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Cementing 1
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Introduction
Primary cementing is the cementing operation performed immediately after the casing has been run downhole. The materials, tools, equipment, and techniques to be used vary depending on the hole conditions, depth of the well, and the people planning the job. Successful primary cementing presents a constant challenge and requires up-to-date knowledge and technology. C. Slurry Weight and Volume Calculations D. Primary Cementing Calculations Example
Learning Objectives
Upon completion of this section, you should be familiar with: How to calculate the amount of cement for a Primary job. How to calculate the mixing water required for the cement. How to calculate the pressure required to land the top plug
Topic Area
The units in this section are: A. Capacity Calculations B. Annular Volume Calculations
Sample Problem
What is the capacity, in gallons, of 1000 ft of 27/8 in., 10.4 lb/ft internal upset drill pipe? Use the sample of Section 210 shown in Figure 5.1 to aid your calculations.
Solution
Find the appropriate capacity factor (in gal/ft) in Figure 5.1. Then multiply by the length of the drill pipe. Capacity Factor = 0.1888 gal/ft Capacity = 0.1888 gal/ft 1000 ft = 188.8 gal
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Figure 5.1
Fill-Up Calculations
Fill-up of pipe is defined as the length of pipe a specified volume will fill. Fill-up factors are also listed in Section 210 of the Red Book.
Displacement
Displacement is defined as the volume of fluid displaced by an object when it is placed in that fluid. In the oilfield, the terms displacement and displace may be confused. The word displace often refers to pumping the fluid inside the pipe out of the pipe, as in displacing cement with fresh water. To do this, the volume of fluid pumped is usually equal to the capacity of the pipe. This is totally different from the definition of displacement as given in the first sentence of this paragraph.
Sample Problem
How many feet of 3-1/2 in., 15.50 lb/ft internal upset drill pipe will 25 barrels of oil fill? Use Figure 5.1 to aid in your calculations. Solution: Fill-up Factor = 152.05 ft/bbl Fill-up = 152.05 ft/bbl 25 bbl = 3801.25 ft
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Bull-Plugged Pipe
Figure 5.2 illustrates the volume of fluid displaced when bull-plugged pipe is run in the hole. This volume is equal to the outside diameters flat surface area multiplied by the length of the pipe: Displacement = OD Area Length or Displacement = 0.7854 OD OD Length
3 in. 1.5 in.
Open-Ended Pipe
When the pipe is open-ended (that is, some opening permits the pipe to fill up on the inside as it is lowered into the well), it will displace less fluid than the bull-plugged string. As shown in Figure 5.3, open-ended pipe will displace a volume equal only to the volume of steel placed in fluid. This displacement can be calculated by multiplying the cross-sectional area by the length: Displacement = Cross-sectional Area Length
3 in. 1.5 in.
Dry 1,000 ft 1,000 ft Bottom BullPlugged Outside View Sectional View Outside View Dry
Sample Problem
What is the displacement, in barrels, for the string of bull-plugged pipe shown in Figure 5.2? Solution: 3 in. = 0.25 ft Displacement = 0.7854 0.25 ft 0.25 ft 1000 ft = 49.09 ft3 Conversion factor = (located in section 240, page 85) 0.1781 bbl/ft3 Displacement = 49.09 ft3 0.1781 bbl/ft3 = 8.74 bbl
Sample Problem
What is the displacement, in barrels, for the open-ended pipe illustrated in Figure 5.3? Solution: OD = 3 in. = 0.25 ft ID = 1.5 in. = 0.125 ft OD Area = 0.7854 0.25 ft 0.25 ft = 0.0491 ft2 ID Area = 0.7854 0.125 ft 0.125 ft = 0.0123 ft2 Cross-sectional Area = 0.0491 ft2 0.0123 ft2 = 0.0368 ft2
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Displacement = 0.0368 ft2 1000 ft = 36.8 ft3 Conversion Factor = 0.1781 bbl/ft3 Displacement = 36.8 ft3 0.1781 bbl/ft3 = 6.55 bbl
NOTE: In the above examples, it has been assumed that the tubular goods were flush joint; that is, no allowance was made for internal upsets, external upsets, or couplings. Section 130 of the Red Book contains factors that allow for upsets and couplings, as shown in Figure 5.4.
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Unit A Test:
For items 1 and 2, fill in the blanks. For items 3 to 5, use your Red Book as a reference and find the solutions to check your progress in Unit A. 1. The volume that a certain length of pipe will hold is known as the pipe's ______________________. 2. ____________________________is defined as the volume of fluid displaced by an object when it is placed in that fluid. 3. What is the capacity, in barrels, of 10,000 ft of 7 in., 23.0 lb/ft casing?
4. How many feet of 4-1/2 in., 16.6 lb/ft internal upset drill pipe will 25 barrels of oil fill?
5. What is the displacement, in barrels, for this open-ended pipe? OD = 4.5 in. ID = 2.0 in. Length = 2000 ft
Now, check your answers against the Answer Key at the back of this section.
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Figure 5.6 Note: Diameters and lengths must be in the same unit of measurement. Rather than calculating cross-sectional areas to determine annular volumes, you can refer to the Red Book, which provides factors that you can multiply by the length of the annulus to more simply arrive at volumes. There are two sections in the Red Book that you should become familiar with regarding annular volumes: Section 122 is a set of tables of annular volume and annular fillup factors with tubular goods in various size holes. It also lists the factors for multiple strings of tubular goods in various hole sizes. Section 221 lists factors for pipe strings inside other pipe. There are tables for tubing, drill pipe, and casing inside of larger casing. Like Section 122, there are also tables for multiple tubing strings inside casing.
Figure 5.5
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Figure 5.7 Annular Volume = 0.0479 bbl/ft 1000 ft = 479 bbl You can also use these tables to determine the length that a given volume of fluid will fill.
Sample Problem
Find the annular volume, in barrels, between 6000 ft of 2-3/8 in. (2.375 in.), 4.7 lb/ft tubing and a 6-1/8 in. hole. Use Section 122-A of the Red Book (see Figure 5.7). Solution: Annular Volume Factor = 0.0310 bbl/ft (from the Red Book) Annular Volume = 0.0310 bbl/ft 6000 ft = 186 bbl
Sample Problem
How many feet of annular space between 4-1/2 in., 10.5 lb/ft casing and a 6 in. hole will 100 bbl of cement fill? Use Section 122 of the Red Book. Solution: Annular Fill-up Factor = 65.3597 ft/bbl Annular Fill-up = 65.3597 ft/bbl 100 bbl = 6535.97 ft Another way of calculating annular volume between a string of casing and the ID of the hole is by using Section 210 of the Red Book. This contains the factors for different size cylinders or holes with a length of 1 foot. Annular volume can be calculated by subtracting the annular
Sample Problem
What is the annular volume, in barrels, for 1000 ft of 5-1/2 in., 17 lb/ft casing inside 9-5/8 in., 36 lb/ft casing? Use Section 221 of the Red Book. Solution: Annular Volume Factor = 0.0479 bbl/ft
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volume factors for one foot of height and then multiplying by the desired annular height.
Solution: Volume Factor for 6-1/8 in. hole = 0.0364 bbl/ft Volume Factor for 2-3/8 in. tubing = 0.0055 bbl/ft Annular Volume Factor = 0.0364 bbl/ft 0.0055 bbl/ft = 0.0309 bbl/ft Annular Volume = 6000 ft 0.0309 bbl/ft = 185.4 bbl The differences between this way of determining annular volume and using Section 122 can be explained by the methods used when rounding off of decimals in establishing the tables.
Sample Problem
Find the annular volume, in barrels, between 23/8 in., 4.7 lb/ft tubing and a 6-1/8 in. hole. Use Section 210 of the Red Book.
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Unit B Test
Calculate the answers for the following: 1. What is the annular volume, in gallons, between 5000 ft of 9-5/8 in., 53.50 lb/ft casing and 12-1/4 in. hole? Use the Red Book to find the appropriate factor.
2. What is the annular volume in cubic feet, for 7675 ft of 2-7/8 in., 6.5 lb/ft tubing inside 7 in., 26 lb/ft casing? Use the Red Book to find the appropriate factor.
Now, look up the suggested answers in the Answer Key at the back of this section.
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Density
Density can be defined as the weight of a substance per unit volume. In the English system, one cubic foot is a unit of volume, and one pound is a unit of weight. In the metric system, a unit of volume is cubic centimeter (cc) and weight can be measured in grams (g). If you measured the weight of a specific volume of iron, wood, lead, and water, you would find they have widely different weights. Therefore, a term is needed to refer to the weight of a unit-volume of substance -- that term is density. For example, a cubic foot of water weighs 62.4 lb, so the density of water is 62.4 lb/ft3. If you know the density and the volume of a material, you can calculate its weight: Weight = Density Volume Some densities of common materials are listed here for your reference.
For practical purposes, the densities of gases are compared with air at atmospheric pressure instead of with water. Using air as a comparative reference, the vapor densities of the gases listed above are: Air Oxygen Nitrogen Carbon Monoxide Hydrogen 1.00 1.120 0.983 0.979 2.004
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Specific Gravity
Specific gravity (abbreviated Sp Gr) is the weight of a volume of material divided by the weight of the same volume of material taken as a standard. For solids and liquids, the standard is water; for gases, the standard is air. Another definition of specific gravity is the ratio of the density of a substance to the density of water or air. The density of water is 8.33 lb/gal. It is a simple matter to convert density to specific gravity (or vice versa).
API readings are standardized at a temperature of 60F. If taken at any other temperature, readings must be converted to 60F to be accurate. Tables for this conversion and for conversion of API gravity to specific gravity can be found in the API Standard 2500 bulletin and in various engineering handbooks. Formulas for conversion are: Degrees API Gravity = Specific Gravity =
141.5 - 131.5 Sp Gr
Sample Problem
What is the specific gravity of a 10 lb/gal brine? Solution
density of substance Sp Gr = density of standard
Sp Gr =
Sp Gr = 1.2 If you were given the specific gravity of a liquid as 1.2, the density can be calculated: 1.2 8.33 lb/gal = 10 lb/gal
Absolute Volume
Absolute volume is the volume per unit mass. Here is an example of absolute volume. Let's assume we have a container (Figure 5.8) that measures one cubic foot (1 ft high, 1 ft deep, 1 ft wide). This container is filled with golf balls. There are void spaces between the golf balls filled with trapped air. We want to know the volume in gallons that is occupied by the golf balls only.
API Gravity
Baumes gravity is a scale that uses salt water as a reference rather than fresh water. It is used in refineries to determine the gravity of acids and alkalis only. API gravity is used in most other instances in the oil field. Water is used as the standard. Water's API gravity is 10 degrees. As the specific gravity increases, the API gravity decreases. Crude oil with a 42 API gravity has an actual specific gravity of 0.82. American crude is commonly run from 0.768 to 0.966 specific gravity, which would range from 52.6 to 10.5 on the API gravity scale.
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The volume occupied by the golf balls can best be determined by first calculating the volume occupied by the void spaces. For this, we could add water to the container and measure it. After obtaining the number of gallons of water needed to fill the void spaces, we can subtract from 7.4805 gal/ft3 to determine the volume occupied by the golf balls alone. The volume of golf balls determined in this way is called the absolute volume. While this example is exaggerated, it does help explain the concept. We work with sand, cement, etc. rather than golf balls, but the balls can be seen as a magnification of sand or cement particles. Void spaces exist in sand; the volume we add to fracturing fluids is actually the absolute volume of the sand. Calculating absolute volume for sand or cement can be simplified by using the tables for "Physical Properties of Cementing Materials and Admixtures" provided in the Technical Data section of the Halliburton Cementing Tables (Figure 5.9).
1 ft
1 ft 1 ft
Figure 5.8 The volume of golf balls is less than the total volume because of the spaces between them.
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The left-hand column lists the material, the second column gives the bulk weight in lb per ft3. The third column gives the specific gravity, and the fourth column provides absolute volume in gal/lb. Note: When using fluids in absolute volume calculations, you will not find a gal/lb factor in the Red Book. However, you can calculate this factor if you know the fluid density in lb/gal. Simply divide 1 by the fluid density. For example, water is 8.33 lb/gal, so: gal/lb = 1 8.33 lb/gal = 0.12 gal/lb
Total lb Total abs gal = lb/gal 12.33 lb 1.1824 gal = 10.427943 lb/gal
Sample Problem
What is the absolute volume (gallons) and weight (lb per gallon) of this slurry? Base Fluid is water @ 8.33 lb/gal Additive is 3% KC1 4 lb of sand is added
ABSOLUTE
Solution
MATERIAL MATERIALS (lb) 8.33 0.2499 4.0 12.579 lb Water 3% KC1 Sand TOTALS FACTOR (gal/lb) 0.1200 0.0443 0.0456 = VOLUME (gallons) 1.0
Sample Problem
What is the absolute volume (gallons) and weight (lb per gallon) of this slurry? Base Fluid is water @ 8.33 lb/gal 4 lb of sand is added.
Solution We will use the chart below to help in our calculation of absolute volume. First, list the materials and their weights in the first two columns. Then, using the Red Book table, list the absolute volume factors (gal/lb) in the third column.
ABSOLUTE MATERIAL MATERIALS Water Sand TOTALS (lb) 8.33 4 FACTOR (gal/lb) 0.1200 0.0456 VOLUME (gallons)
Total lb Total abs gal = lb/gal 12.5799 lb 1.1934705 gal = 10.5 lb/gal Note: Generally, when working with sand and water (or base fluid) slurries, the calculations are based on 1 gallon of base fluid and the weight of that 1 gallon of fluid.
Sample Problem
What is the absolute volume (gallons) and weight (lb per gallon) of this slurry? Class H Cement Water @ 8.33 lb/gal
Multiply the materials (lb) by the factor (gal/lb) to obtain the absolute volume and add these values to the table. For the totals, add the materials (lb) together and add the absolute volumes together:
ABSOLUTE MATERIAL MATERIALS Water Sand TOTALS (lb) 8.33 4.0 12.33 lb FACTOR (gal/lb) 0.1200 0.0456 = = VOLUME (gallons) 1.0 0.1824 1.1824 gal
Solution For this cementing problem, we will add a column to the chart for mixing water requirements. Proceed as in the last two sample problems until you need to fill in the mixing water requirements for the Class H cement. This quantity you can find in the Technical Data section of the Red Book in the table for Water Requirements. For Class H cement, the requirements are 4.3 gal/sk. Enter this under the appropriate column:
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ABSOLUTE MATERIAL FACTOR VOLUME MATERIALS Cement Water TOTALS (lb) 94 (gal/lb) 0.0382 8.33 = (gallons) 3.6
MIXING WATER (gallons) 4.3 MATERIALS Cement Water TOTALS (lb) 94 35.82 129.82 lb =
ABSOLUTE MATERIAL FACTOR VOLUME (gal/lb) 0.0382 8.33 = (gallons) 3.6 4.3 7.9 gal
Enter 5.2 gal for the absolute volume for water. Divide the water factor by the absolute volume to determine the materials (lb) for water. Then calculate the totals:
Total lb Total abs gal = lb/gal 129.82 lb 7.9 gal = 16.4 lb/gal Find the yield of cement (ft3 per sack) by using this formula: Total abs gal 7.4805 gal/ft3 = ft3/sk 7.9 gal/sk* 7.4805 gal/ft3 = 1.06 ft3/sk *NOTE: When working with cement slurries, the calculations are usually based on one sack of cement and the weight of that sack.
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Unit C Quiz:
For items 1 3, fill in the blanks. For items 4 and 5, calculate the answer. 1. In dealing with specific gravity, the weight of a volume of a material is ________________________ by the weight of the same volume of a material taken as a_______. 2. Absolute density considers only the___________ ____________ occupied by the material. 3. Volume per unit mass defines ______________ _______________. 4. Calculate the weight (lb/gal) of the following slurry: base fluid is 10 lb/gal brine sand at 10 lb/gal (0.0456 gal/lb)
5. Using Class H cement (94 lb/sk) and 4.3 gallons mixing water, what is the cement slurry density (lb/ gal) and yield (ft3/sk)?
Now, look up the suggested answers in the Answer Key at the back of this section.
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1 2 3
Critical Circulating Pressure Pressure required to lift (pump) the casing out of the hole Cement volume The volume of cement required to fill the required footage of the annulus plus the shoe track capacity. Sacks of Cement Converting the required volume of cement into sacks. Mixing water required for given slurries. Displacement fluid required to the top plug from surface to the top of the shoe track. Pressure to land the plug Differential pressure required to pump the plug to the top of the shoe track. Resulting Force The calculated hook load at the top of the casing once the plug has landed.
4 5 6
7 F A B 5 C
Well Parameters A B C D E F G
Pipe Size Well Fluid Hole Size Pipe Depth Shoe Track Length Required Cement fill-up Excess volume required (percent)
2 3 4
Calculation Guidelines
Do not apply any decimal places for pressure or sacks
6 E
Apply one decimal place for lb/gal Apply 2 decimal places for psi/bbl cubic feet pounds feet area gallons barrels For psi/ft use same number of decimal places as in Red Book Hydrostatic Pressure And Fluid Weight Conversion Tables Show one decimal place for bbl/min Rounding numbers if the last number is to be dropped, round up if 5, down if < 5.
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gal
Cement Density (lb/gal) ==> Cement Yield (ft3/sk) ===> Mixing Water required ===> gal/sk
lb/gal ft3/sk
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1 2 3 4 5 6 7
Critical Circulating Pressure Pressure required to lift (pump) the casing out of the hole Cement volume The volume of cement required to fill the required footage of the annulus plus the shoe track capacity. Sacks of Cement Converting the required volume of cement into sacks. Mixing water required for given slurries. Displacement fluid required to the top plug from surface to the top of the shoe track. Pressure to land the plug Differential pressure required to pump the plug to the top of the shoe track. Resulting Force The calculated hook load at the top of the casing once the plug has landed.
In the Essential Red Book course, you were introduced to the basic calculations and concepts needed in preparing for a primary cementing job. In this unit you will be shown the steps for calculating a surface casing cement job. Later, youll be asked to actually make the calculations for a similar job on your own.
Well Parameters
Pipe Size Well Fluid Hole Size Pipe Depth Shoe Track Length Required Cement Fill-Up Excess Volume Required (percent) 9 5/8 in 36 lb/ft 8.7 lb/gal 12.25 in 300 ft 40 ft To surface 100%
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possibly lift the pipe out of the hole, so you need to chain the pipe down during the operations. 1. First, the area of the casing must be found. a) In the Calculations and Formulae section of the Red Book (see also Figure 5.13), look up the formula for the area of a circle. Area = 0.7854 D
2
d) The buoyancy factor (Step 2a) multiplied by the weight per foot of casing (Step 2b) times the length of the casing (Step 2c) equals the weight of the pipe hanging in fluid: 0.8671 BF 36 lb/ft 300 ft = 9364.68 lb (The arrow indicates the direction of this force.) 3. Now you have enough information to calculate the amount of pressure to apply to the casing at the surface, pumping downward through the casing below the casing shoe, to start the lift (or to balance the pipe). The larger the diameter of the pipe the less pressure is required to lift the string. This is why you need to chain down large diameter casing during the pumping operation (chain it to the substructure or a leg of the derrick, but not to the rotary table). The downward force of the pipe (step 2d) divided by the area of the pipe (step 1b) is the pressure needed to start the lift: 9364.68 lb 72.76 in. = 129 psi When applying pressure to start circulation, caution should be taken to prevent the pipe from blowing out of the hole and causing damage. The casing should be chained down and all personnel except the operator, should be cleared off the rig floor.
Figure 5.13 b) Plug the diameter (9 5/8 in.) into the formula for area of a circle (area of the casing): 9.625 in. 9.625 in. 0.7854 = 72.76 in.2 2. The next step is to calculate the weight of the pipe when it is hanging in fluid (the downward force of the pipe in the wellbore.) a) First, look up the buoyancy factor for the wellbore fluid you are working with. Keep in mind that this buoyancy factor relates to the fact that open-ended pipe weighs less in a fluid than it does in air. The weight of this fluid is 8.7 lb/gal. Referring to the Displacement section of the Red Book (see also Figure 5.14), you will see that the buoyancy factor is 0.8671 for a fluid of that weight. b) You also need to know how much your casing weights in air. From the casing stamp, you can find that this casing weigh 36 lb/ft. c) Since it is not known at what depth the annulus might become bridged, use the overall length of your casing (300 ft) for these calculations.
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You will find Class G slurry properties on page 3 of the Class G Section in the Technical Data Section of the Red Book. We will work through the absolute volume calculations as an example. Refer to the gray pages in the Technical Data: section of your Red Book (see also Figure 5.9). You will see that the table labeled Physical Properties of Cementing Materials and Admixtures contains much of the information needed to calculate the slurrys absolute volume (as well as its weight that will be calculated later). To aid in these calculations, the Worksheet for Slurry Weight and Volume Calculations has been developed (Figure 5.11). This worksheet will be completed as the following calculations are worked out. 1. First, find the bulk weight of API cements listed in Figure 5.9 94 lb/ft3. The factor for absolute volume of API cements is 0.0382 gal/lb. 2. Then calculate the correct figures for each of the additives and the water being used. a) Calculate how much the calcium chloride will weigh by multiplying the weight of cement by 2%: 0.02 94 lb = 1.88 lb b) Look up the factor for absolute volume of Calcium Chloride, which is 0.0612 lb/gal. Figure 5.14 c) Look up the absolute volume factor for Flocele, which is 0.0845 gal/lb. 3. To find the absolute volumes of the cement, Calcium Chloride and Flocele, multiply the numbers in the materials column by the numbers in the factor column: 94 lb 0.0382 gal/lb = 3.6 gal 1.88 lb 0.0612 gal/lb = 0.12 gal. 0.25 lb 0.0845 gal/lb = 0.02 gal
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Figure 5.15 Class G data from Red Book 4. To find the mixing water requirements for a sack of cement with its additives, refer to the gray pages in the Technical Data section of your handbook (see also Figure 5.15). These requirements are 5.0 gal., 0 gal and 0 gal for the cement, Calcium Chloride and Flocele respectively. Add these figures together for the waters absolute volume: 5 gal + 0 + 0 gal = 5 gal 5. To obtain the weight of the water required, multiply the weight per gallon of water by the volume of water (step 4): 8.33 gal/lb 5 gal = 41.65 lb 6. Total the materials and absolute volume columns:
Water Totals
137.78
Total mixing water must be entered under absolute gallons before totaling. Find the weight of the mixed cement by using this formula: Total Pounds Total Absolute gallons = lb/gal Find the cement yield in cubic feet per sack by using this formula: Total Absolute gal 7.4805 gal/ft (constant) = ft /sk The mixing water per sack is the sum of the gallons in the far right column Cement Density Cement Yield Mixing Water Required 137.78 8.7270 8.7270 = 7.4805 = 15.8 1.17 5.00 lb/gal ft /sk gal/sk
3 3 3
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8. Then find the yield by dividing the total absolute volume in gallons (Step 6) by the constant which can be found in the table Conversion Constants (Figure 5.16) 7.4805 gal/ft3 8.7270 gal 7.4805 gal/ft3 = 1.17 ft3/sk Now assume that you have circulated through the surface casing down to a depth of 300 ft and that you have a well-conditioned hole. It is necessary to calculate the volume of slurry needed for the job. This is a combination of the slurry needed to fill annular space and to fill the shoe joint. 9. To determine how much slurry is needed to fill the annulus, the ft3/ft for the annulus is multiplied by the length of the annulus. a) First, refer to the Volume and Height Between Tubing, Casing, Drill Pipe, and Hole section in the handbook. (To use this table, you need to find the table with the correct number of strings. For example, see the four different tables for tubing with an OD of 3 in). Look on the table for 9 5/8 in (see also Figure 5.17). The ft3/ft for this annulus is 0.3132. b) You know that the length of the annulus is 300 ft. Multiplying this by the ft3/ft value found in Step 9a results in the volume needed to fill the annular space. 300 ft 0.3132 ft3/ft = 93.96 ft3. Figure 5.16 7. To find the weight of the cement slurry in pounds per gallon, divide the total pounds by the total absolute volume in gallons: 137.78 8.7270 gal = 15.8 lb/gal c) Excess cement knowing we need 100% excess (double the calculation volume) we calculate the following: 93.96 ft3 2 = 187.92 ft3
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Figure 5.17 10. Now, the amount of slurry in the shoe joint (or track) needs to be calculated in the last step, to determine how much slurry is in the shoe joint, the capacity factor of the joint is multiplied by its length. a) To find this capacity factor, turn to the Capacity section of the Cementing Table (See also Figure 5.18) You need to know the OD (9 5/8 in.) and the weight (36 lb/ft) of your casing. The capacity factor is 0.4340 ft3/ft. b) The length of the shoe track was given as 40 ft. c) Multiply the capacity factor for the shoe joint (10a) by the length of the shoe joint (10b) for the capacity for the shoe joint: 0.4340 ft3/ft 40 ft = 17.36 ft3 11. Add the volume of slurry to fill the annulus (step 9c) to the volume of slurry to fill the shoe joint (step10c) to determine the total numbers of barrels of cement that you need: 187.92 ft3 + 17.36 ft3 = 205.28 ft3
3 Sacks of Cement
1. Now that you know the cubic feet needed (Step 11), you use the yield (Step 8) to calculate the number of sacks needed: 205.28 ft3 1.17 ft3/sk = 175 sk
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Figure 5.18 to barrels since tanks on trucks are marked off in barrels. 1. First, find out how much mixing water you need in gallons: 5 gal/sk 175 sk = 875 gal 2. Since there are 42 gal in a barrel, convert to barrels: 875 gal 42 gal/bbl = 20.83 bbl Therefore, it will take this amount of water to mix your cement. You will need more water on location, considering the water used for cleanup, spacer, etc. bottom plug is not run, the top plug will wipe down the walls and mud will collect in the shoe joint between the top plug and the cement slurry. When all of the cement has been mixed, the top plug will be pumped down to a depth of 260 ft. The number of barrels needed to do this is the same as the capacity of the casing to the float collar. 0.0773 bbl/ft 260 ft = 20.1 bbl
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Hydrostatic Outside Cement 300 ft 0.8208 psi/ft Total: 300 ft Hydrostatic Inside Cement 40 ft 0.8208 psi/ft Well Fluid 260 ft 0.4519 psi/ft Total 300 ft = = 33 psi 117 psi 150 psi = 246 psi 246 psi
calculations Step 1) for a fluid weighing 15.8 lbs/gal. The hydrostatic pressure in a casing job is the pressure in the annular space. The plug will close off the pressure in the casing when it lands on a float collar. If you do not land the plug or run a float collar or back pressure valve, but only stop the plug in the casing, then you will close in the cementing head and the pressure to land the plug will remain on the casing until the cement has set. To calculate the hydrostatic pressure at a given depth, multiply that depth by the psi/ft of the fluid in the annulus in this case, cement slurry: 300 ft 0.8203 psi/ft = 246 psi
Differential Pressure (At top of shoe) = 246 psi 150 psi = 96 psi
Always re-total the depth. If you dont end up with the same depth then something is wrong. NOTE: You must slow the pump rate down to a half-barrel per minute to read this on a chart or gauge because high rates create friction pressure (which can give you a false pressure reading). When the plug has been pumped to its landing position and 96 psi is readable on the gauge, this job has been done successfully. Remember that you will not be able to correctly read the pressure to land a plug on all jobs. Losing cement into the formation or developing channels in the cement will alter the pressure reading. Release the pressure when the plug lands; this will prevent a microannulus. Keep in mind that most companies will require more pressure than what is required to land the plug in order to test the plugs seal. Depending on the situation, some customers will pressure test casing after the plug lands.
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amount of cement calculations. To find the buoyancy factor for this weight, you must look up 15.8. Now the length and weight of the piece of pipe in question are needed. Cement is inside the pipe in the shoe joint (40 ft) and displacement fluid is inside the pipe above the float collar (260 ft). The weight of the pipe is 36 lb/gal. Using the formula for downward force, determine the downward force contributed by the displacement fluid: Length of pipe buoyancy factor for the displacement fluid inside the pipe pipe weight per foot = pounds of downward force 260 ft 0.8671 BF 36 lb/ft = 8116.06 lb
3. In the same way, calculate the downward force contributed by the cement: 40 ft 0.7586 BF 36 lb/ft = 1092.38 lb 4. Adding these two downward forces together (Step 2 and 3) will give you the total downward force: 8116.06 lb + 1092.38 lb = 9208.44 lb 5. Subtract the upward force (Step 1) from the downward force (Step 4) to obtain the resulting force: 9208.44 lb - 6984.96 lb = 2223.96 lb Although this is considered a downward force, it will be necessary to chain down the casing as a precautionary measure.
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Well Parameters
Pipe Size Well Fluid Hole Size Pipe Depth
13 3/8-in. Casing
13 3/8 in., 68 lb/ft 8.5 lb/gal 17.5 in. 2400 ft 80 ft 400 ft 2000 ft 120%
Shoe Track Length Required Cement Fill-Up (TAIL) Required Cement Fill-Up (LEAD) Excess Volume Required (percent)
17 1/2-in. Hole
1
2,000 ft
Area Of Pipe 2 13.375 in 13.375 in 0.7854 = 140.50 in. (Section 240 Page 85) Hook Load 2,400 ft 68 lb/ft 0.8701 = 142,000.32/lbs (Section 130 Table 132 Buoyancy Factor)
2,320 ft
Pressure to lift (pump) pipe out of the hole 2 142,000.32 lb 140.50 in. = 1010 psi
2
Lead Tail Displacement
Cement Volume
Given Sl. Wt 13.6 lb/gal 3 Sl. Vol. 1.55 ft /sk Water 7.62 gal/sk Given Sl Wt 16.4 lb/gal 3 Sl. Vol 1.07 ft /sk Water 4.3 gal/sk = = = 277.84 ft
3
Lead Slurry Composition Halliburton Light Cement 2% Calcium Chloride 1/4 lb/sk Flocele
2,400 ft
Figure 5.20
Tail Slurry Composition Class H Premium 1% Calcium 1/4 lb/sk Flocele Tail 3 400 ft (openhole) 0.6946 ft /ft 277.84 ft 2.2 (excess) 3 80 ft (shoes) 0.8406 ft /ft
3
= =
3056.24 ft (lead)
NOTE: We are required to pump 120% excess cement on this job; 120% excess is equal to multiplying the perfect hole volume by 2.2.
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65% Class H Cement 35% Poz 6% Bentonite 2% Calcium Chloride .25lb Flocele Water Totals
Water
Totals 131.009
Total mixing water must be entered under absolute gallons before totaling. Find the weight of the mixed cement by using this formula: Total Pounds Total Absolute gallons = lb/gal Find the cement yield in cubic feet per sack by using this formula: Total Absolute gal 7.4805 gal/ft (constant) = ft /sk The mixing water per sack is the sum of the gallons in the far right column Cement Density Cement Yield Mixing Water Required 157.68 11.5820 11.5820 = 7.4805 = 13.6 1.55 7.62 lb/gal ft /sk gal/sk
3 3 3
Total mixing water must be entered under absolute gallons before totaling. Find the weight of the mixed cement by using this formula: Total Pounds Total Absolute gallons = lb/gal Find the cement yield in cubic feet per sack by using this formula: Total Absolute gal 7.4805 gal/ft (constant) = ft /sk The mixing water per sack is the sum of the gallons in the far right column Cement Density Cement Yield Mixing Water Required 131.009 7.9695 7.9695 = 7.4805 = 16.4 1.07 4.3 lb/gal ft /sk gal/sk
3 3 3
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3
Tail 3 3 678.50 ft 1.07 ft /sk
Sacks of Cement
= 634 sk
7
Force Down
Resulting Force
= = 137266.98 lb 4,076.74 lb 141343.72 lb
2320 ft 68 lb/ft 0.8701 BF 80 ft 68 lb/ft 0.7494 BF 2400 ft Total Down Force Up 140.50 in 661 psi
2
1972 sk
Hook Load
= =
2400 ft (Total Pipe) - 80 ft (Shoe Track) = 2320 ft (Top of Shoe) 2320 ft 0.1497 bbl/ft = 347.30 bbl
Hydrostatic Outside Tail 400 ft 0.8519 psi/ft Lead 2000 ft 0.7065 psi/ft Total: 2400 ft Hydrostatic Inside Tail 80 ft 0.8519 psi/ft Well Fluid 2320 ft 0.4416 psi/ft Total 2400 ft = = 68 psi 1025 psi 1093 psi = = 341 psi 1413 psi 1754 psi
Differential Pressure (At top of shoe) 1754 psi 1093 psi = 661 psi
Hint: Always re-total the lengths to make sure both outside and inside pipe segments are calculated. If the lengths are not the same then the calculations will be incorrect.
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Required cement fill-up (TAIL) Excess volume required (percent) GIVEN: Cement through casing as follows 30 bbl spacer @ 11.4 lb/gal
Followed by: Premium Class G Cement containing 0.5% CFR-3 + 0.1% HR-5. Displace plug with 10.4 lb/gal WBM. Due to drillout and deepening displace with mud instead of water.
9,620 ft
9,700 ft
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Cementing 1
= = = = = = X
5.00 gal
Total mixing water must be entered under absolute gallons before totaling. Find the weight of the mixed cement by using this formula: Total Pounds/Total Absolute gallons = pounds/gallons Find the cement yield in cubic feet per sack by using this formula: Total Absolute gallons / 7.4805 gal/ ft3 (constant) = ft3./sack The mixing water per sack is the sum of the gallons in the far right column
Cement Density (lb/gal) ==> Cement Yield (ft3/sk) ===> Mixing Water required ===>
15.8 1.16
lb/gal ft3/sk
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Cement Volume
3
Open Hole: 500 ft 0.1503 ft /ft 3 25% Excess: 75.15 ft 25% 3/ Shoe Track: 80 ft 0.2025 ft /ft Total:
= = =
2 3
Sacks of Cement
3 3
95 sks
4 5
Unknown Height of Spacer (for worst case) Height of Cement (for worst case) Discussion: In calculating the pressure to land the plug, we want to anticipate worst case which would be an increased pressure over plan. We planned our cement volume based upon hole washout (in this case 25%). We need to calculate the height of cement & spacer (Which are heavier than the mud) in a perfect hole situation which will give us a taller column & higher differential pressure. Height Of Cement Open Hole Volume 25% Excess Volume Perfect Hole Fill-up Factor (7 in OD 8 3/4 in hole) 3 3 93.94 ft x 6.652 ft/ft Height Of Spacer 30 bbl spacer (given) 30 bbl 37.3484 ft/bbl = ** Working from the bottom up** Height Of Mud 9700 ft - 624.89 ft - 1120.45 ft Hydrostatic Outside Cement: 624.89 ft 0.8208 psi/ft Spacer: 1120.45 ft 0.5922 psi/ft WBM: 7954.66 ft 0.5403 psi/ft Total: 9700 ft Hydrostatic Inside Cement (in shoe): 40 ft 0.8208 psi/ft WBM: 9660 ft 0.5403 psi/ft Total: 9700 ft Differential Pressure (at top of shoe) 5475 psi - 5252 psi = = 33 psi 5219 psi 5252 psi 223 psi = = = 513 psi 664 psi 4298 psi 5475 psi = 7954.66 ft 1120.45 ft spacer = = = = 75.15 ft (From 1) 3 18.79 ft 3 93.94 ft 3 6.652 ft/ft 624.89 ft cement
3
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Unit D Quiz
Fill in the blank with one or more words to check your progress in Unit D. 1. When using the Worksheet for Slurry Weight and Volume Calculations, the first thing you need to know is what ___________ of cement is being used. Then you can look up the ingredients ______________ and _____________ volume factors. 2. An absolute volume for each material is calculated by multiplying its _____ by its ___________. 3. To obtain the density of the cement mixture, divide the ________________ of the materials by the ________________________________________ of the materials. 4. To find the yield, the total absolute volume in gallons is divided by the constant, ___________ gal/ft. 5. To calculate the total volume of slurry needed for this job, add the slurry needed to fill the _________________ and the slurry needed to fill the ____________________. Your unit of measure will be ___________ which needs to be converted to __________. 6. To calculate the number of sacks needed for this job, divide the amount of slurry in _____________ by the _______________________________ in cubic feet per sack. 7. To obtain the total amount of mixing water you will need, multiply the number of ______/sk water by the number of __________.Then convert to the unit of measurement used in tanks, ___________, by dividing gallons by _______gal/bbl. 8. You need to calculate the pressure needed to land the plug, since a pressure build up might indicate_________ and a loss of pressure may mean ______________________________________________. 9. For the pressure to land the plug, you will need to use the ____________ ___________________________________ conversion tables in the Calculations and Formulas section of you handbook. You will look up the _____/ft of the fluids (extrapolating, if necessary), then multiply these by the depth of the float collar (or the length of the _____________ part of the hole).
Now, look up the suggested answers in the Answer Key at the back of this section.
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Items from Unit C Quiz 1. Divided, standard 2. Actual volume 3. Absolute volume
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4.
ABSOLUTE MATERIAL MATERIALS Brine Water Sand TOTALS (lb) 10 10 20 lbs 0.0456 FACTOR (gal/lb) = = VOLUME (gal) 1.0 0.456 1.456 gal
5.
Find the weight of the mixed cement by using this formula: Total Pounds/ Total Absolute gallons = pounds/gallon. Find the cement yield in cubic feet per sack by using this formula: Total Absolute gallons / 7.4805 gal / ft3 (constant) = ft3/sack The mixing water per sack is the sum of the gallons in the far right column.
Cement Density (lb/gal) ==> Cement Yield (ft /sk) ===> Mixing Water req (gal/sk)===>
3
7.8908 = 7.4805 =
16.5 1.05
Items from Unit D Quiz 1. type, water requirement, absolute 2. gal/lb, weight 3. weight, gallons 4. 7.4805 5. annulus, shoe joint, ft3, sk 6. ft3, yield 7. gal, sk, bbl, 42 8. bridging, lost circulation 9. hydrostatic pressure & fluid weight, psi, unbalanced
Refer to Page
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