5.1.1 Remediation of leakage through wells by well intervention

CO2 leakage from the storage reservoir through operating and especially orphaned, abandoned and even old wells is considered to be a potential leakage pathway for a CCS project, which is worth considering carefully (Ide et al.,2006). The possible reasons why a well may be leaking are (Kuuskra and Godec, 2007):

  • The well was poorly designed or completed, allowing gas migration along the well or wellbore;
  • An unanticipated well failure occurred (such as parted casing);
  • When abandoned, the well was inadequately plugged and sealed.

In contrast to the natural geological system, the wellbore system is an engineering structure. A general downhole well configuration consists of multiple casings, usually made of steel. In many cases the annular space between geological formation and the steel casing is (partly) filled with cement. Injection or production wells often are equipped with injection or production tubing. Abandoned wells will be sealed with several cement and potentially mechanical plugs (Guidance Document 2, EC, 2011b).

Wells drilled for the purpose of CO2 storage operations can be designed, completed and abandoned according to requirements applicable to long-term containment. Even previously drilled wells, configured without taking into account future CO2 storage purposes, can often be modified to comply with requirements. The main problem lies with already abandoned wells that are no longer accessible. Well flaws leading to leakage through or along the wellbore is nothing new. The oil and gas industry has decades of experience and offers standard techniques as well as advanced technologies to repair leaks in the various parts of a well. If required, injection tubing and packers can be replaced, leaking casing can be repaired, or cement can be squeezed behind the casing. In the case of a blow-out, standard oil and gas industry techniques are available to 'kill' a well (e.g. injecting heavy mud/weighted brine into the casing). A good overview of well remediation measures is provided by Meyer (2007).

In case of leakage of injection tubing, first of all the well must be "killed". After killing the well e.g. by injecting heavy mud or weighted brine into the casing, the failed tubing string needs to be pulled out of the hole. At the surface the tubing can be hydrotested, after which the leaking tubing joint can be replaced. In case no leaks are detected, failure may have occurred in a tubing collar which was remedied as the tubing was rerun.

Leakage of casing is usually caused by a damage to casing steel due to, e.g, mechanical erosion or chemical degradation. There are many measures available to repair such damage (Meyer, 2007):

  • A squeeze job, forcing cement or a chemical sealant through leaks or intentional perforations into specified locations of the annulus, may prevent communication between the inside casing and casing-formation or casing-casing annuli.
  • Alternatively, a new liner (either fiberglass or steel) can be placed over the leaking section, effectively covering the leak.
  • A special application of the latter involves the use of expandable tubulars. This technology enables expansion of the casing or liner by up to 20% in diameter after being run down-hole. For this purpose, an expansion tool that exceeds the inner diameter of the tube by the required amount of expansion is forced through the pipe.

In case of leakage behind the casing due to lacking or inadequate cement sheath, several methods can be applied to remediate the cement sheath and achieve isolation (Arts et al., 2009):

  • Squeeze cementing involves the process of forcing by pressure cement slurry into a specified location in a well through perforations in the casing or liner. Once the slurry encounters a permeable formation, the cement solids are filtered out of the slurry as the liquid phase is forced into the formation matrix in the form of cement filtrate. Squeeze cementing is a remedial cementing technique used to repair flaws in primary cement or damage incurred by corrosive fluids. A properly designed squeeze-cement operation will fill the relevant holes and voids with cement filter cake that will cure to form an impermeable barrier. Also chemical sealants are available for squeeze jobs.
  • Block cementing is used to isolate a permeable zone. To this purpose the sections above and below the target formation are perforated and squeezed.
  • A circulating squeeze involves circulating cement between two sets of perforations, isolated in the string by a packer or cement retainer. The operations consist of an initial circulation with water or acid as receding fluid, a subsequent circulation of the interval with a cleaning wash fluid, and pumping and displacing of the cement slurry. This method is a low pressure squeeze. Except for some increase in hydrostatic pressure resulting from the increasing cement column in the annulus, no pressure build-up is associated with this type of cement squeeze. The exact amount of required cement is unknown, leading to the use of excess cement. This holds the risk that cement slurry enters the casing above the packer or retainer. If this cement would cure, the tubing may become stuck in the hole.
  • Alternatively, expandable tubulars could be applied on the outside of the casing.

Leaking injection and observation wells where repair is impossible should be plugged and abandoned. The same goes for leaking old abandoned wells that need to be re-plugged. Procedures of well abandonment are well-known from the oil and gas industry (Randhol et al., 2007).