UNIVERSITAS INDONESIA

OIL WELL CEMENT RETARDER

FOR HIGH PRESSURE HIGH TEMPERATURE WELL
PRODUCT DESIGN

Draft Report Assignment 2

GROUP 11
GROUP PERSONNEL:
I GEDE EKA PERDANA PUTRA
(1306370676)
IMAM TAUFIQ RAMADHAN
(1306370612)
JEREMIA JAN CHANDRA PRANATA (1306414223)
NYDIA AMELIA MADIADIPURA
(1306449214)
YUNI DWI LESTARI
(1306370575)

CHEMICAL ENGINEERING DEPARTMENT

ENGINEERING FACULTY
UNIVERSITAS INDONESIA
DEPOK
MARCH 2016

OUTLINE

CHAPTER V GENERATING CONCEPT

5.1
Background Of Ideas
5.2 Problem Decomposition
5.3 Existing Ideas Concept
5.4 New Ideas Concept
5.5 Combination of New and Existing Concept
6

CHAPTER VI CONCEPT SELECTION

6.1 Concept Screening
6.1.1 Preparing the Matrix of Concept Idea Selection
6.1.2 Determining Rate of The Concept
6.1.3 Ranking The Concept
6.1.4 Combining and Improving The Concept Ideas
6.1.5 Choosing One Concept Idea or More
6.1.6 Re-checking The Result
6.2 Concept Scoring
6.2.1 Preparing Metric Concept Selection
6.2.2 Rating The Concept
6.2.3 Ranking The Concept
6.2.4 Combining and Improving The Concept
6.3 Concept Testing
6.3.1 Determining The Purpose From Concept Testing
6.3.2 Determining The Survey Population
6.3.3 Determining The Survey Format
6.3.4 Communicating The Product Concept
6.3.5 Calculating The Customer Respond
6.4 Product Description
6.4.1 Product Position
6.4.2 Final Specification of Product Design

I Gede Eka
Perdana
Putra
Jeremia Jan

Nydia Amelia
Madiadipura

Yuni Dwi
Lestari

Imam Taufiq
Ramadhan

CHAPTER V
GENERATING CONCEPT
5.1 Background Of Ideas (I GEDE EKA PERDANA PUTRA)
In the previous chapter, we have identified needs of consumer on oil well
cement retarder. Interviews showed all respondents wanted retarder product that
can accelerate hardening time and increase compressive strength. Some
commercial retarder are already have good performance, but there are still some
disadvantages that can be remedied. To be able to compete with existing products,
we strive to develop the concept of retarder that better meet consumer needs. Here

are consumers demand for the retarder products that we use as a reference in
determining the final concept of our retarder products.

Table 5.1 Product Properties

No

Needs

.
1
2
3
4
5

A retarder that has a wide temperature range

A retarder that is easy to use
A retarder that is multi-functional and works as a dispersant too
A retarder that is insensitive to temperature changes
A retarder that accelerates compressive strength development (less time

6
7
8
9
10

for WOC)
A retarder in liquid phase
A retarder that is packaged in a drum
A retarder that costs less than US$ 50 per gallon
A retarder that is not hazardous to your health
A retarder that is compatible with all cement types in HPHT well

11
12
13
14

conditions
A retarder that is compatible to other additives
A retarder that is eco-friendly
A retarder that is manufactured in Indonesia
A retarder that is inflammable
In summary from the properties listed above, by the end of all processes of

the product design, we want to have a retarder that :

1.

Has good performance (quick hardening time and improve

compressive strength)

2.

Flexible usage (compatible with all types of cement and with other
additives)

3.

Safety to use, both for consumer and environment

4.

Has packaged properly.

5.2 Problem Decomposition

The first step we do to generating concept is decomposing the main problem
to the sub-problems. From the problem of Oil Well Cement Retarder we
breakdown the word by word and analyze every single sub-problem by make
questions based on those sub-problems. Here are questions for each sub-problem.

Oil Well Cement Retarder for HPHT Well

Oil

Why do we need to drill oil?

Can we live without oil?
Well

Can we get oil without drilling wells?

How do we make an oil well?
Cement Retarder

Why do we need cement retarder?

What is the mechanism of retardation?
Could the retarder have a wide temperature range?
Could the retarder be easy to use, multi-functional (working as a dispersant

too)?
Could the retarder be insensitive to temperature changes?
Could the retarder accelerate compressive strength development (less time

for WOC)?
Could the retarder be in liquid phase and packaged in a drum?
Could the retarder cost less than US$ 50 per gallon?
Could the retarder be not hazardous to your health, eco-friendly, and

inflammable?
Could the retarder be compatible with all cement types in HPHT well

conditions and other additives?

Could the retarder be manufactured in Indonesia?

HPHT Well
Why do we drill in HPHT well?
How does it impact to the cement?
The next step on problem decomposition is identifying the problem that will
happen if the retarder is not used in the HPHT well cement slurry. In high
temperature and high pressure oil well condition, cementing may face a challenge

of hardening faster, which means it might harden before it reached the desirable
cementing place. Therefore, drilling can not be done and casing is not protected.
5.3 Existing Ideas Concept
After identifying sub-problems derived from the main problem, we go on to
analyze the concepts of the existing products. Previously, we had analyzed
specification some existing products through by benchmarking their product
specification. In this section, we create a mind map to explain concepts of existing
product that have available on the market as shown in figure 5.3.

Figure 5.3. Mind Map for Existing Concepts of Oil Well Cement Retarder

5.4 New Ideas Concept (JEREMIA JAN CHANDRA PRANATA)

In this part, we discussed and thought deeply to create some new concepts
for our product. We tried to be more creative and explored many new ideas which
will probably be applied to our product later. We produced some innovations of oil
well cement retarder, in terms of working principle, materials, form, and its
functionality. Below is the explanation of our new concepts.

5.4.1 Form
There are many forms which a cement retarder can be in.

Powder
Powder can be packaged in sack. It is easy to calculate the
concentration when using powder. Powder is not volatile. The leakage

of package is easy to identify.

Liquid
Liquid can be packaged in can or tank with very large volume. Liquid

retarder is sometimes volatile.

Aerosol
Aerosol can be packaged in small can and safe from impurities.
Cementer can use the retarder by only pressing the button, it decreases
the chance of contact between cementer and retarder so it is very safe.
The spray is will spread effectively to the cement. It can be kept for

the next use. It is hard to calculate the concentration.

Paste
Paste can be package in small and big tube. Paste has ability to absorb
very well. Paste is hard to move so the leakage can be minimalized. It
will stay on cement because of its viscousity. It is hard to calculate the

concentration.
Gel
Gel can be package in small and big tube. Gel will stay on cement
longer because it is so viscous. It is easy to calculate the concentration

and mix well with the cement.

Liquid Foam
Liquid foam can be packaged in can with sprayer. It decreases the
chance of contact between cementer and retarder so it is very safe. It is

hard to calculate the concentration.

Solid Foam (Styrofoam)
It is easy to be packaged and carry, but it is hard to manufacture.
5.4.2 Working Principles

Adsorption
The adsorption theory suggests that the retardation occurs due to the
adsorption of the retarder onto the surface of the hydration products
thereby inhibiting contact with water.

Precipitation
The precipitation theory suggests that the retarder reacts with calcium
and/or hydroxyl ions in the aqueous phase and forms an insoluble and
impermeable layer on the cement grains. Osmosis will drive water
through the semipermeable membrane toward the anhydrous mineral,
and eventually the flow of water creates higher pressure inside the
protective coating and the layer bursts, allowing hydration to continue

at a normal rate.
Microorganism
Microorganism can have two poles: hydrophobic and hydrophilic. The
hydrophobic side will wrap the cement so it cannot contact with water

and delay the hydration process.

Cool Water
By using cool water in cementing, cement will take longer time to
thicken so it can be pumped until it reaches certain depth.
5.4.3 Materials
There are many materials which can be used as a retarder. Some of
them come from nature, such as lignosulfonate, cellulose derivatives,
saccharide compound. Other materials are obtained from other industries,
such as beet molasses, sugarcane molasses, black liquor, and agricultural
residue ash. Some are produced from experiment in laboratory, such as copolymer polycarboxilic, hydroxicarboxilic acid, and NMTP. All materials
mentioned above have been examined and published in international papers
or journals, but yet to use in a recent retarder.
5.4.4 Other uses
We have an idea to create a retarder that can be used not only in oil
well drilling but also in buildings concreting in hot weather area, like
Middle East. Furthermore, that retarder can be used in acrylic paints.
Retarder can slow the drying time of acrylic paints, therefore it gives more
time for blending or layering highlights.

5.4.5 Desired Criteria for Packaging

Criterias of packaging that are desired:

Double Seal Protection

It is important to make sure that there is no chance of leakage.
Therefore, there will be no contamination because purity is the key to

calculate the concentration needed in cementing.

Product with big size packaging.
Retarder is used in large amount so it is quite important to put it in big
size of package. It can be in drum or totetank.

Figure 5.4.5 New Concept of Cement Retarder

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5.5 Combination of New and Existing Concept

The existing and new concepts are combined to provide alternative ideas for
better oil well cement retarder product. Here is the mindmap for combination of new
and existing ideas.

Figure 5.5 Mind Map for Combination of New and Existing Concepts

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CHAPTER VI
CONCEPT SELECTION

In the previous chapter, we have obtained the combination of new and existing
product ideas for our oil well cement retarder. The many ideas are then narrowed into
few to find the best concept in creating our product. There are three steps in concept
selection in total; concept screening, concept scoring and concept testing. Each step
will be elaborated in the sections below
6.1 Concept Screening (NYDIA AMELIA MADIADIPURA)
The first step in selecting the concepts we have is by screening it. Concept
screening is used to reduce the number of concepts we had by eliminating the most
unlikely ideas, until we reached the best concept in making our product. The method
of screening, widely known as Pugh Concept Selection, is first introduced by Start
Pugh in 1980. According to him, there are several strategies to select a concept,
which are:

Environmental friendly
The product we designed should have no or low impact to the environment

Safety
The product we designed should be safe to use and has minimum risk

Cost-effectiveness
The product we designed should be cost-effective. We prefer low cost product without
sacrificing the quality

Scientific background
The product we designed should be based scientific knowledge that we already
had at this stage

Engineering ease
The product we designed should be technically feasible and is based on the
engineering principle

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The first step of screening process is by eliminating the concepts that are
improbable to develop based on the scientific background and other factors, which
allows us to have a smaller number of ideas. The concepts are sorted into three
groups, Redundant (R), Foolish (F) or Vague (V).
(In progress)
Table 6.1 First stage of Concept Sccreening (Elimination Concepts)

Concept
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

Concept

Ad

Reason

After eliminating the concepts, we now have a few concepts to undergo the
second stage of screening. The next elimination process is based on the
comparison with the existing product. If the existing product has a better concept
than our product, the concept should then be eliminated.
The second stage of screening consists of six stages, such as:
6.1.1

Preparing the Matrix of Concept Idea Selection

13

Matrix of Concept Idea is depicted in a table consisting of columns that

contains concept ideas and the criteria of selection. The concept ideas should
be compared to reference concept that is used in existing product. The selection
criteria, which are formulated from our group, should consider consumers
need. Reference concept is a group of familiar ideas which can be found in the
existing product. To make a matrix of concept screening, we have to list the
criteria selection as follows:
Table 6.2 List of Selection Criteria

No

Selection Criteria

1
2
3
4
5

6.1.2

Determining Rate of The Concept

For each concept, the criteria should be rated as :
+ : Showing the ideas that are better than the reference concept
- : Showing the ideas that are worse than the reference concept
0 : Showing the ideas that are the same as the reference concept

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Table 6.3 Concept Screening

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6.1.3

Ranking The Concept

No

Criteria

Concept
1

10

1
2
3
4
5
Number of 0
Number of +
Number of Total
Decision
Ranking the concept can be done by summing all the criteria ratings for
each concept. After counting, the idea is then sorted and ranked according to the net
scored achieved. The concept with the highest number will be ranked first, and so on.
Table 6.4 Concept Rank

Ran

Concept

No.

6.1.4

Concept

Combining and Improving The Concept Ideas

(in progress)

6.1.5

Choosing One Concept Idea or More

Net
Score

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(in progress)
6.1.6

Re-checking The Result

The last step is reviewing the result and the process on
selecting the ideas of concept in concept screening. Then, we
have to recheck the score related to the criteria stated before.

6.2 Concept Scoring (YUNI DWI LESTARI)

The next step after concept screening is the concept scoring.
This step would specify the ideas to get the best idea. In concept
scoring, every selection criteria in this step would have its weight
factor. The weight factor is based on how important the criteria.
Concept idea that has the highest score would be chosen as the
best concept for new anti-rust product. Every rating would be
multiplied with its weight factor to get its score for each criteria.
Before we go further to the criteria, the next step is to re-expand
the concept from concept screening even further. The screened
concept will be detailed by giving each of the idea the material or
ingredient that our team members want.
6.2.1

Preparing Metric Concept Selection

Selection and score criteria that we use in scoring concept
for choosing best concept for our retarder are :
a. Quality of improve the early compressive strength weight
factor = 20%.
This is the main focus of our product in order to be able to

b.

solve the existing problems in oil well cementing.

Control thickening time, weight factor = 13%.

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After benchmarking we know that the exsiting retarder

already has a good efect in control thickening time, so in
order to be compete our product have to be good in
c.
d.

controling thickening time.

Ability to use high temperature, weight factor = 10%.
This is the main concept of our product.
Compatible with other additives = 9 %
In oil well cementing there are so many additives other
than retarder, such as : dispersant, weighing agent, fluid
loss controlling and etc. So our product have to be

e.

compatible with those additives while applied.

Compatible with all HPTP cement type = 10 %
Another exsiting problem in oil well cementing is that the
retarder can only be use in spesific cement type. It is
means that our product can be more innovative if can

f.

require this creiteria.

Safety in use, weight factor = 5%.
This criteria describes the use of the product whether it is

g.

safe or not for the user.

Eco friendly, weight factor = 10 %.
Some customers has already thought that environment
now in danger by a lot chemical substance. They hope
that there will be a product that has minimum impact to
the environment.
h. Has packaged properly = 9 %.
One of biggest consideration of generating and scraping
off the idea is this criteria. This will determine whether a
product is easy or difficult to distribute. This criteria also
includes the material in use to determain how our product
will be packaged and also determine the price.
i. Easy to use, weight factor = 9 %.
This criteria contain a step in using retarder and also
measurment dosage.
j. Can be use for other purpose = 5%

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This criteria is kind of our product innovation. Other

purpose such as retarder that can be use as additive
concrete in high temperature area.
6.2.2

Rating The Concept

After the criteria and weigth factor have been prepared, we give rate the

concept. We gives five parameters for each criteria. The scoring parameter for
each criteria are :

1 = very poor compared to the reference.

2 = worse than the reference

3 = same as reference

4 = better than the reference

5 = very good compared to the reference

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Table 6.2.2 The Description of Rating Score

Rating

Improve

Control

Ability to

Compatib

Criteria
Compatibl

compress

thickeni

use in

le with

e with all

ive

ng time

high

other

HPTP

temperat

additives

cement

properl

type

strength

ure

Safety

Eco

Has

Easy

in use

friend

packag

to

ly

ed

use

Can
be
use
for
other
purpo
se

Cost

20

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6.2.3

Ranking The Concept

We made a matrix and scoring each concept to know the best concept to

be applied to our product. We rank each concept by summing the total score for
each concept. Total score is calculated by multiply weight factor with rating.
The best concept is the concept which has highest score.
6.2.4

Combining and Improving The Concept

Metric table of concept scoring for concepts that got in

screeningprocess is shown in the following table. After the concept

scoring, we have one concept that have score above the other concept as our
final concept. Next step, this concept will be tested to consumer.

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Table 6.2.4. Concept Scoring
Concept
Criteria

W
R

Improve
compressi
ve
strength
Control
thickening
time
Ability to
use in high
temperatu
re
Compatibl
e with
other
additives
Compatibl
e with all
HPTP
cement
type
Safety in
use
Eco
friendly
Has
packaged
properly
Easy to
use
Can be
use for
other
purpose
Cost

B
TS

C
TS

D
TS

E
TS

TS

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*Notes :
W = Weight
R = Rating
TS = Total Score (TxW)
6.3 Concept Testing (IMAM TAUFIQ RAMADHAN)
After completing some of our concept selection series which include concept
screening and concept scoring, we conducted a concept testing as the last part of
concept selection. We came to the consumer with our proposed concept and we
tested the acceptability of our product to them. In doing concept testing, we went
with the following steps:
6.3.1

Determining The Purpose From Concept Testing

The purpose of concept testing was to see whether the concept we

proposed fulfilled the consumers needs and to see their interest on our product.
To answer the aforementioned questions, we needed to ask respondents, which
are our market target, with list of questions about acceptance of our concept
through questionnaires. Firstly, we explained the concept that we proposed,
starting from the work principle until the cost and benefits of our product.

6.3.2

Determining The Survey Population

The population of our survey came from our market target, which are

existing user and experts of oil well cement retarder. We also gave questions to
determine both their profession and the frequency to which the user uses an oil
well cement retarder, thus assuring the validity of their insight. In addition, we
also gave open-ended questions that can only be answered if you have a
specific knowledge about oil well cement retarder.
6.3.3

Determining The Survey Format

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The form of the survey were questionnaires distributed to 6 respondents.

Aside from personal credentials, we asked the respondents about both the
specifications (such as, but not limited to, form, packaging, and price) of
current retarders and expected improvements and innovations of our groups
retarder.
6.3.4 Communicating The Product Concept
(in progress)
6.3.5

Calculating The Customer Respond

The respondents that filled out our questionnaire came from professions

explained in the previous part. Here are the pie charts that described the
distribution of respondents professions, respondents usage frequency, and the
methods they use to acquire a retarder.

Profession

17%

Field Specialist
Cementer

83%

Figure 6.3.5.1 Respondents Professions

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Frequency

40%

40%

Often
Sometimes
Very often

20%

Figure 6.3.5.2 Respondents Frequency in Using a Retarder

How Respondents Get A Retarder?

Manufacture it by
yourself

33%
67%

Purchase from other

partnership
company

Figure 6.3.5.3 How Respondents Get a Retarder

In Figure 6.3.5.1 and 6.3.5.2, are considered aspects in targeting the

respondents which are their profession and their frequency in using retarder.
Based on the result, their professions are quite similar as seen from Figure 6.1.
Given that, we are sure that those answering our questionnaire are those that
have technical experiences in using a retarder for oil well cementing. So they
know exactly what the weaknesses of the existing products are and can help us
to develop a better retarder. Figure 6.3.5.2 tells us about respondents usage
frequency of retarder, and most of the respondents are professionals in this

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field. In Figure 6.3.5.3, we gathered a piece of information about the existing

product which is how their company gets the product. The result shows that
existing products are mostly purchased from other partnership company.
From the concept testing, we could confidently conclude that there are
still rooms for improvements and innovations for the market, ergo it is
absolutely plausible for us to occupy a spot in the market.
From the result, we have the choice to optimize the market that
responded positively in regards to welcoming a new and improved retarder or
to persuade those that now uses their own retarder brand.

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6.4 Product Description

We combined our specification with our final product concept to define the
product description. Based on five criteria of our concept product which are
temperature range, control over thickening time and hardening time, ratio of change
of consistency and change of temperature, price, and compatibility to cement types
and additives we chose a liquid retarder with calcium complexation retardation
mechanism as our product concept. The work principle of this concept is calcium
complexation prevents the formation of portlandite in cement and prevents the
nucleation of CSH. Phosphates are believed to retard cement in this way.

6.4.1

Product Position
In order to compare our product with another existing retarder, we use

Conceptual Mapping method. Conceptual Mapping is a chart that describe the

position of our concept based on the criteria that we used in screening and
scoring process. On the conceptual mapping, we can compare our product
design to another existing product by seeing its position in the map. We use
existing products which is used in our benchmark in the first assignment.
Those are Diacel HTR-100 and CH210L. Figure 3.3 shows the result of our
conceptual mapping.

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Chart Title
Diacel HTR-100

CH210L

Own Product

Temperature Range
5

Compatibility with Cement Types and Additives

Control Over Thickening and Hardening Time

0

Price

Ratio of Change of Consistency and Change of Temperature

Figure 6.4.1 Conceptual Map

The rating is given from 1 to 5. Rating 5 is given for the best, while
rating 1 is for the worst.
Temperature Range
Most of our consumers felt that current retarder are not able to withstand
the extreme heat of some oil well in Indonesia, thus making this an important
factor in mapping out our own product. Even though existing retarders are not
perfect Halliburtons Diacel HTR-100 works in most high temperature well
thus making it earn the score of 4. While CH210L only scored a 1 on the scale
due to its limited usage (i.e. only for well with temperature below 90 degrees
celcius). Our product scored a 5 in this aspect due to its ability to withstand
High Pressure High Temperature wells.

Control Over Thickening and Hardening Time

This is the main function of a retarder so usually companies invest on
making sure that this aspect hits the mark. Unfortunately, CH210L only scored
a 2 on this aspect due to its weakest ability to extend the thickening time,
although it is still satisfactory according to some reviews, and its slow ability to
accelerate the compressive strength development. In comparison, Diacel HTR-

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100 scored a 4 due to its balanced ability to control both of these times. Our
own product on the other hand scored a 5 due to the strong nature of our base
component that extends the thickening time significantly according to the
consumers need but hasten the thickening time.
Ratio of Change of Consistency and Change of Temperature
We need an insensitive retarder when it comes to this one. CH210L once
again scored a 2 due to its sensitivity to temperature change. Diacel HTR-100
on the other hand score a 4 because it was significantly better than CH210L but
didnt score a 5 like our product because it is still in a way sensitive.

Price
Diacel HTR-100 is the most expensive one on the bunch thus scoring a 5,
which is the absolute highest for someone to want to buy a retarder and
CH210L on the other end with the score of 1 due to it being the cheapest
retarder in the market. We realized that our product cant be that cheap and
therefore is not that cheap, ergo scoring a 4.

Compatibility with Cement Types and Additive

Both existing retarders are not compatible with most additives thus not
being able to achieve a perfect score. CH210L scored a 1 again due to its
limited usage in only 2 cement types while as Diacel HTR-100 got a 4 again
due to its compatibility with all cement that is commercially used. The
innovation here is making our retarder compatible with other necessary
additive and for doing that, it grants us the score of 5.
Based on the perceptual mapping above, we can conclude that the
advantages of our product concepts are:

A very flexible temperature range, one that encompass the most common
to the hottest well available in Indonesia

Precise control over thickening and hardening time, one that fulfills the
initial function of a retarder but accelerates the compressive strength
development in an unprecedented feat

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Insensitive to temperature change

Reasonably priced for such complete functionality

Can be used with just about anything known and used by mankind today
in the oil refinery industry.

6.4.2

Final Specification of Product Design

The data of concept testing shows that our new concept of oil well

cement retarder product is a retarder in liquid form using the calcium

complexation retardation mechanism. This chosen concept meets the needs of
our consumer. The chosen concept will be joined with our specification in
assignment 1. This concept will lead to our final specification on this product.
We eliminated some specification in assignment 1 and added some new
specifications to adjust to the consumers need and help the manufacturing
process of our product. The final specifications are given in metric below.
Table 6.4.2 Final Specification of Groups Product
Specification

Unit

PERFORMANCE
Temperature range
Concentration
Thickening Time
Concentration of lignosulfonate
Ratio of change of consistency and change of

Score
Own

C
Gallon/sack
Hour
% BWOC

65 232
0.005 0.25
5 24
0.5 0.6

BC / oC

0.3

Hour

12

Liquid phase

y/n

Package Volume

Gallon

55

Price (per Gallon)

US$

18 23

Availability in Indonesia

y/n

Number of steps

dimensionless

Acidity

pH

7.4 7.8

temperature
Hardening time
RETAILING

PERCEPTION

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Percent volatile

LD50

ppm

40,000

Solubility

100

Acute oral toxicity

g/kg

NFPA health hazard

NFPA scale

Compatible with type E-cement

Compatible with type F-cement

y/n

y/n

Compatible with type G-cement

y/n

Compatible with type H-cement

y/n

Compatible with type J-cement

y/n

Compatibility to other additives

y/n

NFPA Fire hazard

NFPA scale

mg/m3

PROPERTIES

REGULATION
Concentration of Calcium sulfate hemihydrate less
Concentration of Sodium hydroxide

mg/m

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