Cementing

Cementing

Objectives Primary and remedial placement techniques Applicable tools Job Sequences Slurry composition Job design calculations Required slurry testing

Cement Job Planning

1. 2. Identify purpose for placing cement
a) Primary - casing, liner, or tieback b) Remedial sidetrack or abandonment

Identify wellbore parameters

a) b) c) d) Pressure Temperature Fluid types Formations

3. 4. 5.

Determine TOC, and cement density and volume

a) Coverage b) Fracture limitations

Downhole equipment tools and procedures Communicate job details to Service Company

Primary Cementing
DefinitionPrimary cementing is the process of effectively displacing the drilling fluid and placement of cement slurry(s) to form a continuous and competent cement sheath within the wellbore annulus, while maintaining well control.

Primary Cementing: Objectives Support

Tension Lateral buckling, pressures

Isolation
From Surface Cross flow between zones

Compliance
Government requirements Company requirements

Isolation
Isolation between zones Isolation to surface For the life of the well Production Environmental Well Control

Aquifer

Isolation

Gas Sand

Intermediate Objectives
Objective Action

Remove mud / debris Hole condition, centralizers, spacers/washes, from area to be cemented flow rate, wiper plugs, pipe movement Maintain control of the wellbore Calculate hydrostatic pressure effects of fluid columns, Monitor and control U-tube effect

Deliver slurry volume with Choose cement type and additives for performance properties needed density, rheology, filtration, yield, required for job compressive strength, etc. Calculate cement volume required. Design job for best placement.

Primary Cementing Technique and Issues

Prepare wellbore for casing and cementing operation
Clean cuttings and debris out of hole Condition mud for easy removal Float equipment, stage tool, liner hanger Centralizers, external casing packer, liner top packer Cement Additives Mix water Mud Removal Cement coverage Timing Time Temperature

Run casing string with appropriate tools for the job Mix a dry cement blend on surface with mix water

Pump it into place in liquid form from the surface

Allow the cement to hydrate and harden in place

Running the Casing

Pull wear bushing. Confirm unobstructed access from v-door to rotary table. Rig up casing handling tools spider, elevator, tongs, hydraulic power, torque turn, fill up line. Pick up / make up shoe joints. Test floats. Run in hole. Continue running casing, filling as required. Add centralizers.

Float Equipment

Float Shoe Float Collar Acts as check valve Prevents cement back flow into casing Typically run in pairs Available in differential fill design All components drillable

Float Equipment Valve Operation

Centralizer Types
Bow Type Welded bow Turbolizer Spiral Bow Rigid Bow Solid Type Spiralizer Shorty spiral Straight Subs

Wiper Plugs
Purpose - to mechanically separate fluids (drilling fluids, washes, spacers, cement, displacement fluid) within the drill pipe or casing during cementing operations

Bottom Plug Top Plug

Job Types Conventional Casing

Job Types Inner String Casing

Job Types Liner

Wiper Plugs Ahead of Spacers or Behind?

Uncontaminated Slurry in Wiped casing behind plug

Uncontaminated Spacer and Slurry in Wiped casing behind plug

Spacer ahead of plug Film of Drilling Fluid not wiped from casing ID

Drilling Fluid

Inner String Stab-in Adapters

Latch-In Screw-In Tag-In

Provides hydraulic seal between inner string bore and float equipment. Piston effect tries to disengage seals during cementing. Inner string handling tools use false rotary mounted on casing.

Stage Cementing Tools

Also available in hydraulically actuated opening sleeve. Closing plug is pumped down as wiper plug after slurry. Both plugs are drillable.

External Casing Packer (ECP) / Stage Tool

Casing Flotation for ERD

Trapped air pocket above shoe creates buoyant force. This reduces drag due to normal force and allows casing to slide longer distances at high angle. One time conversion to normal circulation mode.

Well Security and Control

Fracture Gradients Formation Pressures Hydrostatic Pressures Equivalent Circulating Density (ECD) U Tubing, Cement Free Fall

U-Tubing and Cement Free Fall

Cement slurry density inside pipe is greater than the density of the fluid in the annulus, so it will fall to seek an equilibrium. With a closed system this will tend to pull a vacuum at the wellhead. How fast will it fall?
Depends on density differential and friction factor. Hold back pressure if needed.

Modeling with cementing simulator

Key Points
When cement is a liquid, it transmits hydraulic pressure like other fluids When cement is a solid, it is resistant to hydraulic or gas pressures. During the transition phase from a liquid to a solid, cement loses the ability to transmit hydraulic pressure but is not yet able to resist hydraulic or gas pressures

Volume Calculations
Capacity annular, between pipe and pipe or pipe and hole internal, within a pipe or hole Cement Volume annular volumes pipe or hole volume % Excess, accounts for actual hole size being greater than gauge Displacement Volume

Annular Volume
To calculate the annular volume between casing and hole equation is: CapacityAN x length = volume 12-1/4 ID of Hole

Capacity in bbl/ft = ((ID2 - OD2) x 0.0009713)

9-5/8 OD of pipe

(12.252 9.6252) x 0.0009713 = = 0.0558 bbl/ft

2500 ft

0.0558 bbl/ft x 2,500 ft = 139.5 bbl

Casing Volume
To calculate the internal volume of a casing the equation is: CapacityIN x length = volume 8.677 ID

Capacity in bbl/ft = ID2 x 0.0009713 = bbl/ft 8.6772 x 0.0009713 = 0.0731 bbl/ft 126 ft 0.0731 bbl/ft x 126 ft. = 9.2 bbl

Volume Calculations

Volume of Cement = Cased Hole volume + Open Hole Volume + Shoe Joint Volume

Cased Hole Volume VCH = CCH x LCH Open Hole Volume VOH = COH x LOH x Ef Shoe Joint Volume VShoe Joint= CCasingx LShoe Joint

72lb 13-3/8 Casing 12.341 ID

Cased Hole Volume CCH x LCH = VCH 0.058 bbl/ft x 500 ft = 29 bbls
TOC @ 1000 ft 1500 ft

47lb 9-5/8 Casing 8.677 ID

12-1/4 Hole

Open Hole Volume COH x LOH = VOH 0.0558 bbl/ft x 2500 ft = 139.5 bbls + Excess
126 ft

Shoe Joint Volume CCasingx LShoe Jt = VShoe Jt 0.0731 bbl/ft x 126 ft = 9.2 bbls

4000 ft

% Excess Calculation
% Excess is used to compensate for hole size being over gauge size. Generally use standard recommendations for % excess in open hole, unless there is caliper data available or it is otherwise agreed upon to use a different value. Open Volume including Excess = ((% Excess 100) + 1) x Volume For 100% excess this means 2x the calculated volume. For 50 % excess its 1.5x the calculated volume.

Recommended % Excess for Open Hole

Depth (feet) 0 4,000 4,000 8,000 8,000 10,000 10,000 18,000 Greater than 18,000 % Excess with WBM 100 75 50 35 25 % Excess with OBM 50 25 15 15 15

Volume of Cement = Open Hole volume 279 bbls + + Cased Hole Volume 29 bbls + + Shoe Joint Volume 9.2 bbls = 317.2 bbls
TOC @ 1000 ft 1500 ft

126 ft

4000 ft

Displacement Volume 8.677 ID

Equation for the Volume of casing is: Capacity x length = bbls Capacity = ID2 x 0.0009713 = bbl/ft (8.677)2 x 0.0009713 = 0.0731 bbl/ft 3,874 ft Length = Sfc. to Float Collar @ 3,874 ft Volume = 0.0731 bbl/ft x 3,874 ft. = 283.2 bbls

To determine the % excess for an enlarged hole diameter. % Excess = ([(ID22 - OD2) / (ID12 - OD2)] -1) x 100 % Excess = ((14.752 9.6252) / (12.252 9.6252) -1) x 100 = 118 %
ID1 = gauge hole diameter, in. (12.25 in this case) ID2 = enlarged hole diameter from caliper, in. (14.75 in this case) OD = casing size, in. (9.625 in this case)

Summary of Calculations
Phydrostatic = MWppg x .052 x TVDft MWppg = Pressurepsi .052 TVDft TVDft = Pressurepsi .052 MWppg Gradientpsi/ft = MWppg x .052 Gradientpsi/ft = Pressurepsi TVDft MWppg = Gradientpsi/ ft .052 Capacitybbl/ft = Hole Diameter2 x 0.0009713 Annular Capacitybbl/ft = (Hole diameter2 - Pipe Diameter2) x 0.0009713 Or Annular Capacitybbl/ft = (Hole diameter2 - Pipe Diameter2) / 1029.4 Fluid Column Height in ft = Volume in bbls Capacity bbl/ft Volume Excess = Calculated Volume x %Excess / 100 Volume including Excess = ((%Excess / 100)+1) x Calculated Vol Deq = SQRT((% excess /100+1) x ID2 )(OD2 x % excess /100)) %Excess = ((ID22-OD2) / (ID12-OD2)-1)x100 Casing ID = SQRT[OD2 - (Cwt x 0.3692)]

Cement Slurry Properties Density (ppg) Yield (ft3/sack) Rheology (PV, YP) Free Water (%) Solids Settling Fluid Loss (cc) Thickening Time (hh:mm to 100 Bc) Transition Time (hh:mm) Compressive Strength (psi)

Thickening Time
Thickening Time is dependent upon: 1.Temperature 2.Water content 100 3.Additives 120 F 80 4.Cement type 150 F 60 5.Pressure
Bc
40 20

Temperature Thickening Time

0 10 20 30 40 50 60 70 80 90 100 110 Time

Thickening Time
What Thickening Time is: It is a dynamic laboratory simulation conducted under standard conditions and procedures It provides an estimate of time in which cement slurry remains pumpable

Thickening Time
What Thickening Time is not: It is not an exact simulation of wellbore conditions It is not a measurement of cement setting It is not the amount of time the cement will remain pumpable if there are any unplanned shutdown periods during the job

Thickening Time
Time that is assumed to be available for placing cement Mixing and pumping: volume / rate = time Batch Blending = time Displacement: volume / rate = time Safety Factor = time

Static times that are not adequately accounted for in the Thickening Time test Planned Interruptions = static time Unplanned Interruptions = static time

Transition Time
Definition: Time between which a cement slurry behaves as a liquid and behaves as a solid Liquid - fully transmits hydraulic force Solid - resistant to any hydraulic force During this transition time the cement develops gel strength and loses its ability to transmit hydraulic force.

Transition Time
Generally accepted gel strength values Initial Set = 100 lb/100ft2 for initial set Final Set = 500 lb/100ft2 Transition Time = time from 100 lb/100ft2 to 500 lb/100ft2 The initial set value is now more often referred to as the critical static gel strength. This value can and should be calculated. The 500 lb/100ft2 value is a rule-of-thumb, useful for comparison purposes .

Cementing Materials
Cement API Construction Water Fresh Sea Additives Generic Proprietary

Oilwell Cement: Applications

Class Typical Use
North America, Limited to local regions of manufacture when conditions require moderate to high sulfate resistance. North America, Conductor and Surface casing jobs when special properties are not required. Conductor and Surface jobs, when conditions require high early strength. International, standard for oilwell cement. Most common cement for Gulf Coast operations.

A B C G H

Water
Fresh water, Drill Water
Standard for API specification test Typical for land operations City or potable water should be used. Water from a stream, lake, bayou or irrigation ditch may contain organic compounds which will interfere with the cement performance.

Sea Water
Typical for offshore operations. Tends to accelerate so often the switch is made to fresh water.

Brackish water
Can be used but must monitor quality.

Oilwell Cement: Units

1 sack of cement weighs 94 lbs 1 sack = 1 cubic foot Regardless of whether it is in bulk form or sack the standard unit of measure is the sack, and one sack = 94 pounds. Bulk # of sacks x 94lb/sk = pounds of cement Pounds of cement / 94lb/sk = # of sacks

Oilwell Cement: Water requirement

Compressive Strength
6,000

Hydration Water

Standard Water
Settling

2,000

Not Pumpable 30 40 Water Content %

Pumpable 50

Cement Hydration
Tricalcium Aluminate in the cement grain begins to interact with the water. A layer of Calcium Silicate Hydrate forms over the grain, causing osmotic pressure to increase as water diffuses inside the grain. Calcium Silicate Hydrate fibrils form and grow and interlink between grains, thereby increasing strength and decreasing permeability.
From Schlumberger

Water Requirement for API Cements

Type of Cement API Class C API Class A API Class G API Class H Water Requirement 6.3 gal/94-lb sack or 56% 5.2 gal/94-lb sack or 46% 5.0 gal/94-lb sack or 44% 4.3 gal/94-lb sack or 38%

Cement Additives
Definition: A cement additive is any material added to cement for the purpose of modifying the physical or chemical properties of the cement slurry or the set cement. Physical forms of additives are: Dry powder, granules and flakes. Liquids and liquid emulsions.

Cement Additives
What properties of the cement slurry or set cement can be controlled by additives? Density Rheology Free water Solids settling Fluid loss Thickening time Transition Time Compressive Strength Strength Retrogression Expansion Bond Strength

Cement Additives: Categories

Extenders - Yield, Cost, Density Weighting Agents - Density, Maintain well control Fluid Loss Control - Dehydration Accelerators - Thickening time Retarders - Thickening time Dispersants - Viscosity Lost Circulation - Slurry loss to formation Strength Retrogression Preventatives - CS Loss Gas Control - Transition time Anti-foam - Air entrainment

Cement Additives: Inconsistencies

Salt accelerates at concentration below 10%, but at concentrations above 10% it retards Some Fluid Loss additives viscosify, but others disperse Most retarders disperse, but some viscosify Dispersants almost always retard, but at low temperatures they can accelerate

Cement Additives: Inconsistencies

High temperatures require high concentration of retarder, but in some cases excessive retarder decreases pump time With slurry designs containing large amounts of additives, 5 or more, the synergistic effects often overcome the primary effects

Cement Additives: Units of Addition

Dry bwoc, by weight of cement lb/sk, pound per sack of cement bwow, by weight of water Example: 1% bwoc = 1 x 94 / 100 = 0.94 lbs Liquid gps or gal/sk, gallon per sack of cement gphs, gallon per hundred sacks of cement

Slurry Design
Cement Slurry design consists of determining the optimum mix of Cement, Water and Additives to provide the required properties for placement and long term performance of the cement sheath. Design Concepts General Designs Basic Requirements Special Conditions

Design Concepts
Designs should be simple Minimum additives Easier to take from lab to field Designs should be consistent Same blends, similar additive Designs should be flexible Not sensitive to minor fluctuations in additive concentration or well conditions Designs must meet requirements

Wellbore Conditions vs Slurry Properties

Parameters Pore and fracture pressures Lost circulation Hole and casing geometries Formation properties Mud Properties Cement Fill Properties Density Thickening Time Rheology Fluid Loss Compatibility Volume, Yield

Temperatures, BHST, BHCT -

Lead, Tail and Single Slurries

Lead Slurries Extended, higher yield per sack, lighter weight Lower cost, lower performance Tail Slurries Mixed at normal density Optimized properties Single Slurries One slurry at one density

Slurry Design Guidelines

When there is oil or synthetic mud in the hole
Must test compatibilities

Across salt zones

Cement slurry must be salt tolerant

For temperatures greater than 250 F

Silica sand or flour must be added

Slurry Design Priorities

1. 2. 3. 4. 5. 6. 7. Density Thickening Time Mixability Rheology Fluid Loss Control Compressive Strength Free Fluid and Settling

Slurry Design: General Requirements

Density + 1.0 ppg > drilling fluid density + 0.5 ppg > spacer density < Equivalent Circulating Density (ECD) to fracture formation Thickening Time Job time plus safety factor, one hour plus Production / gas control - right angle set

Slurry Design: General Requirements

Rheology Conductor / Surface - mixable and pumpable, thixotropic for lost circulation Intermediate PV < 150, YP < 40 Production PV < 100, YP < 20 Fluid Loss Surface < 500cc/30min Intermediate < 250 cc/30min Production < 100 cc/30min Gas Control < 50 cc/30min

Slurry Design: General Requirements

Compressive Strength 8 hours maximum for WOC, 500 psi 24 hr, 1000 psi Perforating, 1500 to 2000 psi Free Water Surface strings Deviated wellbores Production strings < 1.0 0% 0%

SLURRY PROPERTIES

Conductor and Surface Casings

Intermediate Casings and Drilling Liners

Production Casings and Liners

Deep Production Liners and for Gas Control

+ 1 lb/gal > drilling fluid density DENSITY < Equivalent Circulating Density (ECD) to fracture formation Job time plus at least one hour for safety factor THICKENING TIME For Production casings or for gas control, the TT chart should display a right angle set (transition from 40 to 100 Bc less than 15 minutes) FREE WATER FLUID LOSS RHEOLOGY PV YP Compressive Strength WOC (hrs to 500psi) 24 hr < 12 1,000 <8 2,000 <8 2,000 <8 2,000 < 150 < 50 < 150 < 40 < 100 < 25 < 100 < 20 < 1.0% NA < 0.5 % < 250 0% < 100 0% < 50

Thickening Time
When specifying Thickening Time requirement: Calculate, Do Not Estimate Temperature. Use simulators as necessary. Time to mix and pump lead and tail. Time to drop plugs. Displacement time. Safety factor Evaluate risks TT must be long enough to insure placement. Excessive TT increases the risk of well control problems and poor isolation Remember lab test is a dynamic test

Densified Slurries
Cement Slurry density be increased by using less water through the use of dispersants to maintain rheological properties Class G cements can be mixed at up to 16.5 ppg and Class H cements can be mixed at up to 17.2 ppg. Hematite common weighting agent.

Remedial Cementing
Squeeze - The placement of a cement slurry, under pressure, against a permeable formation causing the slurry to dehydrate and create a cement seal across the formation face.
Repair a primary cement job or casing leak Add height to cement column to produce upper zones Eliminate water from the hydrocarbon zone Reduce the producing gas:oil ratio Seal the annulus of a liner top or casing shoe Plug zone(s) in a multi-zone injector or production well

Balanced Plug - The placement of a cement slurry, under normal circulation, to provide isolation between the lower and upper portion of the wellbore.
Sidetrack Plug back Abandonment

Spacers for Plugs

Separate mud and cement with an adequate volume of spacer or wash WBM: Chemical wash or spacer SBM: add surfactant to water wet surfaces Volume of spacer/wash ahead to be equivalent to 500ft of annular fill Spacer behind at volume calculated to balance Always calculate the loss in hydrostatic pressure when using water or base oil/synthetic ahead of a cement plug assuming gauge hole

Plug Cement Volume

Use a caliper log to determine the cement volumes and where to set the plug Set plug in a near gauge section of the hole If no caliper, use the recommended excess Actual excess should account for knowledge of the particular area and hole conditions
Hole Size (in) 30-26 24-30 14-3/4 17-1/2 12-1/4 6 8-1/2 % Excess (WBM) 200 100 50 30 30 % Excess (SBM) 20 20 20

USI CBL comparison

Cement Heavy, medium, good bond Very light, good bond De-bonded, dry microannulus Liquid microannulus Mud Layer Mud Channel Contaminated Gas Channel
Good interpretation Ambiguous

USI

CBL

Very ambiguous or not detectable

Acknowledgements Thanks to Unocal for their assistance in the preparation of this material Many of the casing tool examples are from Davis-Lynch company. Many of the casing handling tool examples are from Varco and BJ as provided by Weatherford.

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