Applied Well Cementing Engineering

Front-Matter_2021_Applied-Well-Cementing-Engineering
Front Matter
Copyright_2021_Applied-Well-Cementing-Engineering
Copyright
Contributors_2021_Applied-Well-Cementing-Engineering
Contributors
Foreword_2021_Applied-Well-Cementing-Engineering
Foreword
Acknowledgments_2021_Applied-Well-Cementing-Engineering
Acknowledgments
Chapter-One---Introduction-to-cementing-en_2021_Applied-Well-Cementing-Engin
Introduction to cementing engineering
What is well cementing?
Why do we cement wells?
How do we cement wells?
Avoid common cementing problems
Overview of the contents
Chapter-Two---Casing-string-and-desig_2021_Applied-Well-Cementing-Engineerin
Casing string and design
Casing string and design
Casing types and functions
Casing types and functions
Casing setting depth
Casing size selection
Casing grades and performance properties
Casing grades
Non-API casing grades
Casing performance properties
API casing burst strength (API historical)
API casing collapse strength (API historical)
API casing tension strength
Non-API casing performance properties
Casing triaxial yield
Casing derating under elevated temperature and casing wear
Casing design fundamental
Casing design principle
Casing strength
Casing collapse under combined loads
Casing design factors
Casing loads
Casing load in burst design
Casing load in collapse design
Casing load in tension design
Casing load in triaxial yield design
Casing connection
Casing connection types
Connection performance, evaluation, and qualification
Casing connection selection
Cementing quality and planning consideration in casing design
Casing external pressure of cemented casing
Top of cement in deepwater well
Casing design example
Further Reading
Chapter-Three---Casing-equipment_2021_Applied-Well-Cementing-Engineering
Casing equipment
Casing centralizers
Bow-spring centralizers
Conventional bow-spring centralizers
Semipositive bow-spring centralizers
Rigid bow centralizers
One-piece bow-spring centralizers
Spiral bow-spring centralizers
Solid body centralizers
Low-friction solid body centralizers
Pipe-bonded centralizers
Integral centralizer subs
Stop collars
Selection of casing centralizers
Anticipated or experienced drilling challenges
Washouts
Differential pressure sticking
Formation interactions
Formation abrasiveness and wear resistance
Keyseats or axial grooves
Breakouts
Bedding plane instability
Hole cleaning
Drag forces
Axial load
Casing rotation
Annular clearances
Axial and side forces
Cementing practices and objectives
Cementing program and practices
Displacement efficiency
Casing stand-off
Rotating while cementing
Reciprocating while cementing
Fluid agitation
Equivalent circulating density
Considerations for simulations
Logistics
Testing of casing centralizers
Closing remarks on casing centralizers
Float equipment
Functions
Valve types
Flapper valves
Plunger valves
Inner string cementing
Options and specifications
API test category
Nose type
Float-shoe ports
Overall dimensions
Burst and collapse
Back pressure and bump pressure
Reamer shoes
Jamming angle
Blade OD
Flow-by area
Reaming structure
Other considerations
Guide shoes
Single vs. double valves
Field service
Storing and transportation
Inspection
Installation
Running in hole
Circulation
Casing autofill
Cementing
Drillout
Testing of float equipment
Stage-cementing equipment
Applications
Stage tool types
Equipment specifications and selection considerations
Field service
Equipment inspection
Operations planning and reporting
Drillout
Quality and testing
Cementing plugs
Plug specifications
Operational considerations
Quality and testing
Quality
Closing remarks
References
Further reading
Chapter-Four---Casing-running_2021_Applied-Well-Cementing-Engineering
Casing running
Casing running equipment and field practices
Casing running preparations
Casing running equipment
Running procedures
Drag
Compression
Floating casing
Torque and drag reduction methods
Tension
Torque
Swivels
Surge and swab
Circulating subs
Chapter-Five---Fluids_2021_Applied-Well-Cementing-Engineering
Fluids
Introduction
Wellbore in the context of cement fluid design
Well design
Drilling fluid in the context of the cement fluid design
Drilling fluid properties
Hole conditioning and prejob circulation
Filtrate
Filter cake
Formation properties
Formation fluids
Permeability and porosity
Fractures
Salt
Clays and formation sensitivity
Temperature
Regulatory requirements
Regulating agencies
Volume and length requirements
Compressive strength requirements
Incorporation by reference
Select the fluid sequence
Washes
Spacer
Lead and tail cement slurry
Displacement fluid
Fluid design considerations
Density
Drilling fluid density
Spacer density
Cement slurry density
Rheology
Temperature
Pressure
Stability
Solids content
Thixotropy
Set cement properties
Operational considerations
Location
Onshore
Offshore
Extreme heat
Extreme cold
Arctic
Well site logistics
High pressure treating lines
Communication system
Mix water supply rate
Bulk supply rate
Displacement fluid supply
Rig returns
Water supply quality
Onshore (fresh) water supply
Offshore water supply
Water temperature
Bulk cement
Bulk vessels
Blend contamination
Blend stability
Bulk temperature
Slurry design
Slurry specifications
Absolute volume calculations
Density
Yield
Mix water
Solid additives
Liquid additives
Salt
Performance requirements
Strength and permeability
Long-term stability
Flexibility
Pumping time
Rheological stability
Static gel strength development
Fluid loss control
Stability (free fluid and sedimentation)
Gas migration control
Cement chemistry considerations for slurry design
Cement manufacturing and clinker components
Hydration products
Heat of hydration curve
Preinduction period
Induction period
Acceleration period
Deceleration period
Preinduction period
Volume changes
Class of cement
Class A
Class B
Class C
Class D
Class G
Class H
Class K
Class L
Construction cement
Additives
Silica
Extenders
Clays
Pozzolans
Fly ash
Lightweight particles
Sodium silicates
Nitrogen and foamed cement
Weighting agents
Accelerators
Retarders
Dispersants
Fluid loss control
Gas migration control additives
Gelling agents
Foaming agents and stabilizers
Lost circulation materials
Antifoams and defoamers
Additives for flexibility
Self-healing additives
Expanding agents
Thixotropic agents
Surfactants
Interaction of additives
Spacer design
Performance requirements
Displacement efficiency
Fluid compatibility
Corrosion prevention
Additives
Base fluid
Weighting agents
Dispersants
Gelling and viscosifying agents
Surfactants
Laboratory testing
Sampling
Slurry preparation
Thickening time
Compressive strength
Destructive testing
Nondestructive testing
Long-term testing
Rheology
Static fluid loss
Slurry stability
Compatibility
Deepwater
Foamed cement
Shrinkage and expansion
Static gel strength
Additional tests
Dynamic settling
Mechanical properties
Compatibility and rotor testing
Laboratory test results in the context of cement hydration
Conclusion
References
References
Further reading
Chapter-Six---Cementing-hydraulics_2021_Applied-Well-Cementing-Engineering
Cementing hydraulics
Fluid rheology
Newtonian fluids
Bingham plastic fluids
Power-law fluids
Herschel-Bulkley fluids
Dilatant fluids
Hydraulics models
Hydrostatic pressure
Friction pressure
Flow regimes
Newtonian fluids
Bingham plastic fluids
Power-law fluids
Herschel-Bulkley fluids
Frictional pressure loss
Newtonian fluids
Bingham plastic fluids
Power-law fluids
Herschel-Bulkley fluids
Flowing BHP
Displacement pressure
Surge and swab pressure
Summary
Exercise problems
References
Chapter-Seven---Job-simulation-and-desi_2021_Applied-Well-Cementing-Engineer
Job simulation and design
Introduction
Cement job objectives in the context for simulation
What is a cement job simulation?
Overall recommended workflow: Cement job simulation
Cement job simulation outputs: What are they used for?
Recommended workflow for cement job simulation
Collect and input the well description and any available well data
Surface equipment description
Tubular(s) description
Hole size
Directional survey
Formation data
Formation pressures
Formation fluids
Lithology
Temperature details
Temperature input mode
Centralizer
Collect and input all the known fluids data
Define drilling fluid
Define spacer/wash
Define slurries
Slurry composition
Sack sizes
Calculation results
Blend properties
Concentrations
Mixing parameters
Silica ratio
Post addition
Additive breakage
Laboratory tests
Define displacement fluid
Design additional fluids
Design fluid based on density
Design fluid based on rheological properties
Design fluid based on compatibility
Design fluid based on component availability
Design fluid based on set cement properties
Design fluids volumes, pump schedule, and fluids preparation requirements
Recommended workflow-Fluid volumes
Recommended workflow-Pump schedule
Recommended workflow-Fluid and blend preparation
Perform hydraulics and temperature simulation
Simulate prejob well circulation
Simulate cementing operations
Minimum hook load
Compressible simulations
Simulating temperature schedule for cement laboratory testing
Standalone calculation aids
Perform casing centralization simulation
Centralization standoff calculations
Optimizing the centralization design
Fluid positions
Running forces
Surge and swab
Casing stretch
Hook load and surface torque during cementing
Iterate on the centralizer design
Perform annular displacement simulation
Perform the annular displacement simulation
Top of simulation
Type of simulation
Mechanical separators
Imposed standoff
Perform special case simulations examples
Critical static gel strength
Gas migration
Gas migration risk factors
Special well conditions
Liner top and external casing packers
Shallow gas well
Iteration on the design
Plug design
Recommended workflow-Plug-Volume optimization
Recommended workflow-Plug-POOH fluid mixing simulation
Cement sheath stress simulation and calculation
Section analysis and possible failure modes
Compression failure mode
Traction failure mode
Microannulus failure mode
Output plots may be used to understand the stresses and when they occur
Compressive stress plot
Tensile stress plot
Microannulus plot
Sensitivity analysis
Iteration on the cement design based on cement sheath stress calculations
Foam cement simulation and design
Foam cement design
Temperature selection
Nitrogen ratio selection
Back pressure
Foam placement simulation
Generate job program and reports
Simulation for job evaluation
Recommended workflow-Placement evaluation-Importing data
Recommended workflow-Placement evaluation-Setting the job sequence
Recommended workflow-Job evaluation-Pressure matching
Recommended workflow-Job evaluation-Additional comparisons
Detailed workflow described in this chapter
Summary of the overall workflows in this chapter
References
References
Software
Web pages
Chapter-Eight---Temperature-predictio_2021_Applied-Well-Cementing-Engineerin
Temperature prediction
Introduction
Temperature logging
The physics
Physical principals
Contributing factors
Numerical modeling
Circulating temperature
Flow rate and temperature evolution
Well inclination
Pipe diameter
Fluid viscosity
Temperature in cementing
Prejob circulation
Temperature during cementing
Effect of flow rate
Effect of lithology
Water temperature
Temperature recovery
Heat of hydration
Predicting slurry temperature
Using simulators
Thermal parameters
Fluid viscosity
Sensitivity study
References
Chapter-Nine---Displacement-efficienc_2021_Applied-Well-Cementing-Engineerin
Displacement efficiency
Introduction
Cement logs
The physics
Nonuniform axial velocity
Flow irregularity
Transverse flow
Flow transition
Multiple non-Newtonian fluid system
Buoyancy driven flow (gravity-induced flow)
Diffusion and instability
Casing movement
Methods
Equations
Semiempirical approach
A simple dual-pipe model
Lubrication model
Reduced CFD model
Velocity
Mesh
Fluid transport
Full CFD model
Experimental models
Using simulators
Know the limitations
Spatial and temporal accuracy
Memory cost and CPU time
Validating simulation results
Improving displacement efficiency
References
Chapter-Ten---Job-execution_2021_Applied-Well-Cementing-Engineering
Job execution
Introduction to job execution
Prejob preparation
Basis of design
Design summary
Acceptance criteria
Hazard assessment
Assumptions
Cementing fluid designs
Operational requirements
Bulk plant or facility
Inventory
Dry blending
Blend transfer
Dispatching and transport
Samples
Laboratory testing
Ambient temperatures
Operational sequences
Mixing style
Equipment operations
Cement unit
Liquid additive unit
Batch mixer or mixing tank
Treating Iron
Bulk storage system
Top connections
Data acquisition
Equipment maintenance and certifications
Contingency planning
Excess quantities and transfer losses
Job execution events
Equipment redundancy
Competency management
Wellsite execution
Health, safety, and environment
Site assessment
Logistics
Equipment setup
Water source
Communications
Rig-up
Equipment setup
Equipment readiness
Cementing fluids preparation
Container selection
Source water temperature
Order of addition
Hydration times
Materials management
Inventory
HSE
Measurement
Samples
Wellsite confirmation of job design
Prejob execution wellsite meeting
Mix fluid quality assurance
Viscosity
Density
Job execution
Pressure testing
Wellbore fluid conditioning
Pump schedule
Spacer
Cement
Displacement
Equipment cleaning
Postjob reporting
Material balance
Electronic data
Lessons learned
Final words
Chapter-Eleven---Cement-job-evaluatio_2021_Applied-Well-Cementing-Engineerin
Cement job evaluation
Introduction
Cement job information
Well observation and monitoring
Pressure integrity tests
Cased-hole acoustic logging
Types of logging tools
Method of acoustic log interpretation
Construction of the wellbore
Comparison of log sections
Correlation at points of change
Consideration of the key factors that affect bond
Conclusion of the interpretation
Interpreting channels
Small channels
Large channels
Mud channels
Crossflow
Temperature logs
Summary
References
Chapter-Twelve---Plug-and-abandonment_2021_Applied-Well-Cementing-Engineerin
Plug and abandonment
Well control and cement plug considerations
Cement job computer simulation
Preventing cement contamination
Mechanical separation of fluids
Work string considerations
Operational considerations
Example cement plug job procedure
Additional slurry laboratory test
Cement blending, storage, and surface equipment
Index_2021_Applied-Well-Cementing-Engineering
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