Wellhead Seal Isolations
Rigless wellhead integrity repair solution using sealant technology
Page last modified
August 1 2025
Wellhead Seal Isolations are a technology provided by KCI Ltd to address well integrity issues related to annuli communication through the wellhead hanger seals. It involves deploying a time-activated sealant in its liquid phase into the voids or leak paths around the wellhead sealing areas.
The sealant, available in two variants – Mac-Seal and MS-Sealant, is a two-part product that cures into a solid yet flexible material after being mixed and deployed. Over a curing period of typically 6-8 hours, the sealant converts into a resilient, self-bonding, and pressure-energized solid that acts as a static pressure-retaining barrier, re-establishing well integrity at the wellhead.
The cured sealant remains stable across a wide temperature range, preventing expansion or shrinkage. This rigless solution provides a safe, quick, and cost-effective alternative to traditional methods like pumping hard plastic packing materials or conducting costly rig workover operations to change out wellhead components.
According to the context, KCI's wellhead seal isolation technology has been successfully deployed since 2013, with over 500 jobs completed and a success rate exceeding 99%. For one major client in the Middle East, it has resulted in cost savings of approximately USD 60 million through reduced production deferments and associated rig costs.
Pros & Limitations
1
Reduce Production Deferments
1
Cost-effective solution for onsite Rigless Wellhead Integrity Repairs
1
Saves significant costs by avoiding rig workover operations
1
Successful deployment with over 99% success rate
1
Resulted in cost savings of at least USD 60 million for a major client
Specification
| Title | Description |
|---|---|
| Theme/Discipline | Well OperationsRepair |
| Core Tech | Chemical |
|
Sealant types
|
MS-Sealant. MS-F Sealant
|
|
Sealant description
|
Two-part product, time activated, solid yet flexible once/when cured, various viscosities
|
|
Temperature range
|
Stable from -54°C to 204°C and up to 260°C for short periods
|
|
Sealant composition
|
Base compound and activator, mixed for 5 minutes before deployment
|
|
Sealing life
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At least 25 years, can be used for temporary or long-term
|
|
Typical usage
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Approximate 3-5 litres, depending on casing hanger void capacity
|
Technology Readiness Level
The Technology Readiness Level (TRL) indicates the maturity level of novel technologies. Learn more about the TRL scale used by us.
[9/9]
Development
Technology demonstration
Mature / Proven
Recognising the relentless challenges facing operators to maintain full production and extend the life of mature assets, KCI offers a range of unique products and services specifically designed to reduce costs and minimise downtime, whilst maintaining or increasing production across: sub sea, surface, refinery, down hole, topside pipeline and other applications.
Within its chemical engineering range KCI leak sealing solutions and isolation gel have enabled operators to achieve substantial savings across a range of maintenance, integrity and production issues: quickly, safely and cost effectively, with a high level of sustained success and little or no disruption to production. KCI solutions / isolations can be temporary (short term) or permanent, depending on operational requirements.
KCI also offers a range of easy-to-apply silicone based coatings to protect new and ageing structures and equipment against moisture, corrosion or erosion in mild and hazardous environmental or climatic conditions: internal, external, surface or sub sea. KCI takes a holistic approach to resolving customer issues by providing an in depth investigation / assessment, detailed procedures and highly skilled engineering, all of which are designed to ensure optimum success of individual projects. KCI is also known within the industry for being able to address difficult and often unique problems which do not, or are unlikely to, respond to traditional methods or technology and as a result KCI products have been acclaimed as an example of best practice in the industry.
Country of Headquarters
United Kingdom
Contact:
+44 (0)1224 255480
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