E&PSegment Practice Recommended

Man Cementing Drilling andCompletions Section HPHT Cementing

sRP4.1-0005

This practicewill be subject to periodic revierv.

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April2Ua Revision Date April 2010 Next Review Date April 2012 Technical Authority Daryl Kellingray, Dilling Specialist Cementing and Dilling Fluids Content Approval Scofl Slgurdson,VP Drillingand CompletionEngineering A utho ri z:ati n for /ssue o Barbara Yilmaz,TechnologyVice President,Drillingand Completions Doc um ent A dministrator Drillingand Completions

for PRAGTIGE HPHTCEMENTING RECOMMENDED

Symbols Abbreviations and 1 TNTROpUCTTON 2 FUNDAMENTALS E RtSKq ! W WS C G R E C O M M E N D A T I O NH E NP L A N N I N G E M E N T I NO N H P H T E L L S 41 Temperatures 4.2 Hvdraulics 4.3 ContinqencvPlannino 4 4 Assurance Process 4.5 Experience 4.6 Rig Cementinq Equioment / 4.7 Cementino EquipmentTools
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50 H P H TS L U R R Y E S I G N O N S I D E R A T I O N S D C 5.'1 BulkCement SampliE 5 . 2 Temperature 5 . 3 Pressure trA Cernent Selection Additive Guidance 53 Selection

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5.5.1 5.5.2 5.5.3 5.5.4 5.5.5 6.0

Retarders FluidLossControl Weiqhtins Aoents Silica Additives Other

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TESTING CEMENT SLURRY 6.1 SlurrvSensitivitv 6.1.1 Temperature Mixinq 6.1.2 Mixinq/Shear Energv and Batch 6.1.3 Additive Concentration 6.1.4 Densitv 6 1.5 Additive of Order Addition 6.1.6 Contamination 6.1.7 MechanicalProperties

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7 O SPACER DESIGN 7.1 Spacer Stabilitv 7 .2 Selection Weiqhtinq of Aqent 7.2.1. Barite 7.2 2 Manqanese Tetroxide 7.2.3 Hematite 7.2.4 Brines 7.2.5 Spacer Rheoloqv 7.2.6 SpacerComgatibility 8 O INTEGRATION THE DESIGN WITHEXECUTION OF 9 O EXECUTION RECOMMENDATIONS . 1 R i qs i t e 9.2 General

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Symbols and Abbreviations

Symbol/ Abhreviatio n API
bbl

Definition Petroleum American Institute Barrel Bearden Unit

Symbol/ Ahbreviation PPFG PV

QA/QC

Definition fracture Poreoressure oradient Viscositv Plastic / Assurance Quality Control Qualitv Management Quality Svstem
Recommended Practice

Bc BHCT BHST
bpm

Bottom holecirculatino Q M S temperature

Bottom Hole Static Temperature RP

Barrelper minute
Bv weiqht of cement

rpm
SG

per Revolutions minute

SoecificGravitv

BWOC ECD EPT FG

HPHT

Effective SGSA Circulating Densitv Exploration Production S M E Technology Fracture Gradient SoR Highpressure high SPE temDerature International StandardsTD orqanisation Minute ToG Manaqement chanqe TT of Nonproductive TVD time Hole Open ucA
Oil BasedMud

StaticGel Strength Analvzer MatterExpert Subject of Statement Reouirements

Society of Petroleum Enoineers

rso
mtn

TargelDepih
Too of Cement

MOC NPT OH
OBM

WARP WBM

ppg

Poundsper qallon

psi

Pounds souareinch oer

woc
YP

Time Transition TrueVerticalDepth Cement Ultrasonic Analyzer Barite Micronized Agent Weighting Proiect Research WaterBasedMud Waiton Cement Yieldpoint

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INTRODUCTION
(150oC800oF+) > ppg)and hightemperatr.tre (slurries 2.15G117.5 underhigh pressure Cementing therehavebeen Historically conditions. cementing with normalwell carries moreriskcompared (cement to proportionally cementing setting early,failing set, stuckpipe,etc)on wells failures more ppg there and/or2.35 SG/19.5 230oC/450oF exceed When temperatures withHPHTconditions. technical the are additional risksand uncertainties makeaccessing helpof a cementing that specialist crucial success. for areas: Thisdocument the HPHTCementing addresses following . . . . r . Planning designand testing Slurry propefties SlurrV design Spacer job Integrated design Execution

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FUNDAMENTALS
rates, displacement goodcementing practices apply- mudpropedies, spacers, Normal still centralisation, muststillbe considered. etc wellsand to than for moreconventional HPHTlaboratory testing takeslonger complete planning cyclewhendeveloping requires moretesting.This needsto be included the in plansfor cementing HPHTwell. an in Previous Engineer and Laboratory HPHTcementing experience the Service of Company to Auditof laboraiories be to failures. is critical prevent to basicmistakes leading operational stepto consider. usedon HPHTwellsis a critical time and strength on Pressure havea significant impact cement thickening can development HPHTwells(accelerating in cement setting). with temperature accuratestatjcand circulating and increases Cementretardersensitivity for temperatures becomeeven morecritical slurry designand testing. endsof their oftenbeingused at the extreme HPHTwellsresultin equipment and chemicals of rangeof boththe cementing operational ranges.An understanding the operating nsk to equipment the chemicals theiroperating and rangesis critical minimise of and incuningcementingNPT. and theseneedto be designed contingency strings HPHTwellsfrequently employmultiple cementplugdesignsas the wellprogresses withthe samelevelof detail. Testcontingency operations. or to be prepared any emergency for suspensions, abandonment sidetracking pressure temperature and Locallaboratories not haveequipment may capable simulating of for an HPHTwell;ensurelocalcapability an HPHTproject. for to require silica prevent exposed temperature to 23OoF 11OoC I All slurries exceeding strengthretrogression to Batchmixing recommended is whenthe slunyvolumeallowsthe tolal volume be mixed in a single batchmixer.

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Risk

RISKS

Mitiqation . of Selection cementand chemical with additives, provenHPHTperformance . and designprocedures Slurry laboratory testing r Materials QA/QC . whatis pumpedis whatwas Ensuring designed the laboratory in o' . sampling lsolation representative and cementand additives of specific batches . matching test Laboratory temperatures conditions actual wellbore . in of Sensitivity designto changes and mix density additive concentrations, temoerature testedand understood is with compatibility mud and spacer Contamination cement spaceror Cement of by . optimisation muddue to channelino. Cementplacement Time) (including Transition design HP gas migration kickfollowing or Slurry . cementing Mud Properties . and Conditioning priorcirculation . Compatibility e Muddisplacement . of of Knowledge the HPHTbehavior on mudand spacerand imPact modellinq. displacement Failure achieve to design isolation Slurry . Mud proPerties r and Conditioning priorcirculation . Compatibility e Muddisplacement and completed of sensitivity testing Sensitivity slurry designs small Ensure to changes(temperature concentrations envelope / overwhichslurrydesignsare aoorooriate develooed I pressure shear) / pressure data quality Losses and lowTOC due to the ECD Porepressure, fracture gradient r exceeding fracture the dynamic of Modelling downhole geometries pressures and usingrealistic downhole mud oroperties pumping qualification selection and HighPressure and pressure Equipment tstingdue to the exposureof high pressures closeto the operatinglimits of the eouipment. early(cementleft in Cementsetting-up and failed casing) late(softcement or pressuretests)
Difficulty failureof equipment and/or or operatofto mix high density slurries. Equipmentand personnelqualificationand selection. . Slurrydesign and criteria for mixability in laboratorvand field.

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requirements. Clearzonalisolation modelmechanical Whereapplicable, triaxial usingthe cements loading properties assessbreakdown. to . of of Assessment long term integrity sheathunderhigh the cement stabilitv). re temoeratu (chemical of personnel Auditthe qualifications experience both and Errors due to inexperienced -e.9. blend& additive calculations, fieldand basepersonnel. . preparation and documentation errors,etc. lmplement mixwater procedures ensure theseare adopted and and understood. at has equipment beenqualified the failure Ensure Equipment pressures temperatureswill experience it and operations. during of r the Consider duration any cement jobs can be large, operation sincecement longjob times. complex and require backup and contingencY Review on requifed materials equipment and location. due Lossof longtermisolation to on and loadings mechanical therrnal sheath the cement

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ON CEMENTING WHEN 4 RECOMMENDATIONS PLANNING WELLS HPHT

specialists technical company engage service To achieve successful HPHTcementing, withrelevant experience earlyin the process. ppg and/ortemperatures of Thisis critical whereslurrydensities excess 2.35 SG/19.5 in In are exceed experience knowledge limited. these and 230oC/450oF becauseindustry experience wiih appropriate extreme use internal external independent experts cases, / 2300 exceeding to provide challenge.Planning timeon wellswithconditions technicai and/or2.35SG/19.5ppg can exceed12 months. C/450oF

4.1 Temperatures
The at is It is vitalthatinformation aboutanticipated temperature available an earlystage. downhole pointfor determination cementing starting of is the BottomHoleStaticTemperature temperature (BHST)in the form of a plot of geothermal temperature depthwith all offset data points/log v. temperatures/MDT overlain. temperatures heat wellbore For HPHTwells,determine usingan accepted cementlaboratory temperatures test package (WellCat Cemcade WellTemp). not use conventional API transfer modelling Do / / to equations/schedules sincetheseare basedon insufficient measurements be Cementing alone

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cementing considefed accurate thesewells.lt is good practice builda picture the mostlikely in of to fromas manyinputsas possible including temperature wellbore temperature computer modelling, wireline logs,LWD,flowline temperature Correlations. Deepwater wells(riser API cooling) wheresurface and activevolumeis small(nosurface mud impact surface cooling) lemperatures, thesecan resultin hotteror coolerwellbores effects than predicted with subsequent pumptimeand strength on cement development. phaseof the welllife To understand impact elevated the of temperatures the during production cycle,use a computer model(e.9.WellCat) predict temperature seenon all annulito to the (Section determine whichslurnes require 5.5.4). addition silica mitigate to strength retrogression of Coniact EPTCementing an SMEfor modelling support. temperature Understanding recovery critical evaluating and is in compressive strength development in determining proper the WOC time for cementevaluation logging operations. plot The following depicts temperature (degrees between and at the TOC the TD differences F) duringcirculation, cementing WOC and are accentuated operation and and the during cementing the WOC phase. ln thiscase,the predicted / ISOBHCTwas227oCl44QoF, the simulated API and BHCTat the end of circulating 199oC/390oF TD). To builda safetymarginon the (at was simulated result,a test temperature thickening for time of 215oC/42OoF selected. lt's clear was fromthe predicted recovery temperature the wellbore of at that in aftercementing temperature the TOC hasnot recovered 215oC/420oF hoursafterbumping plug The impactof thiswould to 15 the be low or no compressive strength the TOC and any attempt logging likelyto showfreepipe at at is at the TOC Circulatjsn Cem,en,ting Waiting csmnt en

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4.2 Hydraulics
Detailed, planning critical wellswitha narrowPPFGwindow thorough is for Rheologies fluidswill requirespecial of possibly attention; including special

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to are simulations required Multiple at measurements HPHTconditions. laboratory trends and non-linear responses. discover that and the pressures breakcirculation can to Assesssurgepressures the placement. closeworking between cement relationship cement A compromise primary cementingon is and drilling fluidscompanies criticalto ensuresuccessful HPHT wells. and rheology of modelcannotsimulate impact downhole lf the hydraulics in are density, ensure theseeffects assessed the compressibility downhole on of ECD'sto 990/o the P5g sensitivity analysis. a generalguide,limitcementing As treatments of sandfracturegradientpredicted. Consider application StressCaging to increase rnarginbetweenpore and fracturepressures. the adviceon hydraulics Referto Cement Placement SRP 4.1 0004for further modelling. plot The typical whichis required review to ECDat depthis shownbelow. As the to cement enters annulus the afterabout50 minutes, ECDbegins increase. the After73 minutes, pumprateis reduced prevent finalECDfromexceeding the the to betweenthe the fracturegradient. ln order to manageECD's,closecooperation provider pumping cement service and BP is required designand execute to schedules.

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Spacerand cement (design slunydensity the and hydraulics) musttake intoconsideration actual downhole annular mudweight, temperature pressure.lt is not unusual the downhole at and for density an HPHTOBMto be 0.25 ppg (0.03SG)higher of measured density. thanthe surface

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4"3 ContingencyPlanning
and as slurries developed the wellprogresses are Makesurethatcontingency Do mobilised). not wait until are at materials available the well site(or can be rapidly deepercan havea 9 eventsarise.For example, setting 5/8"casing unscheduled testingif pilot profound effecton the slurrydesignand may take a week of laboratory and plugdesigns readyfor shoesqueezes Have underway. studies not already are kick-offs. to that materials are required ensurecontingency lf losses a potential are concern, materials with contingency testing and that any slurry address losses on location are ECD to be has beentested, lf the pumpratewillpotentially adjusted address slunies havebeentestedat the reduced induced losses, ensurethat contingency pumprateand thata properMOC is followed duringany changeto the designduring phase the execution

4.4 AssuranceProcess
procedures processes Adequate and needto be in placeto ensurethat best practices indentified implemented. is the responsibility the BP Drilling of lt are and plansare in placeto assure: that adequate Engineer ensure to . the quarantine of Materials materials the deeperseclions the well to eliminate for QA/QC: To riskof batchto batchmaterial whichare amplified underHPHTconditions. variations isolate in minimise riskof problems the with slurrydesignonlybeingidentified rig samples, run all the cement and additives a job fromthe samelot, batchor manufacturing ahead for requires sampling, of the well,Dry Blending, and assurance no bulkcontamination, of special attention. selection. temperature Laboratory testing:planned eachcasingstring, for including and gauges, densitometers meters, Galibration equipment:pressurised mud balances, of recording devices. in of and matches uncertainties the data available. Sensitivity slurry designs:reviewed requirements Equipment service, certification, inspection and SOR prepared:reflecting are equipment up to date. are completed. all records pumping for Confirrn maintenance technical on Communication; Ensure fluidsand cementcontractors communicate specific be mustahruays and logistical mudproperties requirements. Integrity the downhole of the maintained. Lastminutechanges drilling to fluidsproperties improve potential to jobs on HPHTwellsare not recommended, (barite sag is a key riskto outcome cemenl of for its be considered). Ensure that changes the drilling to fluidto optimise properlies the job cement is a programmed, process HPHTwellsovera periodof days engineered on beforesectionTD.

. . .

4.5 Experience

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howthe establish havelittleHPHTexperience, engineers company lf the service minimum and in. will expertise/experience be brought Key positions recommended levels are: exoerience . Engineer and has beena software in all Hasa highlevelof competence running modelling on leadengineer an HPHTwell designbefore. LaboratoryStaff and validlaboratory datafor HPHTis verytimeconsuming far in test Getting for excessof that required more commonwells.Reviewrecentauditsand/or in an initiate auditof localcapability HPHTtesting. Cementer testing highpressure and running slunies high density in Experience preparing toolsis required.

personnel thesekey positions, in lf the servicecompanyis unableto provideexperienced performance. to support assure independent technical consider accessing

4.6 Rig CementingEquipment

wells,checkthat air equipment be used for the well.For offshore to the Review cementing wiil properlysince moisturedamageto cernentin storage/transport have driersare working properties. the Address following: a majorimpact on . r . . . . ls therea history bulksupplyproblems? of for adequate the job? What is ihe recordof equipment ls the cementunit and associated jobs? failure conventional on the Do you needto up-grade HP pumpfluidends? be to Are critical slurries be batchmixed?Can the volumes accommodated? on Do you needmorethanone batchtank?Can it be spotted the rig/location? definedand understood?Can clearly equipment Are the limitsof the mixingand purnping whethera slurrydesignis measurements assessfrom laboratory the laboratory realistically ableto be mixedon the rig? Different movements cementbulksoccuron location. of or Ensureno unplanned untracked is unlesstestingconfirmsblending batches(loadouts)of cementare to be kept separate of for pointof accountability any movernent acceptable. The onsitecementeris the single bulkcementor cement blends.

4.7 CementingEquipment/ Tools

headsand launchsystems, cement The selection wiperplugsand darts,linerequipment, of with of for seals,packers needto be reviewed HPHTwells. Compatibilities elastomers all of Seekassurance a HPHT underHPHTconditions. fluids(mud/spacers) be different may

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process. in company the planning service the sME and engage cementing High pipeworkand reliefvalves. of suitability surface confirm testing, For highpressure duringhigh slipsto limitcasingdamage packers aviilablewith lessaggressive pressure are pressure testing.

CONSIDERATIONS DESIGN 5.0 HPHTSLURRY

in to whichis not sensitive smallchanges composition, slurry design, a Achieving robust Key conditions. areasto be for is or density, testtemperature, verychallenging HPHT include. considered . . . o o sampling Bulkcement Temperatures Pressures Bulkcementselection selection Additive o Retarder o FluidLosscontrol

. Welghting Agent o Silica grindsizeand silicaquantity . Otheradditives o SlurrySensitivity avoiduse of HPHTcementing; designis key to successful in Simplicity HPHTslurry aids (e.9.anti-settling to the to or addiiives, additives counteract actionof others secondary unlessjustifiedby test resultswith aid mixability) used to counterthe effectof dispersants an develop HPHTdesignbasedon local and without addition. Oftenlaboratories the of fromfirstprinciples ratherthandesigning combinations, additive successful cement HPHTexperience.

5.1 Bulk CementSampling

silica a will usedin HPHTconditions involve dry bulkblendcontaining Cementsystems a Obtaining additives. agentsand other (flourand/orsand)and,possibly, weighting the to is samples critical managing risksof adverse blendand representative nomogeneous during execution. slurrybehaviour of control the accurate will the testing finalise blendcomposition involve to Pilotlaboratory for process and capability the Review blending of concentrations eachof the components. impacton the riskof havea significant preparation homogeneity and HPHTblends. Blend betweenpilot tests and samples failure;this is often the cause of differences operational this willalsominimises risk to fromthe rig site Attention rig siteand bulkplantsampling

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the procedures). Approaching sampling (consult SMEif in doubtaboutplanned Cementing resultin job failure. job, uncertainty testresults can resultin job delaysor possibly over and followed procedures rigorously are sampling risk,it is vitalthatcorrect To minimise include Practices Recommended API/lSO protected stored correctly. and samples these follows Company Service that the Cementing guidance sampling, is critical it on practices a minimum. as process, whenthe of at Cementblendsshouldbe sampled the completion the blending tanKs.J and at transport tanks, to system the holding fromthe blending is material transferred 'Y (bulkblend performed thesesamples on shouldbe testing lf timeallows, laboratory at beforethe cementblendarrives the rig site blendquality cement samples) ensure to at arrives the rig site(rigblendsamples) againwhenthe material shouldbe sampled Blends on and testingshouldbe conducted thesesampleswith waterfrom the rig site beforethe { job is performed. designbeforepumprng. the Thiswillvalidate finalslurry at points testing requirements eachsamplepointshould and laboratory acquisition Sample to pfogram shouldbe developed ensure sampling beforethejob. The overall be defined to to components the finalblenddelivered the cement quality the blendfromthe individual of unitat the wellsite.

5.2 Temperature
>1.9oF/100 (35oC oF/150oc) and/orthe thermal /km) ft gradient For HT weils(BHST>300 be modelshould run heatlransfer validated or WellCat. Welltemp, CemCade an equivalent lt to the will temperature cement be exposed duringcementing. is to predict mostlikely the 'mostlikely' and 'worst to analysis develop a includes sensitivity importanl thismodelling that modelling Temperature can at case'temperatures whichcemenlproperties be assessed. sirnulations Multiple froma singlesimulation. answerderived correct doesnot havea single to to are needed gaugerangeand sensitivity variables.

may I-WD/MWD ternperatures be a usefulguide,but do not use thesefor designof the heatfromthe Heatfromthe bit (drilling), cementslurryas theycan also be misleading. to of electronics, the position the sensorrelative the flow streamcan all skew or measurements.

5,3 Pressure
only on to thereis a tendency concentrate temperature and neglect For HPHTcernenting, it pressure a lesseraffecton slunyproperties, is has Although the influence pressure. of columnplus testsfromthe hydrostatic for significant. the Calculate pressure laboratory the at pumppressure. trying assessthe strength development a linertop (forexample), to lf mud columnabovethe from the hydrostatic UCA needsto be run at a pressurecalculated

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laboratory pressure somecommon of may exceedthe working Thispressure liner. equipment.

5.4 CementSelection
doesnot / (below30OoF 149oC) of Goodperformance an oil well cementat lowtemperature vary phasesin an oil well cement The chemical goodHPHTperformance. indicate always in resulting batchto batch and manufacturer the dateof manufacture; withbulkcement can of The reactivity somecements underHPHTconditions. beingamplified variability "difficult disperse" to to makethemvery difficult retardat high temperature.Use of so-called to agentrequired createa of and the amount weighting slurryrheology cements impact will to can conditions be verychallenging at pumpable slurry.Slurryperformance HPHT and specifications testing with cementcomplies API/ISO optimize eventhoughthe base for requirements oil wellcements. wellcement highquality that For HPHTwells,it is recommended a recognised with an responses) and linearretarder (littlebatchto batchvariation manufacturer of The selection the for (Dykerhoff Lafarge example). or is track-record used established earlyin the planning be usedin an HPHTwell needsto be addressed to bulkcement timeto reactcan withoutadequate with the bulkcement pfocess. a Determining problem properties) job and mechanical (inappropriate in teadto compromises finalcementquality WOC or NPT). time(extended

5.5 Additive Selection Guidance 5.5.1 Retarders

in are retarders not appropriate HPHTsections' lignosulphonate In general, costcalcium low the upperand lowerworking around sensitivity have VioOifieO lignosulphonates undesirable and to (morelinearresponses temperature are retarders superior synthetic ranges.Modern particularly the lower at sensitivity; exhibit undesirable but concentration), eventhesecan type and cement usingthe planned testing ranges Extensive end of theiroperating that assurance slurrydesignis not to is slurrylormrtation necessary provide representative for too sensitive the application. in retarders and in plot variation lignosulphonate synthetic The following showsperformance time (after time is shownon the X axis. Additional Thickening designs. HPHTslurry on is strength represented 50 to time)required achieve psi compressive thickening reaching the Y axis. 4hr timesof around thickening similar (circled red on the chart)thatprovide in Two designs The timeto achieve development. to strength responses different 15 minhavesignificantly whilethe synthetic retarder, hr an 50 psirequires additional6 10 minforthelignosulphonate t onlyan additional hr 25 min. requires retarder

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5.5.2 FluidLoss Control

is fluidlosscontrol wellswhereBHSTis lessthan 350oF(177oC) not on Getting adequate generally problem. However, gettingthe appropriate testingdone at the correct a is temperature important. products to Some FluidLossAdditives proprietary are whichvaryfrom company company. in viscosify causing resulting slunystability mixingproblems but thinwithtemperature, problems. stability. Dueto Others disperse makingmixing easy- but alsoreduceslurry possible believe slurry testing has low fluidloss equipment limitations, is sometimes to a it control.Forexample, slurrytestedat HPHTconditions 4-5 a may exhibit timesthe fluidloss valuesseenat 185oF(85oC).For thisreason, of evaluation fluidlossat, or as closeas possible predicted and viscosity acceptable to, downhole conditions critical. Achieving is stability high density conditions alsobe very can of slurries bothsurface at and downhole challenging. time more alsoretard, Somefluidlossadditives whichmay makethickening difficult control to Fluid and sensitive variations retarder to in and fluidlossconcentralions. losscontrol control HT at effective additives may alsorequire additional additives provide to at conditions. of stability BHCT Achieving combination goodfluidlosscontroland slurry the is one of the majorchallenges HPHTslurry in design.

5.5.3 Weighting Agents

possible, Weighting agentsare generally required not below-2.05 SG/17ppg.Whenever

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less cost.Fordensities slurrydesignand increase avoidtheiruse sincethey complicate to (friction are ppg dispersants reducefs) recommended design than2.05SG/17.0 'reduced-wate/ as agentsat densities low as 1.97SG/ 16-4 The use of weighttng slurries. "difficult disperse" to withsomelocally ppg can be required when silicaflouris blended cements. agents: weighting thereare threepotential are densities required, Wherehigher barite- 4.3 SG hematite 5.0 SG tetroxide, Micromax- 4.7 SG manganese for cost,is notwell suited use in and lowest available although mostreadily the Barite, sizeand low density. due cementslurries to its particle Batchmixingis alwaysrecommended agentusedis hematite. weighting The mostcommon capability' aboutlocalblending exists and whereuncertainty for HPHTslurry designs, has to agentscan be addeddirectly the batchmixer. Wheredry-blending been weighting has been transfer and pneumatic duringshipping of used,separation the hematite careful requires of coarseness the hematite and The density difference relative observed. is out of the finalslurrydesign. Hematite available prevent settling hematite slurry design to slurrydesign(selection grindselection influence will grinds(particle sizeranges), in different the to of is a balance easeof mixingand ability slurry suspend hematite). of in agentand has an advantage weighting (Micromax) a very effective is tetroxide Manganese prevents rapid (typically micron) 1 to that it can be addeddirectly the mixwater;its fineness tn changes and operation alsoallowsfor last-minute the settlement. simplifies mixing This when is hygiene a majorconsideration Occupational density rneetwell conditions. to slurry risksneedto be carefully its usingMicromax, dust is a knownhealthhazardso exposure of witha recentdevelopment the improved and safetyis greatly assessed.Handling on that re-disperses tetroxide of version manganese FF, material Micromax a compacted for withwaterand is moresuitable dry blending. contact Based favourMicromax. preferusingHematite, and Hallibufton BJ Schlumberger Currently, tetroxide is the BP on proprietary research, BP recommendationto not use manganese manganese (40OoF). Below2o4oc (4000F) (Micromax) the BHSTexceeds 2O4oC if somedesignand execution agentthatprovides is weighting tetroxide an acceptable particularly to related slurrysettlement. advantages,

5 . 5 .4S i l i ca
exposed overlongperiods 230 oF (11ooc),cements Wherethe BHSTexceeds This retrogression. is causedby a (months/years) exhibit phenomenon calledstrength a will ratio by and at solidstatephasetransformation hightemperature is influenced the lime/silica to prevent to the slurry reducethe is silica added in the cement. To thistransformalion, deterioration, The permeability stableproduct. lime/silica and createa morethermally ratio to relevant HPHTGas Wells. is degradation, particularly the whichaccompanies strength

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but retrogression, frequently resistance strength to haveinherent blends SomePozzolanic blending are flouris alsorequired. Sincethe materials dry blended, silicasandand/orsilica of procedures sampling the flourcontent the blend and becomecritical.Confirm silica on (normally a pycknometer) variations havea largeimpact pumptimeunderHPHT as with to by Wherethe BHSTis lessthan 177oC(350oF a 35o/o weightsilicaaddition conditions. ) temperatures, retrogression. higher At strength to cement recommended prevent is above to the testingis recommended determine propersilicaconcentration; additional chemical for is required long-term of 45OoF, concentration silicaabove50o/o probably a of to stability. is alsocommon thesehighertemperatures use a combination sandand lt at flourto assist mixability the HPHTsluny. of silica

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0l rime Curing lmonths)

time Curing {monrhs)

permeabilrty bth'dvtorof various Portland ard :ement Compressvo Efenglh il?ter (rom 1SE5l and slstemd silica ternperatures Nelson Etln6. walhout addition eevated at

(beyond simple fiowtest)determine a as Forwellswhichare planned longterm producers production. Whereany is to ea6hannulus exposed durrng the maximum temperature > 230oF(11OoC) the duringproduction, slurrydesign's to cement sheathis exposed figure The following needsto be confirmed. strength retrogression suitability resist to to are casingstrings exposed sheaths shallower of temperature cement the highlighis the is cement for duringproduction a wellwith a 600oFBHST. In thiscaseeventhe conductor requiringsilicaflour additions. exposedto temperature

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60o F

lJc

Tenrperature

properties the silicameet of and physical that mustdemonstrate the chemical The supplier size in Variation particle batchto batchvariation. and specification, thatthereis minimal of and the reactivity the silica of and mixability stability the finalslurry impacts distribution to may permitsome initialstrengthrelrogression occur). flour (a low reactivity

5.5.5 OtherAdditives
include: usedin HPHTslurrydesigns Otheradditives o Dispersants mixability rheology and for . Anti-foam reduceair entrainment duringmixing to r Anti-settlement (to preventsolidand/orliquidseparation) aids o Synergistic (usualto support fluidlossaid) a additives aboveits o Retarder (e.g.borax)usedto extendthe rangeof a retarder intensifiers retarder. high temperature normalrangeor suppressreactionnot retardedby a

SLURRY TESTING 6.0 CEMENT

usedfor usesthe sametestsand equipment testing usedfor HPHTslurries The cement is with HPHTslurries The key difference in as slurfies detailed SRP 4.1-0003. conventional to the rangeof testingand numberof tests that need to be completed providethe necessary

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of and assurance its slurry of envelope the proposed of understanding the operating are HPHTslurries assured to in behavior the field. Theteststhatare required develop below. described

6.1

Slurry Sensitivity
and testsbeingcompleted withoutthe following be No HpHTstringshould cemented reported: . o o . o . Time Thickening FreeFluid FluidLoss strength Compressive Rheology testing Compatibility

o Sensitivity testing o Settling Stability of limitation the available be WhentestingHPHTslurries, awarethat the temperature to may and additionalequipment be required may be exceeded equipment laboratory can well conditions be simulated. properly and slurryperformance ensure evaluate mechanical e.g.Transition Time,gas migration, testsmayalsobe required, Additional strength). property (other thancompressive measurements well to sincethesecan varyaccording specific to ranges parameters for It is difficult specify for criteria any slurryusedin is However, following seenas minimum the circumstances. HPHTconditions: rate a Time= job time+ 1 to 2 hours(assume displacement of 3 Thickening pumpsto mitigate job losscirculation) slowing bpmto deiermine timeto mitigate a FreeFluid:< 1olo a FluidLoss:< 100mll30minutes > a the strength: 500psiin 4 hoursafterbumping plug Compressive > 300 are to be avoided) o Slurry (slurries with a 300 rpm reading mixability, a Sfurrystability(twicethe 3 rpm FANN reading- 6 rpm readingto be greaterthan 7) > whereP is the annular (P hierarchy, displacing 1,2 x P displaced) Frictional pressufedrop per unit length) and mud,Reviewadverse spacercompatible withcement testing: Compatibility in methoddetailed API RP10B(lSO 10426-2). spacer/mud/cement interaction, in (mud/spacer) detailed API as of Checksensitivity slurryto contamination RPIoB(rSO10426-2).

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and < o Settling Stability. 3mmcolumnheightreduction < 0.5 ppg density top between and bottomof columnusingthe BP Settlement difference Procedure. may be usedat the upperend of their and additives can HPHTslurries be verycomplex, by are the range. As a consequence, slurryproperties muchmore likelyto be influenced and theseneedto be than mightbe anticipated in smallchanges the following relatively designdevelopment: / assessed duringpilottesting slurry . . o o r . . temperature energy mixing/shear concentrations additive density orderof addition additive contamination pressure

6.1.1 Temperature
a complete sensitivity has design temperature beendetermined, Oncethe laboratory -15 oF (8oC)hotterthan BHCT. at by of timeto temperature testing assessment thickening job slurry time,the proposed timeis lessthanthe planned timethickening lf the thickening -15 oF (8oC)cooler timefor pumptime needsto be increased. ldeallycheckthe thickening (near)linearresponse.lf the and assure the bracket response than BHCT,to adequately re-evaluate provides at retardation the lowertemperature, selectedretarder unacceptable to design lowerthan expected slurry to adaptthe planned The the retarder selection. ability in temperatures thewell may be difficult. also at development the lowertemperature needsto be assessed, Compressive strength at testing 15 oF (8 oC) loweror at strength device.Compressive usinga HP UCAtesting (useSRP-0003 select to shouldbe conducted whichever cooler, is the linertop BHST; within36 is strength not achteved lf appropriate temperatures). 50 psi compressive test shouldbe re-addressed. hours,retarder selection

6.1.2 Mixing/Shear Energy and BatchMixing

and thatis homogeneous lessproneto a for Batchmixing the bestoption producing slurry is in or properties fluctuations, fluctuations additive variations in causedby density addition/concentration. Becauseof the of by are Slurryproperties affected bothshearenergyand duration mixing. are HPHTslurries more high solidscontent largenumberof additives, and relatively When an HPHTslurryis batchmixed,modifythe sensitive thisthanstandard slunies. to periodbefore holding procedure include anticipated surface the to laboratory tesling (BHCT/P). When batch increasing and pressure downholeconditions to temperature mixer(to ensure a mixingis through jet or recirculating it that mixing, is importani the initial intothe mix directly dry and not by blowing cement dispersion effective and waierwetting)

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a waterthrough hose. seen in a batchmixer' to When the slurryrs subjected the extendedmixingconditions has beenmixedto the a slurry can vary. Once energy mixingshearand totalmixing in usingthe paddles the mixeralone lf the can suspension be maintained density required energycan mixing periods additional the pumpis usedfor extended cehtrifugal reiirculating of pumplngtime and the effectiveness some additives.ln the lattercase,the slurry reduce periodsof high shearfollowedby longerperiodsof low shear' will see intermitient will of with a simulation the shearthe slurry designeither In this eventtestthe finalslurry simple or duringbatchmixing, usingthe following the by experience, estimating energyinput programmes. mixing Mix for 1 minuteat 1,000rpm Mix for 20 seconds 12,000rPm Mix 1 minute1,000rPm Mix 20 seconds1,000rpm Mix 1 minute1,000rpm Mix 20 seconds12,000rPm Mix 1 minute1,000rpm Mix 20 seconds12,000rPm test.Some in to This is equivalent abouttwicethe mixingenergyreceived a standard which behaviour in thisprocedure; timeby rnorethan 30% can reduce thickening slurries needsto be avoided. and development sirength the to Use a low shearsimulation assess impacton compressive (not Testprocedure the API RP stability withthe BP Settlement Assess slurrystabitity. otherwise, for mixers low shear; will adoptedmethod). Somelaboratodes have specific modifythe aboveby makingallsteps1000rpm. the above30 Bc during surface whichshowa risein consistency Eliminate slurries time. conditioning should circulation continuous in is Oncethe slurry mixedand homogenised the batchmixer, by bothshearenergyand the effectscaused detrimental be avoided orderto minimise in increase. resulti temperature ng

6.1.3 AdditiveConcentration
in whichcan be achieved the addition of the It is good practice consider accuracy additive to in fieldmixedslunymay be inaccurate concentrations The additive field mixingsituation. due to: system, a) The additive measurement

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variation, densitY b) Mixing suchas silica additives of or c) rnaccuracy lackof homogeneity highconcentration agent, flourand weighting of consideration dead volumesin linesprimedwith freshwater or in tank d) lmproper beforemixing. bottomsfilledwith freshwater and will the In general, laboratory be ableto mixthe slurrymuchmoreaccurately checkthe concentration, to the than reproducibly thefield.To assess sensitivity retarder guidance use concentration, the following retarder timewith+l- 1Oo/o thickening less r pumptimeto be greater thanjob timewith 10olo retarder morc retarder o pLlmp time to be lessthan fuvicethat of the baseslurrywith 100/o therels ensure concentration, retarder with increasing that pumptimeincreases Confirm or inverted(shorterpump time with moreretarder) with not a rangeof concentrations flat responses. theseare to be tested retardation, or aid/intensifier the fluidlossaid is providing lf a retarder in the sameway. and sensitivity consider assessadditive continuously, lf a slurryis beingmixedand pumped Additive Liquid in of control accuracy field. AvoidAutomated the expected to with respect (i.e. phvsical measurement do not rely real-time that do not havean accurate Systems LAs is being pumprevsor strokes).where an automated of solelyon a readout metering of irrelevant within+l- 5o/o concentrations additive that usedrlsrecommended it can control mixingrate.

6 . 1 .4D e n si ty
and slurry for density bothwell control thatthe slurryis pumpedat the designed It is critical couldresultin morethan5% errorin the performance. 0.2 ppg errorin mixingdensity A raiio due concentrations to the changein cementto waterand additive additive chemical for (calibrated the mud balance usinga pressurised aftermixing density Checkthe slurry appropriate range). flour lf the slurryis to be mixedon the fly and lt rs a blendof cemenVsilica and weightagent, Thesemix are systems usedwhenavailable. mixing recommended solidsfraction that it is of fraction by mixer) the volume control density (standard automatic density on a measured agent of weighting in for solidsbeingused. Thishelpsaccount variations the concentration density.In on impact waterdemandto mixto a controlled whichcan havea significant whenonly being the slurrycan becomeunmixable serious casesof blendsegregation, density. mixedto a controlled

6.1.5 AdditiveOrderof Addition

This of by has Slurrysensitivity beenshownto be affected the orderof addition additives. aheadof thejob, and when high is when mixwater prepared particularly important may be are and suchas microsilica Micromax used.Onlyadd retarders surfaceareaadditives

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by provided the the priorto starting mixthe slurry. Follow orderof addition to immediately by impacted the orderof effectsbetweenadditives in casethereare synergistic laboratory if mixwater thereis a timelimitfor holding beforepreparing addition. Checkwiththe supplier lmpact commercial can of on mixwater surface.Disposing this mix\,ivater havea significant Additionally are backup rnaterials nol available. and maydelaythejob if sufficient of simple disposal the fluid. restrictions prevent may environmental

6 . 1 .6C o n ta mi n a ti o n
pumping time on impact slurry can havea substantial by Contamination mudand/orspacer witha '10% development time and strenglh the and rheology. Confirm thickening For of contamination bothmud and spacer. linerjobs wherethereis the riskof the a include shutdownduring contaminated occurring abovethe hanger, contamination any integral whilesetting the timetests to simulate timecementmay be static thickening oacker.

Properties 6.1.7 Mechanical

in of the for Wherethe well is intended longterm production, impact changes pressure the needsto be assessed.Similarly, impactof and during well consiruction operation on formations fromdeeper changes suchas the impactof highertemperature ternperature pumping duringhighratestimulation temperatures sheaths, lowering or shallow cement of measurernent the may require Theseassessments needsto be assessed. operations and timescales at realistic properties the cement overextended of mechanical gas and temperatures pressure.Forhigh pressure wells,wherethereis significant shouldbe determined. for in drawdown laterlife,the potential creationof micro-annuli graph levelsof crossflow on somewells. The following Thesemay permitunacceptable a cementsealon a HPHTwell lt highlights of to highlighis datacollected assesthe integrity it is that sealintegrity poorwherea cementsealis lessthan20ft in length; can fail permitting zone to from communication a highpressure a low pressure

lsolation Breakdown: Pressure Differential vs Standoff lw G@dqualivcerent i$lEions- rc oovious qualtylsola0ons

E rz,ooo ) ro,ooo E 3 ! eooo

E r ^^^^ o.UUU
E

E z.ooo

250 200 150 ZonE (ft) CenentedSlandoffBtween

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properties setcementin an of for the In orderto evaluate requirements the mechanical usingService performance can modelling be conducted HPHTwell,cementsheath lt modelling. is or (CemStress, Welllife or lsoVision) BP EPTfiniteelement Company guidance. for recommended an EPT SMEis consulted appropriate that

7.0 SPACERDESIGN
designare: The mainareasof concemwithspacer
a

underHPHTconditions stability spacer agent selection weighting of underHPHTconditions rheology compatibility

and provides sections an HPHTwell,a singlecompany of that It is recommended in critical design. and spacer cementslurry integrated

7 . 1 Spacer Stability
and under agenton surface to the of Confirm ability the spacer support weighting the gradient margins critical whereporeand fracture conditions. This is particularly downhole can The surfacestability be resultin spacerdensitybeingverycloseto mudweight. in the freewatertest. Priorto pumping, density the usingthe standard cement assessed shouldbe pit shouldbe confirmed mud balance.Rheology with a pressurised and recorded shouldbe assessed downhole The stability usinga rheometer. confirmed recorded and of for any tube and determining freefluidafterleaving a minimum 4 usingthe BP settlement the unable support to the lf conditions. thistest indicates spaceris hoursunderdownhole out settling in the weighting agentconsider usinga baritesag testto quantify riskof solids tne spacer.

7.2 Selectionof WeightingAgent

The options weighting for agentare:
I

Barite Manganese Tetroxide Hematite Brine

7 . 2 .1B a ri te .

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7.2.2 Mlanganese Tetroxide

Manganese Tetroxide

Y .u. n.joi "', p" $'J;ffi H5liH:X,l ""|. T;"::? i ;il p wA :l: ?:""t;nrrj;;;;."-Yityp"stabilitv x1""1 rino"'i . no R (propnetaryi;l5d.l1i:.and ir is ""i??::?n ba rite) t"
; ;;HJ ff#;*" "
(Microm

Barite the mostcommonlv is rheologycan b" ;;;;;,,rrll:_l r systemr

ru,eriarand is re

o..,ou,,lXllillfl ngsitewhen j:i*"f,j:"Ti?:*t",",resu, ft:';f;1;:.#?:d?i,;li:iy. me mixing rvriciomlx a oJ."ilo""ur.

7.2.3 Hematite
Not recon unlessspace rormutati,nmended nn a staore ns stables;;;#ffit^ltisitv precludes thr of otherweighting spacerwth hematil* agents. ir r"r" oiinelse 7.2.4 Brin"

themoststable spacers rhebest l"glogy,^::t,at more with ruanganese Barite to "*o"n.uuiJYllj:0""-"Tetroxide o-"un nu" o"tt"i Jp"."l L!"i i"""i",rrction with .produce spacers

resrc,.nsin{::i:T?ffi=r,*,13'3;fl.,',F :_ frr:t;i,jf
r unstable highdensity solids.

s ib h uh s *ip pt, l'Iff!T"" g ffii': n we'ii;;;:*: sc a i ffi1#:J#iliiY,[f ", fluidscontair

hematite. J :??l!9

theuseof brine turbule stabiIity r no ." rtii"I' :"': :'^,::Tytentflow spacers,consir capacitv or

:"'"'s;:Jrs'"gi:ii:fi:l:":*k?;;ffi #"[:#s"T[:,il1,"r'uids,somebrines lf planning

or nign ruids roridJ;ffiJ:ffi!;*11" irln3ct these onrhe

;l*littmnt;;^r"Jjt#;Ti:f"*'J":,ffi i.Eiii iii{,tfff j*",';""J"'".

,['l;fr:,i:i#iJJ:i!T;i:"#T::: l,lasbecome tl.qormurare nossil]3 row orsorids solids,

7.2.SSpacerRheofogy sucit as tot to u.nieul'tuiiul' in brines' be rares. on li:g:-""Tenrshourd based unres.ifil., grr",irriprrlencetheannulus 'lte.iest in" p[n,iud ol p"1un.,lltPi1s maKes cannot achieved rr "t iobpump be rriition';;;#"'l"e *i ipui anominirnis,"':9^:ii gcota n toa ie in .5"1JJl tn,. n m ati ch v
Any decision t-o"Y::,ry""'ton n ia fluic tne predicted

opi-i,,iul"n ir"":F35{:jftg:::f'"""'"nt under actuar,.r"lll,i,?1"#;:il'## rI the plannedspacer design

7.2.6 SpacerCompatibitity
confirm the compatibility of the spacerwith both mud and cement. procedures for this are

tr" sortware. rnir"^i;]n "Lr!"ri"?t

;;' ; i; rl'Jj:"iil', fi :31.", s; ilil;l e en ". m t a p t 5i;ff1"1"T['"1":::::,'qa::, rheologies H Hr nd s(usq The trn.r H upur tnuJ"o'l' 'ln:oteter) ",s,flilr :orosythen co ition in an will
beu.slo]'ur"'"n'*Y,n ,r,

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fuilydocume:i:g Refer spacer to i" AptilSO. design r 4 1-0003 rurther andcompatibirtv ror io";=J, suiderines SRp in ;":?;::::::ig::,io condition;;i;:;;H:essary use HPHr atHPHr a "oui""" viscometei'L-i;;o'.=,,10?fi:ff;
Alsoconduct usinga 113 1/3.'^:/3 combination mud- spacer -19tt of -

to

cement ffi'J"",,'JiJI+?]l:,1,'!iJ rr wo..,-"'it"lin" resuriis and review ,."., +::;,'l;:;.:Tff,:Ju,#il.{modeling assess channeling resuttl"fi;;id;" couto acement to

ir

the [i11t'3i;fl?r*Jmine thickenins.oT^:no impeoance a acoustic (usinsUcA) the with5%tpu"-"," of cemenr

provides Irontog ,.11" 3".ou.ti;;;;4r". varuabre for data if ultrasonic "u",u"?ln"t"dinterpretation areused. "u"ru"iiJr],,ogs

8.0 INTEGRATION OF THEDESTGN W,THEXECUTION apprvHpHr just tooth ro wers as ff:fl*m'ilii3.1""r

i"1'";il:5'#ffffi:#:,.'i:'i-orpi,sj'1"'s',=,10 on pressures,"f,,1,1,1ti31."''. r2000 conrirm r,p,o psi), and bump caiabilities

:ffli,lff Ji"?,::,l"r,il;.;#8,i;!,1"-iiff,[:3i;i_li;d!:',:i
rng strings HpHTw on wellswithsimilar

quariried ror the'approp'i"," "njiii;;'.:?'jxil,::J::H,1.*:ffi?:"yr'i#Ti#:fi1 and spacer the atHr i?:ftll!::li,|y;:yrff:,f,;Jlffltre rud the as chemica,s
*il ;#'#;,.",[ffi:?*.

jr?ff titrh4iuii*ltilf :fr"'' if,*i:?'ifi

are contained in_SRp

i".$iffi iij;i#lJil,;#il":i'l:n'.i:L""."J t:*tfiirll#fi:il,:r"xifl';,il;il',rHililt::;;:,f

to racesrrrictio re n ro np,-",,,'e n il;#; :,LjT,ii1trlfiu'g: u." Sf**m ;ln::?io shourd be 5u,|#::J#:jji;.il'il.q*ted team with in sra dt."''iri iu; ther ffi* ".n?ffi#""J.,:' te te rormed l"=.,fi d rv r;; ;=" li,3?i,,I!is ei e i";: " ";l "t . Holecondition
. . . . Mud properties Pipemovement possible _ if

r"J1llil?*ll"tl"::'enr 4 1-0003, a' and comrnonty narowpprC *inio*l.ii,.T? keydifferencein HpHT is *",,",nJr!"#

orthis;;'o"li";,.,l,!l

Recomrnendationr

manuracrurer,s the srarrins, H:?"X1";?nt!-* the ,"n;;s data ror centrariser

spacer compatibirity _ spacerchemistry optimization

Ceniralisatior

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'

A documented system maintained the designated by responsible person, which unambiguously controls records and movements fromand between to, tanks.On offshore/ remotelocations ensurecementerhas responsibility be consulted to beforeany bulkmovements. Physically checkand keepa documented recordon locationof all BatchNumbers on all materials be used. to Often the complexity HPHTcementblendsand the number of of additives often lead to complexcementslurrycalculations. Reviewthe catculations officebased with servicecompanypersonnel confirmagreement to with detailedlaboratory desrgn.

' '

9.2 General
' ' ' ' QA/QCin HPHTbrending operations criticar A documented approved is Bp process shouldbe in placebeforeblending. Batch mixingis the preferred methodfor mixingail HPHT srurry designs.

when batchmixing not leavecentrifugal do pumpson for extended timeperiods, these pumpscan generate excessive heat in the slurry. Weighting agentscan be addedto the batchmixeraftermixingihe slurry if doubts existaboutthe abirity deriver quarity to a brend the rig site. to Mixingof HPHTsrurry designs"on-the-fry" needs carefurreview. Mixingequipment withsmall(<8 bbl)recirculating tanksis not recommended HPHTslurries shouldbe mixedwitha recirculating mixer. In caseswherea batchmixercan not accommodate entire the srurry volume, consider usinga largeblending tank. Mixfrom the recirculating mixing system into the largerblender.Lineup the downhole pumpsuction ii""r i" the btending tank. Thiswill provide larger a surface slurryvolumeto distribute mixing any inconsistency across. Additiveorderof additionduringexecution shouldbe matchedexacflywrthlab test order of additionto preventunexpected additiveinteractions. smallvolume jobs,alrdeadvolumes the mixing in systempiping surface lot lines, between tanks,etc.should considered be when catcutaiing uo'oitiu" requirements for the mix fluid. lf pre-hydrating fluidpriorto the cement mix job, service suppliers shouldnot add retarders untilit is timeto pumpthe slurrydownhole. Any mix fluidageingon location shouldbe minimized. Any potential from mix risk fluidageingshouldbe considered beforepumping HpHTslurryintoa well (ageing an

' ' . '

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