26/06/2013

INSTITUT ALGERIEN DU PETROLE

School of Boumerdes
UFR: Drilling and Production

Cementing & cement evaluation

PREPARED BY: A.NACEF
DRILLING INSTRUCTOR

Contents

Introduction

Types of cementing

Primary cementing

Methods of primary cementing

Primary cementing-casing

Designing a cement job

Casing & cementing accessories

Cementing additives

Remedial cementing

Plug cementing

Squeeze cementing

Cement chemistry and additives

Cement evaluation

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Introduction
3

A critical Well Construction process used worldwide

Cementing is an important steps in the wells finishing

process.

Cementing is done by pumping a slurry of cement and

water at a strategic point around the casing to bind these up

to the formation

Types of cementing
4

When drilling oil and gas wells, several different cementing methods
can be needed:

Primary Cementing : is the introduction of cementacious material

into the annulus between casing and open hole

Remedial jobs : to repair primary cementing jobs (Squeeze

cementing, Cement plug)

Other cementing: plugs for abandonment, sidetracking, loss zones

etc

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Primary cementing
5

The placement of a cement slurry into the annulus between the casing

and the formation exposed to the wellbore (open hole) or previous

casing.

The most important objective of primary cementing is to provide zonal

isolation (that is, to prevent communications between the different

zones in a well). In addition, the cement provides support for the
several casing strings run in a well.

Zonal Isolation
6

Poor Zonal Isolation:

improper reservoir evaluation

crossflow of unwanted fluids

corrosion of pipe and scale production

annular pressure and environmental hazards

more than $45 Billion/year spent on unwanted produced water

management

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Purpose of primary cementing

7

Fasten the casing to the formation

Reduce the possibility of blowout from high pressure zones

Protect all Production zones

Prevent fluid movement between different formations, or between

formation and the surface

Strengthen and protect casing/tubing against corrosion

Support the borehole

Methods of primary cementing

8

Thru-Drill Pipe Cementing (Stab-in)

Outside Cementing (Top Job)

Single stage cementing ( two plugs cementing)

Two Stage Cementing

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Primary Cementing - Casing

9

Conductor

Surface

Intermediate

Production

Liners

Conductor Casing (stove pipe)

10

Confines circulating fluids

Prevents washing out under rig

Provides elevation for flow nipple and bell nipple

BOP are usually not attached to conductor casings.

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Conductor Casing (stove pipe)

11

Set from 40 to 100 feet

Casing is large; 36/42 inches inches

diameter
Hole may be eroded severely.
Casing can be pumped out easily and must
be tied down.
Large excess
Stab-in cementing common
Accelerated neat cement

Surface casing
12

Protect water sands.

Case unconsolidated formations.

Provides primary pressure control.

(BOP usually nippled up on surface

casing)

Supports subsequent casings.

Case off loss circulation zones.

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Surface casing
13

Characteristics:

(Set from 100 to 3000 feet)

Casing may stick easily in unconsolidated
formations.

Loss of circulation may be a problem.

Most areas require that cement be circulated.

Guide shoe, or float shoe, and stab-in shoe
commonly used.
18 5/8 casing in 26 hole

Light weight lead and neat tail slurries
or

Large excess ( 50 - 150 %)
13 3/8 casing in 17 hole
@
100 ft 3000 ft

Surface casing
14

Characteristics:

Often cemented through drill pipe with

stinger.

Top plug should be prepared for any
failure to seal with stinger.

Shoe Bottom joints should be centralized
and thread locked to prevent loss down
hole.

Cemented to surface /top job

18 5/8 casing in 26 hole

or
13 3/8 casing in 17 hole
@
100 ft 3000 ft

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Itermediate casing
15

Cases off loss circulation zones, water flows, etc.

Isolates salt sections

Protects open hole from increase in mud weight

Prevents flow from high-pressure zones if mud weight must

be reduced

Basic pressure control casing BOP always installed

Supports subsequent casings

Intermediate casing
16

3000 to 10,000 ft (vertical or deviated)

13 3/8 casing in 16 or 17 hole

9 5/8 casing in 12 hole

Guide shoe, or float shoe, and float collar commonly used.

Cement volumes usually largest in well

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Intermediate casing
17

Potential problems: over-pressured, loss zones, salt formations

or heaving shales

Narrow pressure window, between pore @ bottom & frac @ top

Long casing string may 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

Specialized slurries (light, heavy, salt etc)

Production casing
18

Conduit for Completion String

Provides pressure control

Cover worn or damaged intermediate casing

Setting depth through producing zone

Common sizes 4 1/2 and 7 " casing

Generally cemented back to intermediate casing

Good cement job is vital to successful completion.

Can be a liner

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Production Liner
19

Isolates the pay zone from other

formations and the fluids in them.

Protective housing for production

equipment.

usually cemented and perforated

Common sizes:
3 ,4 , 7,

Can be blanked or slotted

Liners
20

Key Points:

Pump Down Plug

Dart

Requires less casing

Liner Hanger

Deeper wells

Liner Wiper
Plug

Small annular clearance

Liner Over Lap

Specialized equipment

Previous Shoe

10

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Methodes of primary cementing

21

Thru-Drill Pipe Cementing (inner string cementing)

Outside Cementing (Top Job)

Single stage cementing ( two plugs cementing)

Two Stage Cementing

Thru-Drill Pipe Cementing (Stab-in)

22

Key Points:

Less cement contamination

Less channelling

Small displacement volume

Pump until cement to
surface

Less job time (rig time)

Less cement

Stinger.exe

11

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Inner string cementing

23

Operational Sequence for running & cementing 18 5/8

Prepare and measure the 18 5/8 string (prepare the landing joint
according to section TD).

Remove the 30" conductor pipe raiser, respecting all the time the safety
procedures.

Run 18 5/8 casing in the hole circulating from the cellar with a jet
pump.

Connect last casing joint with the minimum torque.

Center the 18 5/8 string (see figure 1) with metal rig-made slips.

Install the IPN in the top of the cellar, perpendicular to the 18 5/8
casing.

Install the 18 5/8 casing elevator between the IPN and the next joint
couple. The side door elevator needs to be landing on top of the IPN.

Land casing.

Inner string cementing

24

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Inner string cementing

25

Disconnect landing joint.

Check the condition of the O rings of the cementing stinger nipple.

Use 18 5/8'' X 5 1/2'' DP Centralizer

Run in hole stinger string.

Set stinger in casing shoe. circulate through the cement stinger, and

ensure the stinger seal is not leaking.

R/U CMT head, R/U cementing lines. Well Service flush lines with
water and test lines to 3000 psi

Have enough cement and additives on location for 100% excess over
required volume

Conduct a pump efficiency test and report the results on the daily
drilling report

Stinger
26

13

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Inner string cementing

27

Inner string cementing

28

Cement 18 5/8 casing, pump cement slurries (lead then tail)

While cementing closely monitor any return from DP X Csg annulus.

Observe returns from the well for any indication of hole losses or

instability
Displace cement, check for mud return
Disconnect stinger from float shoe, flush & POOH the stinger string,
Proceed to weld the centralizing slips.
Cut 18 5/8 casing as detailed in the procedures to install casing head
housing.
Install casing head housing.

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Outside Cementing (Top Job)

29

Key points:

Bring cement to surface

Macaroni tubing used
Max. depth 250-300 ft
High friction pressures
Non-standard connections

Tubing
moved
during
job

Single stage cementing ( two plugs cementing)

30

It is conventional method

The most method used in drilling

Long pumping times

High pump pressures

SingleStage.exe

15

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Single stage cementing ( two plugs cementing)

31

Run 13 3/8" to TD w/Circulation. Adjust column

R/D WFT running gear & LA Fleur

Offline Verify the cement top & bottom plugs type and load it on the

plug holder
perform pump efficiency tests and record it in the daily drilling report
R/U CMT head and lines
Pressure test lines to 4000 psi
Circulate prior cementing: Circulate to cool down, hole clean and break
gelled up mud. Reciprocate casing gently and continuously at 3m up
and 3m down. Meanwhile mix cement.
Mud conditioning (low viscosity = good mobility) is the most important
variable in achieving good cement placement behind the casing.

Single stage cementing ( two plugs cementing)

32

Pump spacer ahead

Release bottom plug

Pump cement

Release top plug

Pump spacer

With rig pump displace cement, wait for bottom plug bump

Record final displacement pressure, bump top plug and continue

pressure up to 3000 psi

If the plug does not bump after finished theoretical displacement

volume do not over displace at all (max half shoe track volume)

In case of float equipment not holding back press keep the CMT head

valve closed till CMT set

R/D CMT head, Unscrew & hang BOP'S, Set casing hanger, Cut,

Beveled and L/D L.Jt

16

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Two Stage Cementing

33

The cementing of a string of casing in 02

Stages, using a stage collar

Stage
Collar

1st Stage

Two Stage Cementing

34

Why?

Potential Casing Collapse due to Hydrostatic Pressure of a full column

of Cement
Lost circulation zone or low Frac gradient
Cement very long intervalle (time/volume limitations)
Reduce use of expensive slurries due to special well problems (salt
zone, gas zone)
Incomplet fill up (Can leave zone in the annulus uncemented)

TwoStage.exe

17

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Two Stage Cementing

35

Hardware

Stage collar

Plugs
First stage wiper plug (bottom
plug is optional)
Opening plug/bomp
Closing plug

Stage collar
36

CLOSING
PLUG
SHEAR
PINS

Running in Position

OPENING

OPENING

BOMB

BOMB

Cementing Position

Closed Position

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Two Stage Cementing

37

Where to place stage collar?

Problematic formations (lost circulation, salt zone etc)

Inside previous casing to:
Avoid jetting effect on the formation while circulating
cement
To ensure that if the collar fails to open, at least the open
hole section is cemented

Two Stage Cementing

38

Some other points

The stage collar is eventually drilled out leaving the same

drift as the rest of the casing

3 stages cementing is the same as 2 stages, but with 2 stage
collars

A stage collar is considered to be a weak point in the casing
by many clients and so avoid using them.

Alternatives: use of lightweight slurries (foam cement)

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Two Stage Cementing job procedure

39

Pressure test lines

Pump wash/spacer

Pump slurry

Drop first stage plug

Slowdown when the first stage plug passes the stage collar

Displace, bump plug, check returns

Drop bomb, wait allocated time (rule of Thumb 200ft/min)

Pressure up to open stage collar

Circulate (W.O.C if required)

Pump wash/spacer then pump slurry

Drop closing plug

Displace close stage collar

Check for returns

Two Stage Cementing examples

40

Calculate

First stage cement
and displacement
volume

Second stage
cement and
displaced volume

13 3
3//8 68 lb/ft Casing

Top of cement at 2461 feet

4
13 3
3//8 shoe at 2789 feet
3

9 5/
5/8 Stage collar at 4265.
4265.3 feet
12 1
1//4 O.H.
9 5/
5/8 53.
53.50 lb/ft Casing

9 5/
5/8 Float collar at 6348.
6348.8 feet
2
9 5/
5/8 Shoe at 6398 feet

20

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Two Stage Cementing examples

41

Frac Gradient: 0.8 psi/ft

MW = 12 ppg

1. Would you recommend a 2-stage ?

Why ?

2. What depth would the Collar be?

3. What is the maximum density of

slurry possible during the first stage

2400

(assume cmt to stage collar)?

4. Where would the TOC be for the first

5500

salt zone

salt zone
5850

stage
TD:8400

Two Stage Cementing examples

42

4100

Frac Gradient: 0.8 psi/ft

MW = 11.2 ppg
weak formation

7100 -7250
FG: 0.6 psi/ft

weak formation

8400 - 8450
FG:0.68 psi/ft

TD:10200

21

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Liners
43

Any string of casing whose top is located below the

surface, hung inside the previous casing and is run to

its setting depth by drill pipe.

LINER
HANGER

OVERLAP 50 - 500 FT

CASING
SHOE

Liners
44

Way liners?

Prime reason:

Save money (Cost of 1 Joint of Casing can be $3,000!)

Cover Corroded/Damaged Casing

Cover:
Lost Circulation Zones.
Shale or Plastic Formations
Salt Zones

Deep Wells: Rig Unable to Lift Long String of Casing

22

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Types of liners
45

Production:
Most common
Save$$
Slotted liner
Blanked liner

Intermediate/drilling:
Cover problem zone in order to be able to continue drilling

Tie-back/liner complement:
From top of existing liner to surface, or further up casing to cover

corroded or damaged zone.

Types of liners
46

Tie-Back (Liner Complement)

This is often done if production is
commercially viable or there is damage
to casing above the liner

TIE BACK
STINGER WITH
SEALS

LINER

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Liners
47

Procedure for Setting Liner

48

RIH hole with drill pipe

At liner hanger depth, condition mud (Reciprocation / Rotation)

Release slips (liner hanger) (Rotation - mechanical pressure

hydraulic)
Set slips, release liner weight, check to see if running tool is free
Pump mud - to ensure free circulation
Cement/ Displace/ Bump plug/ Bleed off
Release setting tool
POOH above TOC and circulate

24

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Liner cement job procedure

49

Pressure test lines.

Pump wash/spacer.

Pump slurry.

Drop "Pump Down" plug (or drill pipe wiper dart).

Displace
To running tool and slow down the rate
Shear "Wiper Plug
Displace to Float Collar. Slow down while approaching end of

displacement

Bump plug/checkf or returns.

Release tool.

Pull up to T.O.C. and reverse circulate / circulate

Liner.exe

Liner overlap
50

Cementing the liner "lap" is critical.

Too much cement above the liner hanger is not recommended

So make sure that "uncontaminated" cement is present at the liner lap -

washes and spacers / WELLCLEAN

If not, there is communication from the annulus to the formation

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Recommendations for Liner Cementing

51

Ensure rheology of cement System is adequate for 100% mud removal

Turbulent flow, if possible

Consider 5 -10 min. "contact time" at liner lap

Batch mix cement

Minimize U-tubing effect

Adequate mud conditioning prior to cementing

Liner example: well data

52

1) Well Information:
9-5/8" 47 Ib/ft intermediate casing surface to 6500
7" 29 Ib/ft intermediate liner 6200 ft to 10,500
6OH to TD at 14,500
DP 3-1/2" 13.30 Ib/ft G105
4-1/2" 16.90 Ib/ft liner required 14,400' to 400' inside 7" liner.
FC 80' above shoe.
2) Cement required to TOL with 20% excess in OH
3) Calculate Slurry and displacement volumes
4) Give Job Procedure

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Liner exemple: well schematic

53
9 5/8 casing 47 lb/ft
3 1/2 drill pipe 13.3 lb/ft
9 5/8 casing shoe at 6,500 ft
7 liner 29 lb/ft Top at
6,200 ft
7 liner shoe at 10,500 ft
6 Open hole + 20% Excess
4 1/2 liner 16.6 lb/ft top
@ 10,100ft ; collar @
14,320 ft
4 1/2 liner shoe at 14,400
ft

Designing a Cement Job

54

Compute fluid volumes

Slurry

Wash, Spacer,

displacement volumes
based on :

Hole capacity

Casing capacity

Annular length

27

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Designing a Cement Job

55

Check that well security is respected:

Simulate cement pumping process to compute hydrostatic and

dynamic pressures and compare them to :
pore pressure
Fracture pressure
Tubular burst pressure

Ensure well security when Running In Hole

Check Temperature and thickening time

Designing a Cement Job

56

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

28

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Parameters required
57

WELL PARAMETERS

FLUID PARAMETERS

Hole size and depth

Casing tally
PP and FP
Temperature
Centralization

Densities
Rheology, PV and Ty
Cement additives

Cement calculations
58

Prior to a cement job, the following calculations are made

Cement volume requirements

2. Cement displacement volume
3. Cement slurry composition calculations
1.

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Cement calculations
59

The following categories are involved:

Cement volume (annular volume)

Amount of water to make the cement

Cement density and yield

Displacement for landing top plug

Pumping pressure for landing top plug

Hydrostatic pressure on the formation

Pressure for casing axial force during pressure test after the top cement

plug is bumped

Cement calculations
60

Cement slurry volume

Before a cementing job can be carried out, volume calculations are

needed.

Depending on the drilling fluid program and types of formation, the

hole diameter will be somewhat larger than the drill bit diameter.

Annular volume is calculated to determine the amount of cement to be
mixed.

The amount is decided by making calculations based on the drill bit
diameter, plus an extra amount based on experience or what is known
about the formations in that particular area or caliper log.

This forms the basis for the cement company's calculation of the total
time needed for mixing and pumping the required.

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Cement calculations
61

Cement slurry volume

After the casing is put into place, this calculated amount will normally

be adjusted, based on data collected via the caliper log.

The caliper log does not give completely reliable results, and is usually
used to find out whether the calculated cement volume, based on the
drill bit diameter, is satisfactory.

We normally use between 1.25 and 2 times the cement volume which
was calculated by using drill bit diameter, this to compensate for washout in the well

Cement calculations
62

Cement slurry volume

This is especially important with regard to deviation drilling, as these

wells have a tendency to become oval, and so excess cement is needed.

This can often vary up to as much as 50% of the calculated hole volume.
The ratio of fullness in the annulus will vary somewhat, depending on
practice in the different companies, and the demands from the
authorities.
The two upper casings are always cemented back to the surface.
Normal cement volume is 100-200% more than calculated volume,
based on ideal diameters.
12 1/4" and 8 1/2" sections often have 30-50 % excess.

31

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Cement calculations
63

Cement slurry volume

The required volume of cement slurry is based on the following factors:

Length of open hole

Diameter of the open hole (drill bit diameter and degree of washout)

External and internal diameter in the particular casing

Top of cement in the well

Cement calculations
64

Cement slurry composition calculations are based on kilos or liters per

100 kg cement powder.

Slurry composition is characterized by:
1.
2.
3.
4.
5.
6.

Slurry Density
Thickening time
Ultimate cement strength
Slurry permeability
Slurry viscosity (Pressure loss)
Fluid loss

32

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Cement calculations
65

A 7" liner cementation require 43 m3 cement slurry volume.

From cementing company laboratory
The slurry density is 1,90 kg/liter
Slurry yield is 96,88 LHK

Additives
Micro Block: (Gas Block Additive)
CFR3L: (Thinner)
SCR-100L (Retarder)
HALAD (Fluid loss reducer)
NF-5 ( De-foamer)
Fresh Water

18 LHK
1,15 LHK
2,0 LHK
6,5 LHK
0,1 LHK
37,38 LHK

Cement calculations
66

Step 1 : Calculate cement requirements:

Cernent Requirement = CementVolume.x.100/slurry yield (LHK)

= 43000 x 100/96.88
= 44.39 ton

LHK = Litre per Hundred Kilo Cement

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Additive calculations
67

Additive calculations exercise

68

A 9 5/8" casing cement job require 123 m3 cement slurry volume.

Calculate cement and mix water and liquid additives per measuring
tank.

From cementing company laboratory
The slurry density is 1,92 kg/litre
Slurry yield is 95,88 LHK
Additives
CFR3L:
(Thinner)
1,27 LHK
SCR-100L (Retarder)
1,40 LHK
HALAD
(Fluid loss reducer)
5,70 LHK
NF-5
(De-foamer)
0,15 LHK
Fresh Water
35,38 LHK

34

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Cement calculations
69

Displacement Volume

After the cement is mixed and pumped into the well it is

displaced down the casing and up the annulus

The displacement volume is the volume needed to send the top
plug from the cement head to the float collar.

This is normally done by multiplying the length with the capacity
for the string.

A pump efficiency is used for these calculations
This capacity varies normally between 96% - 99%

Pumping Pressure to Charge Top Plug

70

When the cement leaves the casing shoe and start to move up in the

annulus we will notice the u -tube effect by the heavier slurry in the
annulus.

Example

A casing is cemented with 1,90 sg slurry and displaced with 1, 35 sg.

Top Of Cement, TOC, is at 1000 m. Cement shoe is at 2000 m and the
float collar is at 1976 m. What is the differential pressure just before the
top plug lands (ignore friction)
AP = (1976 -1000) x 0,0981 x (1,90 - 1,35) = 52,7 bar

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Hydrostatic Pressure
71

To ensure we are not fracturing the formation during the cement job, it

is necessary to calculate the hydrostatic pressure in the cement slurry to

be used.

Get an idea of whether there is a risk of the well fracturing when we are
cementing.

We must calculate pressure at different levels in the well, based on the
geological conditions.

In very weak zones, we must take extra care with regard to friction
pressure, in addition to the hydrostatic pressure.

Casing & cementing Accessories

72

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Guide Shoe
73

Attached to first length of casing to be

lowered into hole

Guides casing into borehole and
around obstructions

Can be drilled out with the bit

Float collar
74

Float Collar:
This is set about two-three joints above the casing shoe, and act
as a one way valve,
When it is used, the cement plugs land on top of it.

Ball Type

Flapper Type

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Wiper Plugs
75

To Separate Fluids,
(cement/wash/spacer/mud)

Wiping the casing clean,
Top Plug (Solid)

Surface indication of

Bottom Plug
(pump through)

placement

Others
76

Centralizer: to centre
casing in bore hole to
promote even distribution
of cement around casing

Cementing Basket: to
minimize losses in weak
zones.

Scratchers; to scratch off

the mud cake to improve
cement bond

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Cement Heads
77

Conventional cement head

Equipment On-Shore
78

Bulk Plant
Silos, WBB, Compressor, Dust
Collector

Batch Mixer

Fill

Diesel Engine

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Equipment Off-Shore
79

Batch Mixer
CPS

LAS
Liquid Addtive System

Cement Pump Skid

Slurry Chief

Cement Head

Mixing System

(Sub Sea System)

Mixing & Surface equipment

80

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Mixing & Surface equipment

81

Casing String Components from bottom up

82

Float shoe
guide and check valve to prevent
cement back flow

2 Casing joints
to capture any contaminated cement

Cement
Head

Rig Floor
Ground Level

Drilling Fluid
Cement

Float collar

Casing

Centralizer

Centralizers

Scratchers

Float
Collar

Float Shoe

Figure 9 Typical cementing equipment.

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REMEDIAL CEMENTING

What is remedial cementing?

84

Why do we do it?
Plugs

Squeeze

Lost circulation
Kick off
Abandonment
Primary cement job repair
Unwanted Water Production
High Gas-Oil Ratio (GOR)
Casing Splits or Leaks
Nonproductive or Depleted Zones

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PLUG CEMENTING

Plug Cementing
86

Purposes
To side track above a fish or to initiate directional
drilling.
To plug back a zone
To plug back a well (abandonment or later re-entry)
To solve a lost-circulation problem during the drilling
phase
To provide an anchor for OH tests.

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Side Track and Directional Drilling

87

Design considerations

Kick Off Point

CEMENT
PLUG

NEW
HOLE

High compressive
strength, typically with
high density
Length should be enough
to kick off

Plug Back a Depleted Zone

88

Design considerations

Cement
Plug

Depleted
Zone

Sufficient length to provide

a long term barrier
Legal requirements
dictated by authorities
Reservoir zones may
require additional
additives

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Lost Circulation
89

Design considerations
Sufficient length to cover
the thief zone
Successive treatments may
be required, depending on
losses
Lower density to minimise
hydrostatic pressure

CEMENT
CEMENT
PLUG
PLUG

ThiefZone

Abandonment
90

Design considerations
CEMENTPLUG

CEMENTPLUG

CEMEN PLUG
T

Sufficient length to provide

a long term barrier
Legal requirements
dictated by authorities
Reservoir zones may
require additional
additives

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Test Anchor
91

Design considerations
Test String

Sufficient compressive
strength to withstand
pressure testing
Reservoir zones may
require additional additives

Zone to be Tested
CEMENT
PLUG

Weak
Formation

Cement Plugs - design

92

Design criteria

1. Quality
Cement hardness
Cement weight
Cement permeability

2. Time

Cement setting time (Pumping time): The minimum thickening time

should be the job time plus a safety factor

2. Cement hardening time (ultimate strength) For kick off plugs the
ultimate setting time should be achieved prior kick off operation

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Cement Plugs - design

93

Cement testing should be carried out using samples of the

actual materials to be used during the job (samples of mix

water and lead/tail slurries)

Calculate the hydrostatic pressures throughout the job and

check that the formation is never under balanced. Weighted

spacers or mud must be used to maintain primary well
control at all times.

Cement Plugs string design

94

Wherever possible run a slim tubing stinger below the main

pipe. The minimum stinger length should be the plug

length plus 30m.

The natural tendency for cement slurry is to travel
downwards when it leaves the string, since the slurry will
generally be heavier than the drilling fluid.

This can be avoided by spotting a viscous pill below the
plug setting interval.

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Slurry Properties
95

Compressive Strength

Density

lighter for Lost Circulation

heavier for Sidetracking
homogeneous - batch
mixing

Rheology

higher for Sidetracking

less important for Lost
Circulation
minimum 500 psi for drill
out

Thickening Time

higher for Lost Circulation

Optimum (mud removal)
for Sidetracking
lower for placement with
Coiled Tubing

enough for placement,

POOH & circulating clean

Optimising Cement Plugs - Slurry mixing/placement

96

1.
2.
3.
4.
5.
6.
7.

8.

Pump a spacer ahead of the slurry to give a separation between

the drilling mud and the cement slurry.
Cement slurry should be batch mixed.
A slight under-displacement is required in order to pull a dry
string
Pump a spacer behind the slurry to give a separation between
the drilling mud and the cement slurry.
Displace at maximum rates
If possible rotate the string during the slurry placement and
displacement.
Pull back slowly above the plug and circulate out excess cement.
At the same time the inside of the drill pipe will be cleaned for
cement.
Do not run back into the cement plug after pulling clear

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Reasons for Cement Plug Failures

97

Lack of hardness (sidetracking).

Poor isolation (plug back, abandonment).

Wrong Depth.

Not in place due to sinking to the bottom .

Not in place due to loss to thief zone.

Balanced Plug Placement

98

Most commonly used

method.
Set using drill pipe and
stinger

49

26/06/2013

Balanced Plug Placement

99

Balanced Plug Placement

100

Water or other fluid of different density from that hole is run ahead

and behind cement slurry. The volume of fluid ahead and behind
slurry is calculated so that height in casing is same as height inside the
string.

mud
water
cement
water

hW
Height of
plug with
pipe in place

Height of plug
after pulling pipe

mud

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26/06/2013

Balanced Plug Placement

101

Procedure:
1.
2.
3.
4.
5.
6.
7.

Pump required spacer volume

Mix and pup required cement volume
Pump spacer behind cernent inside stinger
Displace with mud
POOH above cement plug
Circulate
POOH

Balanced Plug Placement

102

Example

When the cement stinger is pulled
above the plug, The last "drop" of
cement is leaving the stinger,

Then the displacement volume is:
V = Stinger capacity X distance to top
plug.

5"DP19,5# -> 9,15lpm

V= 9,15 x 1450 = 13267 Litre mud +
50 m Spacer = 457 litre

Total displacement volume: 13724
litre

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Balanced Plug Placement

103

Exercise:

Set 200m balanced cement plug inside 12 14" hole.

Use 3 13,3 Ibs/ft DP, cap. 3,86 lpm.

50 m spacer between DP and open hole

Bottom of plug at 3000 m
Calculate
1. Required plug cement volume,
2. Spacer volumes ahead and behind
3. Displacement volume.

Balanced Plug Placement

104

Question

If the mud density is greater than the cement density

should you over displace or under displace?

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SQUEEZE CEMENTING

Squeeze Cementing - Definition

106

Injection of Cement Slurry into

packer

the voids behind the casing

tubing
FORMATION

Dehydration of cement requires:

fluid-loss, porous (permeable)

matrix, differential pressure,
time.
Injection below or above

fracture pressure

casing
DEHYDRATED
CEMENT

cement
slurry

cement
nodes

PRIMARY
CEMENT
CHANNEL BEHIND
CASING

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Squeeze Cementing - Applications

107

Primary cement job repair

Unwanted Water Production
High Gas-Oil Ratio (GOR)
Casing Splits or Leaks
Non-productive or Depleted Zones

Squeeze Cementing - Methods

108

 Squeeze techniques:



High pressure - above formation frac pressure

Low pressure - below formation frac pressure

 Pumping techniques:



Hesitation
Running

 Placement techniques:



Packer/Cement Retainer
Bradenhead

 Coiled tubing

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Low Pressure Squeeze

109

Squeeze pressure below fracture pressure

Best way to squeeze the pay zone

Use small volume of slurry

Applicable for :

Multiple zones

Long intervals

Low BHP wells

Naturally fractured formations

High Pressure Squeeze

110

Fracturing is necessary to place cement in the void

Requires placement of large volumes of slurry

Wash or acid ahead to minimize pump rates required to

initiate fracture

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Running Squeeze
111

Continuous pumping until final squeeze pressure is attained

Clean fluid in the hole

Large slurry volumes without fluid loss control

Low or high pressure squeeze

Applications

Water flow
Abandon perforations
Increase cement top
Casing shoes
Liner tops
Block squeeze
Lost circulation zones

Hesitation Squeeze
112

Intermittent pumping

Low pump rates

Small slurry volumes

Long job times

Applications

Channel repair
Long perforated interval
Long splits in casing
Lost circulation

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Bradenhead Squeeze
113

Done through tubing or drill

pipe without packer

Advantages

No tools are used (simplicity)

Cost

Disadvantages

Casing and wellhead are
exposed to pressure

BO
P

CEMEN
T
Sand
BRIDGE
PLUG

Packer with Tailpipe Squeeze

114

Downhole Isolation tool

Casing and wellhead

protection
Tailpipe for placement
or setting a bridge plug
Long intervals

Packer
Tail Pipe

CEMENT

57

26/06/2013

Cement Retainer Squeeze

115

Drillable Isolation Tool

Similar to packer without
tailpipe
Applications
Squeeze pressure trapped

CEMENT
RETAINER
CEMENT
Sand
BRIDGE PLUG

Coiled Tubing Squeeze

116

Applications

Producing wells

Through tubing

Advantages

Cost

Accurate placement

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Cement Chemistry & Additives

The Clinker and Its Components

118

Cement is made of Limestone and clay or shale mixed in

the right proportions

Each run may be slightly different due to impurities

Cement is heated in a rotary kiln from 2600 to 2800
degrees F

What comes out of the kiln is called clinker

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26/06/2013

The Clinker and Its Components

119

The clinker is the mixture formed by the clinkering process.

The clinker has four components: C3S, C2S, C3A, and C4AF

The letters in the clinker names are not chemical formulas.
Instead, the letters represent abbreviations of chemical
formulas:

C CaO

S SiO2

A Al2O3

F Fe2O3

The Clinker and Its Components

120

Clinker

Scientific Name

Chemical
Formula

Properties in Cement

C3S

Tricalcium silicate

3CaO . SiO2

Major component (50 to

60%)
Strength development

C2S

Dicalcium silicate

2CaO . SiO2

Final compressive
strength

C3A

Tricalcium
aluminate

3CaO. AlO3

Sets rapidly
Controlled by gypsum
Early strength
development

C4AF

Tetracalcium
aluminoferrite

4CaO . Al2O3. Fe2O3 Little influence

60

26/06/2013

Portland Cement
121

After the clinker is formed and cooled, it is moved to a second grinding

mill where it is combined with 1.5% to 5% gypsum (CaSO4. 2H2O), by

weight of clinker. When added in this amount (generally +/- 3%),
gypsum prevents "flash set" by controlling the hydration of C3A.

If more than 5% gypsum is added to the clinker, the cement undergoes

a "false set." Excess gypsum causes false set because it tends to hydrate
quicker than the cement. The clinker and gypsum mixture is ground
and blended to form Portland cement.

Cement reactivity to water depends a lot on surface area, which is

related to the size of the cement grains. Cement grain size ranges from 1
to 100 microns (average size around 30 microns).

API Cement Classes

122

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26/06/2013

API Cement Classes

123

Cement Additives
124

Cement must be placed in wells ranging from shallow to

very deep

Additives are used to adjust cement properties and tailor
the cement to specific needs

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26/06/2013

Cement Additives
125

Extenders

Lightweight additives or extenders are used to decrease

the density of cement

Excess mix water can be used to decrease the density to
a limited extent

Excess water increases thickening time, increases free
water and reduces compressive strength

Cement Additives
126

Extenders

Bentonite is the most common light weight additive

Bentonite will tie up extra mix water reducing density
Light weight cements have as much as 12% bentonite
Adding bentonite thickens the cement slurry and it must
be thinned by adding a thinner or friction reducer

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26/06/2013

Cement Additives
127

Extenders

Perlite is volcanic glass bubbles that has some times been

used in geothermal wells because of its insulating

properties
Perlite is considerably more expensive
Gilsonite and kolite are used to reduce density; however,
their primary function is as a lost circulation material
Gilsonite is a black asphalt
Kolite is crushed coal

Cement Additives
128

Extenders

Foamed cements are also used to reduce the density of the

slurry

In a foamed cement, nitrogen is added to the cement
mixture

Very low densities can be obtained with foamed cement but
they are more expensive

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26/06/2013

Cement Additives
129

Weighting Agents

Hematite is one of the more common additive for high

density cement due to its high specific gravity

For smaller increases in density, barite can be used

Barite is ground fine and requires more mix water to keep
the slurry pumpable

Sand can be added to increase the density due to low mix
water requirements

Cement Additives
130

Densified slurries can be used up to 17.5 ppg

A densified slurry is produced by reducing the mix water

and adding a dispersant to make it thin enough to pump

Salt can be used to increase the density of a slurry

Salt increases the density of the liquid phase

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26/06/2013

Cement Additives
131

At low temperatures, it would

take too long for the cement

to set up so accelerators
are added to the cement

Decrease the thickening time

of cement for shallow, low

temperature applications

Cement Additives
132

As a rule of thumb,

accelerators are
inorganic
compounds

Calcium chloride is the most common accelerator

It is used in concentrations from 1 to 3%

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26/06/2013

Cement Additives
133

A little salt will

accelerate

A lot of salt will
retard the
cement

Cement Additives
134

Retarders

Increase the thickening time of cement for deeper, hotter
applications

Typically retarders are organic compounds

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26/06/2013

Cement Additives
135

Retarders

One of the most common retarders is calcium

lignosufonate

Sodium Chloride is a retarder at high concentrations

As bottomhole temperatures change, the type of
retarder will change

Cement Additives
136

Friction loss additives (Dispersants): are used to

thin the cement slurry

Organic acids

Lignosulfonate

Alky aryl sulfonate

Phosphate

Salt

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26/06/2013

Cement Additives
137

Lost circulation material

Granular material such as gilsonite, kolite, perlite and

walnut hulls
Organic compounds can

retard the cement

Other Additives
138

Antifoam/ defoamer agents

Bonding agents

Gas migration control additives, etc.

Fluid Loss Control

69

26/06/2013

139

Cement Evaluation

Cement evaluation
140

Cement bond logs are used to:

Determine hydraulic isolation between zones of

interest
Locate cement top
Determine feasibility of a cement squeeze
Evaluate the quality of the cement

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26/06/2013

Cement evaluation
141

Pipe to Cement Bond

Directly related to surface finish of the pipe.

A clean surface greatly enhances the bond potential.ie, no

grease, oil spots or paint on the pipe exterior.

The pipe to cement bond was formerly the top priority. Today

the cement to formation is now considered more critical.

Cement evaluation
142

Cement to Formation Bond

Generally determines whether there will be gas or liquid

communication in the annulus.

Hydraulic bond across permeable zones is largely influenced by

the presence or absence of mud filter cake.

Permeable formations will leach fluids so cement with water

loss additives must be used in these conditions.

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26/06/2013

Cement evaluation
143

Two types of cement evaluation tools :

 The

Sonic Tools
 The Cement Bond Log
 The Radial Bond Tool

The Ultrasonic Tools

 The Circumferential Acoustic Scanning
Tools

Acoustic Bond Logs

144

Acoustic cement bond logs do not directly measure hydraulic seal.

Instead they measure the loss of acoustic energy as it propagates

through casing.

This loss of acoustic energy can be related to the fraction of the

casing perimeter covered with cement.

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26/06/2013

Travel Time (Transit Time)

145

For free-pipe, the travel time should match the expected time for that

casing size.

For bonded pipe the travel time should increase as it triggers later

arrivals.

If the travel time decreases below casing arrival time and the

amplitude drops then suspect eccentralization.

If the travel time decreases below casing arrival time and the

amplitude increases suspect fast formations.

The travel time difference between the 3ft and 5ft receivers should be

114 s. If it less than this suspect fast formations.

Amplitude
146

For bonded pipe the amplitude should be low.

For free-pipe the amplitude will be high.

If the amplitude is intermediate cross check with the cement

map to see if its due to cement channeling or low

compressive strength cement.

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26/06/2013

Decentralized Tools String

147

Centring of the Tool is critical for valid measurements.

If the tool is eccentered there are 2 paths for the sonic
signal to take
the travel time will be less than the expected travel time
and the amplitude will be low which will falsely indicate
good bonding.

CBL Tool
148

Advantage:

Widely Used Method to Evaluate the Cement Job.

Used to Evaluate the Zonal Isolation, Bonding to Casing, Bonding to

Formation, and Cement Compressive Strength.

Tool Response Characterized and Well Documented.

74

26/06/2013

CBL Tool
149
Casing

Formation

Cement

TRANSMITTER

G
3 FT
RECEIVER

F
5 FT
RECEIVER

CBL Log
150

Free Pipe

Partial Bond

Good Bond

75

26/06/2013

CBL Tool
151

Disadvantage:

Affected by tool centralization, fluid attenuation, pressure and

temperature.

Affected by fast formations, thin cement sheath.

Gives only qualitative cement-formation bonding information.

Omni-directional signal- Assumes uniform distribution of cement

in the annulus.

Cannot evaluate the radial placement of cement materials in the

casing formation annulus.

Does not provide positive channel identification.

Sector Tool (Radial Bond Tool)

152

Measures the quality of the cement bond laterally around

the circumference of the casing.

It has a single omni-directional transmitter

The 3 foot near spaced receiver is divided into 8 radial
segments measure 45 increments to produce cement
map for channel identification.

The receiver located at 5 feet is the traditional
omni-directional sensing.

The amplitude of the received acoustic signal in
each of the segments represents radial
variations in material in the casing-formation
annulus. These radial variations in the signal amplitude
could be possible channels or voids in the cement

GR

Electronics

Transmitter

3 Ft. Receiver
& 8 Radials

5 Ft. Receiver

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26/06/2013

Sector Tool (Radial Bond Tool)

153

Advantages

Less affected by heavy drill fluids. Can log in #18 ppg mud

Not affected by oil based mud.

Identifies channels.

Not affected by casing thickness. Good in wells with corrosion.

Centralized very easily in deviated wells up to 60

Sector Tool (Radial Bond Tool)

154

Disadvantages

Three foot spacing will be affected by fast formation arrivals.

Reads incorrect amplitudes in presence of micro annulus( unless run

under pressure)

The RBT has sensors with 60 degree or 45 degree azimuthal resolution
which cannot resolve the detection of small azimuthal channels.

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26/06/2013

Ultrasonic Tools
155

Use a single rotating transducer combined

transmitter and receiver.

Acquire ultrasonic waveform data for both cement

evaluation and casing evaluation in the same

logging run or pass.

The sampling rate of the rotating transducer can

provide 100% azimuthal coverage of the casing.

Allows to distinguish cement, liquid, and gas in the

casing-formation annular space, based on the

acoustic properties of the received waves

Ultrasonic Tools
156

Ultrasonic transducer is located 1.25 to

2.5 from the casing wall

Sends a beam of ultrasonic energy in the

500 kHz band.

Ultrasonic energy causes the casing to

vibrate or ring

Frequency and decay rate of return

signal is measured

Casing thickness and impedance of

cement sheath is calculated

By measuring the energy of the vibration

the presence or absence of cement can be

detected.

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26/06/2013

Ultrasonic Theory of Measurement

157

Ultrasonic transducer acts as transmitter & receiver

Transmits short pulse of acoustic energy
Receives multiple echoes from the casing, cement & formation

Casing Resonates

Casing resonance dampened in the presence of cement
Transducer

Mud

Casing

Cement

Formation

Acoustic Impedance
158

The Impedance of a material defines the sound properties for that

material. It is a product of the density of the medium and the velocity
of sound of the medium.
Z= p x c
Where Z = Impedance in MRayls
P = the density in kg/m3
C = speed of sound in m/s
Example: Zwater = 1000 kg/m3 * 1500 m/sec = 1.5 MRayls
At any bed boundary (Z1 / Z2) with different Impedances, sound
energy will be reflected and refracted.
Acoustic impedance of steel: Zsteel = 45 MRayls

79

26/06/2013

Ultrasonic Technique
159

The amplitude of the signal is proportional to the acoustic

impedance of the material behind pipe

Color

Acoustic Impedance

Material Behind Casing

White

0.00-0.38

Gas

Light Blue - Dark Blue

0.39-2.30

Liquid Gas - Fresh Water

Yellow - Light Brown

2.31-2.70

Heavy Drilling Fluid Light Cement

Light Brown - Dark Brown

2.71-3.85

Low Impedance Cement

Dark Brown

3.86-5.00

Medium Impedance Cement

Black

> 5.00

High Impedance Cement

Acoustic Impedance Map

160

White color = Z < 1.4 Mrayls

Blue color = 1.4<Z<1.8 Mrayls
Yellow color = Z>1.8 Mrayls

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26/06/2013

Ultrasonic Technique
161

Advantages

Identifies Presence of Channels, Large and Small

Not sensitive to Micro-annulus

Not Sensitive to Fast Formations

Can be used to Evaluate Light Cements and Foam Cements

Indicates Casing Geometry and Thickness
Disadvantages

The ultrasonic measurement is of the casing-cement interface only,
cannot provide cement-formation interface information.

Cement Evaluation Affected by Casing Corrosion

Scanner head difficult to rotate in heavier mud.

Signal Affected by Heavy Drill Fluids or Oil Based Drilling Fluids (1416 ppg mud weight limit)

Affected by Thin Cement Sheath

Ultrasonic Technique
162

The amplitude and travel time of the reflected pulse received by the

transducer depends upon:

Centralization

Geometry of the borehole

corrosive condition of casing

The acoustic impedance contrast between the borehole fluid and

the borehole wall, i.e. the relative hardness of the rock

Mud attenuation, i.e. in heavy weight or oil-based mud, the

reflections are lost, especially those with high solids content

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26/06/2013

Cement Evaluation-Difficulties
163

Channel in the cement

Micro-annulus

Fast formations

Channel in the cement

164

Cement channels are longitudinal pockets with no cement.

May happen when the mud is not adequately flushed from the wellbore during the
cementing process (accentuated when the casing is not centralized).
Channeling could be caused by gas or water migration during the time that the
cement is curing and or in high angle wells where heavy cement sinks to the low
side of the wellbore leaving little or no cement on the high side.

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26/06/2013

Micro-annulus
165

A micro annulus is a microscopic gap between the

cement and the casing which causes poor acoustic
coupling.
The gap has been estimated in the range of 0.0050.01 (0.12 to 0.25 mm).
A micro annulus does not compromise hydraulic
isolation
Log indicates moderate casing amplitude and
formation arrivals.
Indicates poor bond when good hydraulic
isolation is present
If a micro annulus is suspected re-run the log with
the casing under pressure (500 to 1000 psi).

Micro-annulus
166

Pressure differential placed on casing

Pressure on a cement plug

Pressure testing casing
Stimulation (acidizing, fracturing, etc.)

Different hydrostatic pressures on casing

Change of wellbore fluids while cement is curing

Mechanical

Moving pipe after cementing, etc.

Thermal Micro-annulus

Heat generated by curing cement

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26/06/2013

Fast formations
167

A Fast formation is a formation where the sonic velocity is higher or

faster than the sonic velocity in casing.
Formation signals can arrive at the 3ft receiver before the casing signal.
Formation signal arrives in the amplitude gate resulting in
interpretation as poor bond.
As a check the travel time to the first arrival should be examined;
Indications on the log are increased amplitude and decreased Travel
Time

168

The End

84