Practical Issues Related to sc-CO2

Well Construction for CO2

Sequestration Projects
Brookhaven National Lab
Supercritical Carbon Dioxide &
Materials Interaction

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Overview
Cement Systems &
Cementing Casing and Well Design
• Chemical Durability of • Casing Design
cements – Connections
• Mechanical durability of – Metallurgy
cements • Well design Optimization
• Mud
M d Displacement
Di l • Identify
Id if chemistry
h i off
Factors injection fluid
• Cement Placement &
Reverse Circulation
• Case History

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Chemical Durability of Cement
Temperature Related Chemical Attack
• Previously 30 – 40% • Chemical attack
y
additional crystalline – CO2
silica was thought – H2S
enough to provide • Need resistance to
strength stability chemical attack
• New published data up to – Latex Cements
600 °F shows a need of – Fly Ash / Calcium
up to 70% Silica added Aluminate cement blend
for strength stability (Developed by Sugama of
BNL)

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Mechanical Durability
Cyclic Stress Loading Cement Failure
• Pressure induced
– Injection
j
– Stimulation
– Swapping out fluids of
different density
• Temperature Induced
– Drilling
– Production
– Injection

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Conventional Cement – 2D Modeling

Time = 0 sec Time =100 sec

Th
Thermal
l Stress,
St ΔT
T = 200°C (360°F)
Tensile Failure Occurs!!
Ductile Cement – 2D Modeling

Time = 0 sec Time = 10 sec

Thermal Stress, ΔT = 200°C (360°F)

During heating plastic strains develop
but NO cracking or de-bonding occurs
Cement Durability
bl
Conventional Cement Ductile Cement
 M d Ch
Mud Channeling
li
• Allow contact of
casing with well
fluids - CO2 & Water
• Allow Interzonal
Communication
– Lost Production
– Unwanted Production
– Corroded Casing
Displacement
Di l t
Factors
• Mud Conditioning
• Mechanical Aids
– Pipe
p Movement
– High Port Up-Jet Float Shoe

• Centralization
• Fluid Velocity
• Spacers & Flushes
 Definition of Standoff and
Di l
Displacement t Effi
Efficiency
i

Formation

Standoff = C / (A-B)
(A B)
M d
Mud B
C A

Casing

Cement
Cemented Area
Displacement
=
Efficiency Annular Area
 Mud Conditioning
g
LOW
MOBILE
MOBILITY
MUD
MUD

FILTRATE CEMENT

FILTRATE
FILTER
CAKE
FORMATION CASING
Pipe
Movement
•Removes Gelled
Mud
•Rotation or
Reciprocation
Centralization
• Centralization critical
for complete mud
displacement
C t li ti
Centralization
Standoff Displacement
17 45
35 77
60 88
72 97
Aff t off Fl
Affect Flow R
Rate
t
Plug Flow Laminar Flow Turbulent Flow
V l it
Velocity
Rate (bpm) Displacement
1 48
4 75
7 98
Spacers and
Flushes
• Fluid Compatibility
• Fluid Separation
• Aid in Mud Displacement
• Formation Protection
• Solids Suspension
Cement Placement

Reverse Circulation Cementing

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Reverse Circulation
Key Advantages Conventional vs.
vs Reverse
• Reduced hydraulic horsepower
• Reduce ECD’s
• Shorter cement thickening
times
• Reduced cost for retarder
• Quicker strength development
• Improved safety and
environmental management

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 Lower ECD – Reverse Circulation

Conventional Circulation Reverse Circulation

Reverse Circulating Pressure and Density at Fracture Zone.
Conventional Circulating Pressure and Density at Fracture Zone. Downhole Annular Pressure and ECD vs. Liquid Volume
Downhole Annular Pressure and ECD vs. Liquid Volume Circulating Pressure Hydrostatic Pressure
Circulating Pressure Hydrostatic Pressure
2000
2600
13

2500 1950
10.0
2400
12 1900

2300

P ressu rre (p si)

E CD (llb/gal)
P ressuree (psi)

E CD (lbb/gal)
1850
2200 9.5
11

2100 1800

2000
10 1750
9.0
1900

1700
1800 5
9
3 4 6 3 4 5 6
1700 1650
0 200 400 600 800 1000 0 100 200 300 400 500
Volume In (bbl) Volume In (bbl)

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Key Advantages
Reduced ECD ECD on Reverse Job
• Conventional circulation
g heavyy
involves lifting
cement in a small
annulus
• Reverse Circulation
involves lifting drilling
fluid through nearly
entire job with little flow
restriction of mud in
casing
Key Advantages Un-foamed
Cap
Cement

Short TTT/Reduced Cost$

• Conventional
C i l circulation
i l i Foamed
Stage 2
Cement
– 100% of cement exposed
to BHCT
– Added time to displace
• Reverse Circulation
– Only lead portion exposed Foamed
F d
Stage 1
to BHCT Cement

– Retarder can be staged /

reduced during job
– No Displacement time
• Faster Set Time Un-foamed
Un foamed
Shoe
Cement
Operational Challenges
Float Equipment
• Determining Cement
Location
• Rig-up
• Job Design and Execution
• Float Equipment
Case Histories
Pipe Size, Slurry
Depth, ft Slurry Type
• 26 Jobs have been done 5,012
in.

8 5/8 Conventional
Volume, bbl

135

i the
in th West
W tC Coastt 3 774
3,774
5,012
1,700
13 3/8
13 3/8
9 5/8
L t
Latex
Conventional
Conventional
721
731
130

Region since 2002 3,180

1,802
9 5/8
13 3/8
Conventional
Conventional
232
230

– All g
geothermal except p 3 3,645

—
13 3/8

13 3/8
Foam Latex

C
Conventional
i l
548 (base)

140
jobs 1,989 13 3/8 Conventional 450

3,675 13 3/8 Foam 635 (base)

– Majority were volumetric 1,450 7 Conventional 80

w/ ggamma ray y tool and 5,000

16,593
11 3/4

7
Foam

Conventional
995 (base)

506
radio active tracer 5,000 11 3/4 Foam 440 (base)

• Locations
9,900 7 Conventional 1200
7,902 7 Conventional 325
3,608 13 3/8 Conventional 370
3,350 13 3/8 Latex 665
– CA 3,290 9 5/8 Latex 100
1,868 13 3/8 Conventional 370

– Hawaii 3,800 13 3/8 Foam 560 (base)

2,065 2 7/8 Foam 60 (base)

– Nevada 3,719 13 3/8 Foam Thermalock 440 (base)

14,007 7 5/8 Conventional 207

11,170 10 3/4 Conventional 426
2,250 7 Conventional 160
Case History
Well Details Solution
• New Production well • Used Foam cement for
• CO2 zone @ 1200 ft. p
improved mechanical
• Past history of casing properties
failure at that depth • Used CO2 resistant blend
• Problem cementing 13- to protect from CO2
3/8 inch casing due to attack
lost circulation • Placed with reverse
circulation

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Casing Design
• Metallurgy of casing
must be considered for
expected environment
• Each Casing String must
be evaluated for each
well
• Carbon steel, high
alloy titanium
alloy, titanium, etc
etc.

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Casing Connections

• High Stress occurs in

connections during
thermal cycling
• Premium connections
preferred over buttress
p

• a – compression loading
• b – Tension loading
• c – Non deformed

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Summary and
d Conclusions
l
• Drilling sc-CO2 wells • Special cement systems must be
involves additional design used when exposed to CO2 in
challenges above normal presence of water
geothermal and/or storage • Casing corrosion must be
wells considered and needed
• Mechanical and chemical metallurgy used to prevent
cement durability must be corrosion
taken into consideration • Factors affecting displacement
• Modeling of stress on efficiency must be considered to
cement and casing insure competent cement sheath
recommended for all designs placement
• Cement must cover entired • Chemical and mechanical
casing annulus considerations for casing design
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Questions??

Comments??

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