SPE 53955

Primary Cementing Optimisation: Well Conditioning Procedure and Foamed Spacer

Use
Carlos D. Degni, Tecpetrol S.A.; Carlos R. Marcinkevicius, Halliburton Argentina S.A.

Copyright 1999, Society of Petroleum Engineers Inc.

Cement Job Design
This paper was prepared for presentation at the 1999 SPE Latin American and Caribbean Cement jobs were designed using a dynamic computer model
Petroleum Engineering Conference held in Caracas, Venezuela, 21–23 April 1999.
that allows monitoring the equivalent circulation density
This paper was selected for presentation by an SPE Program Committee following review of (E.C.D) at weak zone(s) depth(s) during whole cementing job.
information contained in an abstract submitted by the author(s). Contents of the paper, as
presented, have not been reviewed by the Society of Petroleum Engineers and are subject to Predicted cement job simulator pressure curves are quite
correction by the author(s). The material, as presented, does not necessarily reflect any
position of the Society of Petroleum Engineers, its officers, or members. Papers presented at similar to actual recorded job data thus helps to improve
SPE meetings are subject to publication review by Editorial Committees of the Society of
Petroleum Engineers. Electronic reproduction, distribution, or storage of any part of this paper
cement job designs continuously.
for commercial purposes without the written consent of the Society of Petroleum Engineers is
prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300
words; illustrations may not be copied. The abstract must contain conspicuous Foamed spacer and lightened preflushes
acknowledgment of where and by whom the paper was presented. Write Librarian, SPE, P.O.
Box 833836, Richardson, TX 75083-3836, U.S.A., fax 01-972-952-9435.
To assure a proper annular drilling mud displacement and
filter cake removal and to contribute to cement bond design
Abstract we include the following spacer and preflushes sequence:
Since late 1993, in El Tordillo Field, Chubut, Argentina,
Tecpetrol S.A. has experienced severe cleaning and loss of Foamed spacer
circulation problems while drilling and cementing production It is designed to give 2000 ft annular height at bottom hole
casing in very depleted zones located from 4265 ft to 6562 ft, conditions
El Trébol and Upper Comodoro Rivadavia formations. 60 bbl crosslinked water base gel + 1% Foaming/Stabilizer
The average depth for the wells studied is 9843 ft, the Agents + 500 SCF/bbl N2
desired cement top for isolating primary and secondary Lightened chemical wash
production zones is 4265 ft. It is designed to give at least a ten-minute annular contact
Several drilling fluids and cementing procedures were time
optimised through the fifty-well drilling program. In spite of 90 bbl water + 2% KCl + 1% Surfactant+ 250 SCF/bbl N2
this optimisation procedure, random results were experienced Lightened reactive flush
while cementing the production casing, either single or two- A 30-bbl + 250 SCF/bbl N2 sequence is batch pumped
stage cementing jobs.
In the last thirteen wells a different approach to circulating A 5-bbl water/2%KCl (non-reactive spacer w/o N2) volume is
and cementing the production casing was adopted. pumped in order to separate the spacers from cement slurries.
The 7-inch production casing was circulated while running
at pre-selected depths. Preflushes for the cementing job were Cement Slurries
lightened with nitrogen, thus providing a low density, high Normal density range cement slurries were used in the
viscosity foamed spacer in the front of the primary cement job. cement job designs. There follows a general design slurries
The foamed spacer was used to improve displacement pumping schedule:
efficiency in open hole. The results were positive, the low-
density spacer and preflushes reduced loss of circulation while Scavenger Slurry
cementing the production casing and improving hole cleaning. Cement: 58.5 SK
So far the thirteen wells were cemented in one stage using Yield: 2.55 cu ft/SK
foamed spacer and lightened preflushes ahead of normal Density: 11.9 ppg
density cement slurries. Results have been very good with
cement columns rising up to 4265 ft. The casing and formation Lead Slurry
bond for these jobs have been excellent, achieving consistent Cement: required from 8200 ft to top of cement
results and a total saving over 42% of the total cementing Yield: 1.62 cu ft/SK
costs. Density: 13.8 ppg
2 C.D.DEGNI, C.R.MARCINKEVICIUS
Tail in Slurry
Cement: required from casing shoe to 8200 ft
Yield: 1.49 cu ft/SK
Density: 15.6 ppg
Dynamic computer model plots contribute to prove
conventional job designs (normal density spacer and
preflushes) that before cement slurries reach the weak zone,
during cement free fall, E.C.D exceeds the maximum safety
level. On the other hand, when the spacer is foamed and the
preflushes lightened, displacement is completed without
overcoming maximum safety level (see Fig. 1).
Well Conditioning Procedure
The main objective is to overcome 7-inch casing-running
difficulties observed in previous wells and to improve the
whole conditioning process.
Previous mud conditioning
Drilling mud fluid loss, filter cake thickness, Yield Point
(YP), Plastic Viscosity (PV) and Static Gel Strength (SGS) are
conditioned while circulating the well previous to POOH
laying down drill pipe and BHA to increase mobility and
facilitate the mud displacement process.
Good conditioned mud with low solid content has the
following values:
♦ Fluid loss: 6.5 cc
♦ Filter cake: < 3/32 inch
♦ Yield Point: < 11-lb/100 sq. ft
♦ Plastic Viscosity: < 15 cp.
♦ Flat gel strength profile 10 sec/10 min = 2/4
♦ 24 hours SGS: < 45 lb. / 100 sq. ft
The well is circulated, at least with a hole capacity plus
surface circuit volume, while conditioning mud rheology
sweeping with two 60 bbls mud viscous pills to ensure that the
hole is cleaned from cuttings.
Casing running considerations and intermediate hole
interval circulations
The casing running is performed carefully trying to avoid
surge pressures that overcome formation-fracturing gradients.
Any attempt to run casing without intermediate
circulations implies the strong possibility that the eroded
cuttings and partially dehydrated mud mobilisation can lead to
an induced loss of circulation. Therefore it is necessary to
circulate the annulus at intermediate depths before the bottom
of the hole is reached.
The well is circulated with a hole capacity – one annular
plus casing volume – at three pre-selected depths trying to
avoid an excessive pressure build-up when circulation is
resumed after several hours.
At every circulation depth, a 60 bbls mud viscous pill is
injected ahead to sweep the annulus and carry removed solid
materials out of the hole. Circulation is stopped when the
viscous pill reaches surface and mud shakers screens are solid-
free.
SPE 53955
Final well conditioning
When casing running is completed, final well conditioning
starts circulating at reduced flow rate bottom up while
reciprocating casing until the moment when shaker clean mud
return is observed.
After that, the following sequence is initiated and repeated
to the well conditioning process ends: a viscous pill is pumped
and flow rate and reciprocating strokes are increased. During
the entire final well conditioning process drilling fluid runs
through all available solid-control equipment.
Surface pumping rates are increased step by step while
monitoring mud displacement efficiency through software that
calculates the well annulus circulating percentage after
processing circulating pressures and flow rates measured on
the surface.
Maximum flow rate is established in advance, for each
particular final well conditioning, depending on previous
records obtained while drilling, to avoid inducing mud loss
circulation during this process.
Circulation is stopped when an acceptable circulating well
percentage is reached and mud shakers screens are solids free.
There are no previously fixed totals well conditioning times;
in each well, times are established following the procedure
and observing mud returns.
It is important not to allow mud to remain static for a long
period before the job is started; otherwise, there is a significant
decrease in displacement efficiency.
To reduce static period, double-plug, double-inlet
cementing heads were used. Both upper and lower
displacement plugs are pre-charged before cementing head is
made-up. See Fig.2 for details.
Injecting mud with drilling rig pumps through the mud line
inlet starts well circulation. After the final well conditioning is
completed, and the safety meeting is held, cement slurries are
batch-mixed and the cementing set is ready, the mud pump is
shut-down, the cementing line valve is opened, the well
circulation line valve is closed and cementing job starts as
soon as possible.
Previous to casing running a table is prepared to control
and post-evaluate the intermediate hole interval circulations
and the final well conditioning; e.g. El Tordillo Field type
well: Table 1 was prepared to control and post-evaluate the
intermediate circulation during running casing and the final
well conditioning process.
Location layout
A Nitrogen Unit was added to the cementing set used for the
previous conventional one or two-stage cementing operations
in El Tordillo field.
A foam generator and a check valve were added to the surface
line allowing injecting of N2 to the liquid phase without
affecting the cementing pumps normal operation.
The location layout used for the foamed spacer design is
shown in Fig.3.
SPE 53955 PRIMARY CEMENTING OPTIMIZATION: WELL CONDITIONING PROCEDURE AND FOAMED SPACER USE
Foamed Spacer
General description
The spacer is a stabilized system obtained by injecting “on
the fly”, and through a foam generator proper amounts of
nitrogen to the cross-linked gel that includes foaming
surfactant and stabilizer agents in its formula.
The tee foam generator provides the level of mixing
energy required to incorporate gaseous nitrogen into the
external liquid phase as discrete high-energy bubbles. It is a
very important device that contributes to the foamed spacer
stability.
Nitrogen is pumped at 1200 to 1500 SCFM constant flow
rate, adapting the cross-linked gel flow rate in order to obtain
500 to 750 SCF / bbl N2 concentration in the foamed spacer.
The shear experienced while is circulating downhole through
the casing contributes to foamed spacer homogeneity.
Nitrogen concentration is programmed to obtain the
required density to prevent formation breakdown and cement
slurries loss to weak formations. Computer assisted programs
are used to pre-plan changing nitrogen concentration, if
necessary, by adapting the design to particular job
requirements.
Foamed spacer density decreases as it ascends in the
annular space, compensating ECD increase caused by the
cement slurries annular circulation.
Nitrogen effects on the foamed spacer properties
The main effects caused by the addition of nitrogen to the
cross-linked spacer are:

Yield increase.

Density decrease.

Apparent viscosity increase – the flat profile allows to
maintain a neat interface between the displaced mud
and the foamed spacer thus helping to avoid
channelling.

Effectiveness of gelled and partially dehydrated mud
removal increases due to the enhancement of the
spacer erodability properties. The foamed spacer
contains a large amount of energy through the
entrained nitrogen gas that strongly contributes to the
annular cleanliness.

Solid suspending properties improvement. It allows
better solid transport.

An increase in temperature stability range.

Fluid loss reduction.

An excellent drilling mud compatibility kept
throughout the process.
Bottom hole, weak zone and wellhead foamed spacer
properties planning
A computer-assisted program is used to determine
commingled fluid to liquid ratio (VLR) foamed spacer quality
as nitrogen concentration and depth function; e.g. El Tordillo
Field type well: Table 2 shows the main properties estimated
3
for the foamed spacer - on surface, weak zone and bottom hole
depths.
The foamed spacer property evolution from casing shoe to
surface was plotted as depth function. See Fig.4.
We have prepared Fig.5 with the pore pressure data
obtained during the open hole logging using the computer
program output information. It shows ECD’s behavior in
contrast with well depth. The foamed spacer allows the
maintenance of the required ECD’s avoiding the inflow of
formation fluid or cement slurry loss towards weak
formations.
Foamed spacer lab test and field research
Water base gel formulation
50 lb./1000 gal Gelling Agent (HPG) + Gel stabilizer + pH
Buffers + Surfactant & Foam stabilizer agents
Intensive quality control test are conducted in the
laboratory using standard foam fracturing fluids procedures:
Cross-linking time test
Optimum cross-linker concentration test prevents the
harmful loading variation effects.
Over cross-linking results in loss of stability, reduction in
the fluid loss control and loss of viscosity. Under cross-linking
results in lower viscosity and instability. Variations of pH
could cause the same effect.
Foam stability test
Foamed spacer stability depends on texture with good
bubble size distribution and high level of dispersion
characterized by many very small bubbles that have a high
specific area.
Cross-linked water base gel viscosity has an elastic surface
layer optimum for foam stability.
The basic tests are repeated at the wellsite as part of final
fluid quality control to assure a proper performance.
Foamed spacer pumping procedure
Cross-linker additive is injected to the cementing-pump
suction, maintaining lab test determined ratio, with the batch
mixed linear gel. The implemented system assures a shorter
cross-linking time than the one required to reach the foam
generator.
The cross-linked gel quality and cross-linking time are
checked through a sampler located at the cementing pump
outlet, which shows the appearance of gel at surface
conditions and eventually allow us to modify the cross-linker
injection rate.
Nitrogen gas is injected to the cross-linked gel at the foam
generator, with a proper size selected choke; assuring that
sufficient energy is provided to the system to create stable
foam.
Foamed spacer surface handling procedure
The foamed spacer return to surface is controlled by the
following standard procedure:
♦ Stop casing reciprocation before foamed spacer
wellhead circulation.
4 C.D.DEGNI, C.R.MARCINKEVICIUS SPE 53955

♦ Close annular BOP. The registered cement logs were classified, according to
♦ Divert annular flow through a choke that allows, casing and formation bonding and general zonal isolation as:
maintaining a 100-psi to 300-psi backpressure, to ♦ 4 Very good
control the nitrogen expansion from annulus to ♦ 3 Good
atmospheric conditions. ♦ 2 Fair
♦ 1 Bad
Fig.6 shows the foamed spacer after having circulated An important cement quality improvement was obtained
down through the casing and returning to surface, cleaning the through well conditioning procedure and foamed spacer
annulus. design implemented as shown in Fig. 10.

Evaluation
Up to now thirteen wells have been cemented in one-stage
jobs using foamed spacer and lightened pre-flushes ahead of
normal density cement slurries.
Initially two wells were cemented using foamed spacer and
lightened pre-flushes, but without proper circulation at
intermediate depths while running casing. A total loss of
return was observed at total depth in both wells.
The cementing job was initiated without circulation and in
spite of the normal surface operations only fair results were
obtained. Cement columns barely reached from bottom to the
weak zone depths, showing a good quality of cement in
general. Both wells were squeeze cemented in order to correct
lack of isolation until the programmed top of cement.
As a direct consequence, the well conditioning procedure
was established and maintained up to date due to its
importance to the cementing operation success.
After that, an improvement in the general cost and quality
was observed for the rest of the wells.
For evaluation purposes we should consider these main
cementing job indicators:
♦ Cementing cost
♦ Cement column heights
♦ Cement column quality
Total cementing costs
Due to this procedure cementing costs were significantly
reduced (more than 42%).
Fig. 7 shows the total cementing costs obtained by using
both systems:
♦ Conventional: fourteen wells (28 cementing stages)
♦ Foamed Spacer: thirteen wells (13 one-stage jobs)
Cement column heights
Fig.8 shows the improvement arising from comparing the
programmed cement columns heights and the ones actually
achieved.
For conventional primary cementing jobs the determined
ratio includes the column heights in both stages.
Cement quality qualitative interpretation
Analysis of the CBL - VDL and ultrasonic logs - Fig.9 -
gives qualitative information about cement job results – casing
and formation bonding, mud channelling, occluded gas, etc. –
that contribute to the evaluation of the specific zone isolation.
Conclusion
The following conclusions can be drawn from the present
experience:
1. Mud rheology and well conditioning procedure while
running casing were important issues to be aware due to
their fundamental incidence on whole cementing job
results.
2. A proper casing centralization and reciprocation while
conditioning and cementing were maintained.
3. Final circulation process on bottom completes well
conditioning and assures a clean annulus previous to the
initiation of cementing job.
4. Foamed spacer contributed to the efficient displacement
of drilling fluid, helping to erode the partially dehydrated
filter cake. Foamed spacer shear stress exceeds the one in
drilling mud, allowing the solids removed from the
wellbore to be eroded and transported to surface.
5. Lightened chemical wash contributed to improve drilling
fluid removal by additionally eroding partially dehydrated
mud filter cake. Its water wetting effect leads to better
cement bonding to casing and to formation.
6. Lightened reactive flush helped to reduce permeability
across thief zones, to prevent loss of circulation and to
improve cement bonding to formation.
7. Due to the well conditioning procedure and foamed
spacer use, total cementing costs were significantly
reduced and a general quality improvement was observed.
8. The new approach also reduced well completion time and
allowed normal perforation, evaluation and production of
the selected pay zones.
9. Productivity of the drilled wells has risen together with
other technical advances that have improved drilling
economics both IRR and NPV.
Acknowledgements
We wish to thank TECPETROL SA and HALLIBURTON
ARGENTINA SA managements for their support in
preparation and presentation of this paper.
Nomenclature
VLR Commingled fluid to liquid ratio
IRR Internal rate of return
NPV Net present value
POOH Pull out of the hole
BHA Bottom hole assembly
 Table 1
Flow Lost Inicial Final
Joint Depth Time REMARKS
Rate volume pressure pressure
[ft] [gpm] [min] [bbl] [psi] [psi]
Injected 60 bbl viscous pill +
44 1962 278 26 30 325 300 + 1 Sk biopolymer + 2 L.C.M Sks

Injected 60 bbl viscous pill +

102 4491 282 60 170 500 400 adding 4 L.C.M Sks

Injected 60 bbl viscous pill +

186 8291 278 95 145 1200 700 adding 10 L.C.M Sks

278 60 700 650 Injected 60 bbl viscous pill +

217 9650 380 100 19 800 750 + 1 Sk biopolymer + 15 L.C.M Sks

450 120 830 780

Table 2

 

Gelled Chemical Reactive

Mud
Spacer Wash Spacer
Density 9.7 8.5 8.5 9.7
Viscosity - cP 20 407 1 1
N 2 Concentration - SCF/bbl 0 500 250 250

ECD - ppg 9.9

(*) Surface backpressure - psi 300 (*) applied when leading Foamed
Weak zone top - ft 4500 spacer edge reaches 400-500 m
Casing shoe depth - ft 9650

 

Bottom Weak
Surface
hole zone
Temperature [°F] 244 157 80

Pressure [psi] 4964 2317 300

Foam Quality [%] 30 41 82

Foam Density [ppg] 6.55 5.49 1.70

VLR [bbl mix. / bbl gel] 1.43 1.70 5.52

6 C.D.DEGNI, C.R.MARCINKEVICIUS SPE 53955

Figure 1

CEMENT JOB SIMULATOR

Circulating pressure and density at weak zone

4000 14

3500 12
Weak zone Fracture pressure

3000
10

2500
8
2000
6
1500

Weak zone Pore pressure 4

1000

500 2

0 0
0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 850

Volume [bbl]

Conventional Job Foamed spacer job

Fig 2

CEMENTING LINE MUD LINE

CEMENTING LINE

DOUBLE-PLUG, DOUBLE-INLET CEMENTING HEAD

SPE 53955 PRIMARY CEMENTING OPTIMIZATION: WELL CONDITIONING PROCEDURE AND FOAMED SPACER USE 7

Fig. 3

LOCATION LAYOUT

Manifold

BULK

BATCH
MIXER
NITROGEN TRUCK
CEMENTING
UNIT FLUSHES TANKS
COMPU VAN
8 C.D.DEGNI, C.R.MARCINKEVICIUS SPE 53955

Figure 4
FOAMED SPACER DENSITY & QUALITY PLOT

FOAM QUALITY [%]

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

500

1000

1500

2000

2500
FOAM
3000 QUALITY

3500
DENSITY
4000 QUALITY
4500

5000

5500

6000

6500

7000

7500
FOAM
8000 DENSITY

8500

9000

9500

10000
0 1 2 3 4 5 6 7 8 9 10
FOAM DENSITY [ppg]
SPE 53955 PRIMARY CEMENTING OPTIMIZATION: WELL CONDITIONING PROCEDURE AND FOAMED SPACER USE 9

Figure 5

PRESSUR E GRADIENTS
7" CASING CEMENTING JOB

5,000

PORE
5,500
FRAC

ECD máx
6,000

ECD mín.

6,500

7,000
DEPTH [ft

7,500

8,000

8,500

9,000

9,500

10,000
0 1,000 2,000 3,000 4,000 5,000 6,000 7,000

PRESSURE [psi]
10 C.D.DEGNI, C.R.MARCINKEVICIUS SPE 53955

Figure 6

FOAM RETURN TO SURFACE

SPE 53955 PRIMARY CEMENTING OPTIMIZATION: WELL CONDITIONING PROCEDURE AND FOAMED SPACER USE 11

Figure 7

AVERAGE CEMENTING WELL COSTS

100 %

57.5 %

CONVENTIONAL TWO STAGES FOAMED SPACER

Figure 8

CEMENT COLUMN HEIGHTS

100

90

80
91.0
70

60
71.3
50

40

30

20

10

0
CONVENTIONAL FOAMED SPACERS
12 C.D.DEGNI, C.R.MARCINKEVICIUS SPE 53955

Figure 9

CEMENT QUALITY
4

3.85
3

2 2.50

0
CONVENTIONAL FOAMED SPACERS

INDEX 4 = V.Good ; 3 = Good; 2 = Fair ; 1 = Bad

Figure 10

Interval 7900 - 8100 ft

SPE 53955 PRIMARY CEMENTING OPTIMIZATION: WELL CONDITIONING PROCEDURE AND FOAMED SPACER USE 13

71° 70° 69° 68° 67° 66°

0 30 44°
44°
MILES SOMOCURA MASSIF

45° NORTH- NORTH 45°

ARGENTINA

CHILE

OCEAN
WESTERN CENTRAL
AREA AREA

ANDEAN
BELT
COMODORO
WESTERN RIVADAVIA

ATLANTIC
46° AREA CENTRAL 46°
BASIN OFFSHORE
COMODORO
RIVADAVIA SOUTH-
WESTERN
AREA SOUTH
47° FLANK 47°

DESEADO MASSIF
71° 70° 69° 68° 67° 66°

TORDILLO FIELD
EL TORDILLO

PERIMETRO=154 Km
8.8 Km
2
SUPERFICIE=116 Km

21 Km

Location of San Jorge Basin, prominente oil field are indicated.