Professional Documents
Culture Documents
CEMENTING
1
Habiburrohman, B.Eng, M.Eng.
Cement Manufacture
Dry Process
LIMESTONE CLAY
COAL
GRINDER UNIT
PULVERIZER
DRYER ROTARY KILNS
COAL
STORAGE BASINS GRINDING MILLS GYPSUM HOPPERS
PULVERIZER
KILN FEEDERS CLINKER HOPPERS GYPSUM
DRYER
4
Clinker Grain Structure
C3CS C3A
C2S C4AF
Silicates are approximately 80% of total material
5
Principle Components of
Portland Cement
• C3S Tricalcium silicate
• C2S Dicalcium silicate
• C3A Tricalcium aluminate
• C4A Tetracalcium alumino ferrite
– Wetting
SHARP EXOTHERMIC PEAK; LASTS < 5 MINS
– Induction
ACTIVITY SEEMS LOW; CEMENT REMAINS FLUID
– Setting
SUSTAINED EXOTHERMY; CEMENT THICKENS
– Hardening
LOW HEAT FLUX; STRENGTH STILL INCREASING
7
Heat Flow During Hydration
% Hydrated Cement
Heat Flow Acceleration Deceleration
% Hydration of Cement
Heat Flow
Pre-induction Diffusion
40-50%
Period Hydrated Cement
(2%to 3% Hydration)
Induction Period
(Silicates Have Low Reactivity Setting and
During This Period) Hardening
Time
8
Hydration Mechanisms
9
Protective Coating Theory
• On contact with water, C3S AND C2S
react to form calcium silicate hydrate (C-
S-H) gel
• Initial surge or reactivity due to heat or
hydration of free lime occurs
• C-S-H external reactions inhibited by
semi-permeable gel coat, but internal
reactions continue
• This is called the “dormant” or “induction”
phases 10
Cement Hydration (C3S)
C3S
H2O
Ca2+
2 OH-
MIXWATER
11
Cement Hydration (C3S)
H2O
Ca 2+
2 OH -
MIXWATER
12
Protective Coating Theory
• Osmotic pressure within C-S-H builds due to
internal reactions
• This causes C-S-H membrane to rupture
• Materials released include Ca(OH)2.
• Tubular growths of C-S-H (fibrils) form a
network of interlocking with other hydration
products
13
Cement Hydration (C3S)
H2O
Ca 2+
2 OH -
MIXWATER
14
Delayed Nucleation Theory
• C3A enters into reaction with gypsum to form
ettringite (calcium-sulpho-aluminate-hydrate)
• Ettringite coats C3A surface, reducing reaction
until all gypsum present is consumed
• Ettringite then converts to calcium aluminate
hydrates
15
Cement Hydration (C3A)
C3A
CaSO4
MIXWATER
16
Cement Hydration (C3A)
C3A CASH
(Calcium Alumino
Sulphate Hydrate)
CaSO4
Ca 2+ + SO4 2-
MIXWATER
17
Thickening Time
19
Oil Well Cementing ?
• CEMENTING
• What is Oil Well Cementing ?
• Oil well cementing is a process of mixing a
slurry of cement and water and pumping it
through the casing pipe into the annulus
between the casing pipe and the drilled hole.
• Cement plugs are also set in the wellbore to
isolate zones e.g. loss zones, water bearing
zones
20
Oil Well Cementing
21
OBJECTIVES OF CEMENTING
• Primary Cementing
• Main objectives of primary cementing are :-
to support the casing pipe
to restrict the movement of formation fluids
behind the casing
• Cement also provides the following advantages :-
seal off zones of lost circulation (fractured
formation)
protect the casing from shock loads during
drilling deeper section
22
protect casing from corrosion
OBJECTIVES OF
CEMENTING (continued)
• Secondary Cementing
• Most common secondary cementing jobs
are :-
Circulation squeeze
plug back cementing
squeeze cementing
23
OBJECTIVES OF
CEMENTING (continued)
• Secondary Cementing
• Circulation squeeze
• Cement slurry is circulated into the annulus
through perforation, which are at the top and
the other at the bottom of desired interval
• Reason for circulation squeeze are :-
supplementing a faulty primary job
extending the casing protection above the
cement top
24
OBJECTIVES OF
CEMENTING (continued)
• Secondary Cementing
• Plug back cementing
• Hole is plugged by cement in order to initiate a new
drilling operation
• Plug back is carried out for a number of reasons:
Abandonment of the hole
Sidetracking the hole
Seal off lost circulation
Shutting off of water or gas encroachment 25
OBJECTIVE OF CEMENTING
(continued)
• Secondary Cementing
• Squeeze Cementing
• Squeeze cementing involves forcing the
cement slurry under pressure into open holes
or channels behind the casing or into
perforation tunnels.
• The operation is performed during drilling,
completion and workover operations
26
OBJECTIVE OF CEMENTING
(continued)
• Secondary Cementing
• Main purposes of squeeze cementing :-
• Supplementing a faulty primary cementing job
• Repairing casing defects
• Stopping lost circulation in open hole during
drilling
• Shutting off old perforation for recompletion
• Reducing water cut in a producing well
27
API Classification of Cements
• The of API cement above are used for wells with moderate
bottom hole conditions
• It is necessary to modify cement properties to meet specific well
conditions such as deep wells, HPHT, lost circulation zones, etc
by adding chemicals
• The chemicals can be classified as follows :-
Accelerators – reduce thickening time
Retarders – increase thickening time
Fluid Loss reducers – control amount of fluid loss to
formation
Weighting materials – increase/decrease density
Lost circulation materials – seal off lost circulation zone.
32
Cement Additives
– Accelerator
• The accelerator is used to reduce the
thickening time and set the cement faster by
accelerating the hydration of chemical
compound of cement.
• Liquid cement (known as cement slurry) will
harden faster by adding accelerator
• Common Accelerators used are Sodium
Chloride, Calcium Cholride and Calcium
Sulphate (gypsum) 33
Mechanism of Accelerators
2 Cl -
H2O INCREASE RATE
Ca 2+ OF OH- EFFLUX BY
2 OH -
COUNTER-DIFFUSION OF CL-
MIXWATER
SECONDARY
CaS04
CaS04 Ca 2+ + SO4 2-
MIXWATER
pH LOWERED
Accelerated nucleation
Cement Additives
– Retarder
• The retarder will increase the thickening time
or prolong the time of cement to set.
• It is necessary since more time is needed to
place cement in deeper wells or to combat the
thickening time reduction in high temperature
environment
• Common retarder are saturated NaCl,
lignosulfonate and its derivatives, cellulose
derivative and sugar derivatives 36
Mechanisms of Retarders
d+
LARGE ORGANIC MOLECULE
WITH NET NEGATIVE CHARGE
NET POSITIVE
HINDERS MOVEMENT OF
CHARGE ON SO3-
IONS ETC. ACROSS
CEMENT PARTICLE
GEL MEMBRANE
SO3-
SO3- H2O
2 OH - Ca 2+ MIXWATER
Ca 2+
2 OH -
MIXWATER
PRECIPITATION THEORY
Mechanisms of Retarders
Ca 2+
2 OH -
MIXWATER
NUCLEATION THEORY
Mechanisms of Retarders
CEMENT C-S-H - Gel
GRAIN d+ CHELATING AGENTS
SEQUESTER IMPORTANT
IONS FROM INTERSTITIAL
WATER AND CHANGE ION
H2O BALANCE ACROSS GEL
MEMBRANE
Ca 2+
2 OH -
Ca 2+
Ca 2+ MIXWATER
COMPLEXION THEORY
Cement Additives
– Fluid Loss
• Fluid loss additives are used to control amount of liquid loss from
cement slurries to the surrounding environment.
• These additives control the fluid loss by one of the following
mechanisms :-
Increasing the particle size distribution of the slurry so that it
holds or traps the liquid in it
Making the interstitial slurry water viscous which increased
resistance to flow through porous formation
Forming an impermeable film or miscells within filter cake
Common fluid loss additives are organic polymers,
dispersants and synthetic polymers
41
Mechanisms of Fluid Loss Additives
WALL BUILDING AND VISCOSIFICATION
PORE PLUGGING OF MIXWATER
ADSORPTION AND
RESTRICTION OF WATER
MOBILITY
SOLIDS PLUG
PORES AND BUILD MAT
MIXWATER
MIXWATER
45
Cement Additives
– Lost Circulation Materials
• The lost circulation materials are used to combat
cement lost into very permeable, cavernous or
fractured formations
• The lost circulation materials prevent the loss of
cement by one or more of the following mechanisms
Preventing fracture inducement by reducing
hydrostatic pressure as in lightweight cement
Cure the lost circulation by forming a low
permeability bridge across the permeable opening
• Common LCM can be classified as fibrous, granular
and flakes 46
Special Problems
• Strength Retrogression
– Silica flour / sand prevents detrimental reactions at > 230 °F
– Up to 210 °F : hydration products differ only in morphology
and microstructure
– Above 210 °F: amorphous silicate hydrates form. Size
range from x-ray amorphous to highly crystaline
– Above 230 °F: onset of retrogression, large crystals, low
strength, high permeability
– Up to 300 °F : 35% silica sand or flour prevent formation of
di-calcium silicate hydrate (orthorhombic phase).
– Above 300 °F: 35% silica flour as increased surface area
required for inhibition.
Special Problems
• Lost Circulation
– Agents which induce thixotropy can help prevent
or cure losses by reducing wellbore hydrostatic or
by building high flow resistance in the fractures
• Microannuli/Poor Bonding
– Agents which induce expansion after initial set, or
materials that impart adhesion or improve elastic
modulus may help provide better isolation
Free Water Control Additives
• Under downhole conditions, it is important to control:
– Free water
– Slurry stability
• Problems
– Zonal isolation
– Collapsed casing (steam) in geothermal wells
• Applications
– Horizontal, deviated and slimhole environments
– Geothermal wells.
• Products
– Impart strength to gel structure of cement
FWC-2, FWC-10, FWC-47, FWC-47L, BJ BLUE
Free Water Channels
Cement
Slurry
45°
END
52