Deepwater Cementing

Offshore Well Planning &
Construction Process
Cementing Deepwater Wells

1
COPYRIGHT © 2001, All Rights Reserved
Presentation Outline
• Specific Deepwater Challenges
• Deepwater Cementing Technology
– CemCRETE slurries
– CemSTONE slurries
– DeepCEM LT additives (cold water)
– UniSLURRY additives
– InstanSeal (lost circulation)
– DeepSea EXPRES subsea tool
– CemCADE software
• Conclusion / Discussion
2
What is Different in
Deepwater?
Expensive Rig Time
Long column of sea water
Cold temperatures
Viscosity, setting, gas hydrates
Shallow Water/Gas Flow Hazards
High hydrostatic pressures
Low frac gradients / Lost Circulation
Narrow margins between pore and frac
pressures
3
Shallow Water Flow Hazard
Turbidite Sand
• Safety and environmental concerns

• Erosion of sea floor and wellbore
• Jeopardizes template stability
• Reduces structural support of conductor
• Reduces integrity of BOP’s and riser
• Leads to potential casing buckling
• Well abandonment problems
4
Gas Hydrates
Formation of Hydrates depends on:

Temperature and Pressure
Composition or type of gas
Composition of drilling fluids
One unit of hydrate can give 170 units of gas
Solid ice-like compounds of natural

HAZARDS :
gas and water, formed in high-pressure • Plugging of BOP choke and kill lines
and low temperature conditions • Dehydration of drilling fluids and/or
cement
• Overloading of Gas Separation
Equipment
5
Deepwater Cementing Requirements
• Exploration Wells • Appraisal and Development
– Temperature Wells
– Density – Same, plus
– Hazards – Cement systems withstanding
stresses due to completion or
production/injection
operations
– Long term zonal isolation
• Producing/injecting hot fluids
• Eliminating (too costly) well
intervention during life of well
– Basis for cost-effective future
6 well abandonment
Deepwater Cement Challenges
• General context: • Objectives:
– Narrow Pore - Frac margin – Achieve short WOC time
– Complex Geometries – Provide a competent
hydraulic seal for all casings
– Low bottom hole temperature
– Provide adequate structural
– Very low temperature at top
support to the first casing
of cement column
– Provide Long-Term
– Geological hazards
Durability for the Life of the
• Shallow gas (hydrates or Well
free gas)
– Even with low density cement
• Shallow water flow
systems
– Even at low temperatures
7
Deepwater Cementing “Solutions with Depth”
Job Simulation Software

DeepCEM Slurry Systems
DeepCEM
Technology
Pumping Equipment
Surface & Downhole Equipment
8
CemCRETE
Advanced Cement
Technology
The concrete science of zonal isolation
9
For oil well cement design,
you need water
With more water,
you have:
• lower density
• lower viscosity
but you also have:
• longer working time
• lower compressive
strength
• higher permeability
Good slurry properties ≠ Good mechanical properties
10
Conventional CemCRETE
cement slurries slurries
Cement particles must be CemCRETE uses particle size

surrounded by water to distribution to maximize solid and
flow as a slurry – Sufficient liquid content : less water is
water must first be added wasted in the void.
to fill the void between the Slurry properties and mechanical
cement grains
properties are optimized
11
Advantages of
CemCRETE technology
• Density is disconnected from rheology
• Lower permeability
• Compressive strengths higher and faster to
achieve
• Improved mechanical durability
• Improved injectability for remediation
• Improved field operations
12
CemCRETE
Advanced Cement Technology
CemCRETE
• Production cements are lighter
• High-density cements have
LiteCRETE greater versatility
• Cold-water cements set faster
DensCRETE
• Remedial cements inject better
DeepCRETE
At any slurry density
SqueezeCRETE
13
LiteCRETE
• Density: 8 - 13 ppg
• Salinity: Fresh Water to 37% salt
• Temperature: 80º - 450ºF
• Pressure: surface to 8000 psi
LiteCRETE slurries can re-draw your casing program.

– low density, high strength slurries replace two-stage
cementing with a single-stage.
– lightweight slurries with low permeability mean deeper
casing setting points.
– longer cement columns can eliminate intermediate liners.
14
LiteCRETE can replace foamed cement
3500 Foamed
cement
Compressive strength (psi)
3000 3
Log Permeability (mD)

LiteCRETE Foamed
Cement
2
2500 1
LiteCRETE
2000 0
-1
1500 -2
1000 -3
-4
500 8 9 10 11 12 13
Density (lbm/gal)
0
8 9 10 11 12 13
Density (lbm/gal)
15
LiteCRETE
LiteCRETE evaluates better than conventional lightweight
6
5
Default
liquid / solid
4
Z (MRayl) cutoff
3
2
1
0
Water Lightweight LITECRETE Neat G
and performs better too …

•Abu Dhabi eliminates stage-tool failures, annular pressures and top-
out jobs (SPE 53283)
•Norway eliminates lost returns and TOC logs on Draugen
•Indonesia replaces three systems with one LiteCRETE etc..
276 LiteCRETE jobs worldwide (1999)
16
DensCRETE
• Density: 17 - 28 ppg
• Salinity: Fresh Water to 37% salt
• Temperature: 100º - 450º
DensCRETE slurries can cement HPHT wells with less risk AND less
cost
– low viscosity lowers the risk of losses during cementing
– higher placement rates allow shorter WOC times and lower rig
cost
– density increase on-location lowers risk and cost of last minute
changes
DensCRETE slurries can also be used for Kick-off Plugs in heavy mud
17 220 DensCRETE jobs worldwide (1999)
DeepCRETE
• Density: 12 – 13.5 ppg
• Salinity: Fresh water to 37% salt
• Temperature: 40º - 80º
DeepCRETE systems isolate deepwater zones and allow drilling to

resume sooner.
– Technology for low density – low temperature conditions.
– low densities maintain returns.
– rapid strength development minimizes WOC time.
– New formulation with DeepCEM LT liquid additives
– CemCADE temperature modeling helps optimize slurry properties.
18
DeepCRETE gets high compressive
strength, quickly, at low
temperatures
5000
Compressive Strength (psi)
4500
4000
3500
3000
2500 DeepCRETE at
40F
2000 DeepCRETE at
1500
1000
500
0
0 10 20 30 40 50 60
Time (hours)
19
DeepCRETE out-performs neat
Class G
Strength development (psi) vs Time (hours)
Slurries of equivalent thickening times
6000
4000
BHP = 3992 psi
DeepCRETE 12.5 ppg
4000
DeepCRETE 12.5 ppg
2000
Class G 15.8 ppg
2000
Class G extended 12.5 ppg
Class G 15.8 ppg
0
0
0.0 25.0 50.0 0.0 15.0 30.0 45.0
20 oC (68 oF)
39 oC (102 oF)
Even larger difference at 10 oC (50 oF)
20
Use of DeepCRETE slurries
• Any conductor, surface,
or intermediate casing at
BHCT < 40 oC when
– low density is necessary
• low ECD / frac gradient
– fast setting is mandatory
• shallow flow, shallow gas
(hydrates or free gas)
• time is key
– Drill-out in 4 hours with
dual derricks
21
DeepCRETE experience
West Africa
Top jobs eliminated, WOC times reduced (12 hrs) with DeepCRETE
Turkey
DeepCRETE plus GasBLOK LT used to cement entire exploration
well
Angola/Nigeria
Replaced foamed cement with DeepCRETE
Norway
DeepCRETE plus GasBLOK LT stopped severe shallow gas
problems
Brazil
DeepCRETE plus GasBLOK LT stopped shallow water flow
22
SqueezeCRETE
SqueezeCRETE repairs well problems when cements won’t

: – Fractures
– Casing leaks – Permeable matrices
– Liner tops – Squeezing a gravel pack
– Channels behind casing
– Old perforations
– Water zones
23
SqueezeCRETE
Narrow slot penetration tests
Well dispersed Micro-cement
Conventional
300 microcement
SqueezeCRETE
250
Penetration (mm)
200
150
SqueezeCRETE technology
100 Injection points
50
0
160 320
Gap width (microns)

CemCRETE worldwide experience
308
145
238
1999 - 691 jobs

25
CemSTONE
Advanced Cement
Technology
CemSTONE Zonal isolation that lasts
Tolerance to pressure and

FlexSTONE temperature changes
DuraSTONE Durable for rugged well bore
conditions
26
Failure Mechanisms Leading to
Zonal Isolation Problems
Tensile cracks due to:
• wellbore pressure increase
• wellbore temperature increase P,T
• shrinkage
Debonding @ cement/rock interface due to:

• formation stress decrease
• wellbore pressure decrease
• hydraulic fracturing
• shrinkage
Debonding @ steel/cement interface due to:

• wellbore pressure decrease
• temperature decrease
• casing movement
• cement expansion
27
Prevention Methods
New cement systems with rock

flexibility that can be adapted
cement
to formation properties. st
Low compressibility and r
sr
shrinkage. sr
Controlled expansion to
minimize debonding and
creation of microannuli.
28
Set-Cement Mechanical Properties
Young modulus 1600
flexibility -1 1400
~ Young modulus ~ Modulus of rupture
1200
Modulus of
Force (N)
rupture 1000
800
tensile strength ~ Toughness
600
Energy at rupture 400 ~ Energy at rupture
energy required to 200
create a crack 0
0 0.2 0.4
Displacement (mm)
Toughness F
energy required to
propagate a crack
Tensile crack
29
F
Isolation should be stronger or
more flexible than the
surrounding rock
t/eisolation > t/eformation
More
Strength
6
t - tensile strength (MPa)
5 To isolate
4 “softer” To isolate
formations “harder”
3
formations
2
0
0 More 2000 4000 6000 8000 10000
Flexible e - Young's modulus (MPa)
30
FlexSTONE
FlexSTONE systems can be “tuned” in order to withstand well stresses
due to temperature and pressure changes, Hydraulic fracturing, or
Reservoir changes
100 Permeability (micD)

Young's Modulus (GPa)
Compressive Strength (MPa)
10
1
Less flexible Very flexible
31
FlexSTONE
range of application
Density range: 12 - 18 ppg

Temperature: 50 - 350F
Young’s modulus: down to
1000 Mpa
Expansion: up to 2%
32
Stress Analyzer Model for
Predicting Zonal Isolation Failure
• Inputs
– Wellbore geometry
– Cement, formation and casing
mechanical properties
– Expected temperature and
pressure changes during life of
the well
• Outputs
– Failure mechanism description
– Stresses in the cement matrix
– Boundary conditions
33
DuraSTONE
A tough cement alternative
m = 8.5
kg
Neat cement DuraSTONE

after 5 blows after 100 blows
Blow of 50 N.m
34
DuraSTONE
DuraSTONE slurries combine engineered-particle-size-distribution technology,
which provides higher compressive and tensile strength than Portland cements,
with steel-microribbon technology that creates a secondary matrix that reinforces
the set cement.
5000
4500
4000
3500
Load (newtons)
3000
2500
2000
Transaxial load
1500
1000
500 Conventional cement

0
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
Displacement (mm)
35
DuraSTONE
Density Range: 9 - 25
ppg
Temperature: 50 - 450F
Flexural strength:
2X conventional cement
Applications :
• Multi-lateral junctions
• Whipstock Plugs
Conventional DuraSTONE
• Casing shoe in Cement
deviated wells
36
Criteria for long term isolation
• Prevent cement sheath failure:
– strength/elasticity criterion
– low compressibility
– post failure behavior/resistance to vibration
• Relatively good CS for casing support
• Low permeability, resistance to chemical attack
• Prevent debonding:
– non shrinking cement, criterion based on the
required amount of expansion
– good elasticity compared to that of the rock
37
DeepCEM LT: Simple System for
Cold Environments Offshore
Any cement D500

or blend GasBLOK LT
DeepCEM LT
DeepCEM LT DeepCEM LT
Set Enhancer Dispersant
(XE934) (XE916)
Two components liquid additives system:

XE 916 Non Retarding Dispersant
XE 934 Cement Set Enhancer
38
DeepCEM LT
ÆSlurries for low temperature,

unconsolidated and unstable
environments (potential shallow
gas/water flows)
z 11.5 -16.4 ppg: neat cements + DeepCEM LT
liquid additives (extended with conventional
additives or foamed)
z 8.0 - 13.5 ppg: DeepCRETE blends +
DeepCEM LT liquid additives
z< 6.0 - 8.0 ppg: low-density DeepCRETE
blends + DeepCEM LT liquid additives + N2 (*)
(*) coming next !
39
DeepCEM LT
Features Benefits
No need for special blends Effective shallow water and gas
(Gypsum/C RAS, etc) flow prevention
Extremely rapid gel strength Simplified and cost-effective
development wellsite logistics
Controlled Right-angle setting Fast compressive strength
in low-temperature development, allowing casing
environments release or unlatching less than 1
hour after slurry placement
Liquid system, allowing
accurate metering Compatible with all cement
types, CemCRETE blends and
Minimized sensitivity to minor
all other SLB additives
temperature variations
Safe and robust system, not
Can be mixed at any density
sensitive to minor variations in
and foamed as required
well conditions and additive
concentration
40
DeepCEM LT : Gel Strength Development
LeHigh Class H Cement
0.5 gps D500
XE934 at 0, 0.05, 0.1, 0.15, 0.2 and 0.4 gps
0.06 gps XE916
2000 density = 16.4 ppg
T = 65°F P = 400 psi
1750
Gel strength (Lbf/100ft )
2
1500
1250
1000
750
500
250
0
0 100 200 300 400
Time (minutes)
41
DeepCEM LT : Gel Strength Development
1750
LeHigh Class H Cement
1500
Gel strength (Lbf/100ft )
0.5 gps D500

2
0.06 gps XE916

1250
0.4 gps XE934
RAS-C System
1000 density = 16.4 ppg
0.2 gps D145A
750 0.3 gps D500
0.1 gps D081
500
0.1 gps D139
250 0.1 gps F104
density = 15.8 ppg
0
0 50 100 150
Time (minutes)
42
DeepCRETE @ 12.5 ppg with
DeepCEM LT additives
20 5000 100 5000
18 4500 90 4500
16 4000 80 4000
Compressive Strength (psi)
Transit Time (microsec/in)
14 3500 70 3500
Temperature (°F)
Pressure (psi)
12 3000 60 3000
10 2500 50 2500
8 2000 40 2000
6 1500 30 1500
4 1000 20 1000
2 500 10 500
0 0 0 0
0:00 8:10 16:20 24:30 32:40 40:50 49:00
Time (HH:MM)
43
DeepCEM LT
Effects of DeepCEM LT Set Enhancer XE 934 on

Thickening time and Compressive Strength
Density (lb/gal) 15.6
Cement Capitol Class A
D500 (gal/sk) 0.5
XE916 (gal/sk) 0.1
XE934 (gal/sk) 0 0.1 0.2 0.4
Thickening Time at 65ºF and 1500 psi (hr:min) 8:31 5:03 4:15 3:58
UCA at 55ºF and 1500 psi
Time 50 psi (hr:min) 13:37 10:00 7:12 5:30
Time 500 psi (hr:min) 22:31 16:21 13:38 10:40
Compressive strength at 24 hrs (psi) 661 1170 1333 1318
44
UniFLAC Fluid Loss Additive
Fluid Loss Control vs Temperature
0.7 Features:
FLAC Concentration
0.6 100 ml API

50 ml API
UniFLAC-L / UniFLAC-S
0.5
0.4 Liquid and Solid Versions
0.3 Temp Range 50 - 500 Deg F
0.2
0.1 Benefits:
0 Simplified Slurry Designs
0 100 200 300 400
Temperature (°F) Improved Slurry Properties
Cement Brand Sensitivity Inventory Control Simplified
120
API Fluid Loss
100 Dyck. North

80 Lone Star H
Dyck. Gulf
60
Saudi
40
20
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7
FLAC Conc’n
45
UniSET Set Control Additive
Hydration rate
• UniSET - 80ºF - 450ºF
– UniSET-LT / UniSET-HT UniSET
No retarder
– Controls dormant period Lignosulfanate
– Linear response to temperature time
– Does not effect speed of Dormant period
hydration
• Long TT with rapid CS 5000
CS (psi)
development
– Insensitive to small variations in
temperature or concentration 2500
• Improved performance on long

liners time (hr)
0
0 10 20 30
46
InstanSeal in Deepwater
• A unique cure for Lost Circulation

Problems
• Rapid and adjustable gelling time
• Significant rig time savings (pumped
through drill bit)
• No Temperature dependency for
activation mechanism
• More than 100 InstanSeal jobs pumped
worldwide
47
Instanseal: How does it work?
• Water-in-oil emulsion prepared in advance and stable until
pumped.
• Polymer in the water phase and cross-linker in the oil phase.
• Upon intense shear (pressure drop of 3.5 MPa or 500 psi) the
cross linking agent contacts the polymer and starts the gelling
reaction
• Adjustable set time by changing the pill composition.
Before After
Ty (lb/100 ft2) 61 73
PV (cp) 13 16
6 rpm 41 47 ∆P = 35 bar
3 rpm 38 44
Rheology before and after shear
Water Phase containing high concentration of polymer
Oil phase
Cross-linker particle
48
InstanSeal - Setting Time
What is the set time?
1.50 31325
Setting
Gel strength (10 4 Pa)
Gel strength (lbf/100ft 2 )

1.20 25060
Initial Final
0.90 18795
0.60 12530
0.30 6265
0.00
0 2 4 6 8 10 12 14 16 18 20
Time (minutes)
49
DeepSea EXPRES
Surface Dart Launcher
Subsea Tool
50
DeepSea EXPRES Skid
Power Pack Storage Box
Plug Baskets
Plug Loading Tool
Surface
Dart Launcher
51
DeepSea EXPRES Benefits/Features
Improved Job Quality
• No fluid contamination
Darts wipe and provide positive fluid separation in drill pipe
• Better cement placement
Uninterrupted pumping schedule improves mud removal
Mud circulation and displacement through top drive
Remote dart release takes seconds
Casing can be rotated and reciprocated during the job
• No micro-annulus
Casing pressure test can be combined with bump
High pressure dart launcher
52
DeepSea EXPRES Benefits/Features
Enhanced Reliability
– Simple plug design
– Provides reliable bump
– Fluids are not pumped through inside of plugs
– No latching mechanism required for sealing
– Plugs do not contact casing wall during rig up
– Surface pressure = positive indication of plug release
– Plugs qualified to be released at up to 20 bpm
Reduced Rig Time
– Remote controlled dart release takes seconds
– PDC compatible plug materials
– Casing pressure test can be combined with bump
– Mud circulation and displacement through top drive
– Casing running tool activated without removing line
53
New Cementing Unit (CPS-764)
Features
• Full redundancy of all operations
• HP pumping services of up to
1,600 HHP
• Simultaneous mixing and down
hole pumping
Components
• Slurry King Mixing System complete with DCS
• Non-radioactive Densitometer
• Stainless steel displacement tanks
• 2 x 1,150 HP air cooled DC electric motors

CemCADE Job Simulation
Software
• Over 15 years of Field Proven Use

• Physics Continually Updated to Include the
Latest Cement Technology
• Job Optimization Package for Designing,
Executing and Evaluating of Cementing
Operations
• Runs on Laptop
• Available at Rig Site
55
Deepwater temperatures
Main Sea Level 0.5 knots

T
~ 0.2 knots ~ 40 oF
Mud Line
56
Temperature Effects on Fluids
• Drilling Fluids:
– Rheology
– ECD control - lost circulation, water flow
– Gelation - swab/surge
– Hole cleaning in riser with gumbo clays
• Cementing Fluids:
– Long thickening times
• Cement hydration follows Arrhenius’law
– Slow compressive strength development.
57 – Temperature prediction - API tables not applicable
CemCADE Temperature
Simulator
Overcomes Limitations of API Schedules
Temperature Prediction Linked to Cementing
Quantify Variable Influences
Adjust Design to Well Conditions
Minimize WOC
Eliminate Premature Set of Cement
Better Evaluation of Compressive Strength at TOC
Proper Additive Selection
58
Wellbore/Sea Heat Exchange
0
• Heat exchange between the fluid -100

0 5 10 15 20 25
annulus & sea is dependent on: -200
-300
– Riser thermal conductivity -400
-500
(insulation) -600
-700
– Sea current velocity -800
-900
– Riser thickness -1000
-1100
– Sea temperature profile -1200
-1300
– Riser geometry
Example of sea water temperature profile
from West Africa
59
CemCADE Temperature Modeling
Treturn Tinjection
Sea Ttemperature Profile
Temperature
drop in drill pipe
Temperature
drop in annulus
Tannulus Tcasing
Geothermal Profile
60
Temperature JIP Project
Objectives • Participating companies
• Collect several sets of – Unocal - Indonesia
circulating temperature – Chevron - Angola
• Validate CemCADE – Petrobras - Brazil
simulator to deep water – JNOC – Japan
conditions – Texaco, Amerada Hess -
GOM
Results
• Very good agreement
Paper SPE 71364
61
CemCADE Temperature Simulation
65
Datatrace Gauge Temperature

60 Simulated Temperature 600 gal/min
Datatrace Temperature (oF)
55 400 gal/min
50
200 gal/min
45
40
0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00 45.00 50.00
Time (min)
62
Deepwater Cementing Summary
• Drilling Efficiency • Continuous research

– Validated temperature • Local field experience
simulator and capabilities
– Fast-setting low density • Worldwide Field
cements
Support Organization
– Shallow flows
• Cope with particular
– Lost circulation
deep water cementing
– Reliable subsea release
plugs
conditions
– meeting cementing
• Production Effectiveness objectives whatever the
– DeepCEM hazards
63
DeepCEM Technology
ACT CemCADE
(CemCRETE, Software
CemSTONE)
DeepCEM
Technology
DeepCEM LT DeepSea
Liquid EXPRES
Additives head
Solutions with Depth
64
Any Question ?
65

Deepwater Cementing

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Deepwater Cementing

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Droits d'auteur :

Formats disponibles

Offshore Well Planning &

Cementing Deepwater Wells

• Safety and environmental concerns

Formation of Hydrates depends on:

One unit of hydrate can give 170 units of gas

Solid ice-like compounds of natural

Job Simulation Software

The concrete science of zonal isolation

Cement particles must be CemCRETE uses particle size

LiteCRETE slurries can re-draw your casing program.

Log Permeability (mD)

and performs better too …

DeepCRETE systems isolate deepwater zones and allow drilling to

BHP = 3992 psi

DeepCRETE 12.5 ppg

Class G 15.8 ppg

0.0 25.0 50.0 0.0 15.0 30.0 45.0

SqueezeCRETE repairs well problems when cements won’t

COPYRIGHT © 2001, All Rights Reserved

1999 - 691 jobs

CemSTONE Zonal isolation that lasts

Tolerance to pressure and

Debonding @ cement/rock interface due to:

Debonding @ steel/cement interface due to:

New cement systems with rock

Young modulus 1600

Energy at rupture 400 ~ Energy at rupture

energy required to 200

100 Permeability (micD)

Density range: 12 - 18 ppg

Neat cement DuraSTONE

500 Conventional cement

Any cement D500

Two components liquid additives system:

ÆSlurries for low temperature,

(*) coming next !

0.5 gps D500

0.06 gps XE916

Effects of DeepCEM LT Set Enhancer XE 934 on

0.6 100 ml API

100 Dyck. North

– Does not effect speed of Dormant period

• Improved performance on long

• A unique cure for Lost Circulation

Gel strength (lbf/100ft 2 )

Plug Loading Tool

Improved Job Quality

COPYRIGHT © 2001, All Rights Reserved

• Over 15 years of Field Proven Use

Main Sea Level 0.5 knots

Eliminate Premature Set of Cement

Better Evaluation of Compressive Strength at TOC

Proper Additive Selection

• Heat exchange between the fluid -100

annulus & sea is dependent on: -200

– Riser thermal conductivity -400

– Sea current velocity -800

– Riser thickness -1000

– Sea temperature profile -1200

Datatrace Gauge Temperature

• Drilling Efficiency • Continuous research

Solutions with Depth

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