Control Line Plugging

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Reduce rig time and increase safety when pulling completions

Page last modified
September 19 2025

Control Line Plugging is a technology used in the oil and gas industry to reduce rig time and increase safety when pulling completions. It involves creating plugs to totally isolate control lines, which are used to operate downhole equipment like injection valves. 

The process begins by flushing each control line with test fluid to remove obstructions and check for pressure. Then, a two-part sealant product called Mac-Seal is injected into the control lines. Mac-Seal is time-activated and cures into a solid yet flexible material, similar to rubber. Once fully cured (typically 6-8 hours, but 24 hours ensures full maturation), the lines are pressure tested to confirm no leaks.

This method offers several benefits compared to traditional approaches. It can be deployed simultaneously with other operations, saving rig time through "Sim Ops". It's more reliable than wireline operations and less time-consuming than workovers or long-term suspensions. The sealant's flexibility allows it to maintain integrity even with temperature fluctuations or movement.

KCI, the company offering this technology, claims it can lead to significant cost savings. In one North Sea project, they estimate it saved around £400,000. The sealant can be used in various temperatures and viscosities are available for different applications. Overall, Control Line Plugging provides a fast, effective way to isolate control lines during well interventions or abandonments.

Pros & Limitations
1
Reduces rig time when pulling completions
1
Increases safety when pulling completions
1
Can be deployed simultaneously with other operations like Deep Set plugging
1
More reliable outcome compared to wireline operations
1
Less time-consuming than other methods
1
Prevents costly workovers or long-term suspensions
1
Saves significant rig time and costs for well owners
1
Creates total plugs to isolate control lines
Specification
Title Description
Theme/Discipline
Well OperationsWell Plug and AbandonmentIntegrity
Core Tech
Chemical
Purpose
Reduce rig time and increase safety when pulling completions
Sealant used
Mac-Seal
Sealant properties
Two part product, time activated, solid yet flexible when cured
Process
Flush lines, inject Mac-Seal, allow to cure, pressure test
Benefits
Can be deployed during deep set plugging operations, Saves rig time due to simultaneous operations, More reliable than wireline operations, Less time-consuming than other methods, Prevents costly workover or long-term suspension
Curing time
6-8 hours typically, 24 hours for full maturation
Temperature effect
Higher temperature leads to faster curing
Deployment window
1 to 1.5 hours after mixing
Cost savings example
Saved one project around £400k
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
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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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