Deviated Wellbore Cementing: Part 2—Solutions R.J. Crook, SPE, Halliburton Services S.R, Keller, SPE, Exxon Production Research Co. M.A. Wilgon, Halliburton Services Center Summary. Field experience suggests and full-scale laboratory test results confirm that mud displacement in high-angle wellbores can be complicated by a channel of hard-to-displace mud forming on the low side of the wellbore. This channel is caused by solids settling while the drilling fluid is circulating. Experimental test results obtained with full-scale, permeable and impermeable deviated wellbores indicate that this channel of solids can be prevented with proper rheological control of the drilling fluid. Results reported also demonstrate the effect of casing centralizers, pipe movement, and preflushes on the removal of this low-side channel of solids. Based on the laboratory results, displacement guidelines to improve deviated-wellbore cementing by climinating the low-side solids-setling channel are presented, Introduction As part of a continuing investigation of factors affecting drilling-Aluid displacement during primary cementing, a study has been carried out to identify factors to improve deviated-wellbore cementing. A previous study identified several potential problems associated with cementing high- angle wells, including the occurrence of mud channels on the low side of the annulus and water channels on the high side of the annulus. The most serious potential problem affecting deviated-well cementing appeared to be the depo- sition of solids caused by setting of weighting agents or drilled cuttings from the drilling mud. The test data from the previous study suggested thatthe rheology of the mud, specifically the yield point, determined whether solids ‘would setle. Setling from the drilling mud creates a con- tinuous uncemented channel along the low side of the wellbore. Occurrences of continuous mud channels in the annu- lus can prevent mud displacement and defeat the purpose of cementing—i.., to surround the casing with a complete sheath of cement that prevents fluid flow in the annulus. Failure to surround and to protect the casing through in- ‘complete mud displacement from the downhole environ- ment can lead to such problems as annular migration of well fluids, casing corrosion or collapse, loss of well con trol, and high remedial cementing costs. Previous studies in vertical wellbores have found that the highest mud-displacement efficiency could be attained by lowering the yield point of the mud and maximizing pumping rates. The initial study of deviated-well cementing! suggested, however, that high-yield-point ‘muds were required to prevent solids settling and that low- yyield-point muds deposited solids to such an extent that ‘complete mud displacement could not be achieved, ‘The purposes of this study were to investigate further (1) the relationship of drilling-mud yield point and the deposition of drilling mud solids and (2) methods known ony 67 Sect of Porn Enprse Journal of Petroleum Technology, Avgust 1957 10 improve drilling-mud-displacement efficiency in ver- tical wellbores and to examine their effectiveness for deviated-well conditions, Factors known to influence displacement in vertical wellbores have previously been identified and studied in 1 simulated vertical wellbore on a large-scale testing ap- paratus.5 These factors were examined on a large-scale eviated-wellbore model at various deviation angles. Fac~ tors studied included use of preflushes, pipe centralizers, and pipe movement. Findings reported here suggest methods of preventing the formation of mud channels by solids setling from drilling mud, and if mud channeling. does occur, methods of displacing the channel of settled ‘mud solids from the low side of the wellbore. Experimental Apparatus and Procedure ‘The apparatus used in conducting this research was de- signed and operated to simulate as closely as possible the actual conditions experienced during the cementing of an oil well. Fig. 1 shows the wellhead assembly used to cir~ culate the various fluids under deviated conditions. ‘A schematic ofthe simulated well is shown in Fig. 2. Each test section consists of manmade, permeable, con- solidated sands enclosed in a perforated pipe 15 ft [4.6 rm] long with a 6%-in. (16.5-cm] ID. During this investi- ‘zation, two downhole conditions were simulated: (1) permeable formation, thus allowing for filter-cake build ‘up, and (2) completely impermeable formation. For the impermeable tests, a 6%-in. {16.5-cm] -ID steel casing ‘was used as the test section. A S-in, [12.7-cm] -OD casing, was installed inside the test section. The casing was cen- alized at the top and bottom of the test section. ‘The test section was lowered into the filtrate jacket and allowed to become saturated with water. Fluid loss to the permeable formation was monitored through an outlet fixed on the filtrate jacket. The filtrate jacket was enclosed in a hot-water heating Jacket. The temperature forthe circulating period was held ‘at [80°F [82°C], and for the mud static and cement curing 61Fig. 1—Schematic of reciprocation/rotation and wellhead assembly. | Fig. 2—Schematic of simulated well and heating jacket. periods, 200°F [93°C]. These temperatures were chosen to simulate as realistically as possible the conditions en- countered in many well cementing operations. Drilling muds used were water-based, laboratory prepared muds with a density of about 12 Ibm/gal [1438 kg/m?]. All properties of the drilling mud (fluid loss, density, and rheology) were measured for each test at 72°F [22°C] Cement slurries used were designed to have a density ‘of about 16.8 Ibm/gal [2013 kg/m*)]. During the displace- ment tests, the cement slurry was mixed with a recirculating-type mixer and was held in a batch holding tank before it was pumped downhole. During this holding period, the theology of the slurry was measured at tem= Perature with a Fann Model 35™ viscometer. The slurry yield point typically ranged from 20 to 60 Ib/100 f [9.6 to 2.9 Pa]. Haut and Crook® determined previously that ‘cement rheology does not play a significant role in the displacement process. Displacement pumping rates were standardized at 4 bbl/min [0.01 m°/s} to eliminate the variable of different pumping rates, This corresponded to a mean annular velocity of about 4 fi/sec [1.2 mis} At this velocity, the cement slurry was in laminar flow, which is believed to simulate field conditions in which the majority of cement jobs are pumped. Ina typical well, the mud is circulated during drilling, circulation is stopped while the well is logged and casing is run, then mud is circulated again just before cementing. ‘The tests were designed to simulate these flow and static periods. ‘The displacement test was begun by circulating the drill- ing fluid at 3 bbl/min [0.008 m/s] for 1 hour at 180°F 962 3—Definition of casing standoff and displacement ef- [82°C] and recording the amount of filtrate loss through the permeable formation. Temperature of the heating water was then raised to 200°F [93°C] and the mud was left static for 24 hours. A differential pressure of 100 psi [689 kPa] was maintained to allow for filtrate loss and thus the buildup of filter cake along the permeable for- ‘mation. The amount of filtrate was also recorded for this period Alter the mud static period, the mud was once again circulated at 3 bbl/min (0.008 m/s] for 1 hour at 180°F [82°C], and the filtrate loss for this period was also recorded, ‘The drilling mud was then displaced with a predeter- ‘mined volume of spacer and cement slurry pumped at 4 bbl/min [0.01 m/s} at the circulating temperature of 180°F [82°C], Filtrate loss was also measured during this displacement period. The volume of cement ranged from 10 to 30 bbl [1.6 to 4.8 m>]. After the cement had been pumped into place, the tem- perature was raised to 200°F [93°C], and the cement was cured for 24 hours. The test sample was then cooled and disassembled. The sample was cut into wafers, thus al- lowing the average casing standoff and average mud- displacement efficiency (equal to cemented annular area divided by total annular area) as defined in Fig. 3 10 be ‘measured. Because the casing was centered atthe top and the bottom, the average casing standoff was close to one forall tests. The displacement efficiency was determined for both the top half and bottom half of the annular area, Variation of the Mud Yield Point A series of mud-yield-point tests was conducted to deter- ‘mine the effect thatthe rheology of the drilling mud had on the displacement efficiency achievable in an imperme- able annulus when mud was displaced with only cement. Results of this testing are arranged in Table 1 according to increasing mud yield points at 85 and 60° [1.5- and I-rad] deviation from vertical Ten of these tests were conducted at an 85° [1.5-rad] deviation. In the first seven tests, a continuous solids chan- nel occurred along the bottom side of the annulus. How ever, when the mud yield point was high enough, the channel no longer appeared. This occurred in Tests 8 through 10 where the yield point was 228 Ibf/100 ft at 72°F [213.4 Pa at 22°C] ‘The same trend can be seen in the five tests conducted at 460? [1-rad] deviation from vertical. In Test 11, a eon- Joarna of Petroleum Technology, August 1987‘TABLE 1—VARIATION OF MUD YIELD POINT UNDER DEVIATED CONDITIONS 16.84omigal Comont Dring Fluid Displacement Deviation at 160°F" a1 72°F" Efficiency ‘Angie, Volume PV Yio Pom PV Vield Poigt %) _ ‘Test (degrees) (bb). (ep) (bNT00N") (ep) (ot00?) Overall Top Halt Bato Hall 7 8S 0 at 2 4 4 65 2 2 8 1020 20 31 6 51 4 5 38 0 8 2 3t 8 80 50 4 8 2m 2 2 eo 2 100 79 5 85 2 a7 3 8 8 100 58 6 8 118 3 5 8 80 9 8 7 8 214 2 2 8 84 99 7 8 8 2 35 a 8 99 97 9 9 85 2% 2 S41 88 100 100 100 10 85 10 20 28 7% aT 9 99 99 n 60 2 25 3 a 8 3 94 70 2 6 2 83 37 a 7 9% 100 90 3 8 2 18 37 et 2 100100, 98 4 6 2 55 2 428 98100 97 1% 8 2 0 2 2 100 100 100 ‘upacanent tons ain = ebrige une maa tinuous bottomside channel occurred. Again, however, as the yield point increased sufficiently (Tests 13 through 15), this channel no longer appeared. The minimum yield- point value to prevent this channel at 60° [-rad] deviation Was about 20 Ibf/100 R? at 72°F (9.6 Pa at 22°C] Results ofthese tests have led to 1wo major conclusi (1) there appears to be a threshold value of the mud yield point below which a continuous solids channel will occur; and (2) the yield-point value required to prevent this chan nel from forming decreases with a decrease in deviation angle. Effect of Preflushes A series of preflush-fluid tests was performed to determine the effect that preflushes, either thin or viscous, have on the displacement efficiency of the drilling fluid ina well- bore deviated 80° [1.4 rad] from vertical. preflush volume ‘was also investigated with this testing. Tests were per- formed under both impermeable and permeable con: tions. ‘The first area of investigation involved determining ‘whether the preflushes would remove the solids channel] caused by a mud designed so that settling would occur during periods of circulation. These tests were performed under impermeable conditions. Tests 16, 23, and 24 used no preflush; Tests 17 through 19 used water; Tests 20 and 21 used a viscous chemical preflush (A); and Test 22 used a nonviscous chemical preflush (B). Tests 16, 23, ‘and 24 were run as control tests because of a slight varia~ tion in the mud formulation used for the preflush series. ‘These tests confirmed the occurrence of the low-side mud channel for low mud yield point that was observed in the vyield-point series. Results obtained for the tests using a ppreflush, listed in Table 2, indicate that neither the thick preflush (A) nor the thin preflushes (water and B) were able to remove the solids channel completely. However, the results of Test 19 suggest that when a settling mud is used, pumping large amounts of thin preflushes will increase the percentage of mud removed. “The second area of investigation involved determining, ‘whether preflushes would improve the displacement ef- ficiency of a nonsettling drilling mud under permeable conditions. Five tests were performed: Test 25 used no preflush; Tests 26 and 27 used water; and Tests 28 and ‘TABLE 2—EFFECT OF PREFLUSHES ON DISPLACEMENT OF A SETTLING MUD UNDER 60° DEVIATED CONDITIONS | Journal of Petroleum Technology, Angust 1987 16.81omigal Coment* Dring Fuis Displacement a1 160°F Preftush” aT eficiency" Voume PV vied Poigt Voume PV Yield Point (99) Test “(bb (e6) (NTO) Type _(Bb)_ (ep) (Ot100n?) | Overall TopHaif Botiom Hall % 29 — ~~ 4 8 95 20 a 34 Water 10k 3 8 8 38 1% OB 1% Water 045 3 84 7 6 we OS 2 Water 48 8 95 8 ry 2 2? 56 aD 080 2 7% 3 4 228 3 ar a + 85 9 n 2 2 OB 2 Bo 4 8t 2 7 3 % 3 2B 20 - = » 5 7 at Pa 2 oe 3 = 05 8 8 Ea 9 83 968