Cementing

DeepwaterWells

Well Services – Schlumberger

Junichi Hagura
 Presentation outline

 Specific deepwaterchallenges &

Overview ofgeo-hazards

 Deepwater cementslurriesrequirements

 Deepwater CementingTechnology

Page2
24Jun. 2003
 What is Different in Deepwater?
 Costs
– Operations take longer
– Expensive Rig Time
 Cold temperatures
– Fluids viscosity
– Cementsetting

 Narrow margins betweenpore and

fracture pressures
– Lost Circulation during drilling
– Lost returns during cementjobs
 Shallow Water/Gas FlowHazards

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24Jun. 2003
 Deepwater temperatures

Sea current velocity Temperature profile

Mean Sea Level 0.5 knots

Mud Line 0.2 knots ~ 4 oC

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24Jun. 2003
 Temperature effects onfluids
 Drilling fluids
– Rheology
– Gelation  swab/surge
– Increased ECD loss of well control
– Hole/riser cleaning with gumboclays
 Cementingfluids
– Long thickeningtimes
– Slow compressive strength development
– Unpredictable gel strength development
– Temperature prediction - API tables not applicable

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24Jun. 2003
 Gas in Deep Water Drilling

 Gashydrates near sea bed

– Destabilization of hydrates byheat
(drilling fluid, cementhydration)
 Shallow gas
– Forming hydrates in well, pipes…

The Burning Snow Ball

Picture of burning methanehydrate mass
supporting its owncombustion

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24Jun. 2003
 Gas Hydrates
 Formation of Hydrates dependson:
– Temperature andPressure
– Composition or typeofgas
– Composition of drilling fluids

– Oneunit of hydrate cangive 170 units

of gas

 HAZARDS :
Solid ice-like compoundsof natural – Plugging of BOP chokeandkill lines
gas andwater, formed in high – Dehydration of drilling fluids and/or
pressure andlow temperature cement
conditions – Overloading of GasSeparation
Equipment

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24Jun. 2003
 Shallow Water Flow Hazard
Turbidite Sand

sea level  Permeablesediments trappedunder slidingdeposits

 Usually present near the mouthof amajorriver
mudline

sealing clays

overpressured sands
(flowing sands)

sealing clay

Normal
Drilling Margin

Page8 Actual(narrow)
24 Jun. 2003 Drilling Margin
 Shallow Water Flow Problems
 Safety andenvironmental concerns
 Flow during drilling or cement
– Jeopardizes template stability
 Lost circulation during drilling or cement placement
– Well Control
 Excessive hole washouts
– Mudremovaldifficult
 Destabilization of near well boreformations
– Integrity of BOP andRiser
 Breakthrough to theseafloor
– Loss of drive pipe, conductor or the well

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24Jun. 2003
 Deepwater Cementing

 Specific deepwaterchallenges &

Overview ofgeo-hazards

 Deepwater cementslurriesrequirements
– Objectives andchallenges for DW cements
– Cementrequirements for shallow
water/gas flow hazards

 Deepwater CementingTechnology

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24Jun. 2003
 Deep Water Cementing:
Objectives & Requirements
OBJECTIVES: REQUIREMENTS:
 Provide Structural Support
– Resistance to buckling andcasingwear Excellent mechanicalproperties
– Foundation for deeper strings of casing combinedwith lightweight
cementdensity (weakformations)
 ObtainaCompetentHydraulicSeal
GasMigration Control
– No fluid migration behindcasing
MudRemovalOptimization
– Seal off shallow gas/water flow zones

 Short WOC Improvedcementhydration at

cold temperature
– Despite cold temperature

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24Jun. 2003
 Paths for Gas/Formation Fluid Migration
Channel, duringplacement
• Due to incomplete MudRemoval
• Excessive Free Fluid

Loss of hydrostatic pressure, post-placement

 Poor Fluid loss Control
 Long Critical Hydration Period
 Free Fluid

 Loss of cement integrity over long term

 Down holestresses
 Shrinkage
 Permeability of set cement
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24Jun. 2003
 Mechanism for fluid/gas migration in the
cement before it sets
 Hydrostatic Pressure transmission is thekey
 During the cementjob:
– Cementdensity insures hydrostatic pressure > pore pressure -> noinvasion
 After placement,cementloses its ability to fully transmit Hydrostatic
Pressure dueto:
– Static Gelstrength development-> decayin HPtransmission
– Downhole volumevariations: fluid loss, temperature andhydration volume
reduction
 Consequence:
 Pore pressure within the gelling cementis decreasing andmay
becomesmaller than formation porepressure
 Gas/watercannowpossibly invade the annulus

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24Jun. 2003
 Fluid/Gas Invasion in the Setting Cement

Temperature

4 Phases in the
Setting Process of
aCementSlurry

Phase1: Fully Liquid Phase2: Early Gelation Phase3: Hydration Phase4: Set Cement
Hydrostatic Pressure

Pore Pressure
Pressure

Cement Set - No
After this point Gas Gas can Invade
can Invade, CWSS

Critical HydrationPeriod Time

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24Jun. 2003
 Definition of terms
 Static GelStrength(SGS)
– Measure of the attractive forces betweenthe particles of afluid under
static (non flowing) conditions. The measure of these sameattractive
forces of afluid under flowing (dynamic) conditions is what is
commonlyreferred to as “yield point” of aslurry.
 Critical Wall Shear Stress (CWSS)
– Ameasure of the amountof gel strength that must developto cause
hydrostatic decayto allows gasentry
– Not aslurry property
– Totally dependentonwell geometry& pressures

 Critical Hydration Period (CHP)

– Period of time whengas/water canenter the annulus
– Begins whenCWSS is achieved
– Ends whenmatrix permeability is sufficient to stop flow
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24Jun. 2003
 Static Gel Strength measurement
Chandler’s SGSA
VaneRheometer
(Static GelStrengthAnalyzer)

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24Jun. 2003
 Transition Time (Time from 100-500lb/100ft2)
Gel Strength (lb/100ft2)
1600
1400
1200
1000
800
600
400
200
0
0 1 2 3 4 5 6 7 8 9 10
Time (x10 mn)

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24Jun. 2003
 Critical hydration period (CHP)

CWSS = 0.25 xgLxcos - Pf] [Dh - Dc] / Lcmt where:

10000

Impermeable
 = fluid density
Gel Strength (lbf/100 sqft)

1000 Matrix g = gravity

CWSS L = length of column
100
 = angleofinclination
Pf = porepressure
10 CHP
Dh = hole diameter
1
Dc = casingdiameter
Tc Tf
Time

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24Jun. 2003
 Controlling shallow water/gas flows
Slurry requirements

 Low density slurry (low frac gradient)

 Excellent fluid loss control (< 50 ml)

 No free water/sedimentation (no pathfor gas/fluid)

 Rapid setting at low temperature (WOCtime)

 Short critical hydration period (gas/fluid migration)

 Low set cementpermeability (no pathforgas/fluid)

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24Jun. 2003
 Consequences of gas migration
 Blow-out: surface or underground
– Dangertopersonnel
– Lost rig
 Less dramatic but important
consequences
– Lost production
– Treatment fluids injected in
wrong zones
– Annular pressure onsurface
– Damageto the environment

 Repair required: prevention is

better than cure

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24Jun. 2003
 Deepwater Cementing

 Specific deepwaterchallenges &

Overview ofgeo-hazards

 Deepwater cementslurriesrequirements

 Deepwater CementingTechnology
– Liquid additives for cold temperatures
– Foamedcement
– PSD Slurry forDeepwater

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24Jun. 2003
 Liquid Additive Packagefor
Cold Environments Offshore (DeepCEM)

Any cement D500

or blend GASBLOK LT

Deepwater System

DeepCEM DeepCEM
Set Enhancer Dispersant

Two components liquid additives system:

- D185 : Non Retarding Dispersant
- D186 : Cement Set Enhancer

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24Jun. 2003
 Liquid additives for cold temperatures

 Slurries for low temperature,

unconsolidated andunstable
environments (potential shallow
gas/water flows)
1.38 –1.97 SG: neatcements + DeepCEM
liquid additives (extendedwith conventional
additives or foamed)
1.26 – 1.62 SG: PSD blends (with DeepCEM
liquid additives)
0.96 – 1.26 SG: low-density PSD blends
with DeepCEMliquid additives

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24Jun. 2003
 Typical DeepCEM properties
Thickening time and compressive strength

Density (kg/m3) 1900

Cement Class A
D500 (gal/sk) 0.5
D185 (gal/sk) 0.1
D186 (gal/sk) 0 0.1 0.2 0.4
Thickening Time at 18°C & 10.3 MPa(hr:min) 8:31 5:03 4:15 3:58
UCA at 13ºC and 10.3 MPa
Time 50 psi (hr:min) 13:37 10:00 7:12 5:30
Time 500 psi (hr:min) 22:31 16:21 13:38 10:40
Compressive strength @ 24 hrs (MPa) 4.6 8.1 9.1 9.1
Compressive strength at 24 hrs (psi) 660 1170 1330 1330
 Static Gel strength development
”Cement Set Enhancer” concentration effects
2000
0.4 gps 0.2 gps 0.15 gps 0.1 gps
1750 D186 D186 D186 0.05 gps
D186 D186
Gel strength (Lbf/100ft2)

1500
No D186
1250
1000
Lehigh Class H Cement
750 0.5 gpsD500
500 0.06 gpsD185
density = 1970 kg/m3T
250
= 18°C P = 2760kPa
0
0 50 100 150 200 250 300 350 400
Time (minutes)

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24Jun. 2003
Reducing CHP byslope change of
Static Gel Strength

10000
Impermeabl
e Matrix
Gel Strength (lbf/100 sqft)

1000

CWSS
100

10
CHP

1
Tc Tf
Time
Benefits of “Liquid additives for cold temperatures”

 Improved setting characteristics in coldwater

 Effective shallow water andgas flow prevention (in
combination with fluid loss or GASBLOKadditive)
 Simplified logistics
 Quick static gel strength development(short transitiontime
i.e. short time from 100 to 500lb/100ft2 gel strength)
 Fast compressive strength development
– short WOCtime before casingrelease
 Compatiblewith anytype of cement(foamedor non-foamed
neatcements, PSD blends cements, etc..)

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24Jun. 2003
 Foamed cement systems

 Pro’s
– Proven technique for controlling Shallow Water Flow
– Adjustable slurry density (nitrogen controls density)
– Flat displacement profile - goodmudremoval
 Con’s
– Equipment andpersonnelintensive
– Variable deckloadconsiderations
– Relatively high permeability
– Safety concerns with pumpingenergized fluids
– Environmental impactofsurfactants

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24Jun. 2003
 Process controlled foamedcement
Bleedoff w/Choke Wellhead

Cement Unit

NRD
Foam
Check Valve
N2 Isolation Generator
Foamer Recirc Tub
Pump Valve

N2 Slurry Check Valve

Bleedoff
Tank Chief
2000 gals w/ N2 Choke Popoff Valve
180 MSCF
Micromotion
N2 Flowmeter

N2 Pump Restricted Area

Tank Process
2000 gals Control
180 MSCF Computer

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24Jun. 2003
 Foamed cement process control

26" Conductor, Process Controlled Foam Cement, Gulf of Mexico April 7, 1996
1600 6

1400
Base Slurry rate 5

1200
Foamer rate scf/min

bbl/min, gal/min, gal/bbl

4 scf/bbl
1000
scf/min, scf/bbl

N2 stroke rate scf/bbl

bbl/min
800 3
gal/min
gal/bbl
600
2 gal/bbl

400 Foamer ratio

1
200 N2 ratio

0 0
0

2142

3528
1008
1134
1260
1386
1512
1638
1764
1890
2016

2268
2394
2520
2646
2772
2898
3024
3150
3276
3402

3654
3780
756
126
252
378
504
630

882

Time (sec)

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24Jun. 2003
 Example of Foamed Cement Slurry

Base System: Class G cement

15.8 lb/gal D500 (Fluid Loss/GASBLOK Additive)
1.89 S.G. D185 (DeepCEM Dispersant)
D186 (DeepCEM Low Temp Enhancer)
F104 (Foaming Agent)
D139 (Foam Stabilizer)

Thickening Time: 4:02 @ 50°F (10 oC)

Fluid Loss: 42 mL/30 min @ 50°F (10 oC)
Foamed Fluid Loss: 5 gm/30 min @ 50°F @ 11.0 lb/gal
Base Rheology: PV = 76, Ty = 19
Free Water: None
Compressive Strength 1000 psi / 24 hrs @ 50°F (10 oC)

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24Jun. 2003
 PSD Slurry for Deepwater

•Density: 8.5 – 14.0 ppg(1.0 – 1.7 SG)

•Salinity: Fresh Water to 37% salt
•Temperature: 0º -55ºC

 Combinesthe advantagesof Particle Size Distribution

Technology with DeepCEMadditives properties for enhanced
slurry performance at lowtemperature
 Abetter alternative to foamedcementfor controlling shallow
water/gas flow hazards

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24Jun. 2003
 Conventional CementSlurries

To beable to mix and pumpcement, we

need cement +water
By adding more water, we get :
 lower density
 lower viscosity
but we also get:
 longer working time
 lower compressive strength
 higher permeability

Goodslurry properties  Goodmechanicalproperties

 Conventional
cement slurries
Cementparticles must be
surrounded bywater to
flow as aslurry – Sufficient
water must first beadded
to fill the void betweenthe
cementgrains
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24Jun. 2003
PDS slurries
Particle size distribution technology
is used to maximize solid andliquid
content : less water wasted in voids.
Slurry properties and mechanical
properties are optimized
Advantages of “PSD Slurry for Deepwater”
“PSD Slurry for Deepwater” is particularly suitable at cementingweak
deepwater zones with or without shallow water/gas flowhazards
– Simplified logistics andimprovedsafety (no needfor foamedcement
equipmentto achievelowdensities)
– Low densities maintain returns.
– Rapid strength developmentminimizes
waiting-on-cement (WOC)time.
– Combinedwith GASBLOK additive, It is animprovementover foam
cementfor shallow water/gas flow hazards, thanks to its lower
permeability, very quick gel strength developmentandexcellent
mechanicalproperties

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24Jun. 2003
“PSD Slurry for Deepwater” performance
For atypical “PSD Slurry for Deepwater” of 12.5 lbm/gal (1.50 SG)
– Slurry composition
– PSD Blend (Porosity: 45%):
– DeepCEMandGASBLOK LT Additives
– Slurry properties
– Plastic viscosity: 105cp
– Yield point: 19 Ibf/100ft2
– Fluid loss: 23 mL/30min
– Set cement
– Thickening time: 4:00 at50°F (10 °C)
– Transition time: 12 minutes (2 hrs conditioning)
– Compressive strength at50°F (10 °C) :
Time to 50 psi: 5:30
Time to 500 psi: 13:20

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24Jun. 2003
 “PSD Slurry for Deepwater” performance
D e e pC R E T E DeepCRETE
@ 1 2 ppg @ 13.5 ppg

Conventional Conventional
G @ 15.8 ppg G @ 15.8 ppg

E x te nde d E x te nde d
Lightweight @ Lightweight @
12 ppg 13.5 ppg

0 20 40 60 80 0 500 1000 1500 2000 2500 3000 3500

Solid Fraction (%) Compr e s s i ve strength (psi)

DeepCRETE
D e e p C R E T E @ 13.5 p p g
@ 12 ppg

Conventional B e ntoni te E x t e n d e d @ 1 3 . 5
G @ 15.8 ppg p p g Lightw eight

Extended S o d i u m Silicate E x t e n d e d @
Lightweight @ 13.5 ppg
12 ppg

0 0.05 0.1 0.15 0.2 0 200 400 600 800 1000

Permeability (mD) Natural Fluid L o s s (ml) : n o F L additive

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24Jun. 2003
 “PSD Slurry for Deepwater”
vs foamed cement
3500 3
Foamed cement FoamedCement
3000

L ogPermeability (mD)
“PSD Slurry for 2 “PSDSlurryfor
Compressive strength(psi)

Deepwater”
2500 1 Deepwater”

2000 0
1500 -1
1000 -2
500 -3
0 -4
8 9 10 11 12 13 8 9 10 11 12 13
Density (lbm/gal) Density (lbm/gal)

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24Jun. 2003
 “PSD Slurry for Deepwater”
vs foamed cement

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24Jun. 2003
 “PSD Slurry for Deepwater” Case History
Shallow Water Flow Hazard

 Located in 1204 metres of water inTrinidad

 Set 26” casing at1692 metres RKB (462 metres BML)
 Shallow water flow andgas hydrates were encountered
 CemCADEtemperature simulator predicted BHCT = 8°C
 Operator wanted alternative to foamedcement
 Pumping Sequence:
• 32 m3MUDPUSH XL @ 1500 kg/m3(with greendye)
• 78 m3of “PSD Slurry for Deepwater” with DeepCEM@ 1515kg/m3
• Displacement withseawater
 Full returns observed atwellhead with ROV– TOC@mudline
 No Flow aftercementing
 Drilled out hard cementat 26” shoe 14 hrs after placement

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24Jun. 2003
 Other System CaseHistory
Conventional (Low S.G. Glass Bead Extender)

 Located in 750-1000 metres of water in Brunei (3 wells)

 Set 13 3/8” casing at1177, 1716, 1598 metres RKB ( 673, 748, 351meters BML)
 No Shallow water flow andgas hydrates were found bysite survey
 Surface BOP system (Semi sub rig) used andLeadslurry early strength development
was not required at near seabed
 CemCADEtemperature simulator predicted BHCT = +- 19°C
 Pumping Sequence:
• 10 m3Drill Water
• LeadSlurry @1.6SG
• Tail Slurry @1.90SG (50-150mcolumn)
 Full returns observed at wellhead with Camera– TOC@mudline
 Drilled out hard cementat 13 3/8” shoe without problems

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24Jun. 2003
 Summary
Deepwater cementing solutions

 Rig time costs

– ReducedWOC Liquid additives for coldtemp.& PSD Slurry
for Deepwater
– Improvedlogistics  Liquid additives for coldtemp.
 Well control (lost circulation & shallow water/gas flows)
– Low density systems  Foamedcement& PSD Slurry for
Deepwater
– Short critical hydration period  Liquid additives for cold temp.
– Low fluid loss andgas-tight  GASBLOK LT
 Cold temperatures
– Temperature modeling  Computertemperaturesimulator
– Low temperature performance Liquid additives for coldtemp.
& PSD Slurry for Deepwater
 Needto evaluatewell condition including rig dayrate, then optimize
cementsystem
Page42
24Jun. 2003