Cement and Cementing PDF

SPE Distinguished Lecturer Program
The SPE Distinguished Lecturer Program is funded principally through a

grant from the SPE Foundation.
The society gratefully acknowledges the companies that support this
program by allowing their professionals to participate as lecturers.
Special thanks to the American Institute of Mining, Metallurgical, and
Petroleum Engineers (AIME) for its contribution to the program.
Society of Petroleum Engineers

Distinguished Lecturer Program
www.spe.org/dl
Cement and Cementing:

An Old Technique With a Future?
Bernard Piot
Schlumberger
Society of Petroleum Engineers

Distinguished Lecturer Program
www.spe.org/dl
Outline
Cement
Cementing: a necessary evil?
Alternative isolation techniques
Todays well challenges
Cement versatility
Well architecture tool for the future
Cement
Material and Regulations
Portland Cement
1004,000
Inexpensive
Available everywhere
3500
3,500
8080 3000
3,000
Compressiv e Strength T ype B (psi)
Strong
Impermeable
Thickening
time test (neat
class class
G) G)
Strength
development
test (neat
100 4000
2500
2,500
60
60
V isc osit e (Bc)
Consistency,
Bc psi
Compressive
strength,
Hydraulic binder
Suspension (paste or
slurry) for placement
Controllable setting
Solid
2000
2,000
40
1500
40
1,500
1000
1,000
20
20
500500
000:000 0 0
0:000
150:30
150:30
30
30
1:00
Time (HH)
Tim e1:00
(HH:MM)
Time,h h
Time,
45
45
1:30
60
75
2:00
1:30 60
2:0075
History of Oilfield Cement

Before our era
Clay, lime
Ca(OH)2 + CO2 CaCO3
API created 20 Mar 1919

1940: ASTM Types 1 to 5
1948: API Code 32 released
Roman times
Pozzolanic cements
1824: Portland cement

Selected raw materials
1903: Portland cement in oil wells

1917: Oilfield cements
Became API RP10B in 52
1952: 6 classes of cement

1953: API Std 10A
API Spec 10A in 72
ISO 10426 since 2000
Cement Types
Construction cements
Plain Portland cement
Common cement
API classes A, B, C
Classes G, H
Quality control, reproducibility
More universal
Retarded cements
Deeper wells
Classes D, E, F
Pressurized consistometer
Cementing companies
Abandoned early 80s
Class J cement
Replaced by G/H + Silica
Slag cement
~80s Brine resistance
~90s Mud compatibility
Others
7
Use of Cement
USA
~ 80% class H and G
~ 10% class A, ~ 10% Class C
Rest of the world (international service companies)

>95% class G (often imported)
Class A or C; or local common cement: preferentially
Type V (ASTM), or CEM-I 42.5 or 52.5 (EN 197-1)
Logistics allowing
If good and even quality
If adequate quality control
8
From API to ISO (since 1998)

API Committee 10
ISO TC 67 /SC 3/WG 2
ISO 10426 well cements
ISO 10426-1 (ANSI/API 10A) - specification

ISO 10426-2 (ANSI/API RP 10B-2) - testing
ISO 10426-3 (ANSI/API RP 10B-3) deepwater wells
ISO 10426-4 (ANSI/API RP 10B-4) - foam cement
ISO 10426-5 (ANSI/API RP 10B-5) shrinkage/expansion
ISO 10426-6 (ANSI/API RP 10B-6) static gel strength
Other work groups:

Evaluation (logs), High Temperature, Deepwater
9
Cementing: A Necessary Evil?

Evolution of Equipment and Technology,
and an Outline of Their Shortcomings
10
Technology Older Than a Century

First well cementing ~ 1903
Perkins Oil Well Cementing Co., Calif.
Shovel/cement mixer
First use of an eductor

Jet mixer invented 1921
High pressure mixing
In use till the 1970s
Still used by some
Gravity cement feed
11
Primary Cementing Objectives

Casing anchor (axial
support)
Protection against corrosion
and erosion
Support of borehole walls
Hole
Casing
Cement
Gas zone
Zonal isolation
Oil zone
12
Unsuccessful Zonal Isolation
NPV
Interzonal
fluid flow
Risk to
HSE
ACP/SCP
Remedial
work
Early
water
prodn
Loss of
prodn
Loss of
well
13
Cementing Process at Surface

Cement
Bulk
Blend
Dry Additives
Dosing and
Mixing
Slurry
Additives
Water
Well
Pumping
Homogenizing/
Control
14
Handling Dry Cement

From cutting sacks to
pneumatic handling
Storage
Transport
Blending
Typical problems
Contamination
Humidity (air)
Deliverability
Homogeneity
Fully automated blender
15
Control of Mixing
SG - 1.0
CEMENT
SG - 3.2
=
SLURRY SG ~ 1.9
Density Control
16
Cement Quality = Slurry Performance

Density
Density
1
EarlyStrength
strength
Early
0.8
0.6
Viscosity
Viscosity
Dispersant / viscosifier
0.4
0.2
Pump Time
time
Pump
W/C ratio; extender;

weighting agent
Gelation
Gelation
Anti-settling agent
Fluid loss agent
Free Fluid
fluid
Free
Dehydration
Dehydration
Retarder/accelerator
Stability
Stability
17
Cementing Additives Key Milestones
Lignosulphonates and cellulosics

Sugars and superplasticizing agents (~ 1960s)
Polyamine/imine ( ~1970s)
SB Latex ( ~ 1980s)
Co/ter-polymers AMPS (~ 1980s)
Temperature stability
Biopolymers (~ 1990s)
Not based on Xanthan gum
Environmentally friendly additives (end 1990s)

OSPAR (OSlo-PARis) convention 1998
18
Cementing Process Downhole

Failures identified 30-40s
Field practices
Turbulent displacement
High Reynolds ~50s
10 min contact ~60s
SloFlo / Plug Flow ~70s

Fluid with yield stress
Displacement studies
Yield stress fluids ~end 60s
Mobility ratio/differential
velocity ~70s
Pump as fast as you can
All semi-empirical
Very mixed results

Even in vertical wells
V=0
DIRECTION OF FLOW
V max
V=0
19
Mud Removal Modeling

More complex wells
Deviated, horizontal
& extended reach
More critical wells

Deepwater, high-pressure
high-temperature
Importance for Zonal Isolation

Very difficult modeling
Computational Fluid Dynamics
(CFD) tools not applicable
Eccentricity effects
Modeling ~ end 80s
Turbulent/Effective Laminar Flow
Rheology/Density contrast
Erodability / PDGM concept

Polymer muds
Numerical 2D Modeling (2002)

Lubrication analytical model (2003)
20
10
Cement Evaluation Logs

Sonic logs
Flexural Attenuation (2006)
CBL ~60s
Compensated CBL ~80s
Segmented Compensated
1 + 3 sensors
Ultrasonic logs
8 sensors ~80s
1 rotating sensor ~90s
Limitation of cement logs
Strength or Impedance ~80s

Microannulus/Isolation???
Microdebonding ~mid-90 s
Casing interface exclusively
Full cemented annulus width

3rd interface
Differentiate lightweight
cements from liquids
Confirm hydraulic isolation
Visualize casing in borehole
21
Alternative Isolation Techniques

Other Fluids and Mechanical Means
22
11
Organic Resins
Very limited applications
Cost
Shelf-life
Sensitivity
Health, safety, and environment
Compatibility (water, mud)
Placement
23
Mechanical Systems
Complementary to cement
Casing drilling, expandable casing (EC)
Swellable elastomer layer
Exclusive of cement
EC/Casing with (oil or water) swellable
packer
Another form of completion
May still require cement for most other
casings
24
12
Todays Well Challenges and

Versatility of Cement
25
New Reservoir Isolation Challenges

Aging and depleting fields
Completions at lower pressures

Steam injection, stimulation
Workovers and repairs
Plugging and abandonment
Exploration and new developments

Isolation under higher pressure and temperature
Very narrow pore/frac pressures margin
In deeper water and at colder temperatures
26
13
Need for Ultra-Low Density

Conventional Cement
Slurries
High performance/high solid

cements
Directly linked to W/C ratio

Slurry
Adapted from concrete industry

Same water/solid ratio at all
densities
Very low rheology

Stability
From 900 to 2800 kg/m3
Similar rheology
High strength, low permeability
Set cement
Very low strength, high
permeability, very long
setting times
27
Slurry Quality Control?
+
SG - 1.0
CEMENT
SG - 3.2
=
Slurry Density - 1.0 ??
What if density 1.0?
Solid Fraction Monitoring
28
14
Well Architecture and Logistics

Lighter isolation-quality cements
Depleted reservoirs
Single-stage cementing
Production liner instead of casing
Light cements that set faster at

low temperatures
Deepwater conductors,
surface casings
29
Is Isolation Durable?
Cement is strong, but fragile
rock
cement
P,T
Understanding failures
casing
Cement A
P or T increases
Drilling, milling, repairs
P or T decreases
rock
cement
Modeling capability
Parameter sensitivity
P,T
rock
cement
casing
casing
Cement B
30
15
Isolation Made Durable

Controlled flexibility
and expansion
Isolation maintained
during P, T changes
From construction to
abandonment
31
A Tool in Well Architecture

Summary
32
16
Cement in the Past

A necessary evil?
Commodity?
33
Cementing Today
Solutions portfolio
Early strength
1
Toughness
0.8
0.6
Final strength
0.4
0.2
Durability
Flexibility
Permeability
Shrinkage
Bonding
Not only slurry

performance
Set material properties
Short/long-term well
requirements
Modeling tools
Fit-for-purpose,
cost-effective system
34
17
Cementing Tomorrow:
A Technology for the Future
Evolving
cement
industryhas evolved considerably
Oilwell
cementing
Still considerable academic
Oilwell cementing will continue to quickly adapt
research
New cements from cement manufacturers
CO2emissions
Important
engineering
New
tools from cementing service industry
development
Physically active, chemically re-active or inert materials
Oilfield cementing
Processindustry
design/simulation means
More tools in the toolbox
A true well engineering technology
Materials, simulators
Adapt
tomorrows well
An tointeresting
future
requirements
A true well engineering
technology
35
Thank you for your attention
36
18

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SPE Distinguished Lecturer Program

The SPE Distinguished Lecturer Program is funded principally through a

Society of Petroleum Engineers

Cement and Cementing:

Society of Petroleum Engineers

Well architecture tool for the future

V isc osit e (Bc)

History of Oilfield Cement

API created 20 Mar 1919

1824: Portland cement

1903: Portland cement in oil wells

Became API RP10B in 52

1952: 6 classes of cement

Plain Portland cement

Rest of the world (international service companies)

From API to ISO (since 1998)

ISO 10426-1 (ANSI/API 10A) - specification

Other work groups:

Cementing: A Necessary Evil?

Technology Older Than a Century

First use of an eductor

Primary Cementing Objectives

Unsuccessful Zonal Isolation

Cementing Process at Surface

Handling Dry Cement

Fully automated blender

Cement Quality = Slurry Performance

W/C ratio; extender;

Cementing Additives Key Milestones

Lignosulphonates and cellulosics

Environmentally friendly additives (end 1990s)

Cementing Process Downhole

SloFlo / Plug Flow ~70s

Very mixed results

Mud Removal Modeling

More critical wells

Importance for Zonal Isolation

Erodability / PDGM concept

Numerical 2D Modeling (2002)

Cement Evaluation Logs

Flexural Attenuation (2006)

Limitation of cement logs

Strength or Impedance ~80s

Full cemented annulus width

Alternative Isolation Techniques

Todays Well Challenges and

New Reservoir Isolation Challenges

Completions at lower pressures

Exploration and new developments

Need for Ultra-Low Density

High performance/high solid

Directly linked to W/C ratio

Adapted from concrete industry

Very low rheology

From 900 to 2800 kg/m3

Slurry Quality Control?

What if density 1.0?

Solid Fraction Monitoring

Well Architecture and Logistics