Date: May 95

Dowell
TEACHING GUIDE Module No: CF01
Page: 1

CRITERIA
FOR
SUCCESSFUL
CEMENTING

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 Date: May 95
Dowell
TEACHING GUIDE Module No: CF01
Page: 2

CRITERIA FOR SUCCESSFUL CEMENTING

z Job objective
z Mud removal (ahead of the slurry)
z Temperature prediction
z Slurry properties
z Special slurries
z Placement design (CemCADE)
z Job execution
z Job evaluation

• As a dowell engineer what do we need to consider to provide a sucessful cement job?

• Discuss each one in brief

– Dowell Concept - A method of continous improvement from gaining experiecne from a particular field and
across the company.

– Job Objective - What are we trying to achieve with the cement job

– Mud removal - Given the well conditions / type of mud what is the best method

– Slurry Properties - What is the requirements for the job - 18 5/8” or linerect.

– Special Cement Systems - is there a requirement given the well conditions / possible contingency for
losses ect

– CemCADE Design - Ensure we have all the correct imputs to produce a competent design.

– Job Execution - Carried out as per design. Pumped at the designed rates ect.

– Job Evaluation - Follow up and ensure any key learning is taken forward.

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TEACHING GUIDE Module No: CF01
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DEE
Design - Execute - Evaluate

Job
Planning
& Slurry
Design

Logs Blending
Well/Job Data Slurry Mixing
Well Post-Job & Placement
History

• This is know as Dowell DEE loop

• Consider all relevant aspects of the design well parameters / slurry designs / logistical and operational
constraints ect.

• Program is then passed to the field and the job is executed

• Then the job is analysed and any key learning is taken forward to the next. Bond logs, volumes, losses,
plug bumps ect

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TEACHING GUIDE Module No: CF01
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Job Objective
Complete cement
sheath w/no mud

• Isolation of productive zones or gas channel

• Protection of water zones

Cement bonded
bonded to
to
• Isolation of problem interval
Cement
formations
formations

• Protection of casing Cement bonded to

casing

• Casing support
Oil or Gas pay Zone

• What are the objectives of a cement job? Take a liner as an exaqmple.

• Zonal isolation

– Ensure no annular communication between zones

– Isolation of a hydrocarbon bearing / overpressured zone / water zone

– Protect the casing from corrosive brine flows / moving salt formations

– Casing support - mechanical properties of the cement must provide to the casing

– Mechanical properties reuire to provide a hydraulic seal

– Provide isolation around the shoe to provide a competent leak off to drill ahead

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TEACHING GUIDE Module No: CF01
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Practices Affecting Primary Cementing

Wash out: Incorrect
flow regime

Poor Centralization

Channeling:
Incompatible
preflush or
incomplete mud
removal

• Out of guage hole - As we drill through different formations such as sands or shales different well
conditions will apply

• Gelled mud may be difficult to removed and may become trapped

• Flow regieme and preflush my not be applicable to the washed out sections

• Mud may mix in with the menet and will comprimise a hydraulic seal

• Poor centralisation will make it difficult to remove mud from the narrow side and will channel

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TEACHING GUIDE Module No: CF01
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Slurry Design Factors Affecting Primary

Cementing

High Free
water

Shrinkage or
Gas Intake microannullus

Water Intake

• Slurry Design Aspects

– Slurry needs to be designed for its application

– Stable Competent Slurry

– Fluid loss across permeable or hydrocarbon formations

– Low shinkage propertries

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TEACHING GUIDE Module No: CF01
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Mud Removal

z Well preparation

z Mud removal efficiency during the cementing

operation

• Mud removal is the key to any cemening operation

• Well preparation

– Ensure the hole is clean / stable (no losses)

– Centralise the casing

– Rotate / Recipricate the casing

– Circulate to ensure >95% of mud in the hole is moving

• Improve Mud removal

– Circulate and condition mud to ensure it is in good shape

– Design appropriate spacers / washes

– Design pumping schedules

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TEACHING GUIDE Module No: CF01
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Mud Conditioning
z Lower Density
– by removing cuttings and sand
z Reduce Viscosity
z Reduce Gel Strength by:
– Circulation
– Addition of Dispersants
– Pipe Movement
z Stabilize Well = no losses / no kicks

• How do we condition the mud?

– Define the specification required for cementing

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TEACHING GUIDE Module No: CF01
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Casing Centralizers

Centralizer

• Centralisation is another key issue in cementing

– To ensure competent cement bond we must centralise over the section

– Design to acieve a good stand off

– Centralisation will help towards flow all round the pipe

– Centraliser design must be taylored the the well profile

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TEACHING GUIDE Module No: CF01
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Casing Centralization

R2

R1

Wn

% Stand-off = Wn x 100/ (R1-R2)

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• Calculation of Standoff Example :- 9 5/8” Casing in 12 1/4” OH

R1 = 9 5/8” / 2 = 4.82”

R2 = 12 1/4” / 2 = 6.125”

Wn = 1”

% Standoff = (1 * 100) / (4.82 * 6.13) = 76%

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TEACHING GUIDE Module No: CF01
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Effects Of Standoff on Mud Displacement

Mud

Cement

Decreasing Stand-off
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• If we have an equal pressure drop:

– 1. 100% Standoff - flow will be uniform

– 2. 60% Standoff - Flow will always take the line of least resistance

– 3. 20% Standoff - Very little mud being removed from the narrow side

• To achieve isolation across a zone it must be centralised

• All fluid design is targeted at the narrow side

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TEACHING GUIDE Module No: CF01
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Casing Movement: Rotation

Flowing Cement
Casing Stationary

Rotation Started

Gelled Mud
Re
sis
po ting Mud Almost Removed
sit dr
ive ag
mu for
d d ces
isp ca
lac n b
ing ec
for ome
ce

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• Rotation - The preferred Option :-

– Rotation will help achieve flow all round the pipe

– Move the mud from the narrow side of the annulus

– Place cement into the narrow side

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TEACHING GUIDE Module No: CF01
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Casing Movement: Reciprocation

Poor Standoff

Cement Slurry

Static Mud

Cement Slurry

Cement Slurry
Improved Standoff

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• Reciprocation -

– If you have poor centralisationand trapped mud between centralisers you will be able to
centralisers up and down over the areas

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TEACHING GUIDE Module No: CF01
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Scratchers and Other Mud Removal Aids

Reciprocating sctatcher

Well Wiper

Rotating Scratcher
Hydro-Bonder
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TEACHING GUIDE Module No: CF01
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Cement - Mud Contamination

z Acceleration or Retardation

z Reduction of Compressive Strength

z Reduction of Hydraulic Bond

z Increase of filtrate loss

z Change of Rheological Properties

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• Cement Contamination

– Cement and Mud are not compatable

– These are the effets to the slurry if there is intermixing of the mud

• What can we use st separate these?

– Spacers / Chemical washes which are compatable with both the mud and cement

– Plugs / Wiper darts ect

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TEACHING GUIDE Module No: CF01
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Displacing
Wiper Plugs Mud

Top Plug
z Prevent
– Contamination of Spacer
– Contamination of Cement slurry Cement

z Wipe Casing clean

z Indicate end of Displacement Bottom Plug

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No Bottom Plug
Displacing
Top Plug
Mud
Mud
Film

Accumulated Mud
Cement from Film
Slurry
Mud

Cement

Mud

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TEACHING GUIDE Module No: CF01
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Fill up - No Bottom Plug

Fillup per 1000 ft of
casing *

Mud Film
Thickness bbl/ 1000 ft ft m

1 / 64 in 0.23 15.4 4.7

1 / 32 in 0.45 30.2 9.2
1/ 16 in 0.89 59.7 18.2
1 / 8 in 1.83 122.8 37.4

* Note : 4 1/2”, K-55, 13.5 lb/ft

Volume of mud wiped from casing wall
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TEACHING GUIDE Module No: CF01
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Chemical Washes

z Low Viscosity Fluids

z Usually Water Based

z Contain Surfactants and mud thinners

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• What are Chemical Washes?

– Water + Surfactantnts + sometimes mud thinners (U066)

– Typically 1 SG - Viscosity - 5Cp

– Can be Weighted up with Salt - NaCl, Kcl - Not CaCl2

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TEACHING GUIDE Module No: CF01
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Chemical Washes
What They Do / How They Work

z Separate Mud and Cement

– No incompatibility effect

z Remove mud from annulus

– Turbulence at low pump rate
– Erode, dilute and disperse particles

z Leave casing and formation water wet

– Function of the Surfactant

z Provide less hydrostatic pressure

– Water or oil-based
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• Separate Mud and Cement

– Mud and Cement are not compatible!

– If high oil / water ratio OBM use mud thinners

• Remove mud from the annulus

– The preferred method of mud removal as they act in a turbulent flow regeim

– Act as a mud dilution

• Leave the casing and formation water wet

– Oil and water do not mix on there own

– Change from oil in water to water in oil emulsion

• Reduce the hydrostatic effect on the formation

– If pumped behind the cement, improve the positive pressure of the cement

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TEACHING GUIDE Module No: CF01
Page: 21

Spacers
Definition

z Densified viscous fluid separating mud and slurry

Function

z Thorough removal of mud

Properties

z Compatible with mud and cements

– Mixtures less viscous than thicker fluid
– No gel
z Specified rheology
– Low for Turbulent Flow
– Adjustable for Effective Laminar Flow

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• Viscous Spacer

– Gell used to control weight and viscosity

– Used when pore pressure / hole conditions do not allow the use of surfactants.

– Heavier than the mud 10% density increase

• Compatable with mud and cements

– Use surfactants for OBM

• Rheology

– Low rheology for Turbulent spacers

– Viscous for laminar flow spacers

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TEACHING GUIDE Module No: CF01
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Cement Slurry Properties

z Conventional Cement system:

– Cement Slurry density
– Cement Slurry Rheology
– Free water
– Thickening Time
– Compressive Strength
– Fluid Loss Control
– >> UCA >> Z (Acoustic Impedance)

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• Cement Systems

– Each of the above properties will be covered in more detail

– 15.8 - 16ppg is standard weight for neat cement to yield to give the required qualities - stable slurries

– Below 15.8ppg extenders are required to increase the water content and produce a stable slurry

– Rheology - specified rheology depending on the way the cement will be mixed in the field and the down
hole requirements

– Free Water - if slurry is not stable the cement will settle out and water will be left at the surface - could
allow a channel or micro annulus

– TT - Must be long enough + safety margin for the job

– Compressive strength - enough to support the axial force of the casing +hydraulic seal in the annulus

– Fluid loss control - used if pumping across production zones or pearmeable formations, and for squeeze.

– Maintain solid / water ration - a stable slurry

– Avoid bridging off while pumping

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TEACHING GUIDE Module No: CF01
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Cement Slurry Density

HEAVY WEIGHT
SLURRIES
Settled
Particles

Settled particles do not contribute to

hydrostatic pressure

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TEACHING GUIDE Module No: CF01
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Cement Slurry Rheology

z Friction Pressure

z Flow Regime
Laminar ( sliding motion - zero flow on walls )

Turburlent ( swirling motion )

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Effects of Free Water

z Channelling

z Incomplete Fill-up

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Thickening time

z If BHCT estimated lower than actual:

– OOPS > cement set prematurely in csg

z If BHCT estimated higher than actual

– Slurry takes days to set

– Low set cement strength

– Poor bond

– Fluid migration thru gelled slurry

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Temperature Prediction
z Two Basic influences on downhole performance
of cement
– Temperature
– Pressure

z Temperature has the biggest influence and affects

– Thickening time
– Transition time
– Compressive Strength
– Fluid loss
– Rheology
– Free water
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Compressive Strengh
z Poor protection against lateral forces
Overburden Pressure

Stable System

Unstable System
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TEACHING GUIDE Module No: CF01
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Fluid Loss Control

Annular Bridging
Hydrostatic pressure

Filtrate Filtrate
Dehydrated
Cement

Weak Zone Fractured

Weak Zone

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Why use Fluid Loss Control

z Maintain constant water-to-solid ratio
– Constant Density
– Desired Yield
– Thickening Time
– Compressive strength
– Rheology
– Constant Properties

z Avoid annular bridging or excessive pump

pressure
z Reduce formation damage

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TEACHING GUIDE Module No: CF01
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CemCADE Job Design

z Better zonal isolation
– Optimum mud Romoval
z Flow Regime
z Pump rate
z Mud removal effeciency vs stand-off
– Slurry design
z Well security and control
– No loss circulation
– No fluid influx
– No casing collapse
– Anticipated surface pressure
z Job evaluation
– PRISM
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– CBL Adviser

• CemCADE takes into account all the factors discussed so far to predict the best placement design.

• Closses the DEE Loop.

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TEACHING GUIDE Module No: CF01
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Job Execution

IS
EXECUTION
AS PER
DESIGN ?

Real Time Job Monitoring

PRISM
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TEACHING GUIDE Module No: CF01
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On-site Data Acquisition

z PRISM
– Pressure, Density, Flow rate sensors
– Portable acquisition computer
– Standard remote display
z Quality of treatment execution through:
– Record of treatment in real time
– Accurate, reliable data acquisition regardless of
environmental conditions
– Immediate post-job treatment reports
z Treatment efficiency through:
– Post-job analysis of data which
z (1) ensures pressures and rates were as designed and
z (2) helps to improve future designs

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TEACHING GUIDE Module No: CF01
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PRISM Plot

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• Job Procedures

• The first thing to do on arrival on location, is to meet the company man and check the calculations with him and to
verify that no changes have been made to the programme.

• Rig up all the equipment and lines.

• STEM 1 on all the equipment including priming and testing the units and lines.

• Verify that all the products and materials arrived correctly.

• Perform the prejob safety and organization meeting with everyone that will be involved in the job - the company
man, the Dowell personnel and the rig crew.

• Start preparing the different mix fluids, spacers and washes. The compnay man may want you to wait until the
casing is on bottom and the rig has started circulating - this is to avoid lost products if the casing cannot get to
bottom. If this is the case, make sure everything is ready to go including correct water volumes in the tanks.

• This is a good moment to start taking samples of the different fluids.

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TEACHING GUIDE Module No: CF01
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Post Job Evaluation

z Job Design (CemCADE) vs Job Execution (PRISM)

z CBL Adviser

z Cement Bond and Variable Density Logs (CBL-VDL)

z Cement Evaluation Log

z Pressure Test ( Shoe Bond Test )

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• The job itself starts when the company comes onto the unit:

– The lines are tested again but in the presence of the compnay man.

– The plugs are loaded into the cement head, in the correct order.

– The preflushes are then pumped also in the correct order.

– The bottom plug is dropped by the operator.

– The cement slurries can then be mixed and pumped at the correct density.

– The TOP plug should now be dropped, by the operator.

– Displacement is then done at the rate specified by the programme. The volume that can be pumped above
the calculated displacement volume should be defined prior to the job and agreed to by the company man
to avoid misunderstandings at this critical moment.

– The plug is bumped with the agreed pressure. Always check the returns to make sure that the float
equipment is holding. If there is a constant return flow rate after about the first 4 or 5 barrels of returns, this
can be considered as leaking float equipment. If this happens, then pump the fluid that has returned back
into the well to push the plug back onto the float collar but without allowing the pressure to build up in the
casing above the end of displacement pressure - then install a pressure sensor close to the cement head
and close the line.

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TEACHING GUIDE Module No: CF01
Page: 36

Summary
z Define Cementing Objectives
z Design with CemCADE
z Improve Mud Displacement
– Condition mud prior to cementing
– Use centralizers
– Rotate and / or Reciprocate
– Avoid adverse mud cement reations
– Control displacement rate and sapcer and slurry rheology
z Optimize cement slurry design
z Execute the job as per design
z Perform a Post-job Evaluation
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• The end of the job can be as important as the rest of the operation and can leave a good or bad impression on the
client.

– The washup should be performed to the waste pit of the rig. No water should be thrown on the client’s
location - even though he has no problem with this, his boss may come and visit the rig the next day and he
may not be as happy with our leftovers. The location should be left in as good or better condition than we
found it.

– Rig down our equipment completely - avoid leaving Dowell’s equipment on the rig, the rig crew may not
take the same care of our equipment as we do.

– STEM 1 the equipment. This is important to prepare for the next job and to identify idf there are any
potential problems that appeared during the job.

– All the paperwork should be completed and either signed by the client or left with him. Remember that the
client has probably been awake during the whole running of the casing, so avoid trying to pressure him to
sign your paperwork when he is tired.

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