IDP Feb 2015 - Revised

2014 Baker Hughes Incorporated.
All Rights
Reserved.
Fundamental of Cementing Services
2014 BAKER HUGHES I NCORPORATED. ALL RI GHTS RESERVED. TERM S AND CONDI TI ONS OF USE: BY ACCEPTI NG THI S DOCUM ENT, THE RECI PI ENT AGREES THAT THE DOCUM ENT TOGETHER W I TH ALL I NFORM ATI ON I NCLUDED THEREI N I S THE
CONFI DENTI AL AND PROPRI ETARY PROPERTY OF BAKER HUGHES I NCORPORATED AND I NCLUDES VALUABLE TRADE SECRETS AND/ OR PROPRI ETARY I NF OR M ATI ON OF BAKER HUGHES (COLLECTI VELY "I NFORM ATI ON"). BAKER HUGHES RETAI NS ALL RI GHTS
UNDER COPYRI GHT LAW S AND TRADE SECRET LAW S OF THE UNI TED STATES OF AM ERI CA AND OTHER COUNTRI ES. THE RECI PI ENT FURTHER AGREES TH AT THE DOCUM ENT M AY NOT BE DI STRI BUTED, TRANSM I TTED, COPI ED OR REPRODUCED I N W HOLE OR
I N PART BY ANY M EANS, ELECTRONI C, M ECHANI CAL, OR OTHERW I SE, W I THOUT THE EXPRESS PRI OR W RI TTEN CONSENT OF BAKER HUGHES, AND M A Y NOT BE USED DI RECTLY OR I NDI RECTLY I N ANY W AY DETRI M ENTAL TO BAKER HUGHES I NTEREST.
Additives
API Cement
Classification
Slurry Design
Pre Job
Planning
Objective
2014 Baker Hughes Incorporated. All Rights

Reserved.
What is
Cementing?
Outline
Job
Execution

Reserved.
What is Cementing ???
What is Cementing ???

Reserved.
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.
Additives
API Cement
Classification
Slurry Design
Pre Job
Planning
Objective

Reserved.
What is
Cementing?
Outline
Job
Execution

Reserved.
Classifications of Cementing
Primary
Secondary
Plug
Method
Plug Back
Cementing
Inner String
Method
Squeeze
Cementing
Stage
Cementing
Objectives of Primary Cementing

Reserved.
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
protect casing from corrosion
Secondary Cementing
Supplementing
faulty primary
cement job

Reserved.
Shut off old

perfs for
recompletion
Purpose
Stop loss
circulation
during drilling
Repair casing
defects
Additives
API Cement
Classification
Slurry Design
Pre Job
Planning
Objective

Reserved.
What is
Cementing?
Outline
Job
Execution

Reserved.
API Classification of Cements
10
API provides specs covering eight classes of oil well cement designated as
class A, B, C, D, E, F, G and H
The most common cement used in Malaysia??

Reserved.
API Class G Cement
11

Reserved.
API Class G Cement
12
Considered as basic cement; Can be modified by adding accelerator or retarder to

suit wide range of depth and temperature (etc: deep wells, HPHT, lost circulation
zones)
Intended for use from surface up to 8000 ft depth
The recommended water to cement ratio according to API for class G cement is 44%
(5 gal/sack or 18.9 ltr/sack)
Additives
API Cement
Classification
Slurry Design
Pre Job
Planning
Objective

Reserved.
What is
Cementing?
13
Outline
Job
Execution
Cement Additives
Accelerator
Shorten thickening time
Retarder
Lengthen thickening time
Dispersant
To ease mixability at surface

Reserved.
Fluid Loss Additive Control amount of fluid loss to formation
14
Defoamer
Prevent foam production
Gas Block
Prevent gas migration
Weighting Agent
Increase slurry density
Light Weight Agent Reduce slurry density (maintain strength)

LCM
Seal off lost circulation zone

Reserved.
Accelerator
CEMENT ADDITIVES
15
The accelerator is used to reduce the thickening time and set the
cement faster by accelerating the hydration of chemical compound of
cement.
Common Accelerators used are Sodium Chloride, Calcium Cholride

and Calcium Sulphate (gypsum)

Reserved.
Retarder
CEMENT ADDITIVES
16
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

Reserved.
Dispersant
17
Primary effect to reduce viscosity. As a result, higher

pumping rates are possible.
Secondary effect lengthens thickening time requirement
Common dispersants are synthetic sulfonate polymers, lignins

Reserved.
Fluid
Loss
CEMENT
ADDITIVES
18
Fluid loss additives are used to control amount of liquid loss from
cement slurries to the surrounding environment.
Common fluid loss additives are organic polymers, dispersants and

synthetic polymers
Defoamer
CEMENT ADDITIVES

Reserved.
Foam will formed during mixing the cement slurry with the chemicals
detrimental to good cement jobs
19
Gas Block
Hydration in place the hydrostatic reduce

Reserved.
Gas block chemicals- to fill up the pores between the cement

particles
20

Reserved.
Weighting
DITIVES Agents
21
Weighting materials are used to increase the density of cement slurry

depending on the requirement
The weight of cement slurries can be increased by adding barite or

hematite
Light Weight Additives

Reserved.
The weight of cement slurry can be reduced by :-
22
Adding material that increases the water content such as clay

and silicate materials
Using light weight materials such as microspheres or nitrogen
Light weight cement is used on weak formation or loss circulation

zones
Lost
Circulation
Materials
CEMENT
ADDITIVES
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

Reserved.
23
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
Additives
API Cement
Classification
Slurry Design
Pre Job
Planning
Objective

Reserved.
What is
Cementing?
24
Outline
Job
Execution

Reserved.
Cement Slurry Design
25
Density
Rheology
Fluid Loss
Free Water
Thickening
Time
Compressive
Strength
Cement
CEMENT Slurry
SLURRYDesign
DESIGN
26
Consideration

Reserved.
CEMENT/SPACER DENSITY
Prevent losses to
formation
Prevent flow from
permeable formations
Strength development
Slurry stability
Density
Density
15.8ppg typically used for neat class G based on API recommend water ratio of 44%
RULE OF THUMB :
< <

Reserved.
Density of slurry normally 1 ppg higher than mud weight
27

Reserved.
28
Density
Rheology
Fluid Loss
Free Water
Thickening
Time
Compressive
Strength
Rheology
Determined using rotational viscometer
Concentric bob and rotor to shear cement slurry in small gap
Shear rate versus shear stress relationship is determined
Cement is non-Newtonian fluid
Its flow regime is determined using

Bingham Plastic model
Power Law model

Reserved.
Other models
29
CEMENT
RheologySLURRY DESIGN

Reserved.
Influenced by:
30
Cement density (water contents)
Dispersant
Retarder
Fluid loss additive
Extender
Solids content
Cement fineness
Ratios of cement components
CEMENT
RheologySLURRY DESIGN
Cement slurries more commonly behaves as Bingham Plastic fluids.
Common acceptable values:

Pv = 100 40 cp
Yp = 5 45 lbf/ft3
Good rheology is important for Mud removal efficiency.

Reserved.
Cement displacement efficiency
31
Achievement of turbulent flow
Excessive annular pressure buildup
Excessive pump rate requirements
Potential for lost circulation occurrence

Reserved.
RHEOLOGY
32
Fann viscometer to determine cement rheology

Reserved.
33
Density
Rheology
Fluid Loss
Free Water
Thickening
Time
Compressive
Strength

Reserved.
Fluid
Loss
CEMENT
SLURRY DESIGN
34

Reserved.
Fluid Loss
35
Low Temperature (<194 deg.F) Fluid Loss Cell

Reserved.
36
Density
Rheology
Fluid Loss
Free Water
Thickening
Time
Compressive
Strength

Reserved.
Free
Water,
Sedimentation
CEMENT
SLURRY
DESIGN & Segregation
37

Reserved.
Free
Water
Control
CEMENT
SLURRY
DESIGN
38

Reserved.
Free Water
39
Free Water Test Setup with 250 ml

Graduated Cylinder

Reserved.
40
Density
Rheology
Fluid Loss
Free Water
Thickening
Time
Compressive
Strength
Thickening Time
Defined as elapsed time from initial mixing with water to achievement of a final consistency
of 100 Bearden Units (Bc)
Thickening times should be designed so that slurries set from the bottom to the top of the
well.
Requirements: Slurry Volume, Displacement Volume, Pumping Rates, Logging temperature

Reserved.
Calculating Cement Volumes:
41
CEMENT
SLURRY
Thickening
TimeDESIGN
Calculation
Excess Cement Volumes:
Does not account for washouts
Expressed as % of the slurry required to fill the theoretical volume of the annulus
Excess is based on the OPEN-HOLE ANNULUS volume only
REQUIREMENT

Reserved.
Ensure sufficient time to perform:
42
Slurry mixing and pumping
Shutdowns: Drop plugs, change tanks
Displacement
Safety margin: AT LEAST 1 hour
Rates dependent
43

Reserved.

Reserved.
PRESSURIZED CONSISTOMETER
44
High Pressure Consistometer

Reserved.
THICKENING TIME CHART
Consistometer Chart
45

Reserved.
46
Density
Rheology
Fluid Loss
Free Water
Thickening
Time
Compressive
Strength
CEMENT
SLURRY
DESIGN
Compressive
Strength
Test procedures are governed by API Specification 10A and 10B
Cement is cured under downhole conditions
Slurry placed at BHST
Slurry placed in cube moulds
Typically 12 hrs and 24 hrs are used
Cubes are tested using Carver Press
Destructive cube crush
Unconfined compressive strength (UCS)
Pressure applied uniaxial only

Reserved.
Ultrasonic cement analyzer (UCA)
47
Relative strength determined by measuring change in velocity of

ultrasonic transmitted through cement
As strength develops, transit time through cement decreases, allowing

relative strength to be calculated

Reserved.
Compressive Strength (Destructive Method)
48

Reserved.
Compressive Strength (Destructive Method)
49

Reserved.
Compressive Strength (UCA)
50

Reserved.
Compressive Strength Chart
51
CEMENT
SLURRY
DESIGN
Compressive
Strength
Increasing cement densities typically increases CS
Reduces water: cement ratio
Can also be enhanced without increasing densities:
Adding solid content in cement slurry
Grinding the cement particles into finer grinds
Typical practices:
Adding silica fume additive
Adding colloidal silica additive
Adding silica flour

Reserved.
Using ultrafine cement
52
Compressive Strength cont..
Minimum Compressive Strengths Preferred for Various Functions

Reserved.
FUNCTION
53
COMPRESSIVE STRENGTH SLURRY TYPE/OPERATION
AXIAL LOAD SUPPORT
500 - 1000 psi
LEAD SLURRIES
DRILLING AHEAD
500 - 1000 psi
TAIL SLURRIES
PERFORATING
1200 - 2000 psi
LINER/PRODUCTION CASING SLURRIES
KICK OFF PLUG (WHIPSTOCK)
3000 psi
SIDE TRACK DENSIFIED SLURRIES
ABANDONMENT PLUG
1000 psi
TAGGING/DRESSING OFF
50 psi
THIXOTROPIC SLURRIES
LOST CIRCULATION PLUG
Additives
API Cement
Classification
Slurry Design
Pre Job
Planning
Objective

Reserved.
What is
Cementing?
54
Outline
Job
Execution
PRE JOB PLANNING- INFO REQUIRED

Reserved.
55
MD/TVD/Liner hanger
Accurate log temperature - depth of log and time since circulation
Trajectory
Hole size
Pressure Plot
Casing/ Liner size & weight
Type of mud spacer planning
JOB CONSIDERATION

Reserved.
56
State & Federal Regulation

Formation integrity Hole washout, Weak Zone/Thief Zone, High
pressure Zone
Gas migration
TOC
Mud displacement
Cement Placement Technique
Slurry Properties
Additives
API Cement
Classification
Slurry Design
Pre Job
Planning
Objective

Reserved.
What is
Cementing?
57
Outline
Job
Execution
JOB EXECUTION
Well Conditioning

Reserved.
58
Condition mud
Reciprocate or rotate casing
Circulate at highest possible rate
Use fluid caliper to verify hole volume
Monitor bottoms up gas
Monitor returns
JOB EXECUTION

Reserved.
59
Cement Mixing
Accurately measure density
Control density fluctuations
Use both top and bottom plug
Use preflush or compatible spacer
Mix and displace at the designed rates
Monitor fluid returns
Monitor job parameters using D.A.U.

Reserved.
Q&A
60

Reserved.
CEMENTING METHODS AND SYSTEM FOR THE CO2

WELL
61
Agenda
Challenges for CO2 wells
SealBond & Ultraflush Micro Emulsion spacer
Improved cementing systems for CO2
Expansion feature
Case histories
2012 Baker Hughes Incorporated. All Rights Reserved.
Possible leakage pathways

casing and cement
casing and cement
cement matrix
casing
fractures
cement and formation
SOURCE: Celia et al. (2004)
Results From Field Studies

Portland cement degradation due to CO2: <10 mm / 30 yrs
(J.W. Carey et al. 2007)
Degradation mainly occurs along existing / induced pathways

(B. Kutchko et al. 2009)
Pozz/Portland cement inhibit CO2 migration after carbonation

(W. Crow et al. 2009)
Leakage only due to CO2 attack very unlikely

Cements ability to resist CO2 attack is secondary
Important: Good initial cement bond
Agenda
Expansion feature
Case histories
SealBond - Benefits
Typical
spacer
applied prior
cementing
SealBond
applied prior
cementing
Prevents formation breakdown & fall back of cement tops

Strengthens wellbore for improved cement slurry placement
SPE 140723
More Benefits of SealBond
CO2
Mg2+
H2 S
SO42-
Sealing
Cement
SealBond sealing acts like a condom

Potentially protects cement sheath towards corrosive fluids
Microemulsion Spacer Technology

The MICRO-WASH high-definition remediation system
Removes OBM filter cake damage

Water-wets surface
Requires no energy
Solubilizes oil phase
The MICRO-CURE E2 cased-hole remediation system: nonaromatic solvent
Cleans sand surfaces easily
Improves fluid mobility
Removes in situ emulsions
Increases water-wettability
Mobilizes most asphaltene and paraffin
The MICRO-PRIME spacer system: mesophase spacer
Cleans casing and tools
Provides ultralow interfacial tension
Provides fast phase inversion
Provides excellent rheological compatibility
MICRO-WASH System
Cleaning Plugged Screens
As received
After MICRO-WASH system
After rinse
10
MICRO-PRIME System
South Louisiana Operator Case History
First failed competitor displacement
11
Same tools after MICRO-PRIME system
Purpose of Cement Spacers

Cement spacers are designed to:
Effectively displace the drilling

fluid in the annulus
Convert an oil-wet surface to
a water-wet surface
Provide a clean and water-wet surface
to which cement can strongly bond
Success in the field is defined by:
Shoe test
Cement bonding logs (CBL)
12
New Microemulsion Spacer

The UltraFlush ME microemulsion spacer system
Based on the microemulsion surfactant in

MICRO-PRIME technology
Provides ultralow interfacial tension
Provides a fast phase inversion
Provides rheological compatibility
With S/OBM
With cement
Completely removes SBM quickly
Solubilizes the oil
Cleans and water-wets solid surfaces
Stable at temperatures to 300F (149C)
13
Mesophase
Spacer
Spacer Wettability Apparatus

Used to determine the apparent wettability of cement spacer systems
and clean nonaqueous drilling fluids

Cement will not bond to oil-wet surfaces
When the spacer is properly used:
14
Prevents mud and cement contamination

Provides better bonding potential
Ensures a proper annular seal
Improves displacement efficiency
UltraFlush ME Spacer
Screening Conductivity
Initial: OBM
15
Post-titration with
spacer poured out
Post-water rinse
SSCT with 10-14 ppg SBM

Fresh Water Cement Pre-Flush Spacer
Oil-in-brine emulsion
Water-Wet Surfaces
Brine-in-oil emulsion
Oil-Wet Surfaces
16
Phase
inversion
Goniometer
17
Measurement of Angle of Deflection

A liquid droplet rests on a solid surface and is surrounded
by gas. The contact angle, C, is the angle formed by a
liquid at the three phase boundary where the liquid, gas,
and solid intersect.
18
UltraFlush ME Cleaning Spacers

Cement preflush spacers
Water-wets casing and formation ahead of cement

Improves cement bond
Transition phases for mesophase cleaning solutions
Brine in oil emulsion

(invert emulsion)
oil-wet surfaces
Contact angle 74
19
Phase transition
Oil in brine emulsion

(direct emulsion)
water-wet surfaces
Contact angle < 30
Effective Laminar Flow (ELF)

First ELF rule governs fluid density hierarchy
Each displacing fluid should be at least 10% heavier than the fluid it is
displacing
Second ELF rule governs friction hierarchy
Each displacing fluid should exert a friction pressure gradient (dP/dz) that
is at least 20% higher than the fluid it is displacing
Third ELF rule governs minimum pressure gradients
Each displacing fluid has to be able to break the gel strength of the
displaced fluid on all sides of the annulus, even the smaller side of an
eccentric annulus, in either a vertical or nonvertical wellbore
Fourth ELF rule governs differential velocity
The velocity of the displacing fluid in the wide side of an eccentric annulus
should not exceed the velocity of the fluid being displaced in the narrow
side of the same annulus
20
Effective Laminar Flow (ELF)

If all four hierarchies are met for both the spacer/mud interface and
the cement/spacer interface, then even in the case of laminar flow in

an eccentric, inclined annulus, ELF displacement is possible
21
Optimize Flow Regime

Fluid friction pressure curves
Better design tool insures viscosity and density hierarchy in fluid

sequences
Up to four charts with reference temperatures
22
Fluids Data Rheology

Cementing Simulator & Modules
Allows users to enter up to 12 shear rates

Using more realistic shear rates (300-10 rpm)
Auto calculates best fit model, reports r2
Results tie into mud removal calculations and ECDs
Agenda
Expansion feature
Case histories
27
Main Minerals of Set API Cement

Source: TUM
C-S-H phases
Portlandite = Ca(OH)2
C-S-H grab onto another (e.g. zipper) causing high strength

Portlandite does not contribute to the strength (weak point):
Disruptive, easy to be leached out & increase brittleness
Portlandite in the Cement Matrix
Source: Blaschke, R. 1985
Polarization microscopy of the set API Cement

light: Ca(OH)2 - dark: C-S-H phases or clinker
CO2 Attack in conventional API Cement

Sliced
Cut
into
into
half
2.54 cm
half
1.27 cm
Thin section
See next slide
API class G / silica flour (15.8 ppg)

Exposed to CO2-loaded water (650 psi & 250F)
Static conditions for 30 days
CO2 attack in cement

I. unaltered
set cement
III. carbonated IV. porous

silica (soft)
cement
CO2 +
C-S-H phases
Ca(OH)2
V. corrosive
fluid
dissolve
CaCO3
precipitates
Ca2+aq
OH-aq
Carbonation front
H2O
dissolves
Ca2+aq
H+aq
HCO3-aq
Leaching front
H2CO3
H+ +
HCO3-
Design criteria: pozzolanic reaction

Reducing the amount of portlandite by adding:
selected pozzolanic materials:SiO2 (Al2O3)
Ca(OH)2 + SiO2 (Al2O3) C-S-H (C-A-S-H) phases
Cement matrix will become denser
Improve the Resistance of Cement

1. CO2 / corrosive fluids preferentially react with the Portlandite
=> Eliminate the Portlandite in set cement
2. Carbonation / corrosion of C-S-H phases also takes place

=> Partly substitution of API cement with inert material
3. Corrosion reactions are diffusion controlled processes

Lower permeability of set cement = slower corrosion
=> Reduce the permeability
Improved vs API Class G

Portlandite
Ca(OH)2
Set API Class G
Improved
cured at 200 F,
3000 psi
Water
Ca(OH)2
Slurry permeability portlandite Compressi
density
(micro
content
ve strength
(lbs/gal)
darcy)
(%)
72 hrs (psi)
Improved Systems
15.8
0.002
Not
detectable
Set API Class G
15.8
2.100
9.5
Tensile
strength
72 hrs
(psi)
4,674
459
4,807
378
Improved vs API Class G

Portlandite
Ca(OH)2
Set API Class G
Improved
cured at 200 F,
3000 psi
Water
Ca(OH)2
Slurry permeability portlandite Compressi
density
(micro
content
ve strength
(lbs/gal)
darcy)
(%)
72 hrs (psi)
Improved extended
14.0
0.15
Not
detectable
Set API Class G
14.0
10.80
9.2
Tensile
strength
72 hrs
(psi)
2,529
272
1,633
170
Improved vs. API Class G (96 hrs curing)

Improved
Conventional
CO2 Lab Testings

HTHP curing chamber Improved
Conventional
CO2
Specimens pre-cured at 3,000 psi & 300 F for 96 hrs

Exposure to CO2 loaded water at 3,000 psi & 300 F
Effect of CO2 on Cements Mechanical

Properties
Cement
system
density
(ppg)
Youngs
modulus
(Mpsi)
Confining
Stress: 1000
psi
Poissons
ratio
Confining
Stress:
1000 psi
Compressive
strength
(psi)
Confined
Tensile
strength
(psi)
Unconfined
After 96 hrs curing at 3,000 psi / 300 F (before CO2 exposure)

Improved
15.0
1.52
0.32
>5,800
354
Conventional
15.0
2.07
0.33
>5,860
258
After 30 days exposure to CO2 at 3,000 psi / 300 F

Improved
16.1
0.85
0.26
>5,850
468
Conventional
16.5
1.17
0.23
>5,850
438
After 6 Months Exposure to CO2

Improved cement
Conventional API cement
Cement specimen flaked off (diameter =-0.6 mm)

Cement bond failure / migration pathways
=> Loss of zonal isolation
Durability in 1 M HCl (24 hrs)

Improved
Conventional
Dissolving attack:
2 H+ + Ca(OH)2
Ca2+ + 2 H2O
12 H+ + C6-S5-H6
6 Ca2+ + 5 SiO2 + 6 H2O
Durability in 1 M HCl (250 d)

Improved
Conventional
fell apart
no strength
squishy morph.
C.S.= 1,520 psi

W.P.= 0.00123 mD
Cement Sheath Failure Mechanisms

Vertical radial cracking:
due to tangential stress
producing a tensile failure
Bonding failure:
due to excessive radial stress
producing a compressive failure
Tensile Strength Test Methods
Direct Uniaxial TensileStrength

(UTS) : ASTM C190-85
HTHP Tensiometer
Gato do mato field, Campus basin (off shore Brazil), 11/04/2010
Patent: US 7,191,663 B2
Available only from BAKER HUGHES
HTHP Tensiometer
Testing up to 600 F & 5,000 psi

SPE 97967
Testing Cement Tensile Behavior Under Downhole Conditions
Design giving higher Tensile Strength at HPHT
Improved cement
Field proven technology (SPE 143772)
Agenda
Expansion feature
Case histories
48
Split ring test accurate method?
A split, expandable ring placed between flat metal plates with a screw
Slurry poured in assembly and allowed to initial set
Measurement across the 2 points, spanning the split in the ring
=> Assembly cooled and de-pressurerized

=> Only single point-in-time test result
=> Cured samples undergo stresses & pot. dimensions altering effects
=> Cannot quantify linear expansion in an uninterrupted downhole environment
49
Real-time Expansion & Shrinkage

under Temperature & Pressure
Expansion / shrinkage
mold for cement
Modified curing chamber:

continuous in-situ measuring
at downhole conditions
Example for cement shrinkage
Examples for cement expansion
Right Sample: Class G cement + 35% S-8 + 5.0% EC-2 + 0.8% FL-25 + 0.6% CD-32 + 0.5% R8 mixed at 16.7 ppg, Yield = 1.40 cu ft/sk and fresh water = 5.02 gal/sk
4000
12
Test Pressure
3500
10
Design expansion carefully:

Compensate shrinkage
Slight expansion to support bond
% Linea r Ex pansion or Shrinka ge
3000
2500
6
2000
% Linear Expansion
1500
Test Temperature
Base-line
0
500
Too much expansion results in cracks
1000
10
15
20
25
30
35
40
45
50
Ela psed Time (hr)

0
-2
The cement was heated in 4 hrs to it s final (BHST) temperature and pressure. After 4 hrs, the t emp and pres has est abilized.
Any test data above the base-line are consider expansion and below are shrinkage.
Te st Pre ssure(psi ) and Tempe rature(F)
Out of ranges (expansion device)
Agenda
Expansion feature
Case histories
53
Case history 1: Middle East

Well for an EOR-CO2 project, 07/22/2011
Depth:
Job Type:
BHST:
BHCT:
Cement:
Density:
Yield:
Water:
Thickening Time:
Compressive strength
@24 hrs at 250 F:
Rheology @ 80 F (180 F)
PV (cps):
YP (lbf/100 sqft):
Fluid loss:
Free fluid:
2,672 meters (8,765 feet)

7 Liner
121 C (250 F)
82 C (180 F)
Expanding improved cement (84 bbl)
2002 kg/m (16.7 ppg)
0.691 m/tonne
0.180 m/tonne
5:05 hr:mn (70Bc)
5800 psi
240 (144)
13 (10)
18 cc/30 minutes
0.0 %

Cementation of a 7 liner for an EOR-CO2 project
7 liner run in 8-in. hole to 8,765 ft; prev. 9-5/8 csg shoe at 8,480 ft
Drilling fluid was a non-damaging fluid (NDF) weighted to 10.4 ppg
48 bbls of expansive cement system batch-mixed at 16.7 ppg
Pumped & displaced into 7x8 annulus w/o any operational incidents
Customer: very satisfied w/ technical support, operational performance
& excellent slurry properties witnessed on site
7'' liner USIT LOG available with excellent cement bond results

Results look good for entire interval
>8480 ft. attempt to log in a csg x csg
environment picking up reflection of

the outer csg string
Reason for the large quantity of data
errors seen in the evaluation, which

are presented as green on the log
Some interference in the csg tracks to
the left side that appear to look like

stripes on the log
These errors are transmitted across
the entire log & are not reflective of

the cement quality in the interval
56

In the open hole - no issues that
would lead to believe there are any

isolation problems
In several places cycle skip on the
log, indicating excellent dampening of

the signal
Some minor issues with tool
eccentering, but not significant

Results of the evaluation show a well
isolated interval
57
Case history 2: CO2 Capture Storage

Spain: 09/10/2012
Depth:
Job Type:
BHST:
BHCT:
Cement:
Density:
Thickening Time:
Rheology
300 rpm:
200 rpm:
100 rpm:
6 rpm:
3 rpm:
Fluid loss:
Free fluid:
Compressive Strength:
3.5 MPa (500 psi):
24 hours:
2071 meters (6790 feet)

9 5/8" & 7 CEMENTING
50C (122F)
45C (113F)
tail slurry
15.86 ppg (1.90 g/cc)
5:28 hr:mn (100Bc)
231
165
97
11
4
24 cc/30 minutes
0.0 %
8.00 hours
40.6 MPa (5890 psi)
61

7 production liner cementing job
CBL/VDL shows a good zonal isolation throughout the annulus
Contamination at TOL because job was performed w/o any wiper plugs
Explains the CBL/VDL not very good in upper part of the section at TOL
For the rest the client was very happy about the operation, especially
since no surface release plugs system was used
Case history 3: CO2 wells

Natural CO2/ H2S producer (Neuqun, Argentina), July 2011
Depth (MD=TVD):
Job Type:
BHST:
BHCT:
Cement:
Density:
Yield:
3,300 meters (10,827 feet)

9 5/8intermediate
81C (178F)
76C (169F)
Improved cement (batch-mixed)
1680 kg/m (14.0 ppg)
1002 m/tonne (1,509 ft3/sk)
Thickening Time:
Rheology (76C)
300 rpm:
200 rpm:
100 rpm:
6 rpm:
3 rpm:
Fluid loss (76C):
Free fluid:
5:20 hr:mn (Bc)

255
191
108
12
10
12 cc/30 minutes
0.0 %

Natural CO2/ H2S producer (Neuqun, Argentina), July 2011

8 wells EOR: 4 prod. + 4 inj. (Middle East), 07/15/2011
Depth (MD=TVD):
Job Type:
BHST:
BHCT:
Cement:
Density:
Yield:
Water:
Thickening Time:
2,275 meters (7,465 feet)

4 1/2 Liner
104C (220F)
65C (149F)
Improved cement (25 bbl, batch-mixed)
1953 kg/m (16.3 ppg)
0.604 m/tonne (0.91 ft3/sk)
0.133 m/tonne (1.50 gal/sk)
7:30 hr:mn (100 Bc)
Rheology (149F)
PV (cps):
YP (lbf/100 sqft):
Fluid loss:
Free fluid:
228
42
35 cc/30 minutes
0.0 %

8 wells EOR: 4 prod. + 4 inj. (Middle East), 07/15/2011
The first job in (Middle East) was performed on the first oil-producer well
drilled in an eight-well enhanced oil recovery (EOR) CO2 project, which
will eventually consist of four producers and four injectors. Improved
cement was selected as the customers preferred cementing medium for
the 4-in. liner sections. The liner was run in 6-1/8-in open hole to a
depth of 7,465 ft with the top of the liner placed at 6,731 ft. The previous
7-in liner shoe was at 7,051 ft. The mud was a water-based system
weighted to 10.5 pounds per gallon (ppg) with calcium carbonate. A total
volume of 25 barrels of the improved cement was batch-mixed for the job
and pumped at a density 16.3 ppg. The client expressed satisfaction with
the entire operation, including technical support and operational
execution.

Off shore Brazil, 11/04/2010
Depth:
Job Type:
BHST:
BHCT:
Cement:
Density:
Yield:
Water:
Thickening Time:
Rheology BHCT (ambient)
300 rpm:
200 rpm:
100 rpm:
YP
Fluid loss:
Free fluid:
5850 meters (19,193 feet)

7 liner
108C (227F)
92C (197F)
Improved cement
1797 kg/m (15.0 ppg)
0.846 m/tonne
0.378 m/tonne
6:12 hr:mn (70Bc)
180 (202)
137 (137)
78 (80)
21.9 (13.3)
18 cc/30 minutes
0.0 %

British Columbia
Depth:
Job Type:
BHST: 37C (99F)
BHCT: 31C (88F)
Tail Cement:
Density:
Yield:
Water:
Thickening Time:
Rheology
300 rpm:
200 rpm:
100 rpm:
6 rpm:
Fluid loss:
Free fluid:

production casing
Improved cement
1770 kg/m (14.8 ppg)
0.809 m/tonne
0.432 m/tonne
4:43 hr:mn (100Bc)
249
171
90
8
10 cc/30 minutes
0.0 %

British Columbia
Depth:
Job Type:
production casing
BHST:
56C (133F)
BHCT:
38C (100F)
Tail Cement:
Improved cement
Thickening Time:
4:41 hr:mn (100Bc)

North eastern British Columbia
Depth:
Job Type:
BHST:
BHCT:
Cement:
Thickening Time:
Rheology
300 rpm:
200 rpm:
100 rpm:
6 rpm:
Fluid loss:
Free fluid:
Compressive Strength:
0.35 MPa (50 psi):
0.7 MPa (100 psi):
3.5 MPa (500 psi):
24 hours:

intermediate casing
117C (243F)
60C (140F)
Improved cement
4:53 hr:mn (100Bc)
141
100
58
13
8 cc/30 minutes
0.0 %
5.10
5.13
5.30
15.5
hours
hours
hours
MPa (2250 psi)

Reserved.
SELF HEALING CEMENT A SIMPLE SOLUTION FOR

COMPLEX WELL
62
Agenda
Issue
Causes
Solutions
Why Self Healing

Test Apparatus
Results
When to Use
Summary
Challenge
Sustained casing pressure
Observed in more than 11,000 casing strings in 8,000 wells
in OCS
Magnitude of leak rate is as important as magnitude of
pressure when determining potential hazard
Gulf of Mexico Wells

(LSU Study, 2002)
Causes
High-compressive strength vs. lower compressive
strength compressible systems

Poor cement bonding
Cement best practices
Cement failure
Pressure changes
Temperature changes
Reservoir changes
What Do We Do Today
Follow best practices
Centralization
Spacers
Displacement rates
Pipe movement
Set for Life cementing system designs
DuraSet system
Low Youngs Modulus

Higher Poissons ratio
Improved tensile to compressive strength ratio
IsoVision software modeling application
What if assumptions are incorrect

5
Simple Solution to a Complex Problem

Self-healing cement system
Must be easily blended and mixed in cement
No negative effect on other cement properties
Works over a wide range of temperatures
Must be capable of plugging flow of hydrocarbons
Through cement matrix
Through microannulus
Capable of healing multiple times

Able to define size of cracks in matrix or microannulus
capable of healing
Test Apparatus
Test apparatus designed and built
Cement cured under temperature
and pressure
Adjustment of desired crack or
microannulus width
Cement hydraulically cracked under
temperature
Capable of controlling, measuring
and recording developed crack size
Test through cracked cement matrix
or induced microannulus
Measure and record flow and
pressure
Capable of testing with gas, oil or
other fluids
7
Self-Healing Cement
CLASS H cement + Self-Healing Additives mixed at 15.2 ppg
Curing Time = 96 hrs, room temp, 3000 psi
Fracturing Test, C-Frac WIDTH = 0.013", Crude oil
900
0.016
800
0.014
0.012
600
max PISTON
TRAVEL = 0.0142"
500
max Frac Pressure

= 760 psi
400
0.008
0.006
300
DS bolt adjusted to
= 0.013 "
0.004
200
0.002
100
0
0
0.01
50
100
ELAPSED TIME (seconds)
150
200
DS BOLT and PISTON TRAVEL (inches)
FRACTURING PRESSURE (psi)
700
Self-Healing Cement
Class H cement + Self-Healing Additive mixed at 15.2 ppg
Curing time = 96 hrs, room temp, 3000 psi
BREAK-SEAL TEST, C-FACTURE WIDTH = 0.013" , fractured with Crude Oil
700
25
max Pressure to Break-Seal

= 654 psi.
600
20
Crude Oil Flow

15
400
300
10
200
5
100
0
0
100
200
300
400
500
ELAPSED TIME (secs)
600
700
800
900
CRUDE OIL FLOW (cc)
Pressure to BREAK SEAL (psi)
500
Self-Healing Cement
Fracturing - Break and Seal test
Controlled crack width = 0.003", curing time = 96 hrs, Heal Time = 24 hrs, rm temp
1200
979
1000
Test Pressure (psi)
894
880
791
Crack
Initiation
Pressure
800
Break-Seal # 1
600
Break-Seal # 2
400
357
Break-Seal # 3
250
Break-Seal # 4
200
Break-Seal # 5
0
0
10
3
4
Ageing Time (days)
Results
Material easily mixed and blended in cement at effective
concentrations
No negative effects on cement properties
Enhanced mechanical properties
Tests being performed over a wide
temperature range
Sealed cracks up to .006
Capable of sealing multiple times
Ready for field trials in Q3/Q4 2012
11
Fig # 3: The picture is showing the induced Crack

Width of 0.003across entry and exit port.
When To Use
Every Well?
Fields with a history of sustained casing pressure
High tectonic stress areas
Risk mitigation
Unable to follow all of best practices
Less than optimal centralization
No pipe movement
Gas storage wells

Plug and Abandonment
12
Summary
Sustained casing pressure is a concern
Improvements have been made but there are still issues
Developed test apparatus that can measure
Size of crack
Flow rate and pressure
Look at cement matrix and microannulus
Product capable of sealing multiple times

Not for every well but when used correctly, it can be
effective
Simple solution to a complex problem
13
Questions
14

Reserved.
Q&A
60

Reserved.
THANK YOU
61

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2014 Baker Hughes Incorporated.

Fundamental of Cementing Services

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2014 Baker Hughes Incorporated. All Rights

What is Cementing ???

What is Cementing ???

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2014 Baker Hughes Incorporated. All Rights

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Objectives of Primary Cementing

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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 casing from corrosion

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Shut off old

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API Classification of Cements

The most common cement used in Malaysia??

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API Class G Cement

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API Class G Cement

Considered as basic cement; Can be modified by adding accelerator or retarder to

Intended for use from surface up to 8000 ft depth

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Shorten thickening time

Lengthen thickening time

To ease mixability at surface

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Fluid Loss Additive Control amount of fluid loss to formation

Prevent foam production

Prevent gas migration

Increase slurry density

Light Weight Agent Reduce slurry density (maintain strength)

Seal off lost circulation zone

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Common Accelerators used are Sodium Chloride, Calcium Cholride

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It is necessary since more time is needed to place cement in deeper

Common retarder are saturated NaCl, lignosulfonate and its

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Primary effect to reduce viscosity. As a result, higher

Secondary effect lengthens thickening time requirement

Common dispersants are synthetic sulfonate polymers, lignins

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Common fluid loss additives are organic polymers, dispersants and

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Gas block chemicals- to fill up the pores between the cement

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Weighting materials are used to increase the density of cement slurry

The weight of cement slurries can be increased by adding barite or

Light Weight Additives

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The weight of cement slurry can be reduced by :-

Adding material that increases the water content such as clay

Using light weight materials such as microspheres or nitrogen

Light weight cement is used on weak formation or loss circulation