Rigless Restoration of Tubing Integrity and Esp Performance Using Advanced Tubular Patch Applications: A Cost-Saving Case Study from North Kuwait

Abstract This paper presents the successful application of advanced tubular patch technology as a rigless, cost-effective solution to restore production and mitigate tubing integrity leaks in Sabriyah field, North Kuwait. The scope includes addressing ESP-related failures caused by downhole circulation issues, reducing costly rig workover operations, and demonstrating how this approach restored well productivity, minimized downtime, and provided long-term reliability while maintaining full-bore access for future interventions. To tackle persistent tubing integrity leaks above the ESP discharge, a multidisciplinary asset team conducted detailed well screening based on ESP performance, tubing condition, and commercial oil potential. Instead of traditional rig workover and tubing replacement, an advanced tubular patch system was selected. The system consists of a blank pipe with hydraulically activated metal-to-metal sealing elements at both ends to isolate leaking intervals. The rigless intervention was designed to restore zonal isolation while preserving tubing bore. Pre-job planning, candidate well selection, and execution strategies ensured successful deployment across multiple wells. The tubular patch system was successfully deployed in nine wells, isolating tubing leaks and restoring well integrity without requiring costly rig-based workovers. The intervention delivered a combined production restoration of approximately 3,800 BOPD, while preventing more than 200,000 bbl of deferred oil that would have been lost during extended downtime awaiting rig scheduling. In total, about 300 ft of tubular patches were installed, leading to cost savings exceeding USD 16 million compared to conventional tubing replacement operations. Furthermore, the technology ensured large-bore access for future ESP interventions and well surveillance. The case demonstrated that tubular patch applications can provide a sustainable and repeatable solution for mitigating tubing-related ESP failures, significantly improving asset uptime and reducing operational costs. Based on this success, KOC has expanded the deployment of tubular patches across Sabriyah and other fields to address similar challenges. This paper presents the first large-scale field application of tubular patch technology in Kuwait, demonstrating its effectiveness as a rigless solution for ESP-related tubing leaks and eliminating costly rig workovers. The results include significant production restoration, deferred oil savings, and multi-million-dollar cost reductions. By integrating innovative technology with systematic candidate selection, this case sets a new benchmark for extending ESP run life, enhancing artificial lift performance, and optimizing well integrity management in mature fields.