PNG 451

LAB REPORT 12 Spring 2015

CEMENT HEAD LABORATORY
Cement a Casing String

Department of Energy and Mineral Engineering

Pennsylvania State University

Date of experiment : April 14, 2015

Section

: 009

Group Member

:
Christian Smith (ces5477)
Edward Korkollie Jr (etk5065)
Thishaanthan Samynathan (tys5343)

TABLE OF CONTENT

Summary

------------------------------------------------------------------------------- 2

Objectives

------------------------------------------------------------------------------- 2

Theory

------------------------------------------------------------------------------ 3

Materials

------------------------------------------------------------------------------ 4

Procedure

----------------------------------------------------------------------------- 7

Discussion

---------------------------------------------------------------------------- 8

SUMMARY
The purpose of this lab was to familiarize us with the cement displacement method
technique of wellbore-cementing through computer simulated program. After finding the
volumes of the annulus and the drillpipe, the strokes of cement slurry, water, and mud were
calculated using a pump factor of 0.0432 bbl/stroke. The number of strokes of cement slurry
was 2,704 strokes while the strokes of mud were 665 strokes. In this experiment, 10 barrels
(232 strokes) of water was pumped at the first stage instead of mud to create a water column
ahead of the cement. Cement was pumped next, then mud followed until the cementing was
successful. The cementing process concluded when a spike in pump pressure occurred as a
result of the diaphragm rupturing. In the field, however, another way of knowing when to
shut off the cement pump is when the volume of the water flow back from the water column
is close to the initial volume of water initially pumped in, or simply when the calculated
cement volume is finished.

OBJECTIVE
The main purpose of this lab was to learn how to evaluate the techniques of
cementing a casing in a well. Specific and systematic steps were taught in order to prevent
any disaster in the well which eventually would delay the oil or gas production. Each member
of our group has to have a full understanding on how to calculate the amount of cement slurry
needed for the well and the simulator operations. The casing cementing procedure was later
shown first by the lab instructor for better understanding before we cement by ourselves.

THEORY
Different cementing equipment and placement techniques are used for cementing
casing strings, cementing liner strings, setting cement plugs, and squeeze cementing. A casing
string is different from a liner string in the fact that the casing extends to the surface, while
the liner is attached to the subsurface casing previously cemented in the hole. Cement plugs
are placed in open hole or in casing before abandoning a lower portion of the well. Cement is
squeezed into lost-circulation zones, abandoned casing perforation, or a leaking cemented
zone to stop undesired fluid movement.

Cementing Casing
When the casing string is ready to be cemented the cement slurry is prepared in a
special cementing unit for the type of the job (truck mounted for land jobs, skid mounted for
offshore).
The cement slurry is pumped from the unit to a special cementing head screwed into
the top joint of casing. When cementing begins, the bottom rubber wiper plug is released
from the plug container ahead of the cement slurry. The plug wipes the mud from the casing
ahead of the slurry to minimize contamination of the cement with the mud. The plug reaches
the float collar and stops. Continuing to pump cement causes a diaphragm in the plug to
rupture (a spike will occur in the pump pressure). This allows the cement slurry to be
displaced through the plug and into the annulus. After the desired volume of cement slurry is
pumped into the casing, the top wiper plug is released from the plug container. The top plug
displaces the cement plug by pumping drilling mud into the casing behind the top plug. When
the top plug reaches the bottom plug a pressure increase will be encountered which signifies
the end of the displacement operation.

MATERIALS
Draw works console:
This helps to control the hoisting machinery of the drilling rig and allows the
traveling blocks be raised and lowered. The long handle next to the draw works
console is the main brake; this acts similar to a parking brake. It is the main lifting
control equipment of the rotary drilling rig. Contains five clutches and rheostat
controls that control the drum, rotary, table and pumps. Draw work brake enhances a
mechanism for controlling the weight on bit, penetration rate and the lifting of the
drill string.
Cement pump switch: a rotary switch that engages power to cement pump blower.
Mud pump 1 switch: a rotary switch that engages power to mud pump 1
Mud pump 2 switch: a rotary switch that engages power to mud pump 2
Rotary table switch forward/reverse: a rotary switch that applies power to the rotary
table.
R.T. Limit: rotating control that allows the operator to adjust the maximum power
applied to the rotary table.
Draw works forward/reverse: a forward and reverse switch that applies power to the
draw works.
Draw works: clutch used in engaging or disengaging mud pump.
Emergency Off: shuts power on the draw works in case of emergency.
Make Up: adds water to dilute or maintain the water-mud system.
4

Breakout: controls the breakout tongs, which are large self-locking wrenches used to
grip the components of the drill string and apply force.
Rotary Table: the revolving section of the drill floor which provides power to turn the
drill string.
Draw Works: transmits the torque which is required for hoisting and braking. This
also stores the drilling live which is required to move the traveling block the length of
the derrick. It is the primary hoisting component of a rotary drilling rig.
Drilling console
Contains the analog and digital gauges used to monitor the key parameters
required for efficient drilling and effective well control. It also had four chart
recorders for monitoring pit level, drill pipe, penetration rate and casing pressures.
Rotary torque: a circular 4" face gauge that measures rotary torque with a scale of 0 to
1,000 amps.
Tong torque: a circular 4" face gauge that measures make up or break out torque.
Return mud flow: a circular 6" face gauge that measures the return in the flow line
from the well with a scale of 0 to 100%.
Rotary speed: a circular 4" gauge that measures the rotary rpm with a scale of 0 to 300
rpm.
Stroke counter: a digital readout of total elapsed strokes with rest and run/hold
control.
Drill pipe pressure: a circular 6" gauge that measures drill pipe pressure.

Mud weight indicator: a digital indicator that measures return mud weight.
Casing pressure: a circular 6" gauge that measures casing pressure.
Deviation mud volume: a circular 6" gauge that measures the increase or decrease in
mud volume. It consists of high and low level set controls with two visual alarms.
Mud volume totalizer: a circular 6" gauge that measures the total mud in the system
with a scale of 0 to 1,000. A power on/off switch and four mud tank switches are
provided so the student can add or subtract mug from the system.
Trip tank: 4" circular tank that measures the total number of barrels of mud in the trip
tank.
On/off switch: a switch allowing the geolograph to be turned on or off.

PROCEDURE
For this experiment, we were provided with the depth, hole
diameter, and casing size in order to find the volumes of the annulus and
drillpipe. Afterwards, we were able to calculate the total strokes of cement
slurry and water.

First, the volume of the required cement slurry is calculated using the
outer dimensions of the casing. The volume of the slurry should be the

same as the volume of the annulus in this case.

With the calculated volume of slurry, the number of strokes required

can be calculated.
Water is pumped down the wellbore first in order to create a leading
water column. After 10 barrels of water is pumped (equal to 232
strokes), pumps are switched off and the bottom plug-wiper is lowered
down the hole to remove any remaining mud or water that may
contaminate the cement slurry. The bottom wiper drops till it reaches
the float collar.

Pumping the cement

Before pumping the cement, we switched from the bottom head valve

to the top one.

Now, the calculated cement volume is to be pumped from the

cementing unit through the casing to the annulus.

The pump is switched on, which allows the cement slurry to flow. At the
beginning of this process the pump pressure is expected to rapidly

increase as a result of the cement rupturing the diaphragm in the plug.

The pumping is continued until 2,704 strokes are reached then the
cement pump was shut off and the top wiper plug is released.
7

 After switching back to the bottom head valve, mud is pumped into the
casing until the top plug has reaches the float collar and the number of
strokes achieves 665 strokes; a spike in the pump pressure is usually a
good indicator for the end of the cementing process.

DISCUSSION
1) Describe the method of cementing the casing.
The cement slurry is pumped from the unit to a special cementing
head screwed into the top joint of casing. When cementing begins, the
bottom rubber wiper plug is released from the plug container ahead of
the cement slurry. The plug reaches the float collar and stops.
Continuing to pump cement a spike will occur in the pump pressure.
After the desired volume of cement slurry is pumped into the casing,
the top wiper plug is released from the plug container. When the top
plug reaches the bottom plug a pressure increase will be encountered.
Thus, this signifies the end of the displacement operation.
2) Compare the method completed in the lab with other methods
used in the industry.
Modified techniques from cementing casing are used in special
situations. The techniques include: Stage Cementing, Inner-String
Cementing, and Annular Cementing through Tubing, Multiple-String
Cementing,

Reverse-Circulation

Cementing,

and

Delayed-Setting

Cementing. Stage Cementing allows the use of a cement column height

in the annulus that usually causes surface formations to fracture, and it
can reduce potential gas flow after cementing. The inner- String
Cementing can reduce cementing time. It uses float collar or shoe with
sealing adapters that allows tubing or drillpipe to be landed and
hydraulically closed. Cement is displaced in the inner drillpipe or string
tubing instead of the casing. The Annular Cementing through Tubing
allows pumping cement through tubing in the annulus between two
casing strings or between the casing and the open hole. The Multiple8

String Cementing involves cementing several strings of tubing in the

hole without the use of an outer casing string and it is a multiple
completion

method.

The

Reverse-Circulation

Cementing

allows

pumping the slurry down the annulus and displaces mud back through
the casing. It is used when extremely low-strength formations could be
found near the bottom of the hole. It needs a special float collar or
shoe and it requires a special wellhead assembly. This method presents
difficulty in finding the end of the cement displacement because of the
absence of wiper plugs. The Delayed-Setting Cementing is used to
achieve consistent mud displacement in the annulus. It places retarded
cement slurry with good filtration properties in the wellbore before the
casing.
3) Describe other uses of cementing.
a) Use to prevent the movement of fluids through the annular space
outside the casing.
b) To stop the movement of fluid into fractured formations.
c) To close an abandoned well or a portion of a well.
d) To prevent casing corrosion - cementing a water bearing zone will
help reduce the corrosion of the casing and will also help protect it
from shocks during drilling operations.