2-Criteria for Successful Cementing
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Transcript of 2-Criteria for Successful Cementing
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TEACHING GUIDEDate: May 95Module No: CF01Page: 1Dowell
CRITERIA FOR
SUCCESSFUL CEMENTING
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TEACHING GUIDEDate: May 95Module No: CF01Page: 2Dowell
• As a dowell engineer what do we need to consider to provide a sucessful cement job?
• Discuss each one in brief
– Dowell Concept - A method of continous improvement from gaining experiecne from a particular field and across the company.
– Job Objective - What are we trying to achieve with the cement job
– Mud removal - Given the well conditions / type of mud what is the best method
– Slurry Properties - What is the requirements for the job - 18 5/8” or linerect.
– Special Cement Systems - is there a requirement given the well conditions / possible contingency for losses ect
– CemCADE Design - Ensure we have all the correct imputs to produce a competent design.
– Job Execution - Carried out as per design. Pumped at the designed rates ect.
– Job Evaluation - Follow up and ensure any key learning is taken forward.
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CRITERIA FOR SUCCESSFUL CEMENTING
Job objectiveMud removal (ahead of the slurry)Temperature predictionSlurry propertiesSpecial slurriesPlacement design (CemCADE)Job executionJob evaluation
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TEACHING GUIDEDate: May 95Module No: CF01Page: 3Dowell
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DEE
Design - Execute - Evaluate
Job Planning& Slurry Design
Logs Well/Job DataWell Post-Job
History
Blending Slurry Mixing& Placement
• This is know as Dowell DEE loop
• Consider all relevant aspects of the design well parameters / slurry designs / logistical and operational constraints ect.
• Program is then passed to the field and the job is executed
• Then the job is analysed and any key learning is taken forward to the next. Bond logs, volumes, losses, plug bumps ect
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TEACHING GUIDEDate: May 95Module No: CF01Page: 4Dowell
• What are the objectives of a cement job? Take a liner as an exaqmple.
• Zonal isolation
– Ensure no annular communication between zones
– Isolation of a hydrocarbon bearing / overpressured zone / water zone
– Protect the casing from corrosive brine flows / moving salt formations
– Casing support - mechanical properties of the cement must provide to the casing
– Mechanical properties reuire to provide a hydraulic seal
– Provide isolation around the shoe to provide a competent leak off to drill ahead
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Job Objective
• Isolation of productive zones
• Protection of water zones
• Isolation of problem interval
• Protection of casing
• Casing support
Cement bonded to formations
Complete cement sheath w/no mud or gas channel
Cement bonded to formations
Cement bonded to casing
Oil or Gas pay Zone
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TEACHING GUIDEDate: May 95Module No: CF01Page: 5Dowell
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Practices Affecting Primary Cementing
Poor Centralization
Wash out: Incorrect flow regime
Channeling: Incompatible
preflush or incomplete mud
removal
• Out of guage hole - As we drill through different formations such as sands or shales different well conditions will apply
• Gelled mud may be difficult to removed and may become trapped
• Flow regieme and preflush my not be applicable to the washed out sections
• Mud may mix in with the menet and will comprimise a hydraulic seal
• Poor centralisation will make it difficult to remove mud from the narrow side and will channel
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TEACHING GUIDEDate: May 95Module No: CF01Page: 6Dowell
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Slurry Design Factors Affecting Primary Cementing
High Free water
Water Intake
Gas IntakeShrinkage or
microannullus
• Slurry Design Aspects
– Slurry needs to be designed for its application
– Stable Competent Slurry
– Fluid loss across permeable or hydrocarbon formations
– Low shinkage propertries
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TEACHING GUIDEDate: May 95Module No: CF01Page: 7Dowell
• Mud removal is the key to any cemening operation
• Well preparation
– Ensure the hole is clean / stable (no losses)
– Centralise the casing
– Rotate / Recipricate the casing
– Circulate to ensure >95% of mud in the hole is moving
• Improve Mud removal
– Circulate and condition mud to ensure it is in good shape
– Design appropriate spacers / washes
– Design pumping schedules
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Mud Removal
Well preparation
Mud removal efficiency during the cementing
operation
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TEACHING GUIDEDate: May 95Module No: CF01Page: 8Dowell
• How do we condition the mud?
– Define the specification required for cementing
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Mud Conditioning
Lower Density – by removing cuttings and sand
Reduce ViscosityReduce Gel Strength by:– Circulation– Addition of Dispersants– Pipe Movement
Stabilize Well = no losses / no kicks
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TEACHING GUIDEDate: May 95Module No: CF01Page: 9Dowell
• Centralisation is another key issue in cementing
– To ensure competent cement bond we must centralise over the section
– Design to acieve a good stand off
– Centralisation will help towards flow all round the pipe
– Centraliser design must be taylored the the well profile
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Casing Centralizers
Centralizer
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TEACHING GUIDEDate: May 95Module No: CF01Page: 10Dowell
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Casing Centralization
% Stand-off = Wn x 100/ (R1-R2)
R2
R1
Wn
• Calculation of Standoff Example :- 9 5/8” Casing in 12 1/4” OH
R1 = 9 5/8” / 2 = 4.82”
R2 = 12 1/4” / 2 = 6.125”
Wn = 1”
% Standoff = (1 * 100) / (4.82 * 6.13) = 76%
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TEACHING GUIDEDate: May 95Module No: CF01Page: 11Dowell
• If we have an equal pressure drop:
– 1. 100% Standoff - flow will be uniform
– 2. 60% Standoff - Flow will always take the line of least resistance
– 3. 20% Standoff - Very little mud being removed from the narrow side
• To achieve isolation across a zone it must be centralised
• All fluid design is targeted at the narrow side
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Effects Of Standoff on Mud Displacement
Decreasing Stand-off
Mud
Cement
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TEACHING GUIDEDate: May 95Module No: CF01Page: 12Dowell
• Rotation - The preferred Option :-
– Rotation will help achieve flow all round the pipe
– Move the mud from the narrow side of the annulus
– Place cement into the narrow side
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Casing Movement: Rotation
Rotation Started
Mud Almost Removed
Resisting drag forces can become
positive mud displacing force
Casing StationaryFlowing Cement
Gelled Mud
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TEACHING GUIDEDate: May 95Module No: CF01Page: 13Dowell
• Reciprocation -
– If you have poor centralisationand trapped mud between centralisers you will be able to centralisers up and down over the areas
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Casing Movement: Reciprocation
Stat
ic M
ud
Cem
ent S
lurr
y
Poor Standoff
Cem
ent S
lurr
yCem
ent S
lurr
y
Improved Standoff
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TEACHING GUIDEDate: May 95Module No: CF01Page: 14Dowell
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Scratchers and Other Mud Removal Aids
Reciprocating sctatcher
Rotating Scratcher
Well Wiper
Hydro-Bonder
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TEACHING GUIDEDate: May 95Module No: CF01Page: 15Dowell
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Cement - Mud Contamination
Acceleration or Retardation
Reduction of Compressive Strength
Reduction of Hydraulic Bond
Increase of filtrate loss
Change of Rheological Properties
• Cement Contamination
– Cement and Mud are not compatable
– These are the effets to the slurry if there is intermixing of the mud
• What can we use st separate these?
– Spacers / Chemical washes which are compatable with both the mud and cement
– Plugs / Wiper darts ect
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TEACHING GUIDEDate: May 95Module No: CF01Page: 16Dowell
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Wiper Plugs
Prevent– Contamination of Spacer
– Contamination of Cement slurry
Wipe Casing clean
Indicate end of Displacement
Displacing Mud
Top Plug
Bottom Plug
Cement
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TEACHING GUIDEDate: May 95Module No: CF01Page: 17Dowell
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No Bottom PlugDisplacing
Mud Top Plug
Cement
Accumulated Mud from Film
Mud Film
MudCement Slurry
Mud
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TEACHING GUIDEDate: May 95Module No: CF01Page: 18Dowell
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Fill up - No Bottom Plug
Fillup per 1000 ft ofcasing *
Mud FilmThickness bbl/ 1000 ft ft m
1 / 64 in1 / 32 in1/ 16 in1 / 8 in
0.230.450.891.83
15.430.259.7
122.8
4.79.2
18.237.4
* Note : 4 1/2”, K-55, 13.5 lb/ft
Volume of mud wiped from casing wall
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TEACHING GUIDEDate: May 95Module No: CF01Page: 19Dowell
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Chemical Washes
Low Viscosity Fluids
Usually Water Based
Contain Surfactants and mud thinners
• What are Chemical Washes?
– Water + Surfactantnts + sometimes mud thinners (U066)
– Typically 1 SG - Viscosity - 5Cp
– Can be Weighted up with Salt - NaCl, Kcl - Not CaCl2
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TEACHING GUIDEDate: May 95Module No: CF01Page: 20Dowell
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Chemical Washes
Separate Mud and Cement– No incompatibility effect
Remove mud from annulus– Turbulence at low pump rate
– Erode, dilute and disperse particles
Leave casing and formation water wet– Function of the Surfactant
Provide less hydrostatic pressure– Water or oil-based
What They Do / How They Work
• Separate Mud and Cement
– Mud and Cement are not compatible!
– If high oil / water ratio OBM use mud thinners
• Remove mud from the annulus
– The preferred method of mud removal as they act in a turbulent flow regeim
– Act as a mud dilution
• Leave the casing and formation water wet
– Oil and water do not mix on there own
– Change from oil in water to water in oil emulsion
• Reduce the hydrostatic effect on the formation
– If pumped behind the cement, improve the positive pressure of the cement
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TEACHING GUIDEDate: May 95Module No: CF01Page: 21Dowell
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Spacers
Definition
Densified viscous fluid separating mud and slurryFunction
Thorough removal of mudProperties
Compatible with mud and cements– Mixtures less viscous than thicker fluid– No gel
Specified rheology– Low for Turbulent Flow– Adjustable for Effective Laminar Flow
• Viscous Spacer
– Gell used to control weight and viscosity
– Used when pore pressure / hole conditions do not allow the use of surfactants.
– Heavier than the mud 10% density increase
• Compatable with mud and cements
– Use surfactants for OBM
• Rheology
– Low rheology for Turbulent spacers
– Viscous for laminar flow spacers
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TEACHING GUIDEDate: May 95Module No: CF01Page: 22Dowell
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Cement Slurry Properties
Conventional Cement system:– Cement Slurry density
– Cement Slurry Rheology
– Free water
– Thickening Time
– Compressive Strength
– Fluid Loss Control
– >> UCA >> Z (Acoustic Impedance)
• Cement Systems
– Each of the above properties will be covered in more detail
– 15.8 - 16ppg is standard weight for neat cement to yield to give the required qualities - stable slurries
– Below 15.8ppg extenders are required to increase the water content and produce a stable slurry
– Rheology - specified rheology depending on the way the cement will be mixed in the field and the down hole requirements
– Free Water - if slurry is not stable the cement will settle out and water will be left at the surface - could allow a channel or micro annulus
– TT - Must be long enough + safety margin for the job
– Compressive strength - enough to support the axial force of the casing +hydraulic seal in the annulus
– Fluid loss control - used if pumping across production zones or pearmeable formations, and for squeeze.
– Maintain solid / water ration - a stable slurry
– Avoid bridging off while pumping
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TEACHING GUIDEDate: May 95Module No: CF01Page: 23Dowell
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Cement Slurry Density
HEAVY WEIGHT SLURRIES
Settled particles do not contribute to hydrostatic pressure
SettledParticles
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TEACHING GUIDEDate: May 95Module No: CF01Page: 24Dowell
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Cement Slurry Rheology
Friction Pressure
Flow RegimeLaminar ( sliding motion - zero flow on walls )
Turburlent ( swirling motion )
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TEACHING GUIDEDate: May 95Module No: CF01Page: 25Dowell
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Effects of Free Water
Channelling
Incomplete Fill-up
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TEACHING GUIDEDate: May 95Module No: CF01Page: 26Dowell
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Thickening time
If BHCT estimated lower than actual:
– OOPS > cement set prematurely in csg
If BHCT estimated higher than actual
– Slurry takes days to set
– Low set cement strength
– Poor bond
– Fluid migration thru gelled slurry
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TEACHING GUIDEDate: May 95Module No: CF01Page: 27Dowell
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Temperature Prediction
Two Basic influences on downhole performance of cement
– Temperature
– Pressure
Temperature has the biggest influence and affects– Thickening time
– Transition time
– Compressive Strength
– Fluid loss
– Rheology
– Free water
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TEACHING GUIDEDate: May 95Module No: CF01Page: 28Dowell
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Compressive StrenghPoor protection against lateral forces
Stable System
Overburden Pressure
Unstable System
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TEACHING GUIDEDate: May 95Module No: CF01Page: 29Dowell
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Fluid Loss Control
Hydrostatic pressure
Annular Bridging
Filtrate
Weak Zone
FiltrateDehydrated
Cement
FracturedWeak Zone
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TEACHING GUIDEDate: May 95Module No: CF01Page: 30Dowell
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Why use Fluid Loss Control
Maintain constant water-to-solid ratio– Constant Density
– Desired Yield
– Thickening Time
– Compressive strength
– Rheology
– Constant Properties
Avoid annular bridging or excessive pump pressureReduce formation damage
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TEACHING GUIDEDate: May 95Module No: CF01Page: 31Dowell
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CemCADE Job Design
Better zonal isolation– Optimum mud Romoval
Flow RegimePump rateMud removal effeciency vs stand-off
– Slurry design
Well security and control– No loss circulation– No fluid influx– No casing collapse– Anticipated surface pressure
Job evaluation– PRISM– CBL Adviser
• CemCADE takes into account all the factors discussed so far to predict the best placement design.
• Closses the DEE Loop.
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TEACHING GUIDEDate: May 95Module No: CF01Page: 32Dowell
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Job Execution
IS EXECUTION
AS PER DESIGN ?
Real Time Job Monitoring
PRISM
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TEACHING GUIDEDate: May 95Module No: CF01Page: 33Dowell
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On-site Data AcquisitionPRISM
– Pressure, Density, Flow rate sensors– Portable acquisition computer– Standard remote display
Quality of treatment execution through:– Record of treatment in real time– Accurate, reliable data acquisition regardless of
environmental conditions– Immediate post-job treatment reports
Treatment efficiency through:– Post-job analysis of data which
(1) ensures pressures and rates were as designed and
(2) helps to improve future designs
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TEACHING GUIDEDate: May 95Module No: CF01Page: 34Dowell
• Job Procedures
• The first thing to do on arrival on location, is to meet the company man and check the calculations with him and to verify that no changes have been made to the programme.
• Rig up all the equipment and lines.
• STEM 1 on all the equipment including priming and testing the units and lines.
• Verify that all the products and materials arrived correctly.
• Perform the prejob safety and organization meeting with everyone that will be involved in the job - the company man, the Dowell personnel and the rig crew.
• Start preparing the different mix fluids, spacers and washes. The compnay man may want you to wait until the casing is on bottom and the rig has started circulating - this is to avoid lost products if the casing cannot get to bottom. If this is the case, make sure everything is ready to go including correct water volumes in the tanks.
• This is a good moment to start taking samples of the different fluids.
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PRISM Plot
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TEACHING GUIDEDate: May 95Module No: CF01Page: 35Dowell
• The job itself starts when the company comes onto the unit:
– The lines are tested again but in the presence of the compnay man.
– The plugs are loaded into the cement head, in the correct order.
– The preflushes are then pumped also in the correct order.
– The bottom plug is dropped by the operator.
– The cement slurries can then be mixed and pumped at the correct density.
– The TOP plug should now be dropped, by the operator.
– Displacement is then done at the rate specified by the programme. The volume that can be pumped above the calculated displacement volume should be defined prior to the job and agreed to by the company man to avoid misunderstandings at this critical moment.
– The plug is bumped with the agreed pressure. Always check the returns to make sure that the float equipment is holding. If there is a constant return flow rate after about the first 4 or 5 barrels of returns, this can be considered as leaking float equipment. If this happens, then pump the fluid that has returned back into the well to push the plug back onto the float collar but without allowing the pressure to build up in the casing above the end of displacement pressure - then install a pressure sensor close to the cement head and close the line.
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Post Job Evaluation
Job Design (CemCADE) vs Job Execution (PRISM)
CBL Adviser
Cement Bond and Variable Density Logs (CBL-VDL)
Cement Evaluation Log
Pressure Test ( Shoe Bond Test )
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TEACHING GUIDEDate: May 95Module No: CF01Page: 36Dowell
• The end of the job can be as important as the rest of the operation and can leave a good or bad impression on the client.
– The washup should be performed to the waste pit of the rig. No water should be thrown on the client’s location - even though he has no problem with this, his boss may come and visit the rig the next day and he may not be as happy with our leftovers. The location should be left in as good or better condition than we found it.
– Rig down our equipment completely - avoid leaving Dowell’s equipment on the rig, the rig crew may not take the same care of our equipment as we do.
– STEM 1 the equipment. This is important to prepare for the next job and to identify idf there are any potential problems that appeared during the job.
– All the paperwork should be completed and either signed by the client or left with him. Remember that the client has probably been awake during the whole running of the casing, so avoid trying to pressure him to sign your paperwork when he is tired.
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SummaryDefine Cementing ObjectivesDesign with CemCADEImprove Mud Displacement
– Condition mud prior to cementing– Use centralizers– Rotate and / or Reciprocate – Avoid adverse mud cement reations– Control displacement rate and sapcer and slurry rheology
Optimize cement slurry designExecute the job as per designPerform a Post-job Evaluation