L52282 State-of-the-Art Assessment of Alternative Casing Repair Methods

Many natural gas storage wells suffer damage during normal storage operations. Storage operators spend upwards of $100 million per year recovering lost deliverability. Damage to casings in gas storage wells is largely the result of localized loss of metal from corrosion; however, other types of damage do occur. Individual corrosion pits can be found either on the inside or outside of the casing wall. Repair methods that are currently used for natural gas storage well casings include patches, plugs, liners, etc. While currently-used repair methods can be a cost-effective means of repairing damaged casings as compared to the cost of running an entirely new casing, there is a need to identify and develop alternative casing repair methods that are more economical and/or do not have inherent operational disadvantages. Many of the current repair methods are proprietary, and as a result, are relatively costly to perform. In addition, many of these repair methods (e.g., tube and packer system repairs) result in a decreased cross-sectional area, which creates operational limitations due to flow restrictions and reduces the ability to perform well logging operations. The objective of this project was to review current state-of-the-art casing repair technologies to identify more cost effective alternatives. The most prominent form of underground U.S. gas storage is depleted reservoirs. American Petroleum Institute specification 5CT contains the industry standard design guidance for new casings; however, there are no industry standard repair procedures and each state has their own. The most common state required repair integrity test is pressure testing. Casings must withstand tensile, burst, and collapse loads. Most state repair procedures do not specify a target mechanical property that defines repair success. It is therefore easy to assume that a repair should return a casing back to its original integrity level; however, it may not be necessary. The major types of damage mechanisms are corrosion, threaded connection separation, sealant leaks, split casings, and drill bit damage. While a literature search indicated that the most commonly used types of cost effective repair processes are squeezes, liners, and plating, industry feedback indicated that liner repair is the most commonly used repair process. Adhesively bonded, helically-wound, steel strip repair and magnetic pulse welding are the most promising alternative repair technologies identified, mainly because both are applicable for a broad range of damage types and as an alternative to both traditional casing liner and expandable tubular repair technologies.