn’t recommend deploying sealant as the condition of the Control Line would cobtinue to deteriorate further leading to more leaks.
- A big concern is often regards if the cured IG-FP may affect the open/close of valve, and the extra pressure it may cause, especially when repair the control line is in a very deep position. Is there any lab test data to support?
IG-FP doesn't “cure”. It remains in the same soft flexible state when deployed to move freely up and down the Control Line. It has a high oil content to ensure it is lubricated and reduces any line friction to a minimum.
The deeper the DHSV is, the stronger the return spring should be to close the DHSV so that should support the DHSV closure.
The volume of the IG-FP require will not increase with the depth of the DHSV. The volume of IG-FP is engineered upfront once we know what the operating volume is to open the DHSV. Once we know the amount of fluid it takes to fully open the DHSV we deploy the minimum amount of sealant to cover the leak path.
- Does IG-FP degrade to small pieces which may block other precision instruments over time?
IG-FP does not degrade. Once made it is a stable product that holds together and does not break down in oil or operating fluid. The sealant is deployed down a Control Line which has a “dead end” (DHSV at the end) so it will shuttle back and forth but stay in position.
The sealant should not make its way back up into any precision instruments as normally none are inline.
If Well pressure were to force the IG-FP back up the line for some reason it would be dumped straight in the returns tank and not recycled through the pressure system.
If the customer thinks there is a chance of Well pressure coming back up the line we would recommend using a “GAS INGRESS ISOLATION VALVE” which automatically prevents the return of hydrocarbons into the hydraulic control system.
Why Choose KCI?
KCI has helped a range of oil and gas operators reduce costs and minimise downtime, whilst maintaining production by offering a selection of unique products and services.
Find out more about how we have helped our customers here…
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