INNOVATIVE LOW WEIGHT CEMENT SYSTEMS CHALLENGING ...
Transcript of INNOVATIVE LOW WEIGHT CEMENT SYSTEMS CHALLENGING ...
Freiberger Forschungsforum 65. Berg- und Hüttenmännischer Tag vom 12. bis 13. Juni 2014
KOLLOQUIUM 1 – „Förderung und Speicherung von Erdöl, Erdgas und erneuerbaren Energien“
Lummer, Nils Recalde (Fangmann Energy Services GmbH & Co. KG)
INNOVATIVE LOW WEIGHT CEMENT SYSTEMS – CHALLENGING APPLICATIONS IN GEOTHERMAL PROJECTS
In oil well cementing, the incompatibility of drilling mud and low-weight cement slurries is a well-known
problem. The use of spacer systems to separate these two fluids and to remove residual mud filter cake
from the borehole is a common method. Here, spacer efficiency is essential for the subsequent cement
job and – even more important – for the integrity of the well. In its first part, this paper introduces a
new abrasive spacer, its development and first field application in a geothermal project.
To quantify the mud removal capacity of different spacer systems, we developed a specially customized
lab instrument. The corresponding procedure included build up and removal of mud filter cake under
dynamic conditions. Employing modified cement crushing tests, the evaluation of the spacer efficiency
was determined. Under these lab conditions, we tested the new spacer, compared it with a standard
barite-based system, and optimized its composition.
The quality of the cement job and hence the mud removal capacity of the abrasive spacer was quantified
through wireline logging. Laboratory and field results impressively proved the enhanced efficiency of
this innovative product.
In its second part, this paper presents a customized low-weight cement system specially adapted to
cement glass-reinforced epoxy (GRE) casing and presents field trials in a geothermal project. Corrosion
resistance, even under harsh borehole conditions, reduced thermal conductivity, and extremely smooth
inner-pipe surfaces are this materials main advantage when compared to steel. However, reduced col-
lapse resistance demands specially customized cement slurries. To ensure zonal isolation and hence well
integrity, appropriate adhesion of hardening cement onto the outer-surface of GRE casings is essential.
For the first field trial, the customer planned to cement 7” GRE tubulars in old corroded 9 ⅝” carbon
steel casings. Through extensive laboratory research, we formulated an optimized slurry containing blast
furnace slag cement and lightweight additives. For lab testing, we employed two new laboratory meth-
ods to evaluate the adhesion behavior of hardening cement systems on GRE casings.
The excellent quality of the first application and hence the supreme adhesion efficiency of the new ce-
ment system onto GRE surfaces was verified through wireline logging. Lab and field results impressively
manifest this blast furnace slag cement-based system as an alternative to commonly used API Class G-
based slurries. For premium results in geothermal projects, we at Fangmann Energy Services recom-
mend a combination of both innovative products.
Innovative low weight cement systems Challenging applications in geothermal projects
Berg- und Hüttenmännischer Tag Freiberg, June 10, 2016
Dr. Nils Recalde Lummer
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Introduction
o Increase / decrease of fluid viscosity
o Retardation / acceleration of cement hydration
o Sedimentation / further detrimental chemical reactions
Incompatibility between mud and cement slurries may lead to:
Incomplete cementation / No zonal isolation
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Separate mud from cement slurries
Displace mud from the wellbore
Remove mud filter cake
Ensure a good cement bond
The key is spacer system which aims to:
Introduction
Introducing Power Spacer for premium mud removal
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Development and Validation
Customized lab apparatus for spacer evaluation
Spacer systems
Drilling mud
Test cell
Pump
Sandstone samples
Fluid in
Fluid out
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Development and Validation
Fluids and sandstone samples
Fluid Type ρ, kg/L
Water-based mud Chalk / salt 1.27
Standard Spacer Barite 1.39
Power Spacer Barite / particles 1.39
Cement slurry API Class G 1.90
10
100
1000
10000
1 10 100 1000
Vis
cosi
ty,
cP
Shear rate, s-1
Viscosity at 22°C Power Spacer Standard Spacer
Ibbenbührener sandstone
Porosity: 19% Permeability: 200 mD
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Evaluation of spacer efficiency
Before After
Rear
Class G
Front
Development and Validation
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Hydraulic press Modified cement crushing tests
Quantitative and reproducible
Shear stress = cement bond = spacer efficiency
Direct method for spacer evaluation
Evaluation of spacer efficiency
Development and Validation
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Power Spacer vs Standard Spacer
0
20
40
60
80
100
120
0
58
111
Sh
ear
stre
ng
th,
PS
I Mud removal efficiency
Reference Standard Spacer Power Spacer
Development and Validation
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Well Conditions
MD 2,400 m
TVD 2,400 m
BHP 4,500 psi
BHST 86°C
BHCT 65°C
9 ⅝” Liner cementing job for a geothermal project
Fluids
Tail cement 1.90 kg/L
Lead cement 1.60 kg/L
Power Spacer 1.32 kg/L
Mud 1.20 kg/L 0
25
50
75
100
0 10 20 30 40
Sh
ear
stre
ss,
lb/
10
0ft
²
Shear rate, s-1
Rheological profile
First Field Trial
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Fluid WHP, bar Pump rate, L/min Volume, m³
Power Spacer 30 800 5.2
Lead cement 20 - 25 800 44.0
Tail cement 25 - 33 800 7.0
Pumping schedule
First Field Trial
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First Field Trial
Power Spacer
#5
9 ⅝” Liner shoe USIT logs from 5 different wells
Standard Spacer
#1 #2 #3 #4
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First Field Trial
Power Spacer
#5
Standard Spacer
#1 #2 #3 #4
9 ⅝” Liner overlap USIT logs from 5 different wells
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Summary I
Very successful under lab and field conditions
P remium mud removal capacity
O ptimized fluid design
W ide application range
E nhanced mud filter cake erosion
R emarkable cement bond
S P A C E R
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Introduction
o Corrosion resistance, even under harsh borehole conditions
o Reduced thermal conductivity resulting in less heat losses
o Extremely smooth inner-pipe surfaces leading to optimized flow profile
Characteristics of GRE tubular:
Introducing Fangmann’s low-weight cement system for premium adhesion on GRE surfaces and casing collapse control
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Aromatic
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Material
GRE tubular samples
Aliphatic
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Material
Aliphatic Aromatic
Characteristics
Elastic modulus - axial N/mm² 10,300 – 20,700
Elastic modulus - radial N/mm² 22,800 – 31,100
Poisson’s ratio 0.16 – 0.38
Thermal conductivity W/m/°C 0.30 – 0.40
Material density kg/L 1.80 – 1.96
GRE tubular samples
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100
1000
10 100 1000
Vis
cosi
ty,
cP
Shear rate, 1/s
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Material
Cement slurries Cement Composition ρ, g/L
Slurry A Highly resistant cement, bentonite, retarder, low-weight additive A
1.32
Slurry B Highly resistant cement, bentonite, retarder, low-weight additive B
1.32
Tail slurry API Class G 1.90
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Material
Compressive strength development
2500 psi
1300 psi
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Shear bond test
2 Methods for Validation
Conical Mold
Ferrule
Cement
Base
GRE Sample
Plunger
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Shear bond test
2 Methods for Validation
Conical Mold
Ferrule
Cement
Base
GRE Sample
Plunger
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Lab Results
Shear bond test
Aliphatic GRE Material Aromatic GRE Material
5.3
11.5
4.5
8.9
She
ar S
tren
gth,
N/c
m²
Slurry A Slurry B
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Tension bond test
2 Methods for Validation
Variable Weights
Cement Lever / Mold Assembly
GRE Sample
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Tension bond test
2 Methods for Validation
Cement Lever / Mold Assembly
Variable Weights
GRE Sample
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Tension bond test
Lab Results
Aliphatic GRE Material Aromatic GRE Material
0.8
13.0
0.3
3.8
Tens
ion
Str
engt
h, N
/cm
²
Slurry A Slurry B
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Aliphatic GRE Material Aromatic GRE Material
0.8
13.0
0.3
17.0
Tens
ion
Str
engt
h, N
/cm
²
Without Wash With Wash
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Improvement of cement adhesion
Shaft
Fluid
GRE Segment
Container
Lab Results
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Aliphatic GRE Material Aromatic GRE Material
0.8
13.0
0.3
17.0
Tens
ion
Str
engt
h, N
/cm
²
Without Wash With Wash
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Without wash
With wash
Improvement of cement adhesion
Lab Results
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Adhesion on steel material
Shear Bond Test Tension Bond Test
8.8
14.0 16.7
24.4
She
ar /
Ten
sion
Str
engt
h,
N/c
m²
Slurry A Class G
Lab Results
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Mixing of 20 L cement slurry
Cementation of 1 m 7” GRE tubular into an old 9 ⅝” casing
Use of GT Blend @ 1.32 kg/L and Glass G @ 1.90 kg/L
Calibration for logging
Preparation for Field Trials
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7” GRE tubular cemented inside old 9 ⅝” casings (4 wells)
Field Trials
Well Conditions
MD, m 1,690 – 1,940
TVD, m 1,630 – 1,640
Max. Dev, ° 46 – 49
BHST, °C 64 – 69
BHCT, °C 46 – 53
Fluid Density, g/L Volume, m³ Pump Rate, L/min
Bentonite Pill 1.02 2 600
GT Blend 1.32 19 - 27 600
Class G 1.90 1 - 2 600
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Field Trials
Wireline logs
Excellent Result
GT Blend Class G
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Summary II
Very successful under lab and field conditions
Fangmann‘s GT Blend
Innovative system specially customized for cementing GRE casings
State-of-the-art low-weight cement for casing collapse control
Adhesion verified by two separate lab test methods
Premium cement bonding on GRE and steel tubular
Enhanced adhesion through the use of washes
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Fangmann Energy Services GmbH & Co. KG Stimulation-Cementing-Downhole Tools Brietzer Weg 10 29410 Salzwedel/Germany
Phone: +49 (0) 3901 8363- 0 Mailto: [email protected] Web: www.fangmanngroup.com
Geschäftsführer: Frank Fangmann, Steffan Gerdes · Amtsgericht Stendal HRA-Nr. 117 Pers. haftende Gesellschafterin: Fangmann Salzwedel Beteiligungs GmbH · Amtsgericht Stendal HRB-Nr. 921