I did not expect that a discussion about restoring production casing integrity would generate such strong interest. Following a recent LinkedIn post, I received numerous questions about how we install the Casing Patch and Surface Casing Patch (SCP), how our system differs from competing solutions, and what practical field experience supports our claims.

To address these questions, I’d like to walk through the fundamentals of our technology and explain what makes our approach different—using the Casing Patch 3.0 design as an example.

Casing Patch 3.0: Designed for Deeper Installations

The animation referenced above illustrates the Casing Patch 3.0, which is engineered for deeper installations. Structurally, it is very similar to the Surface Casing Patch 2.0. The key difference lies in the upper section: instead of a Running Nut, the Patch is equipped with an Upper Dognut that seats securely in the Casing Bowl.

During installation, the Patch is run into the wellbore and the sealing elements are expanded, creating reliable radial contact with the production casing.

Optimized Flow and Cost-Effective Testing Options

The lower end of the Patch includes a mule-shoe guide, allowing smooth passage of tools and instruments through the well.

For shallow installations, the Surface Casing Patch can be equipped with a Pressure Test Cup instead of a Pressure Test Element. This option reduces overall cost while remaining fully acceptable for surface casing applications. The final configuration is selected based on customer preference and well conditions.

Key Differences from Competing Systems

Our system was developed specifically to address the shortcomings of traditional casing repair solutions:

  • No drillable plug below the Patch, eliminating the need for post-installation milling

  • No cones or swages used to mechanically expand sealing elements, which reduces the risk of sticking during deployment

  • Consistent radial contact with the production casing throughout the sealing interval

  • No corrugated pipe, allowing the Patch to withstand higher differential pressure than the original production casing

These design choices significantly improve reliability and reduce operational risk.

Efficient Installation and Minimal Downtime

Total time on location is approximately 6 hours for near-surface leaks:

  • Preparation: ~1 hour

  • Running the Surface Casing Patch: ~30 minutes

  • First Setting Tool installation and activation: ~1 hour 45 minutes

  • Second Setting Tool installation and activation: ~1 hour 45 minutes

  • Pressure testing and additional preparation: ~30 minutes

  • Final operations and loading: ~30 minutes

Within this timeframe, a near-surface casing leak can be fully isolated. Once completed, the well is immediately ready for further operations. Deeper installations naturally require additional time due to longer run-in and pull-out operations.

Proven Field Performance

To date, hundreds of Casing Patches have been installed, and the design continues to evolve based on field experience. Over the past five years, there has not been a single case of loss of integrity.

This track record is particularly significant when compared to cement-based repairs in wells with H₂S and high temperatures, where long-term isolation is often difficult to achieve.

Our goal remains simple: provide a reliable, efficient, and long-lasting solution for restoring casing integrity—without unnecessary complexity or risk.