Result
MCGx eliminated a US$90 million subsea intervention and preserved production continuity across multiple offshore gas wells. The solution maintained hydraulic containment, kept ICV seals within pressure limits, and has held stable for over two years, with implementation cost under US$100k and zero downtime.
Problem
Hydraulically actuated inflow control valves showed seal degradation, raising concern that reservoir gas could migrate into control lines. Falling reservoir pressure and energised hydraulic lines would soon drive already-compromised seals beyond their 10k-psi limit. Standard mitigation required maintaining high control pressure, but wells were already at seal limits, leaving the operator facing an imminent, high-cost intervention with no low-risk alternative.
MCGx Insight
MCGx recognised the check valve inside the subsea control module could be repurposed. By venting control line fluid through the valve, the already-occurring fluid loss at degraded ICV seals created a localised vacuum at the check valve, a passive hydraulic lock that prevented further gas ingress and fluid loss without exceeding seal pressure ratings.
Proof
The control line was re-energised after one week, four weeks, and three months. Each cycle confirmed zero gas ingress or fluid loss. The solution remains in continuous use, eliminating the planned intervention.