WellLock Resin System

Report
WellLock® Resin System
WellLock® Resin System – Applications
 Remediation
– Low viscosity
– Penetrates Micron-sizes pores
– Resists Gas Channeling
 Secondary Annular Barrier
– Increased elasiticity
– High-pressure seal
– Compressive Strength
Stress: 4500 psi
Strain: 50%
 Plug to Abandon

– Tolerates impurities
– Withstand high-pressure differentials
Injection (Disposal) Wells
– Fluid compatibility (including water)
– Chemical and corrosion resistant
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WellLock® Resin System
 High pressure seal (1,000 psi/ft)
 Chemically resistant (acid/CO2)
 Withstands contamination (overcomes inefficient mud
displacement)
 Increased elasticity
(up to 20%)
 Compressive
strength
(5 to 15 kpsi)
 No yield point as a liquid
 Drillable
© 2013 Halliburton. All rights reserved.
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WellLock® Resin System
A cross-linking reaction between an amine hardener and epoxides, resulting in
a cured three-dimensional infinite polymer network.
• Control of reaction rate
achieved through
chemistry
• Adjust accelerator
concentration to achieve
desired pumptime and
compressive strength
development
• longer working times lead
to longer compressive
strength development
© 2013 Halliburton. All rights reserved.
4
WellLock® Resin System
A cross-linking reaction between an amine hardener and epoxides, resulting in
a cured three-dimensional infinite polymer network.
• Control of reaction rate
achieved through
chemistry
• Adjust accelerator
concentration to achieve
desired pumptime and
compressive strength
development
• longer working times lead
to longer compressive
strength development
© 2013 Halliburton. All rights reserved.
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WellLock® Resin System
HPHT Thickening Time Chart at 175°F
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WellLock® Resin System – Rheological Behavior
Herschel-Bulkley/
Bingham Plastic
Newtonian
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WellLock® Resin System
When tested in an environmental chamber at a downhole
temperature of 162°F (72°C), WellLock resin achieved 12,500 psi
and remained highly elastic.
®
© 2013 Halliburton. All rights reserved.
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WellLock® Resin System
Annular Hydraulic Seal Test
 System constructed from 1 ft pipe
nipple with steel bar welded into center
 Test fluid chamber and test cell can be
immersed in a water bath for
temperature control
 WellLock® resin system completely
prevented flow at 1,000 psi fluid
pressure
© 2013 Halliburton. All rights reserved.
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WellLock® Resin System

Complements cement

High pressure seal

Chemically resistant

Withstands impurities

Increased ductility

Compressive strength
Resin Film
Formation
Cement
Casing
© 2013 Halliburton. All rights reserved.
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WellLock® Resin System
Lead resin slurry deposits film on formation and casing resulting in
dramatic shear bond improvements.
© 2013 Halliburton. All rights reserved.
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WellLock® Resin System
Mud Contaminated Compressive Strength
Cure Temperature = 180°F
Neat Resin
10% Mud
24 hr. comp. strength
5300 psi
1000 psi
48 hr. comp. strength
7400 psi
4300 psi
 15.2 lb/gal WellLock® Resin
 15.0 lb/gal synthetic based mud
© 2013 Halliburton. All rights reserved.
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20% Mud
520 psi
1700 psi
WellLock® Resin – Properties Comparison
WellLock®
Resin
EPSEAL®
Sealant
Epoxy Resin
√
√
Chemical and Corrosion
Resistance
√
√
High Shear Bond
√
√
High Compressive Strength
√
√
Gas Impermeable
√
√
Elastic Resilient Sheath
√
√
Fluid Compatibility
√
Properties
© 2013 Halliburton. All rights reserved.
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Water
WellLock
Resin
WellLock® Resin System
Field Blending and Placement



Job type
– Secondary barrier
– Remediation
Planning
– Current wellbore conditions
– Placement time
– Fluid train
– Compatibility
– Spacers
Placement
– Batch mix components
– HT-400™ pump
– Coiled tubing
– Drill string
– Tubing
© 2013 Halliburton. All rights reserved.
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WellLock® Resin System
Remedial work where particle-laden fluids are unable to penetrate
problem areas.
 Tight Casing Leaks
 Gravel Packs
After: Resin penetrates for impermeable seal
Before: water breakthrough in gravel pack
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WellLock® Resin System – Application
Remediation
 Offshore Challenge
– Produced water interfering
with production and creating
disposal costs
– Potential for on-going casing
erosion due to gravel-pack
flow back
 Suggested Solution
– Squeeze job
– WellLock® Resin (6 bbl)
 Anticipated Result
– Resin placed at the
breakthrough area
– Water cut eliminated
© 2013 Halliburton. All rights reserved.
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WellLock® Resin System
Secondary annular barrier to help maintain long term wellbore
integrity during aggressive completion operations.
© 2013 Halliburton. All rights reserved.
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WellLock® Resin System – Application
Secondary Barrier
 Shale-Play Challenge
– High-concentration of fracture placement
– Increased regulatory focus on fracture stimulation
– Environmental sensitivities regarding water table
 Suggested Solution – Three-stage cementing
operation inclusive of secondary barrier
– Lead cement (50 to 100 bbl)
– WellLock® Resin (20 bbl)
– Tail cement (50 to 100 bbl of
LifeCem™ Cement)
 Anticipated Result
– Casing-to-casing barrier
– Corrosion resistant, gasimpermeable seal
– Environmental sustainability
© 2013 Halliburton. All rights reserved.
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WellLock® Resin System
Plug and Abandonment
 Withstands impurities
during placement
 High bond strength
 Withstands extremely
high pressure
differentials
© 2013 Halliburton. All rights reserved.
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WellLock® Resin System – From the Field
 Challenge
– Multiple conventional P&A attempts failed
(continuous bubbles rising to the surface due
to small leak in the annulus between the 30-in.
drive pipe and the 20-in.conductor pipe)
– Costs accruing as rig is unable to move off
of well until tests proved successful P&A
 Solution: WellLock® Resin / 2 different operations
– 10 bbl squeeze application
– 50-ft resin plug set in the 13.3/8 casing
 Result
– Successful bubble test (bubbles ceased) allowing
plug operation to proceed
– Successful Plug operation allowed casing to be cut
– Well permanently abandon and rig moved to next well
© 2013 Halliburton. All rights reserved.
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WellLock® Resin System – From the Field
 Challenge: Salt (brine) Cavern
– Micro-annulus on the back side of the production casing with leak off
rate in the <100 bbls/year
– Unable to pass MIT
 Solution: WellLock® Resin
– Bradenhead squeeze from
the top of the annulus
– Extremely tight microannulus
accepted only 0.6 bbl of resin
via surface valve
 Results
– Rain during operations did not negatively affect resin (unlike
conventional epoxies)
– Passed an MIT gradient of .86-.87 ppg
– Expense of running / cementing an additional pipe string avoided
© 2013 Halliburton. All rights reserved.
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WellLock® Resin System – From the Field

Challenge: Marcellus Shale
Annular Pressure Buildup
–
–

Solution: WellLock® Resin
(solids free / neat resin)
–
–

Having cemented the intermediate casing, the
well registered gas flowing to surface
Operator chose to suspend drilling next stage
until successfully remediating for APB
Perforated and set packer at 933 ft.
Squeeze application fluid train:
water (20 bbl)  WellLock resin (10 bbl) 
FineCem™ cement (6 bbl)
Results – First ever application involving
displacement of resin by cement
–
–
–
–
Formation accepted all 10 bbl of WellLock Resin
Pumping pressure drop observed when resin
reach the perforations
Annular gas flow dropped throughout operations
Drill-out began 60 hours after the operation –
zero gas flow detected
© 2013 Halliburton. All rights reserved.
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WellLock® Resin System – From the Field


Challenge: Shale - Annular Pressure Buildup
on the intermediate casing.
Solution: Three-stage WellLock® Resin
operation
1. Set drillable bridge plug, perforate, set retainer,
squeeze 10 bbl resin into perfs followed by
10 bbl FineCem™ cement
2. Perforate higher, set retainer, squeeze
10 bbl resin into perfs followed by 20 bbl
FineCem cement into perfs
3. Perforate higher, set retainer, squeeze
10 bbl resin into perfs followed by 20 bbl
FineCem cement

Results
–
–
Formation accepted all resin, leaving planned
amount of FineCem cement in casing at each
stage – easily drilled out
Gas flow on the backside eliminated
© 2013 Halliburton. All rights reserved.
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WellLock® Resin System – From the Field

Challenge: Shale / Continental Europe
–
–

Solution: WellLock® Resin
–
–
–

Drilling suspended due to damaged inflatable
packer in 4½-in. and
9-5/8-in. annulus
Unable to achieve pressures needed for fracture
stimulation operations to complete the well and
bring it onto production
Using coiled tubing, place 1.5 cubic meters of
WellLock above drillable bridge plug previously
set in 4½-in. casing below leak
Open 9-5/8-in. annulus to circulate 1 cubic meter
of resin through leak into annulus leaving 0.5
cubic meters in casing
Allow to cure
Results
–
–
Resin withstood pressure test of 7500 psi and
was successfully milled out
Drilling operations resumed
© 2013 Halliburton. All rights reserved.
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WellLock® Resin System: Halliburton Firsts
 First time to successfully displace a resin with a cement
– Partial immiscibility allows resin to stay isolated from
the slurry and develop high strength
– Resin system remains pure and uncontaminated,
forming a gas-impermeable infinite polymer network
 Gas flow completely shut down
© 2013 Halliburton. All rights reserved.
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WellLock® Resin System – Summary
 As a product:
– Enhances the long term integrity of
the well
– Unique mechanical properties and
chemical resistance
– Rheological profile leads to deep
penetration into tight crevices
 As a service:
– Engineering and planning to
customize design for maximum
usage and effectiveness of material
– Laboratory support from Houston
Technology Center
 As a solution:
– Addresses gas migration
– Non-porous secondary barrier
© 2013 Halliburton. All rights reserved.
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