Packer and Casing Shoe Isolations

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Avoid Costly Workovers & Support Well Integrity

Page last modified
October 16 2025

Packer and Casing Shoe Isolations are specialized solutions offered by KCI Ltd to address well integrity issues and avoid costly workovers. The technology uses a product called IG-H (Isolation Gel - Heavy), which is specifically engineered to isolate leaks in deep-set Production Packers where integrity has been compromised.

IG-H is a time-activated sealant that cures into a soft, flexible gel with high compression value but low torsion/tear threshold. It is mixed and deployed as a weighted liquid gel heavier than the completion or annulus fluid. The sealant sinks to the bottom of the fluid-filled annulus, settling on top of the Packer element. There, it forms a ring of sealant around the Packer in the annular space, blocking well fluids from passing either upwards or downwards.

This technology is particularly useful when Packer elements start to become brittle, crack, or perish, causing leaks and potential well integrity issues. The IG-H remains soft and flexible, moving with the metalwork in the well, and can be easily broken up and removed when the Packer is retrieved.

The benefits of using IG-H include its effectiveness, ease of deployment, and low risk of causing damage or operational issues to the well. It can be mixed and deployed on-site with minimal personnel and equipment. The solution is engineered onshore and approved by the customer before offshore deployment, ensuring a high chance of success in isolating leaks and maintaining well integrity.

Pros & Limitations
1
Avoids costly workovers and supports well integrity
1
Effective and easy to deploy sealant with high success rate
1
Low risk of creating damage or operational issues to the well
1
Simple to mix and deploy onsite with only two people required
1
All tooling required is air operated and hand portable
1
Can isolate leaks in deep-set Production Packers where integrity has been lost
1
Remains soft and flexible, moving with metalwork in the well
1
Breaks up and falls to bottom of well when Packer is retrieved, allowing easy removal
Specification
Title Description
Theme/Discipline
Well OperationsProduction TechnologyIntegrity
Core Tech
Chemical
Industry
Oil
Product name
IG-H
Purpose
Isolate leaks in deep-set Production Packers
Form
Weighted liquid gel
Curing time
24 hours
Max temperature
175°C
Density range
11ppg to 15ppg
Standard density
13ppg
Max well inclination
50°
Composition
base compound, weighting agent, de-foamer, activator
Consistency
Soft yet solid, like a stress ball
Deployment
Simple, requires only two people
Equipment
Air operated and hand portable
Benefits
Effective, Easy to deploy, Low risk, High success rate
Minimum overbalance
200psi
Typical test pressure
1000psi
Limitations
Cannot seal holes in casing or tubing
 

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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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