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Abstract
This paper outlines the cement slurry design methodology
used to cement one of the worlds longest horizontal well
bores. The work detailed has been carried out on M-Site of
BP Amocos Wytch Farm Development on the south coast of
Dorset, England, over the past 4-5 years. Of the 17 wells, so
far completed on M-Site, none have required remedial
cementing work and all reservoir sections exhibit satisfactory
zonal isolation, as confirmed by bond log results. The
formations to be drilled exhibit very low fracture gradients,
with the possibility of losses during the cement job constantly
present.
The discussion compares and contrasts cementing techniques
between vertical and horizontal casings. It looks at procedures
and concerns common to both, then describes how downhole
temperature calculation and some lab testing techniques, were
modified to account for the nature of the horizontal well bore.
Output from the computer temperature simulator confirmed
assumptions made earlier in the project. Details of the slurry
design criteria and testing procedures are discussed. The slurry
properties included zero free water and low fluid loss, along
with considerable thickening times, to allow for correct
placement.
The discussion includes hole cleaning measures, and the
influences of mechanical contribution, such as centralisers and
pipe movement. Spacers and flushes with controlled flow
regimes have been used to provide optimum mud and solids
removal. In addition, an outline of the computer simulation
programme used for well bore analysis is shown to be
invaluable to the design engineer, by allowing modification of
many inputs very quickly.
Introduction
As exploitable petroleum deposits are found in increasingly
harsh environments so, the technical limits of each discipline
are stretched to meet this demand. This paper aims to
S.A. MCPHERSON
this time the average displacement rate for liner jobs was in
the region of 6-8bpm. During planning for well M11 (the first
well with a liner set at greater than 10,000m MD), it was noted
that the displacement rate would have to be reduced to
approximately 4bpm to ensure the fracture pressure of the
formation was not exceeded during cementing.
Work done previously by Lockyear, Ryan and
Gunningham1 indicated, that as flow rate decreases, so the
degree of channeling increases, except where water is being
displaced. In addition, due to the increased ease of gaining a
turbulent flow regime, less viscous fluids are more effective at
displacing more viscous ones. Based on this work and the
previous successful well cementations, it was decided to
introduce a water only phase to the current spacer system. This
led to the use of a number of fluids with varying densities and
flow regimes. In addition, density differences can help reduce
channelling of the cement during placement 1.
Since well number M11, the following fluids have been
used ahead of the cement on liner cementations. Typically 100
barrels of base oil is pumped first, due to its compatibility with
the low toxicity, solids laden oil based mud used for drilling.
With its viscosity of 1-2cp the base oil is in turbulent flow,
even at very low pump rates. This allows improved mud
removal throughout the annulus, especially below the pipe,
where mud tends to get trapped. The base oil thins and
removes mobile mud ahead of it and contributes greatly to the
breakdown of filter cakes and pockets of immobile mud. The
base oil flush is followed by 75 barrels of sea water. Again the
turbulent flow regime of this fluid promotes the removal of
immobile mud on the low side of the annulus.
Seventy-five barrels of water based spacer containing a
surfactant, is weighted to part way between the density of the
mud and the cement slurry, using barite. Weighting this fluid
ensures the equivalent density of fluids in the annulus does not
fall below the pore pressure of the formation. The surfactant
aids the break down and removal of immobile mud and will
prevent the formation of any incompatibility products at the
spacer/mud interface. As with vertical wells, incompatibility
between oil based mud and water based spacer is usually
manifest as the generation of a thick mixture resembling
putty. Depending on severity, these incompatibility products
can be of great detriment to hole cleaning by changing the
calculated flow regime to something less effective, or by
creating a blockage. In addition, the spacer yield point is kept
low to promote turbulent flow and cuttings removal.
A second sea water flush of 75 barrels follows the
weighted spacer to reduce the ECD and therefore the pressure
on the formation. The sea water contains the same surfactant
as the weighted spacer, which in conjunction with the
turbulent flow regime of this fluid, continues the attack on
immobile mud pockets in the annulus.
The final fluid ahead of the cement slurry is a further 75
barrels of water based spacer. Mixed to the same design as the
previous weighted spacer pill, it has mutual solvent added at
the same loading as the surfactant. The density of the fluid and
the surfactant content work in the same way as before. The
mutual solvent dramatically improves the water wetting of the
SPE 62893
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allows the cementer and rig site personnel to deviate from the
simulated programme, if well conditions dictate. This
flexibility can be used, for example, to heal a fracture created
during cementing in a previously unseen weak spot, by
reducing pump rate and therefore ECD.
On average, liner slurry designs have a thickening time of
10 hours, with the cement job taking in the region of 5-7
hours. The cement slurry used on the liner for well 1M-16-SPz
had a thickening time of 15 hours, with the job taking 81/2
hours to complete.
Fluid Loss Control. Loss of mix water from the slurry, during
displacement, will reduce the slurrys thickening time and
increase its viscosity4. As the slurry loses water it will lay
down a filter cake, against the permeable formation wall.
Uncontrolled, this will change the flow regime of the slurry
from the calculated one to some unpredictable alternative and
may result in excessive ECD being experienced during
displacement. The filter cake will continue to grow over the
whole length of the permeable zone, and in extreme cases may
result in a total blockage of the annulus, preventing further
displacement. To reduce the amount of fluid lost from the
Other Testing. Inherent with the long open hole sections are
large annular volumes and consequently large amounts of
cement are required to fully isolate the annulus. To ensure that
cement used at the end of the job performs to the same
standard as that used at the start, the API thickening time of
the final slurry is re-tested with a second sample of cement
taken from a different sample point to the first. Only when
these two samples are within experimental error limits, is
testing complete.
Table 3 details the cement slurry lab results for 3 recent
liners.
Well bore considerations During Displacement
The ECD values seen while cementing horizontal wells vary
greatly from those experienced with vertical wells. Graph 2
compares ECD values calculated during the displacement of a
horizontal well (demarked by squares) with those for a vertical
well of the same length (demarked by triangles) using the
same fluids and displacement rates. As can be seen the vertical
well exhibits lower ECDs for the majority of the job but these
rise by the end of the displacement to almost 0.7ppg higher
than those seen in the horizontal well. This is due to the
hydrostatic weight of the fluids having greater influence in the
vertical instance.
However, in a horizontal well, the weight of the fluids in
the liner or casing, are spread along the length of the hole.
Centralisers applied using spacing that will support the casing
off the bottom of the hole would have to be increased in
number to support the extra weight of the cement in the
casing. At Wytch Farm the number of centralisers used over
the length of the liner section has fallen as later wells are
S.A. MCPHERSON
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Computer Simulations
Calculation of all the varying factors encountered during a
cement job can be very time consuming. It is not practical to
determine all the changes to all the interrelated factors
experienced during the job by hand. Use of a computer
simulation programme gives much more versatility to the
design engineer. Fluid flow regimes and pump rates can be
changed within seconds and the effects of these changes
studied many times over. Many parameters including fluid
type and rheology, pump rates, well trajectory and excess
cement handling, are used by the simulations algorithms to
generate the job.
As mentioned above the anticipated well bore temperature
during the job is also modelled using a computer simulation
programme. Using similar information as above it calculates
the temperature along the well bore during the pumping,
shutdowns and displacement, of the cement job.
The output of the programmes can be shown graphically,
or as text listings, alternatively both can be incorporated in to
a more detailed report.
These computer simulations can also be used for real time
data collection and post-job analysis. In real time mode the
engineer can study the well bore as the job is being pumped,
allowing any necessary adjustments to be made. The post job
analysis mode allows the engineer to review jobs already
pumped, so that authentic job information to be fed back into
the job design process.
2.
3.
4.
5.
6.
7.
Post-Job Data
Due to their inherent cost cement bond logs are not usually run
on every well within a development. At Wytch Farm cement
logs have been taken twice since well number 1M-10-SP, in
both cases to verify cement coverage for dual
producer/injector wells. During the each test the casing was
filled with sea water and there was no pressure applied during
logging. Conclusions from both these tests found that the
required zonal isolation had been achieved and completion
was to continue as planned. In addition, none of the liners
within the development have reported poor zonal isolation or
required remedial work.
Conculsion
Excellent well bore isolation at Wytch Farm has primarily
been successful through the application of the well grounded,
cementing practices. Due to the limitations on reciprocation of
the pipe and the low fracture gradient of the formation,
annular cleaning has been achieved by other techniques.
Implementation of the multiple spacers, each with a different
flow regime, has allowed improved hole cleaning, while
reducing the placement ECD. The thin low fluid loss slurry is
easy to mix and pump, yet provides excellent zonal isolation
and pipe support. The ability to simulate the job on computer
ensured that the fluids rheology and density, were beneficial
to the job objectives and that the effects of any changes were
accounted for. In addition, the novel use of centralisers, with
rollers during well 1M-16-SPz allowed this long section of
Authors Note
In the text reference is made to API Spec 10a dated 1991.
Please note that this was the most recent issue of the
specification at the start of the project and that test procedures
have been continually compared against more recent issues, as
they have become available.
S.A. MCPHERSON
Table 1
12 Open Hole
10.0 10.4
40 60
28 32
>400
<5
60 / 40
Base Oil
Weight (PPG)
PV (cp)
YP (lb/100ft2)
Stability (volts)
Fluid Loss (mls) @ 200degF
Oil / Water
Fluid Base
Pumping Order
Weight (PPG)
PV (cp)
YP (lb/100ft2)
Surfactant Concentration
(gal/bbl)
Mutual Solvent Concentration
(gal/bbl)
Minimum Rate for Turbulent
Flow (bbls/min)
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1
7.8
1
-
Table 2
2
8.55
1
-
8 Open Hole
9.60 10.0
15 20
10 14
>400
<4
70 / 30
Base Oil
3
11.5
8.5794
3.2612
2
4
8.55
1
2
5
11.5
8.5794
3.2612
2
0.3746
0.34375
3.1327
0.34375
3.1327
SPE 62893
Table 3
1M-14-SP 1M-15-SP
160
Test Temperature (degF)
9:52
Time to 50Bc (Hrs:Min)
10:02
Time to 70Bc (Hrs:Min)
10:11
Time to 100Bc (Hrs:Min)
0
API Freewater (%)
72
Fluid Loss (mls)
78
Rheology @ Test Temperature
600 rpm
42
300 rpm
30
200 rpm
17
100 rpm
3
6 rpm
2
3 rpm
32 hrs;
Compressive Strength Development @ Test Temperature
2108psi
1M-16-SP
150
13:17
13:27
13:39
0
80
79
44
32
18
4
3
32hrs;
2000psi
165
14:42
14:55
15:10
0
54
68
36
24
14
3
2
32hrs; 3272psi
1 1 .5
1 0 .5
10
9 .5
8 .5
23
11
99
87
72
35
15
15
15
14
14
14
24
00
73
13
53
48
14
14
14
13
13
93
33
72
V o lu m e o f F lu id P u m p e d ( b b ls )
12
11
11
10
12
10
95
89
83
77
72
68
62
56
50
44
40
36
30
24
18
12
60
11