Foam Cement Ultra-Lightweight

Cement System

What is Foam Cement?

Foam cement is an energized system consisting of a base cement slurry to which foamers and nitrogen have been added to generate the foam Foam systems are normally light density Foam systems have distinctive properties (advantages)

Foam Quality
Quality (expressed in %) of the foam cement slurry is the % of the total volume occupied by the Nitrogen. For example: A bbl of foam cement slurry of 30% quality consists of 0.70 bbls of solids and liquids (water, additives) and 0.30% Nitrogen.

Why Foam Cement?

There are several reasons for using foam cement. For example when encountering low fracture gradients due to low formation mechanical strength and/or low reservoir pressures. There may be economic benefits of using foam cement. For example, their use can often eliminate stage tools thereby saving cost of the tool and saving rig time. There are situations where good strength is needed, but low densities are required. This is an excellent application for foam cementing.

Why Foam Cement? (cont.)

Another benefit of a compressible system is that it can prevent annular gas migration. The major distinguishing property of foam cement is that it has high strength at very low densities. Conventional water extended cement slurries achieve densities of no less than 11 lbs/gal and l maintain acceptable compressive strength for many applications. Foam cements on the other hand can provide significant compressive strength at densities as low as 8 or even 6 lbs/gal.

Why Foam Cement? (cont.)

Foam cements are very compressible. It is possible to maintain low permeability in a foam cement even at densities as low as 8 lbs/gal. Foam systems inherently have low fluid loss which is a desirable characteristic for a cement slurry. Foam slurries are highly viscous. This can increase circulating pressures and needs to be considered when we actually design a job. Foam cement slurries have very good sweeping properties due to their high consistencies and their expanding properties as they move up the hole.

Other Benefits

Elastic Cement System Resilient / Withstands Pressure Cycling Help Maintain Zonal Isolation Help Prevent Gas Migration Compressibility Fluid Loss Control Improved Mud Displacement Help Prevent Long Term Gas Migration Minimize Remedial Cementing to Repair Casing

Other Benefits (cont.)

Ultra-Lightweight Cement System High Strength / Low Density Help Prevent Lost Circulation Economic saving Eliminate Stage Tool Save Rig Time

Low Thermal Conductivity

Physical Properties
Elasticity

High

Strength
Fluid Loss

Compressibility Low

Physical Properties
High

Viscosity

Low
Low

Permeability
Thermal Conductivity

Pressure Gauge Pressure Port

Pressure Gauge

3 in. 3 in. Cement Returns

3 in. 3 in. Cement Returns

Vent for Annulus Pressure Port

Vent for Annulus Permeability Outlet Permeability Outlet

Water Cap
Water Cap

Strain Gauge
Strain Gauge

Data Data Acquisition

Acquisition

Cement Sheath Stress Fixture

54 in. 48 in.

54 in. Wire Feed Conduit Wire Feed Conduit 48 in.

9 5/ 8-in., 10 3 /4 -in.,
5/ 8-in., /8 -in Outer Casing 913 10 3 / 4 -in., 13 3/8 -in Outer Casing
3

Permeability Inlet

Cement Inlet 6 in. of 20/40 Cement Inlet

Permeability Inlet

6 in.

Mesh Sand Pack

6 in.

Inlet 6Permeability in. of 20/40 Mesh Sand Pack 3 in. 5 / 2-in., 7-in., Permeability Inlet 9 5/ 8-in Inner Casing
1

3 in.

5 1/ 2-in., 7-in., 9 5/ 8-in Inner Casing

Large Scale Stress Testing - TLW @ 12.5

lb/gal

Foamed Cement @ 11.8 lb/gal

Large Scale Stress Testing

Conclusions from Experiments

Foamed cements (Q = 0.18 - 0.38) prevent shear failure during internal casing pressurization Can withstand internal casing pressures up to 10,000 psi without shear failure Compressibility Can withstand mechanical cycling up to 100 times @ 90% of shear failure index Foamed cement generally exhibited no signs of matrix failure, either radially or circumferentially

Compressive Strength
Standard Cement @ 100 F
2000

Strength (psi)

1500 1000 500 0 6 lb/gal 12 Hour 8 lb/gal 24 Hour 10 lb/gal 72 Hour

Compressive Strength
Premium Plus Cement @ 100 F
2000

Strength (psi)

1500 1000 500 0 6 lb/gal 12 Hour 8 lb/gal 24 Hour 10 lb/gal 72 Hour

Compressive Strength
Premium (fine) Cement @ 100 F
1200 1000 800 600 400 200 0 6 lb/gal 12 Hour 8 lb/gal 24 Hour 10 lb/gal 72 Hour

Strength (psi)

Compressive Strength
Premium (coarse) Cement @ 100 F
800

Strength (psi)

600 400 200 0 6 lb/gal 12 Hour 8 lb/gal 24 Hour 10 lb/gal 72 Hour

Permeability of Foam Cement

The permeability of foam cements is surprisingly low even at a density as low as 8 lbs/gal. When we get less than 8 lbs/gal or a quality higher than 50 percent, the permeability does not increase significantly but most foam cement jobs are conducted at densities at around 8 to 10 lbs/gal.

Permeability of Foam Cement

Permeability (md)
160 140 120 100 80 60 40 20 0 4 6 8 10 Density (lb/gal)

Low Permeability

Low Permeability

From this scanning electron microscope slide you can visualize how to achieve low permeability even at densities of 8 lbs/gal. The low permeability is achieved because high compressive strength, low permeable cement will provide a barrier between the various bubbles inside the matrix of a foam cement so that anything passing through the overall matrix of the foam cement will have to pass through that low permeability cement in between the bubbles (bubbles are not connected!). When the foam quality rises above 50 percent, these bubbles start to interconnect and then you have a flow path through the matrix of the foam and you see the permeability increasing.

Foam Cement

Thermal Conductivety of Foam Cement

Thermal Conductivity (BTU/HR-FT-F)
0.25

K-Value (Dried @ 230 F)

0.2 0.15 0.1 0.05 0 10 11.5 12

Density (lb/gal)

Thermal Conductivity
Thermal conductivity of foam cement is fairly low. As can seen from this data of dried foam cerment at 230 degrees, thermal conductivities as low as 0.15 BTU degrees Fahrenheit. Thermal conductivity decreases as foam density decreases.

Applications of Foam Cement

Single stage cement job across weak formation Prevent lost circulation Saves rig time Deep Water Shallow Flow Control Surface Casing Jobs In Deep Water Applications Helps Prevent Water/gas Influx After Placement

Applications of Foam Cement

Squeeze

across weak formation

Prevent lost circulation during squeeze Maintain surface pressure indication throughout job

Job Design

Static Model Determine unfoamed slurry volume Calculate initial nitrogen concentrations

Cement Job Simulator

Determine nitrogen needed for dynamic placement

Optimize pump rates

Job Design

When designing a foam cement job, two computer models are used. First, the static model is used to determine the volume of unfoamed slurry needed for the job and the initial nitrogen concentrations to generate foam slurry of a desired specified density. Then a cement job simulator is used to determine nitrogen needed for dynamic placement. When foam is pumped into place, you have additional pressure on the system due to friction. This additional pressure compresses the foam and increases its density, therefore, you need to add additional nitrogen to expand the foam to the desired slurry density and to fill the entire annulus. The simulator is also used to optimize the pump rates to insure good displacement throughout the job without exceeding the fracture gradient of the open hole.

Example - CEMENT JOB SIMULATOR Comparison of Rates In & Out

CEMENT JOB SIMULATOR Calculated Wellhead Pressure

CEMENT JOB SIMULATOR Circulating Pressure / ECD at 5658 ft

Foam Job Example

In the next figure we see an example of a foam cement job. We have a 5 1/2 casing set in an 8 1/2 hole at a depth of 6400 feet. Fracture gradient of 10.7 lbs/gal exists at 5800 feet. Normally several stages of foam cement are pumped followed by a tail cement that is unfoamed. After the plug is bumped, the annulus is closed and an unfoamed cap cement slurry is pumped at the surface to compress the foam to the desired density and cause the cement to set up quickly at the surface conditions. This has several advantages. It is possible to accelerate the cap slurry so that it will set up within 4-6 hours after placement allowing the operator to continuew well operations in a short period of time.

Foam Cement Example

8 7/8 inch 5 1/2 inch 1400 ft.

10.7 lb/gal Frac Grad BHCT = 96 F

5800 ft 6400 ft.

Example Foam Cement Job

The following figure shows nitrogen rate variation in four stages to achieve an average density of around 8.5 lbs/gal. The top stage has 160 scf/bbl of nitrogen. The next stage has 485 scf/bbl, the next 570 scf/bbl and the last on 920 scf/bbl Below the last stage, there is a tail cement at 12.5 lbs/gal.

Foam Cement Example

Nitrogen 0
160 485 570 920 Density (lb/gal) 12.5 8.0 8.9 8.7 8.5 Depth (ft) 700 1400 2700

4000 5000

12.5

6400

Slurry Design Example

The base slurry consists of cement mixed at its normal mixing water requirement. If the cement slurry needs to be accelerated for application in cool temperatures, calcium chloride can be added to the base formulation. For deeper hotter applications, if the slurry needs to be retarded, a non-dispersing retarder can be used. This is not a typical lignosulfanate retarder which affect the stability of the foam. For some applications, fluid loss additives are added to the base slurry To the slurry, 1.5% by volume of foaming agent and 0.75% of foam stabilizer are injected through the suction side of the downhole pump These surfactants are used to generate and maintain a stable foam. Foam slurry stability is tested in the lab

Foam Cement Testing

Tests conducted with unfoamed base slurry: Thickening time Rheology (simulators use it to predict foam rheology) Fluid loss

Tests conducted with foamed slurry:

Compressive Strength
Foam stability

Free fluid

Performing a Job
Cement Pump Truck
Injection Unit
Pump Foam Chemical

Nitrogen Unit

Foam Generator

Performing a Job
Typically the layout of the job consists of a cement pump truck to mix the base cement slurry Next, an injection unit to inject the foamer and stabilizer into the suction side of the downhole pump. The cement slurry is then pumped to the foam generator. In the nitrogen unit, the nitrogen is vaporized and metered as specified for the job. The nitrogen is also pumped to the foam generator. The generated foam cement slurry is then pumped to the well.

Recent technology includes automation of the nitrogen rate control, base cement density control and surfactant injection control. It is possible to automate the nitrogen rate to proportion a specified amount of nitrogen from the nitrogen pump truck. This eliminates any operator error that could be encountered when relying on simple verbal communication during the job. It is also possible now to automate the cement slurry density control. This regulates bulk cement delivery and mix water rates and eliminates operator error. Also automated is the amount and rate of injection of surfactants into the unfoamed slurry.

Automated Foam Cement System

Automated Foam Cement System

Automated nitrogen rate control

Correlates nitrogen to cement pump rate

Eliminates operator error Can provide ramping nitrogen rates

Automated cement density control

Regulates bulk cement delivery Regulates mix water rate

Surfactant control system

Meters foaming surfactant blend based on pump rate

Offshore Capability

Nitrogen Converter Skid

Self-contained
Automatic rate control 8 x 8 x 10 3000 scf/min max rate 17,000 psi max pressure 100 scf/min minimum rate

Automatic Density Control

Backpressure Control
When conducting a cement job, one thing that needs to be controlled is back pressure, even if foam cement is not expected to return to surface. Without back pressure control, uncontrolled expansion of the foam at the surface can cause whats known as a cement blowout. The highly energized foam cement under pressure can expand quite a bit when it encounters atmospheric pressures. This must be prevented and in order to do that, it is important to maintain back pressure control.

Backpressure Control

Must be able to control the annular flow of a foam cement job Without backpressure uncontrolled expansion of foam at surface will cause Cement Blowout Subsea use can be controlled at seabed by hydrostatics

Backpressure control
Annulus chocking Cement slurry cap pumped after the job Offshore, water hydrostatic is often enough

Foam Cement Quality Control

Slurry

Density and Rate Measurement

Rate Measurement

Nitrogen

Surfactant Foam Foam

Metering

Generator

Density Measurement

Foam Cement may Improve Job Cost

No Stage Tool Reduced Rig Time N2 Unit Chemicals Less remedial work

Bond Log Evaluation

Evaluation of Foam Cement Jobs Cannot Be Done With Conventional Interpretation Methods SVP Process Provides Means to Evaluate Foam Cement