Innovative Cement Spacer System for Effective Zonal Isolation in Lost Circulation Zones Hector Castellanos, M & D Industries

of Louisiana, Inc.

Innovative Cement Spacer System for Effective Zonal Isolation in Lost Circulation Zones

Abstract
Cementing is a critical operation for the construction of onshore and offshore wells. In recent years, cementing spacer developments have been heavily focused on mud removal and water-wetting properties, but minimal consideration has been placed on the abilities of a spacer system to have effective zonal isolation results in lost circulation zones, highly permeable zones, and shallow water flow potential zones. This study includes a specific description of the origins of an innovative spacer system for effective zonal isolation in the previously mentioned scenarios, laboratory testing, case histories and final conclusions.

Introduction
The main objectives of oilfield cementing include sealing fluid flow paths in the open hole by casing annulus and obtaining excellent zonal isolation. A successful cementing intervention is designed to withstand different operations such as perforating, stimulation, and production. However, lost circulation problems while cementing have caused excessive non-productive time, costly remedial jobs, sustained casing pressure, casing failures, communication between zones, and catastrophic blowouts. Critical success factors of cement spacers in the past have focused on drilling fluid displacement features and waterwetting capabilities. Unfortunately, there has been a lack of emphasis on cementing spacers properties to protect the cement slurries from lost circulation zones and extremely permeable formations. M&D Industries of Louisiana, Inc. has focused on developing a robust spacer formulation that can effectively remove drilling mud, water-wet the formation and casing and form a non-damaging barrier along the surface of the formation to prevent invasion of cement filtrates and preserve the formations normal permeability for optimum production.

Product Development
Ultra Spacer is a patent pending blend of functionalized polymers and bridging agents. Ultra Spacer can be used as cement spacer to effectively remove drilling mud and form a non-damaging membrane, reducing fluid/filtrate invasion. Since the unique seal formed by Ultra Spacer raises the formations fracture pressure, cement can be placed at casing depth with higher equivalent circulating densities (ECDs) without increasing the risk of formation break down. This capability is highly beneficial in wells in which a narrow margin exists between the fracture gradient and pore pressure gradient. In addition, the Ultra Spacer system can effectively remove drilling mud and water-wet the formation and casing. It is important to address the fact that poor mud removal creates a path of uneven flow leading to channeling of cement slurry through the mud. A robust spacer system must always address this issue because the partially dehydrated gelled mud and low-mobility mud provide regions of weakness, allowing the passage of water or gas that can result in poor annular isolation. For this reason, the spacer systems density can be designed from 8.34 -19.0 ppg (1.00-2.28 g/cm3) to make sure that a proper mud, spacer, cement density train is followed. The spacer system must also have excellent thermal stability up to 400 F (204 C).

Innovative Cement Spacer System for Effective Zonal Isolation in Lost Circulation Zones

Laboratory Testing
In order to evaluate the spacer performance, M&D Industries of Louisiana, Inc. conducted a series of laboratory tests, including: spacer compatibilities with different mud systems and cement systems, and unique sealing abilities testing. For the compatibilities between the mud and spacer, the procedures consisted of measuring the rheologies of the base systems at 80F (ambient temperature) and the corresponding circulating temperature. Then, the spacer and mud systems were combined using low shear until a homogenous mixture was achieved. This method determined co-mixture rheologies at same temperatures. The samples were then placed in sample bottles for 4 hours to assure no phase separation as seen in Table 1.

Spacer Compatibilities Testing

The testing protocol included requirements made by operators to assure acceptable performance characteristics of the Ultra Spacer product. Some key issues to address were stability of the spacer at circulating temperatures, compatibility with synthetic mud, and compatibility with cement. The results of one of several test samples are discussed below.

FLU ID M IXT U RE 90% Mud 10% Spacer 75% Mud 15% Spacer 50% Mud 50% Spacer 25% Mud 75% Spacer 10% Mud 90% Spacer 90% Mud 10% Spacer 75% Mud 25% Spacer 50% Mud 50% Spacer 25% Mud 75% Spacer 10% Mud 90% Spacer

T EM PER ATU R E ( F ) 80 80 80 80 80 96 96 96 96 96

4-H O U R S TA B I L I TY TES T Stable Stable Stable Stable Stable Stable Stable Stable Stable Stable

Table 1. Mud Spacer Stability Test

FLU ID M IXT U RE
100% Spacer

TE ST TE MP (F )

300 RP M

200 RP M

100 R PM

60 R PM

30 R PM

6 R PM

3 R PM

10 S EC

10 MIN

30 MIN

80 96

142 110

110 90

80 66

64 54

48 40

24 20

20 18

18

24

26

75% Mud 15% Spacer 50% Mud 50% Spacer 25% Mud 75% Spacer 10% Mud 90% Spacer 90% Mud 10% Spacer 75% Mud

80 80 80 80 96

Stable Stable Stable Stable Stable

Innovative Cement Spacer System for Effective 25% Spacer Zonal Isolation in Lost Circulation Zones 96 Stable
96 96 96 Stable Stable Stable

50% Mud 50% Spacer 25% Mud 75% Spacer

The rheologies of the co-mixtures were then reviewed as seen in Table 2 to ensure there were no unacceptable rheology or gelation results from mixing.
10% Mud 90% Spacer

FLU ID M IXT U RE
100% Spacer

TE ST TE MP (F )

300 RP M

200 RP M

100 R PM

60 R PM

30 R PM

6 R PM

3 R PM

10 SEC

10 MIN

30 MIN

80 96 80 96 80 80 80 80 80 96 96 96 96 96

142 110 90 64 86 118 198 214 148 80 100 170 210 120

110 90 70 46 62 90 158 188 120 56 74 140 180 94

80 66 50 38 40 56 106 130 86 34 46 98 138 68

64 54 36 20 30 42 84 110 70 24 36 78 116 56

48 40 26 16 20 30 62 84 54 16 26 68 92 44

24 20 18 8 12 18 30 46 30 10 16 32 60 22

20 18 12 8 10 14 30 40 22 8 14 30 50 20

18 8

24 20 compatible compatible compatible compatible compatible compatible compatible compatible compatible compatible

26 30

100% Mud 90% Mud 10% Spacer 75% Mud 25% Spacer 50% Mud 50% Spacer 25% Mud 75% Spacer 10% Mud 90% Spacer 90% Mud 10% Spacer 75% Mud 25% Spacer 50% Mud 50% Spacer 25% Mud 75% Spacer 10% Mud 90% Spacer

Table 2. Mud Spacer Compatibilities

Innovative Cement Spacer System for Effective Zonal Isolation in Lost Circulation Zones

The rheologies of the co-mixtures were then reviewed as seen in Table 2 to ensure there were no unacceptable rheology or gelation results from mixing.

FLU ID M IXT U RE
100% Cement

TE ST TE MP (F )

30 0 RP M

200 RP M

100 R PM

60 R PM

30 R PM

6 R PM

3 R PM

10 SEC

10 MIN

30 MIN

80 96 80 96
TE ST TE80 MP (F )

276 226 142 110

300 310 RP M

204 168 110 90

20 0 234 RP M

122 100 80 66
100 R146 PM

84 70 64 54
60 R110 PM

50 42 48 40
30 66 R PM

14 14 24 20
6 24 R PM

8 10 20 18
3 18 R PM

18

24

26

100% Spacer

FLU ID 90% Cement 10% Spacer M IXT U RE

75% Cement 25% Spacer 100% 50% Cement Cement 50% Spacer 25% Cement 75% Spacer 100% 10% Cement Spacer 90% Spacer 90% Cement 90% Cement 10% Spacer 10% Spacer 75% Cement 75% Cement 25% Spacer 25% Spacer 50% Cement 50% Cement 50% Spacer 50% Spacer 25% Cement 25% Cement 75% Spacer 75% Spacer 10% Cement 10% Cement 90% Spacer 90% Spacer 90% Cement 75% Cement 25% Spacer 50% Cement 50% Spacer

10 10 30 S EC compatible MIN MIN

80 80 80 96 80 80 80 96 96 80 96 80 96 80 96 80 96 80 96 96

280 276 220 226 212 142 162 110 292 310 268 280 270 220 200 212 140 162 292

220 204 174 168 170 110 130 90 220 234 208 220 212 174 166 170 110 130 220

148 122 118 100 124 80 94 66 138 146 138 148 150 118 120 124 82 94 138

116 84 94 70 100 64 76 54 98 110 110 116 120 94 100 100 64 76 98

86 50 60 42 80 48 60 40 62 66 78 86 90 60 80 80 50 60 62 78 90

60 14 48 14 52 24 38 20 20 24 44 60 60 48 54 52 30 38 20

58 8 44 10 48 20 34 18 14 18 40 58 58 44 50 48 30 34 14

compatible compatible compatible -

18 compatible 26 24 compatible compatible compatible compatible compatible compatible compatible compatible compatible compatible compatible compatible 48 H O U R compatible 3065 psi compatible compatible 6.0 M r a y l s 48 H O U R 44:34 hrs:min 3065 psi

10% 3. Cement Spacer Compatibilities Table Spacer

SYST E M

268 208 5 0 P SI

138 110 500 PS I 150 120

44 40 24 H O U R 60 58 2244 psi 54 50 30 30

Also, a compressive strength test was performed with 5% contamination of the spacer as seen in Tables 4 and 5 to determine
90% Spacer the acoustic impedance. 10% Cement

96 270 212 95% Cement 13:16 hrs:min 25% Cement 5% Spacer 96 200 166 75% Spacer 96 140 110

14:54 hrs:min 120 100 80 82 64 50

SYST E M 95% Cement SYST E M 5% Spacer 95% Cement 5% Spacer

3.27 Mrayls 5 0 P SI 12:29 hrs:min 13:16 hrs:min

4.0 M r ay l s 500 PS I 14:29 hrs:min 14:54 hrs:min

5.0 M r a y l s 24 hrs:min 17:02H O U R 2244 psi

Table 4. Compressive Strength Test

SYST E M Spacer 100 90 3.27 Mrayls 4.0 M r ay l s 14:29 hrs:min 5.0 M r a y l s 17:02 hrs:min 6.0 M r a y l s 44:34 hrs:min

95% Cement 80 12:29 hrs:min 5% Spacer 70 60

90% Spacer 90% Cement 10% Spacer 75% Cement 25% Spacer 50% Cement 50% Spacer 25% Cement 75% Spacer 10% Cement 90% Spacer

80 96 96 96 96 96

162 292 268 270 200

130 220 208 212 166

76 60 38 34 TES T 300 200 FLUID TEMP M 98 138 I X TU R E 62 (F) 20 R PM14 R PM 138 150 120 110 100% Cement 120 100 78 80 44 276 40 204 90 96 60 226 58 168 80 80 54 142 50 110

94

100 60 R PM R PM compatible

compatible

30 R PM

6 RPM

3 RPM

10 SEC

10 M IN

compatible 122 84 100 70 compatible 80 64 compatible

50 42 48 40 66 86

14 14 24 20 24 60

8 10 20 18 18 58

18

24

100% Innovative Cement Spacer System for Effective Spacer 66 54 140 110 82 50 96 30 110 30 Zones Zonal Isolation 64 Lost Circulation 90 in compatible 90% Cement 10% Spacer 75% Cement 25% Spacer

80 80

310 280

234 220

146 148

110 116

compat

compat

SYST test 5 0 P SI 500 PS I 24 spacer 48 Tables Also, a compressive strengthE M was performed with 5%50% Cement contamination80 the 220 R as seen inH O U R 4 and 5 to determine of H O U 174 118 94 60 48 44 50% Spacer

compat

the acoustic impedance.

95% Cement 5% Spacer

13:16 hrs:min

14:54 hrs:min 75% Spacer

25% Cement 10% Cement 90% Spacer 90% Cement 10% Spacer 75% Cement 25% Spacer 50% Spacer

psi 802244212 80 96 162 292

170 130 220

3065 psi 124 100 94 138 76 98

80 60 62 78 90 80 50

52 38 20 44 60 54 30

48 34 14 40 58 50 30

compat

compat

compat

SYST E M 95% Cement 5% Spacer

3.27 Mrayls 12:29 hrs:min

4.0 M r a y l s

5.0 M r ay l s 96 268 208 17:02 hrs:min 212 96 270 96 96 200 140 166 110

6.0 M r ay l s 138 110 44:34 hrs:min 150 120 120 82 100 64

compat

50% Cement 14:29 hrs:min 25% Cement 75% Spacer 10% Cement 90% Spacer

compat

Table 5. Acoustic Impedance Test

compat

compat

100

The Ultra Spacer was compatible with both the mud and 90 separations between the spacer and mud were observed. 70
% of Ultra Spacer

The Ultra Spacer system for the 1/16 slot had a tained. For the 1/8 slot the Ultra Spacer system had
13:16 hrs:min 14:54 hrs:min 2244 psi

TEM 500 PS I 24 HOUR cement designs provided for this particular test. No phase S Y S volume loss 50 PS I with 93% of the system being reof 7% 80

4 8 HO

All mixtures were homogenous with no gelling or settling 5% Spacer a volume loss of 8% with 92% of the system being re60
50 observed. The compressive strength test and acoustic im40 pedance test demonstrated that spacer had no considerable 30 effect in the ultimate strength of the slurry 20

95% Cement

3065 p

tained. The Ultra Spacer system was able to plug off all of the slot sizes tested.
S Y S TEM 3.27 M r ay l s 12:29 hrs:min 1/8" slot % Lost 4.0 M r a y l s 14:29 hrs:min 5. 0 Mrayls 17:02 hrs:min

6 .0 Mr

Unique Sealing Abilities Testing 0

10

95% Cement 5% Spacer 1/16" slot

44:34 hrs

1/32" slot

% Retained Slot The goal of this lab testing was to demonstrate the unique Sizes

Figure 1. Slot Test Chart

properties of the Ultra Spacer system. The slot tests were performed using a modified long fluid loss cell. A plug containing a slot was placed within the cell. Both ends were cawas mixed with 40lb/bbl of Ultra Seal Plus, as it is commonly designed for wells with major lost circulation problems. The system was placed within the cell and 500 psi pressure was then applied to the cell and opened to allow the system to pass through the slot. A measurement of how much slurry escaped was used to determine the percentages of retained and lost fluid. Three different plugs with different slot sizes (1/32nd inch, 1/16th inch, 1/8th inch) were used for testing. The Slot test results are displayed in Figure 1. For the 1/32 slot the Ultra Spacer system had a volume loss of 2% with 98% of the system being retained.
% of Ultra Spacer 100 90 80 70 60 50 40 30 20 10 0 1/32" slot % Retained 1/16" slot Slot Sizes 1/8" slot % Lost

pable of being completely sealed. The Ultra Spacer system

Innovative Cement Spacer System for Effective Zonal Isolation in Lost Circulation Zones

Low-pressure fluid loss testing was performed using a long fluid loss cell. A layer of 100-mesh silica sand was placed in the cell. The sand layer was saturated with de-ionized water. A Class H neat cement system was mixed and placed in the cell on top of the sand layer. The cell was then pressured to 500 psi at the top and opened at the bottom to allow the cement system to flow through the sand layer. Filtrate was collected over time. This test provided a comparison of the penetration rates of filtrate into cleats or high-permeability formations. Simulation of placing the spacer system Ultra Spacer ahead of the cement system was then tested. A layer of 100-mesh silica sand was placed in the cell. The sand layer was saturated with de-ionized water. Ultra Spacer was placed in the cell on top of the sand layer. The cell was then pressured to 500 psi at the top and opened at the bottom to allow the Ultra Spacer to flow through the sand layer for 30 minutes. Pressure was then released and any excess Ultra Spacer removed from the cell. The cement system was then mixed and placed on top of the sand layer. The cell was then pressured to 500 psi at the top and opened at the bottom to allow the cement system to flow through the sand layer for 30 minutes. The low-pressure fluid loss tests across the sand bed demonstrated the ability of the Ultra Spacer system to seal itself off against a formation. Figure 2 shows the neat cement system penetrating throughout the sand layer. The cement system had no fluid loss control and penetrated the sand layer within seconds resulting in a completely de-hydrated layer of cement on top of the sand layer. Figure 2 shows the Ultra Spacer under the same conditions, only penetrating a very small amount into the sand layer. A low permeability membrane is created across the formation, resulting in retention of the Ultra Spacer system on top of the sand layer. This excess of Ultra Spacer is then removed from the test fixture and the neat cement system is placed on top of the sand layer containing the Ultra Spacer membrane. Figure 4 shows the neat cement system not being allowed to penetrate past the Ultra Spacer membrane. There is no fluid lost to the sand layer by the cement system. The Ultra Spacer system successfully plugged off all three-slot sizes and plugged off the sand bed layer. In addition it allowed for the cement slurry to not have fluid loss and dehydrate thus maintaining an uncompromised cement sheath. Figure 4. Ultra Spacer/ Cement Figure 2. Neat Cement Figure 3. Ultra Spacer

Innovative Cement Spacer System for Effective Zonal Isolation in Lost Circulation Zones

Case Histories
The Ultra Spacer case histories include successful cementing operations in depleted or naturally fractured zones, zones with narrow pore and fracture margins, zones with washouts and severely enlarged wellbores, production liners with tight clearances, deeper pay prospects in old depleted existing fields, and zones with shallow water flow potential in deepwater wells. Three of the most promising case histories were selected for this report.

Powder River Basin - (Wyoming-USA)

Completion of coal bed methane wells in the Powder River Basin presented unique, technical and economical challenges. In order to be commercially viable, these wells must be drilled and completed quickly with excellent cement bond to isolate coal seams for fracture stimulation. Low-strength formations prevent the use of standard density cements or high rate cement placement. Lost circulation during cementing is a frequent occurrence, even with low-density cements. This case study describes the use of the Ultra Spacer system to cement wells with standard density cement without lost circulation. There was also an unexpected result of improved productivity from the completed formations. The initial field study included 37 wells completed with Ultra Spacer and standard density cement compared to 26 wells completed with no Ultra Spacer and low-density cement. When the cementing data and production data from the study wells were analyzed, results of the field study indicated the modified cementing method with the Ultra Spacer yielded significantly better primary performance and productivity. The cement volume needed to circulate cement to surface for the 37 wells cemented with the standard density cement/Ultra Spacer was 7% excess while the 26 wells cemented with the low density cement averaged 36%. The well was cemented with cement to surface without lost circulation or fall back. Great hole cleaning along with good bonding resulted across the entire interval. Substantial savings were realized by eliminating the remedial cementing jobs that had been required in previous wells. Fallback and loss circulation are a common experience while cementing the surface hole in this County, resulting in costly top out cementing jobs. Ultra Spacer (@ 60 bbls) was pumped as the primary spacer ahead of the 11.8 ppg lead cement. The density of Ultra Spacer was 10.6 ppg and included 40 ppb of Ultra Seal Plus. In addition, production rates from the wells cemented using standard density cement + Ultra Spacer were significantly greater than corresponding production rates from offsetting wells cemented with low-density cement.

Haynesville Shale - (Shelby County, Texas-USA)

Port Barre, La. (Parish: St. Landry-USA)

The operator requested a specialty spacer to cement a 22 casing at 4,130 MD. The losses encountered while drilling the interval were 8-12 bbl/hr. It was critical for cement to return back to surface to prevent future remedial interventions.

Innovative Cement Spacer System for Effective Zonal Isolation in Lost Circulation Zones

Our engineering team recommended 150 bbl of Ultra Spacer @ 12.0 ppg to solve the operators challenge. All the dry additives were shipped to the cement companys bulk plant facility in ICY prior to the job. During the job, the recommended volume of Ultra Spacer was mixed on the fly at 6 bpm. After pumping 740 bbls of cement the Ultra Spacer reached the surface, after 785 bbls were pumped the cement reached the surface. The Ultra Spacer repaired the lost zone and a successful cement job was accomplished. The operator was able to resume downhole operations avoiding remedial interventions.

Grand Isle Block 37 (GOM-USA)

A 7 open hole had been drilled to TD and a 5 liner run. The drilling fluid was 11.2 ppg OBM. A 30 bbl Ultra Spacer was formulated and weighted up to 13.0 lb/gal. Ultra Spacer was pumped as the lead spacer in front of a 16.0 lb/gal cement slurry. Cement was displaced without loss circulation. Furthermore, there was no sustained casing pressure after the cement job, thus no gas migration issues and no remedial cement squeezes were required.

Conclusions
With over a thousand case histories, the Ultra Spacer technology has proven to the oil and gas industry that a unique cement spacer system is needed for the most complicated cementing jobs. If operators embark on the challenge of cementing depleted production zones, lost circulation zones, washout zones or zones with a narrow ECD margins, the Ultra Spacer technology, with a proprietary blend of functionalized polymers and bridging agents, can be used as cement spacer to effectively remove drilling mud and form a non-damaging membrane, reducing fluid/filtrate invasion and increasing effective zonal isolation.