01 Well Cementing - Day 1 PDF

Quartz School for Well Site Supervisors
Module – 7
Well Cementing Ops.
Schlumberger Private
Section – 1
Well Cementing – I
1
Well Cementing
Day 1
2
Agenda
• Primary Cementing
• Cement Chemistry
• Slurry Properties, Additives and Lab Testing
• Cementing Calculations
3
Knowledge of Cementing (1)
• The Well Site Supervisor must be able to:-
to:-
– Calculate the volumes of a Primary cement job.
– Calculate the volumes of a Secondary/Remedial cement job.
– Understand associated hydrostatics of the cementing operation.
– Give clear instructions to the cementer on the objectives of the job.
– Monitor and witness the pumping of the cement from start to finish.
– Be able to react quickly and make decisions if cement job is not
going to plan.
– Evaluate the competency of a cementing engineer
– Apply the rigors of the steps of the cementing program contained
within the Drilling Program.
4
Knowledge of Cementing (2)
• Over and above the tasks of the Well Site Supervisor, the Well
Engineer must be able to:
– Rationalize the design of a cement job based on objectives, cost
and technology.
– Understand the hydraulics and hydrostatics during a cementing
operation.
– Understand the mechanics of cement placement techniques.
– Evaluate the completed cement job based on logging data and /or
associated pressure tests.
– Formulate a plan by which cementing service companies can be
measured for quality of cementing operations.
5
Primary Cementing
6
Primary Cementing - Objectives
• Definition and purposes
• Types of casing and cementing
• Cement job design basics
• Equipment
7
Primary Cementing
The introduction of a cementacious
material into the annulus between
casing and open hole to :
Fresh water
– Provide zonal isolation
– Support axial load of casing
strings and strings to be run
Shale
later
– Provide casing support and Salt water
protection or oil
– Support the borehole
8
Types of Casings
• Conductor
• Surface
• Intermediate
• Production casing
or or liner
9
Conductor
• Purpose:
– Prevents washing out under the rig
– Provides elevation for flow nipple
• Challenges:
30 ‘’ casing in 36’’ hole
– Possible occurrence of shallow water
flows
or – Low temperatures (offshore)
20 ‘’ casing in 26’’ hole – Drilling through gas hydrates under
deep water conditions (offshore)
@
• Others:
30 ft - 200 ft – Large excess
– Stab-in cementing common
– Accelerated neat cement
10
Thru-Drill Pipe Cementing (Stab-in)
• Key Points:
– Less cement contamination
– Less channelling
– Small displacement volume
– Pump until cement to surface
– Less job time (rig time)
– Less cement
11
Outside Cementing (Top Job)
• Key points:
– Bring cement to surface
– Macaroni tubing used
– Max. depth 250-300 ft
– High friction pressures
Tubing – Non-standard connections
moved
during
job
12
Surface
• Purpose:
– Protect surface fresh water formation
– Case off unconsolidated or loss areas
– Provide a competent mechanical base
for subsequent operations (BOP, etc.)
• Challenges:
– Possible occurrence of shallow water
16 ‘’ casing in 20 ‘’ hole flows
or – Low temperatures (offshore)
13 3/8”
3/8” casing in 17 ½” hole – Drilling through gas hydrates (offshore)
@
100 ft – 3000 ft
• Others:
– Light weight lead and neat tail slurries
– Large excess ( 50 - 150 %)
13
Intermediate Casing(s)
• Purpose:
– Isolate hole into workable sections
• Challenges:
– Potential problems: over-pressured, loss
zones, salt formations or heaving shales
– Narrow pressure window, between pore
@ bottom & frac @ top
13 3/8” casing in 17 ½” hole

or
9 5/8” casing in 12 ¼” hole
@
3000 to 10,000 ft (vertical or deviated)
14
Intermediate Casing(s)
• Others :
– Often need a two-stage job
– Best cementing practices are required
– Cemented to surface or to previous casing shoe
– Typically filler slurries followed by high
compressive tail
– Specialised slurries (light, heavy, salt etc)
13 3/8” casing in 17 ½” hole

or
9 5/8” casing in 12 ¼” hole
@
3000 to 10,000 ft (vertical or deviated)
15
Two Stage Cementing
• Key Points:
– Separation and isolation of zones
– Reduces hydrostatic
Stage
Collar – Can leave zone in the annulus uncemented
(cement at TD and surface)
1st Stage
16
Production Casing(s) or Liner(s)
• Purpose:
– Isolates the pay zone from other formations
and the fluids in them.
– Protective housing for production
equipment.
• Subsurface artificial lift
• Multiple zone completion
• Screens for sand control
– Covers worn or damaged intermediate
Common sizes:
string.
4 ½”, 5”, 7’’, 9 5/8”
17
Liners
Pump Down Plug
“Dart”
• Key Points:
Liner Hanger
– Requires less casing
Liner Wiper – Deeper wells
Plug
– Small annular clearance
Liner Over Lap
– Specialized equipment
Previous Shoe
15
18
Designing a Cement Job
• Compute fluid volumes
( Slurry, Wash, Spacer, displacement volumes )
• based on :
– Hole capacity
– Casing capacity
– Annular length
• Low cost implies:

– Good mixing and economical pumping
19
• Check that well security is respected:
– Simulate cement pumping process
to compute hydrostatic and dynamic
pressures and compare them to :
– Formation pore pressure

– Formation fracture pressure
– Tubular burst pressure
– Tubular collapse pressure (∆ P)
• Ensure well security when
Running In Hole
• Check temperature and thickening
time
20
• Check for an efficient mud removal to
prevent mud channeling and to ensure
good zonal isolation
– Optimize fluid properties
– Optimize the pumping rate
– Optimize casing centralization
• Ensure good wall cleaning
– Optimize pre-flushes volume, and flow rate
21
Casing
• Tapered string used to minimize well cost.
• Casing program for well based on :
– Burst Pressure
• API casing spec
– Collapse Pressure – OD 9 5/8”
– Tensile Load – Weight 53.5 lbs/ft (determines ID)
– Grade C75
– Burst pressure 7430 PSI
– Collapse pressure 6380 PSI
– Thread Buttress
16
22
Thread Types
• 8 Round
– Seals on threads
– Use of couplings
• Buttress
– Seals on threads
• VAM
– Seals on threads & shoulder
• Hydrill
– Seals on threads & shoulder
– Integral
– 2 sets of threads
23
Running Casing
• Inspection of Casing • Running
– Tuboscope – Casing crews
– Pipe tally – Too fast
• Hole Preparation – Landing Casing
– Mud condition – Nippling up
– Clearance
18
24
Casing Running and
Cementing Procedures
25
A Casing String – Reminder!
Casing
Float Collar
Shoe Track
26
Float Shoe
Casing Running Procedures
The objective of running casing is to:
• Prevent the collapse of the borehole during drilling.
• Hydraulically isolate the wellbore fluids from the
subsurface formations.
• Provide a high strength flow conduit for the drilling
fluid to the surface
• With the BOP permits the safe control of formation
pressures.
27
Casing Running/Cementing Procedures
To achieve this the casing must be:
• Centralized to achieve a good cement bond.
• Cemented to a sufficient height that provides isolation.
• Cemented with flow properties that optimize mud removal.
• Balanced (with fluids) inside and out during cementing
to prevent burst or collapse.
• Pressure tested after cementing to ensure integrity and
stability.
28
Casing Running/Cementing Procedures
A good cement job depends on:
• Sufficient mud filter cake and mud removal.
• Correct design densities pumped into the well.
• Correct use of cementing plugs.
• Correct displacement. (No over-displacement)
• Sufficient waiting time for cement to set (WOC).
• Correct pressure testing procedure after cementing.
29
Centralizing the casing
• Requires the fitting of centralizers to achieve a
minimum stand-off of 67% (API)
Ridged Centralizer Spiral & Turbulent Centralizers
30
Fluid Flow Regimes
V=0
Laminar Flow
Velocity Profile V=2 x Vav
(Sliding motion)
Turbulent Flow
Velocity Profile
(Swirling motion)
Laminar and Turbulent Flow regimes are found

anywhere (pipe, concentric or eccentric annuli)
31
Flow in an eccentric annulus
Dp
Do V > v Always
v V
32
Un - Centralized casing
Mud Removal
Turbulent
Flow
Minimal
Mud Removal
Laminar
Flow
33
WellClean II Simulator
Turbulent Main Outputs
–2D map of fluid velocities
–2D map of fluids concentration across the
Lamina annulus
r –2D map of “Risk of mud layer left on the walls”
–2D map of cumulative contact time in turbulent
flow
34 –2D map of flow regime
A.2 Determination of restoring-
restoring-force requirements (API 10 D)
Field observations indicate hole deviation from vertical on an average varies from zero to
approximately 60°.
Therefore, an average deviation of 30° is used to calculate restoring-force requirements.
For casing diameters 273mm (10 ¾ in) through 508mm (20 in), where casing strings are generally
placed in
relatively vertical hole sections, the minimum restoring force shall be not less than:
FR = W sin 30 = 0.5 W
where
FR is the minimum restoring force, expressed in newtons;
W is the weight of 12.19 m (40 ft) of medium linear-mass casing, expressed in newtons.
For casing diameters 114mm (4 ½ in) through 244mm (9 5/8 in), where casing strings are generally placed
in the
deviated hole sections, the minimum restoring force shall be not less than:
FR = 2 W sin 30 = W
35
Centralizer Spacing Equations
T = 0.0408 * TVD * (ρid2 - ρeD2 ) + cos ø * w * S
(WF)b = w + 0.0408 (ρid2 - ρeD2 )
F
CS =
0.0175 * T * DLS + (WF)b * sin ø
CS
F = 2T sin (DLS * ) + (WF)b * CS * sin ø
2
36
Where:
T = tension in the wall of the pipe; lbf

(WF)b = adjusted buoyed force
CS = centralizer spacing; feet
F = force on each centralizer if spaced CS feet apart; lbf
w = weight per foot of pipe (steel only); lbf/foot
Fb = buoyancy factor; no units
ø = average inclination angle near the centralizer; degrees
DLS = dogleg severity; degrees/100 feet e.g. DLS = 0.03
TVD = true vertical depth to the shoe of the casing; feet
d,D = ID and OD of the casing; inches
S = distance from the casing shoe to the centralizer; feet
ρ = mud weights inside and outside the casing; ppg
37
Exercise 1
How many 7” casing centralizers should be used to ensure a
67% standoff for 1500ft of liner at a hole angle of 30°?
The liner is 29ppf. Mud inside 12ppg. Cement outide 15.8ppg.
Centralizer force is 1200 lbf nominal
Which style/type centralizer should be used?
Exercise 2 - Homework
What is the centralizer spacing required from 6122 ft
(36º) to 6302 ft (44º). MD 9989 ft, TVD 4111 ft. Mud
inside 15ppg, mud outside 12ppg. Casing is 9 5/8 (D)
with ID 8.535 inches (d). DLS is 4.79º.
38
Equipment On-Shore
Bulk Plant
Silos, WBB, Compressor, Dust
Collector
CemCAT
Batch Mixer Fill
Density, rate, pressure

Diesel Engine
39
Equipment Off-Shore
Batch Mixer
CPS
LAS Cement Pump Skid
Liquid Addtive System
Cement Head
Slurry Chief (Sub Sea System)
40
Mixing System
Cement Heads
Surface Expres Conventional
cement head cement head
Oil Level Indicator
PDD
41
Primary Cementing - Summary
• Definition and purposes
– The introduction of a cementacious material into the annulus between
casing and open hole to
• Types of casing and cementing
– Conductor, Surface, Intermediate, Production or Liner
• Cement job design basics
– Hole & casing capacities, Formation temperature & pressures, Static &
dynamic hydrostatic pressures, Flow regimes, etc
• Equipments (On-shore & off-shore)
– Cement pump skid, Cement pump truck, Bulk plant, Batch mixer, Cement
heads, Liquid Additive System, Cement mixing system
42
10 Minutes
Break
43
Cement Chemistry
44
Agenda
• Manufacture of Portland cement
• API cement classification
• Hydration of Portland cement
– Silicate phases (C3S and C2S)
– Aluminate phases (C3A and C4AF)
– False set and flash set
• Strength retrogression at elevated temperatures
• Shrinkage
45
Different Steps of the Cement Manufacturing
CALCAREOUS-2 parts ARGILLACEOUS- 1 part
• Limestone (CaCO3) • Clays
• Cement rocks • Shales
• Chalk • Slate and Mudstones
• Raw Materials • Marl • Blast furnace slag
• Marine shells and coral • Ashes (fly ash)
• Alkali waste • Cement rock
Grind + Heat Treat in Kiln Temperature + 1500oC
• Clinker CEMENT CLINKER
• C3S : Tricalcium Silicate
• C2S : Dicalcium Silicate
• C3A : Tricalcium Aluminate
• Addition of Gypsum • C4AF : Tetracalcium Aluminoferrite
• Ca + Mg Oxides, Ca (OH)2, CaCO3, Na2SO4, etc
Controlled Cooling To second grinding mill

• Portland Cement
ADD 3 - 5% Gypsum (Ca.SO4.2H2O), or Blend of Gypsum + Plaster
Pulverise mixture And Blend

PORTLAND CEMENT
C2S + C3S + C3A + C4AF + CaSO4. 2H2O + CaO + MgO
+ (Na2SO4 + NaKSO4 + CaK2(SO4)2 , or K2SO4
(depending on the cement)
46
Proportioning of Raw Materials
• CaO65%
– Too Low Low Early Strength
– Too High Cracking and Unsoundness
• SiO2 22%
– Too Low Rapid Setting
– Too High Slow Setting
• Al2O3 5%
– Too Low Raises Temperature Required for Burning
– Too High Rapid Setting and Gelation
• Fe2O3 4%
– Too Low Rapid Setting and Gelation
– Too High Slow Set
• MgO 1% Unsound Cement if Above 6%
47
Limestone Quarry
48
Transportation of
Raw Materials to
Cement Plant
49
Cement Manufacturing Processes
• Dry process
• Wet process
– More expensive
– Less and less used
50
Raw Materials Preparation:
Dry Process
Grinding and blending of dry materials
Less clinker quality
Cheapest process
51
Raw Materials Preparation:
Wet Process
Grinding and blending of slurried materials
More uniform clinker quality
Expensive process due to fuel required to evaporate the water
52
Burning Process (Continuous Process)
- length of kiln: up to 200 m - rotation speed: 1 to 4 RPM
- diameter: up to 7 m - slope: 3.5%
- weight: up to 1500 tonnes - clinkering temperature ≈ 1500°C
53
Clinkering Zone in the Kiln
Clinker
54
Clinker Composition CaO
Alite
C3S
Bélite
C2S
C3A
Aluminates Liquide
C4AF
{ 2 CaO + SiO2 = C2S
Silicates 80 %
3 CaO + SiO2 = C3S
Aluminates 20 %
{ 3 CaO + Al2O3 = C3A
4 CaO + Al2O3 + Fe2O3= C4AF

55
Cooling Rates & Cement Properties
• SLOW COOLING • FAST COOLING
– Enhances Crystallisation – Glassy Material
• Harder to Grind • Easier to Grind
– Less C3A and free MgO stays in glassy
– More C3A and MgO formed phase
• More unsoundness • Less unsoundness
– C3S & C2S more highly – C3S & C2S less highly ordered
ordered • Lower early strength and higher longer
term strength
• more hydraulically active
• higher early compressive
and lower longer term • OPTIMUM COOLING
strength – 4-5oC/min 1500oC to 1200oC
– 18-20oC/min to ambient
56
Grinding Process and Storage
57
Finish Mill Grinding
58
Quality Control of Cement
- oxide composition
- mechanical properties
59
Storage and Distribution System
60
Cement Plant
1- Quarry 1
2- Raw
materials
2
7- Storage 7
6- Grinding
8- Shipment 8 6 3
3- Preblending
4- Kiln 4 5 5- Clinker silo
61
API Cement Classification
62
ISO/API Cement Classification
• Chemical requirements
• Performance requirements
63
Typical Oxide Composition
of Class G and H Cements
64
Calculating Cement Phase Composition
Oxide Composition: Mineral Composition:

% CaO
% C3S
% SiO2
% C2S
% Al2O3
% C3A
% Fe2O3
% C4AF
% SO3
THE BOGUE EQUATIONS TRANSFORM AN OXIDE
COMPOSITION TO MINERAL COMPOSITION
Mass Balance ‘N’ Equations ‘N’ Unknowns
65
ISO/API Specification of Class G/H
Cements
• Quality Control: Composition and Performance Specifications
– ISO/API Schedule 5 Thickening Time (52oC) 90 - 120 min
– Consistency after 15 min Stirring Max 30 Bc
– 8 hours C/S at 100 degF Min 300 psi
– 8 hours C/S at 140 degF Min 1500 psi
– Free Fluid Max 5.5 ml
– MgO Max 6%
– SO3 Max 3%
– LOI Max 3%
– Insoluble Residue Max 0.75%
– C3S 48% to 65%
– C 3A Max 3% (for HSR)
– C4AF + 2 C3A Max 24%
– Total Alkalis expressed as sodium oxide equivalent Max 0.75%
66
ISO/API Cement Classification (I)
• ISO 10426-1:2000 or API Spec 10A
• General Construction Cements
– CLASS A : Intended for use from surface to a depth of 6,000 ft (1,830 m), when
special properties are not required. Similar to ASTM Type I cement (high C3A
content)
– CLASS B : Intended for use from surface to a depth of 6,000 ft (1,830 m).
Moderate to high sulphate resistance. Similar to ASTM Type II, and has a lower
C3A content than Class A.
– CLASS C : Intended for use from surface to a depth of 6,000 ft (1,830 m) when
conditions require early strength. Available in all three degrees of sulphate
resistance, and is roughly equivalent to ASTM Type III. To achieve high early
strength, the C3S content and the surface area are relatively high.
67
ISO/API Cement Classification (II)
• The retarded cements
– CLASS D : Intended for use from 6,000 ft (1,830 m) to 10,000 ft (3,050 m)
under conditions of moderately high temperatures and pressures. It is
available in MSR and HSR types.
– CLASS E : Intended for use from 10,000 ft (3,050 m) to 14,000 ft (4,270 m)
under conditions of high temperatures and pressures. It is available in
MSR and HSR types.
– CLASS F : Intended for use from 10,000 ft (3,050 m) to 16,000 ft (4,880 m)
depth under conditions of extremely high temperatures and pressures. It
is available in MSR and HSR types.
• Not used anymore (for a long time)
68
ISO/API Cement Classification (III)
• General Purpose Cements
– CLASS G & CLASS H : Intended for use as a basic well
cement from surface to 8,000 ft (2,440 m) as manufactured,
or can be used with accelerators and retarders to cover a
wide range of well depths and temperatures. No additions
other than calcium sulphate or water, or both, shall be
interground or blended with the clinker during
manufacture of Class G and H well cements. They are
available in both MSR and HSR types.
69
Slurry Properties
Additives
Lab Testing
70
Slurry Properties
• Free Water & Slurry Sedimentation
– Water separation from static slurry
– Migrates upward, accumulates in pockets or at top of
cement column.
– Results in incomplete zonal isolation
• Density
– Balance sub-surface pressures
– Cement final strength
71
Slurry Properties - cont.
• Pumpability (Slurry Consistency)
– Length of time slurry remains in a pumpable fluid state
• Fluid Loss
– Slurry dehydration during placement phase
• Rheology
– Slurry flow modeling
72
Set Cement Properties
• Bonding
– Cement - Casing & Cement - Formation
• Sulfate Resistance
– Reaction to magnesium and sodium sulfates
• Loss of compressive strength
• Stress cracking
• Strength Retrogression
– Cement Shrinkage occurs at >230°F (110°C).
• Permeability
– Lightweight slurries
73
Cement Slurry Properties
• Slurry density
• Slurry rheology
• Free water
• Thickening time
• Compressive strength
• Fluid loss control
• Compatibility
74
Testing Process
LAB ANALYSIS
REQUEST
SLURRY DENSITY RHEOLOGY
FREE WATER FLUID LOSS
TEST TEST
CEMENT - SPACER - MUD THICKENING TIME

COMPATABILITY TEST
COMPRESSIVE STRENGTH
TEST
LABORATORY REPORT
75
Laboratory Testing Equipment
Waring Blender - Slurry Mixing
Please Note:
A Waring Blender imparts
much more mixing energy
than is experience in the
field with standard cement
mixing equipment and thus
does not truly simulate
field mixing conditions.
76
Well Conditions
ADDITIVE CATEGORY
PROBLEM SLURRY PARAMETER
SOLUTIONS
WELL CONTROL EXTENTERS
OVER PRESSURE DENSITY
WEAK FORMATION WEIGHTING AGENTS
ACCELERATORS
TEMPERATURE THICKENING TIME
RETARDERS
FLUID STABILITY
PERMEABLE FORMATIONS FLAC
FLUID LOSS CONTROL
MUD REMOVAL DISPERSANTS
FRICTION PRESSURE RHEOLOGY
MIXABILITY/PUMPABILITY GELLING AGENTS
PLUGGING
LCM
LOST CIRCULATION BRIDGING PROPERTIES
DENSITY EXTENTERS
ABNORMAL AND SPECIAL CONDITION
HEAT RETROGRESSION HYDRATION PRODUCT SILICA

STABILIZED FOAM FOAMING AGENTS AND
FOAMERS
CAPABILITY STABILIZERS
FOAM FOAMING TENDENCY ANTI-FOAM
77
Slurry Density
Changing
Lighter of Heavier
slurry density Less Water
More Water*
•Absorbent Neat Cement •Heavy Material
•Light Material 15.6 ppg Class A •Dispersant
15.8 ppg Class G
16.4 ppg Class H
Lower Density Higher Density
78
Pressurized Mud Balance - Density
An absolute must at the rigsite and in the lab
79
Definition of Rheology
Rheology is the science of flow and deformation of matter
FLUIDS
Apply a force will FLOW
SOLIDS
Apply a force will BREAK
80
Applications of Rheology
in Oilwell Cementing
Operations
Laboratory CemCADETM
Mixability / Pumpability Effective Mud Removal HHP requirements
Rheological Parameters Friction Pressures Real Pressures

Rheology (high) – Pressure (high) – HHP (high)
81
Laminar Flow
V=0
V max
V=0
Sliding motion
Velocity at the wall = 0
Velocity is maximum at the centre
Vmax = 2 V
Where V = Average particle velocity
82
Turbulent Flow
DIRECTION OF FLOW
Swirling motion
Average particle velocity is uniform throughout the pipe
83
Dispersants
Cement slurry rheology
– Volume of particles/ total volume
– Inter-particle interactions
– Aqueous phase rheology
Change with dispersants
Why dispersants?
– Reduce viscosity and yield point
– Turbulent flow easier to achieve (Clients like slurry in
turbulent for liner)
– Reduce friction pressures
– Improve cement slurry mixability (lower Ty)
– Reduced water slurries (density up to 18 lb/gal)
– Improve efficiency of fluid loss control additives
84
Types of Dispersants
Sulfonates
• Sodium Polynapthalene Sulfonate (PNS) D065, D080
• Polymelamine Sulfonate (PMS) D145A
• Aromatic polymer D065A, D080A
• Organic polymer D604M, D604AM
Lignosulfonates
• Lignin Derivative/HydroxyCarboxylic Acid D081
• Hydroxy Carboxylic Acid D121
85
Rotational Viscometer - Rheology
Torsion Spring
Inner Cylinder
Bearing Shaft
Rotor
Bob
Cup
86
Slurry Stability
Free Water and Sedimentation
• Channelling
• Incomplete fill-up
Free Water Free Water and Sedimentation
87
Effects of Free Water
• Channelling
• Incomplete fill-up
88
Cement Properties
• Cement Slurry Properties;
– Water Cement Ratio:
• Defines the min and max boundaries of water content in slurry,
– Minimum water content is the amount of mixing water per
sack of cement that will result in a consistency of 30 Bc
after 20 minutes at 80 deg F and 1 atm
– The normal water content is the of amount of mixing water
per sack of cement that will result in a consistency of 11
Bc at the end of the test.
– The free water content is the amount of water that
separates from a 250 ml sample of slurry after 2 hours
– The maximum water content is the amount of mixing water
per sack of cement that will result in 3.5 ml of free water
• Exceeding the maximum ratio will cause pockets of free water
to form and reduce the strength of set cement.
89
Anti Settling Additives
• Anti Settling Additives reduce
– Free water
– Sedimentation
• Compatible with all Cementing products and cement
• No significant effects on slurry properties, except
rheology
• Temperature range: up to 300 deg F
• Antisettling Agent D153: 0.1 - 1.5 % BWOC
• Liquid Antisettling Agent D162: 0.005 - 0.025 gal/sk
90
Thickening Time
• Depending on BHCT Thickening Time can

be adjusted by:
– Accelerators to reduce TT
– Retarders to extend TT
91
Accelerators
• Shorten stage I and II, accelerate stages III and IV
hydration of main cement phases is
increased plus change in C-S-H structure
• Offset retarding effects of other additives
I II III IV V
92
Retarders
• Retarders extend pumping TT
• Mechanism of action depends on:
– Chemical nature of retarder
– Chemical composition of cement
• Theories of mechanism of action
– Adsorption
– Precipitation
– Nucleation
– Complexation
93
Consistometer - Slurry Thickening Time
Atmospheric
HPHT
94
Compressive Strength
• Poor protection against lateral forces
Overburden Pressure
Stable System
Unstable System
95
Compressive Strength
96
Fluid Loss in Cement Slurries
• Definition
– Filtrate (aqueous solution) lost to the formation
– Filter cake deposited at formation face
– Cement particles left in annulus
• Why cement slurry loses water
– Differential pressure
– Permeable medium (formation)
– Water/cement ratio ? Hydration needs
97
Why 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
pressure
• Reduce formation damage
98
Mechanisms of FLAC
Particle Plugging Polymer Plugging
99
Dispersants with FLACs
Mechanism of action
• Disperse cement grains and improve packing
reduce permeability
WITHOUT DISPERSANT WITH DISPERSANT
FILTER CAKE
RANDOM PACKING ORDERED PACKING
HIGH PERMEABILITY LOW PERMEABILITY

100
Filter Press - Fluid Loss
HPHT Low Pressure
101
Cement - Mud Contamination
• Acceleration or retardation
• Reduction of compressive strength
• Reduction of hydraulic bond
• Increase of filtrate loss
• Change of rheological properties
102
Speciality Additives
• Antifoam/ defoamer agents
• Bonding agents
• Expansive additives
• Gas migration control additives, etc.
• Thixotropic systems
• LCM
103
Lunch Break
60 Minutes
104
Primary and Remedial Cementing
Calculations
105
Cementing Calculations
We want to calculate:
• Slurry Volumes
• Sacks of cement required
• Displacement Volume
• Estimated Job time
• Correct Plug bumping Pressure
106
Important Rule
• Cement slurries should always have density specified by API.
• Density can only be changed by using the appropriate additive.
• If water/solids ratio is not correct, may get :
– High viscosity / unpumpable slurry.
– Excessive free water.
• If the cement composition and one of the properties are known,

other two properties can be calculated
107 10/12/2009
Slurry Yield
When water is added to dry cement the resulting
Slurry normally has more volume than the original
Sack of 94lbs based on a material balance calculation.
1 sack of cement = 94lbs = 1 cubic foot
Dry Cement absolute volume = 0.0382 gal/lb
1 sack of cement = 3.59 gal
Class G cement slurry @ 15.8 ppg (1.9 SG) uses 44% mix water or 4.97 gal/sx
7.48 gallons = 1 cubic foot
108
Bulk and Absolute Volumes
Bulk Volume : The volume occupied by a certain weight of dry material
including void spaces between solid particles.
CEMENT 1 Sack = 1 cubic foot (cu.ft) = 94 pounds
Absolute Volume : The volume occupied by the same weight of material,

less the void spaces between particles.
109 10/12/2009
Bulk and Absolute Volumes
B
Cement
1 drum = 1 cu.ft = 7.48 gal
A Absolute Volume of Cement: A
7.48 gal – 3.89 gal = 3.59 gal
Air in pore spaces will

Water
be displaced by water
B A B
3.89 gal
110
Slurry Yield
Definition : The volume of slurry produced when 1 sack of dry cement
(and additives) are mixed with water
Unit: cubic foot/sack (cu.ft/sk)
Class G API mix
1 Sack 4.97 Gal
1 cu.ft 0.66 cu.ft 1.15
cu.ft
CEMENT + AIR
+ WATER
= SLURRY
Slurry Yield = 1.15 cu.ft / sk

111 10/12/2009
Mix Water Requirement
Definition : The amount of water needed to hydrate 1 sack of dry cement
(and additives) to create a pumpable liquid
Unit: gal/sack
Class G API mix
1 Sack 4.97 Gal
1 cu.ft 0.66 cu.ft 1.15
cu.ft
CEMENT + AIR
+ WATER
= SLURRY
Water Required = 4.97 gps

112 10/12/2009
Slurry Density
Definition : The weight of 1 gal of slurry
Unit: lb/gal
Class G API mix
1 Sack 4.97 Gal
1 cu.ft 0.66 cu.ft 1.15
cu.ft
CEMENT + AIR
+ WATER
= SLURRY
1 gal of slurry will weight 15.8 pounds
Slurry Density = 15.80 ppg

113 10/12/2009
Calculations - Example 1
All calculations based on one sack of cement
Note: Absolute volumes from Field Data Handbook, Page:700.005
• Example: Class G cement mixed by API specifications
Material Weight (lb) * Absolute Volume (gal/lb) = Volume (gal)
Class G 94 * 0.0382 = 3.59
H20 (44%) 41.36 * 1/8.33 = 4.97
Total 135.36 * = 8.56
135.36 lb/sk 8.56 gal/sk

1. Density = = 15.81 lb/gal 2. Yield = = 1.144 cu.ft/sk
8.56 gal/sk 7.48 gal/cu.ft
3. Water required = 4.97 gal/sk (from the table)

114 10/12/2009
• Class G, mix @ 15.5 ppg

Class G 94 * 0.0382 = 3.59
H20 8.33X * 1/8.33 =X
Total 94 + 8.33X * = 3.59 + X
94 + 8.33X
Density = 15.5 ppg = X = Water required = 5.35 gal/sk
3.59 + X
3.59 + 5.35
Yield = = 1.195 cu.ft/sk
7.48
115 10/12/2009
• Class G, mix with 5.05 gps of water requirement

Class G 94 * 0.0382 = 3.59
H20 42.07 * 1/8.33 = 5.05
Total 136.07 * = 8.64
136.07 8.64
Density = = 15.75 gal/sk Yield = = 1.16 cu.ft/sk
8.64 7.48
Water required = 5.05 gal/sk (from the table)
116 10/12/2009
• Class G, Given slurry yield – 1.06 cu.ft/sk

Class G 94 * 0.0382 = 3.59
H20 8.33X * 1/8.33 =X
Total 94 + 8.33X * = 3.59 + X
3.59 + X
Yield = 1.06 cu.ft/sk = X = Water required = 4.34 gal/sk
7.48
94 + 8.33 * 4.34
Density = = 16.41 ppg
3.59 + 4.34
117 10/12/2009
• Class H, 3% S001. Mix by API

Class H 94 * 0.0382 = 3.59
S 001 2.82 * 0.0687 = 0.194
H20 94 (0.38) * 1/8.33 = 4.288
Total 132.54 = 8.072
132.54 8.072
Density = = 16.42 ppg Yield = = 1.079 cu.ft/sk
8.072 7.48
Water required = 4.288 gal/sk
118 10/12/2009
Additives Requiring Additional Water
D020, Bentonite
– 5.3% (BWOC) additional water for each 1% D20 added.
D024, Gilsonite
– 1 gal additional water for each 25 lb D24 added.
D030, Silica Sand
– 0.286% (BWOC) additional water for each 1 % D30 added;
– therefore 10% for 35% D30.
D031, Barite
– 0.024 gal additional water for each 1 lb D31 added.
D042, Kolite
– 1 gal additional water for each 25 lb D42 added.
D066, Silica Flour
– 0.343% (BWOC) additional water for each 1 % D66 added;
– therefore 12% for 35% D66.
119 10/12/2009
• Class A, D020 – 2% BWOC. Mix by API
Material Weight (lb) * Abs. Volume (gal/lb) = Volume (gal)

Class A 94 * 0.0382 = 3.59
D 020 1.88 * 0.0454 = 0.085
H20 94[0.46+2(0.053)] * 1/8.33 = 6.384
Total 149.08 = 10.059
149.08 10.059
10.059 7.48
120 10/12/2009
• Class G, D042 - 12.5 lb/sk, D020 – 4% BWOC. Mix @ 13.8 ppg

Class G 94 * 0.0382 = 3.59
D 042 12.5 * 0.0925 = 1.156
D 020 3.76 * 0.0454 = 0.171
H20 8.33X * 1/8.33 = X
Total 110.26 + 8.33X = 4.917 + x
110.26 + 8.33X
4.917 + X
4.917 + 7.75
7.48
121 10/12/2009
• Class H, D020 – 2% BWOC (Pre-hydrated). D030 – 35% BWOC.
Mix by API
Class H 94 * 0.0382 = 3.59
D 020 1.88 * 0.0454 = 0.0854
D 030 32.9 * 0.0456 = 1.5002
H20 94[0.38+8(0.053)+0.1] * 1/8.33 = 10.2012
Total 213.756 = 15.3768
213.756 15.3768
15.3768 7.48
122 10/12/2009
• Class H, D600 – 2.0 gps. D080 – 0.3 gps. D801 – 0.2gps. Mix @
16.5 ppg
Class H 94 * 0.0382 = 3.59
D 600 17.09 * 0.117 = 2
D 080 3.08 * 0.0973 = 0.3
D 801 2 * 0.1 = 0.2
H20 8.33X * 1/8.33 =X
Total 116.17 +8.33X = 6.09 + X
116.17 + 8.33X
6.09 + X
6.09 + 1.92
7.48
123 10/12/2009
Slurry Volume Calculations (1)
A well requires the 9⅝ inch Csg/Csg
Annulus
47ppf casing at 8500 feet
Displacement
cemented to surface with neat Volume
Class G cement. Previous casing 13⅜
13
is 13 ⅜ inch 68ppf set at 5000 inch 68ppf
5000 ft
feet. There are two joints of
OH/Csg
casing between the Float Collar Annulus
and Float Shoe and the open 9⅝

Shoetrack
hole requires an excess of inch 47ppf
21.4%. Bit size is 12¼ inch. 8500 ft
124 Draw a diagram

Vol 1 (Csg/Csg Ann)
5000 x 0.3354 = 1677 ft3
Vol 2 (OH/Csg Ann)
(8500 – 5000) x 0.3131 x 1.214 = 1330.4 ft3
Vol 3 (Shoetrack)
Total Volume
80 x 0.4110 = 32.9 ft3 3040 ft3
Vol 4 (Displ Vol)
(8500 – 80) x 0.0732 = 616.3 bbls
Vol 5 (Sacks cement)
125 3040 ÷ 1.144 = 2657 sx
15 Minutes
Break
126
Slurry Volume Calculations (2 & 3)
(2) A23ppf
well requires the 7 inch
liner cemented at
(3) A well requires the 20 inch 94ppf
casing cemented at 1500 feet
12,200 feet with an overlap using an inner cement stinger
inside the 9⅝ inch 47ppf of made up from 5 inch 19.5ppf DP.
150m using Class G cement + The previous casing was a 30
35% Silica Flour at 16.55ppg. inch, 1 inch wall conductor
Previous casing is set at which was driven to 300 feet.
10,500 feet. There are two There is no float collar only a
joints of casing between the float shoe and the hole seems
Float Collar and Float Shoe large so a guestimate at volumes
and the open hole requires to bring the cement to surface is
an excess of 10%. Bit size is 150% on OH size. Slurry is Neat
8½ inch. Running tool to be Class G.
used is 5” DP, 19.5 ppf.
127
Vol 1 (Csg/Csg Ann) 70.7 ft3
Vol 2 (OH/Csg Ann) 237.1 ft3
Vol 3 (Shoetrack) 17.7 ft3
Total Volume
326.1 ft3
Vol 4 (Displ Vol)
69.73 +177 = 260.9 bbls
Vol 5 (Sacks cement)
128
326.1 ÷ 1.38 = 236 sx
Balanced Cement Plugs
Set a 150m balanced Displacement
cement plug in the open Volume
hole (12¼ inch) with the
base at 3500m and the last
casing set at 2800m using 5 Balanced Steel
inch 19.5ppf DP. Volume Internal Plug
Volume
External Plug
Volume
Draw a diagram Height with
Pipe in place
Plug in place with

pipe
129
Balanced Plug Calculations
Vol 1 (External plug)
150 x 3.281 x 0.682 = 335.6 ft3
Vol 2 (Internal plug)
150 x 3.281 x 0.09972 = 49.1 ft3
Vol 3 (Steel displacement)
150 x 3.281 x 0.0366 = 18.0 ft3 Total Volume
402.7 ft3
Calc 4 (Plug Height)
(18 ÷(0.682 + 0.09972)) + 150 x 3.281 = 515.2 feet (157m)
Vol 5 (Displacement)
130 (3500 – 157) x 3.281 x 0.01776 = 194.8 bbls
End of Day 1
131

01 Well Cementing - Day 1 PDF

Încărcat de

Informații document

Descriere originală:

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

01 Well Cementing - Day 1 PDF

Încărcat de

Drepturi de autor:

Formate disponibile

Quartz School for Well Site Supervisors

• Slurry Properties, Additives and Lab Testing

• Cement job design basics

13 3/8” casing in 17 ½” hole

13 3/8” casing in 17 ½” hole

• Low cost implies:

– Formation pore pressure

• Prevent the collapse of the borehole during drilling.

• Centralized to achieve a good cement bond.

Laminar and Turbulent Flow regimes are found

T = 0.0408 * TVD * (ρid2 - ρeD2 ) + cos ø * w * S

T = tension in the wall of the pipe; lbf

Batch Mixer Fill

Density, rate, pressure

Grind + Heat Treat in Kiln Temperature + 1500oC

Controlled Cooling To second grinding mill

Pulverise mixture And Blend

{ 2 CaO + SiO2 = C2S

4 CaO + Al2O3 + Fe2O3= C4AF

4- Kiln 4 5 5- Clinker silo

Oxide Composition: Mineral Composition:

COMPOSITION TO MINERAL COMPOSITION

Mass Balance ‘N’ Equations ‘N’ Unknowns

– Cement final strength

SLURRY DENSITY RHEOLOGY

CEMENT - SPACER - MUD THICKENING TIME

HEAT RETROGRESSION HYDRATION PRODUCT SILICA

Rheological Parameters Friction Pressures Real Pressures

Average particle velocity is uniform throughout the pipe

Free Water Free Water and Sedimentation

• Depending on BHCT Thickening Time can

RANDOM PACKING ORDERED PACKING

HIGH PERMEABILITY LOW PERMEABILITY

• Reduction of hydraulic bond

• Increase of filtrate loss

• Change of rheological properties

• Density can only be changed by using the appropriate additive.

– High viscosity / unpumpable slurry.

– Excessive free water.

• If the cement composition and one of the properties are known,

Dry Cement absolute volume = 0.0382 gal/lb

1 sack of cement = 3.59 gal

7.48 gallons = 1 cubic foot

Absolute Volume : The volume occupied by the same weight of material,

Air in pore spaces will

Slurry Yield = 1.15 cu.ft / sk

Water Required = 4.97 gps

1 gal of slurry will weight 15.8 pounds

Slurry Density = 15.80 ppg

• Example: Class G cement mixed by API specifications

135.36 lb/sk 8.56 gal/sk

3. Water required = 4.97 gal/sk (from the table)

Material Weight (lb) * Absolute Volume (gal/lb) = Volume (gal)

Material Weight (lb) * Absolute Volume (gal/lb) = Volume (gal)

Water required = 5.05 gal/sk (from the table)

Material Weight (lb) * Absolute Volume (gal/lb) = Volume (gal)

Material Weight (lb) * Absolute Volume (gal/lb) = Volume (gal)

Water required = 4.288 gal/sk

Material Weight (lb) * Abs. Volume (gal/lb) = Volume (gal)

Water required = 6.384 gal/sk

Material Weight (lb) * Abs. Volume (gal/lb) = Volume (gal)

Water required = 10.20 gal/sk