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Free-Fall-Effect Calculation Ensures Better

Cement-Operation Design

Article in SPE Drilling Engineering September 1993

DOI: 10.2118/21107-PA

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FreeFallEffect Calculation Ensures
Better CementOperation Design
Wellington Campos, SPE, A.C.V.M. Lage, and Ademar Pogglo Jr., Petrobras Research Center
Summary. A cement-operation simulator was developed that takes the free-fall effect into account. This simulator allows prediction
of well-fluid behavior and pressure, making proper field-operation design possible. The proposed mathematical model was derived
from mass and momentum conservation laws by means of a macroscopic balance that reduces field equations to a ID model. The re-
sulting initial value problem is solved numerically with the Runge-Kutta method. Special care is taken to control the interfaces between
two different fluids while the system is in free fall. A microcomputer program has been implemented with a user interface that permits
complex well geometries. Other models are compared with the program to demonstrate its software capabilities.
Introduction
In most oilwell primary cement jobs, the cement-slurry densities
initially exceed the drilling-fluid density in the well. This density
difference causes a force imbalance that accelerates flow of the en-
tire fluid column while the heavier fluid is pumped down the string.
Therefore, the fluids in the well fall faster than the pump rate, creat-
ing a low-pressure region between the wellhead and the free-falling
column. The pressure in this region, improperly called a "vacuum,"
corresponds to the water-vapor pressure. Arnold 1 called this dy-
namic phenomenon the free fall or U-tube effect.
When free fall begins, the average fluid-column velocity changes.
Usually, the system accelerates until it reaches a new and temporary
state of equilibrium where the average velocity is kept constant.
If the system fluids are considered incompressible, the rate of return
will equal the rate of free fall. So when equilibrium is attained,
the rate of return is constant and differs from the pump rate. Ini-
tially, during the acceleration period, the flow rate of the free-falling
column exceeds the pump rate.
When the hydrostatic imbalance decreases (e.g., because the ce-
ment slurry passes to the annulus), decelerating begins. During this
period, the free-fall rate decreases to a minimum value, lower than
the pump rate, that may constitute another temporary state of equi-
librium. The low-pressure zone increases initially, while the free-
fall rate exceeds the pump rate. Later, when the free-fall rate is
less than the pump rate, the low-pressure zone diminishes, then
disappears.
Correct pressure and flow-rate predictions are important to plan
the field operation properly. Acceleration and deceleration of the
flow rate make displacement rate design difficult. If plug flow is
desired, care must be taken to avoid problems when the free-fall
flow rate exceeds the pump rate. On the other hand, the decrease
in the system rate can prevent turbulent cement-slurry or spacer
flow in the annulus.
Many authors have studied the causes and effects of this dynam-
ic phenomenon, but few models exist to simulate wellbore behavior
during cementing operations. Beirute 2 proposed a model based on
the assumption that the free-fall rate determines the equilibrium for
the dynamic pressure equation; he uses an iterative procedure based
on the bisection method to find the roots of his algebraic equation.
Wahlmeier and Lam 3 presented only the validation and some re-
sults of their model but showed little of their basic assumptions.
A mathematical model is derived based on the mass and momen-
tum conservation laws to calculate fluid behavior in the well dur-
ing free fall. Field equations are reduced to a ID model by use
of Eulerian area averaging. 4 The system of equations is reduced
to an ordinary differential equation on the basis of the assumption
that the system fluids are incompressible. The resulting initial value
problem is solved numerically by use of the Runge-Kutta method.
SIMENTAR, the cement-operation simulator based on this math-
ematical model, has been implemented. This paper briefly reviews
the theory, software capability, and validation of this simulator.
Theory
Fig. 1 shows the well diagram used to develop the model equa-
tions. It consists of a directional well, which includes the vertical
Copyright 1993 Society of Petroleum Engineers
SPE Drilling & Completion, September 1993
case, with vertical, buildup, and inclined sections. The number of
system fluids, shown in Fig. 2, may vary, although the most com-
mon are drilling fluid, wash, spacer, lead cement slurry, tail ce-
ment slurry, and displacement fluid. The "vacuum" interval also
is treated as a fluid.
Fig. 2 also shows a schematic of the relative position of each
constant diameter section where fluids are placed. The s coordinate
originates at the column entrance, follows the path down the column
and up the annulus, and ends at the annular exit.
The low-pressure zone at the wellhead is partly filled with the
fluid being pumped. As the pressure decreases, water vapor oc-
cupies the vacant volume. A simplifying hypothesis was adopted
to model the flow in the low-pressure zone at the top of the pipe.
The fluids injected are added directly to the vacuum/fluid inter-
face. The fluids in the system are considered incompressible, and
the walls of the pipe, casing, and hole are considered rigid. At the
annular exit, the boundary condition is given by
Pk=S=P a , ........................................ (1)
which holds during the whole process, with or without vacuum.
The boundary conditions at the column entrance depend on the
system state. If there is no vacuum and the fluid column is not free
falling, then
q=qinj .......................................... (2)
and dq/dt=dqin/dt. ,.................................. (3)
If a vacuum exists and the column is free falling,
Pk=1 =Pv' ........................................ (4)
A macroscopic balance is performed with mass and momentum
conservation laws 5 6 to obtain the differential equations. Then,
during free fall,
dq
dt
j=1 i=1 Aj
Eq. 5 contains a set of terms in the numerator that represent con-
tact and gravitational forces and contains inertial terms in the de-
nominator.
The pressures at each interface between constant-diameter sec-
tions are given with or without vacuum by
Pk=Pk+I+ .E
1=2
1Pi(Lij dq +Djghij)+LijldPfll ..... (6)
L Aj dt ds )
Eqs. 1 and 4 through 6 are used when a vacuum exists in the
system. Eq. 5 and the last known free-fall rate set an initial value
problem, solved numerically. When a vacuum does not exist, Eqs.
1 through 3 and 6 are used. In this case, iterations are not neces-
sary and pressures are calculated sequentially from the known an-
nular exit pressure.
175
 interface, MUL TIVIEW. 8 Both parts were developed by use of
Borland's Turbo Pascal Version 5.5, and SIMENT AR runs on IBM
PC, XT, or AT microcomputers or any true compatible.
The data can be imported from a hard or floppy disk. After a
case is run, the results are saved to a disk file. Graphs of pressure
at various locations (at the surface, at the bottom, and at a speci-
fied depth) may be plotted vs. time or cumulative injected fluid
volume. The same may be done for injection and return flow rates.
Some information is displayed on the screen during simulation
of the cementing operation so that the user can follow the calcula-
tions. Any input can be modified to perform sensitivity analyses
easily and promptly. Tables and graphic displays may be printed.

Comparison With Other Models

Wahl meier and Lam 3 presented two cases from their free-fall
simulator results. One case was used to compare their model with
measured oilfield data. Their results predicted observed system be-
havior fairly well, allowing them to consider their model validat-
ed. The other case documents their input data well and thus has
been compared with SIMENTAR results. Fig. 3 shows both curves
together. Good agreement between the predicted flow rates for the
two simulators indicates the reliability of SIMENT AR.
SIMENTAR simulated two field cases (see Table 1), and two
other computer programs were developed by cement service com-
panies. Fig. 4 compares SIMENTAR results with those from one
of these computer programs for a typical well in Fazenda Balsamo
field. 9 Fig. 5 compares SIMENTAR results with those from the
other service-company simulator for We1l3-RNS-125. The results
are very similar. Thus, we can conclude that SIMENTAR gives
answers in accordance with present "state-of-the-art" oil industry
simulators.

Fig. 1-Standard wellbore diagram.
The friction-loss terms are evaluated according to common equa-
tions for Bingham, power-law, and Newtonian fluids. This calcu-
lation was improved as a result of experimental work carried out
at Petrobras Research Center. 7
Computer Program
The computer package was named SIMENTAR from the Portuguese
words "SIMula<;iio" and "cimENTAR," which resemble the cor-
responding words in English (simulation and cement, respective-
Iy). SIMENTAR is composed of a simulator core and a user-friendly
Conclusions
The model accurately simulates an oilwell cementing operation. The
results proved to be in accordance with historical results in the liter-
ature and with results obtained from simulators developed by ce-
ment service companies.
SIMENTAR contains a user-friendly interface that allows the soft-
ware to be used easily and to be accepted by persons involved with
cement jobs. This program accurately estimates system pressures
and flow rates necessary to solve such problems as kicks, circula-
tion loss, and cement/formation adherence.
Acknowledgments
SIMENTAR resulted from the efforts of many people. We thank
Alberto H.V. Sarmento, Carlos F.H. Fonseca, Luis C.R. Rod-

Flow Rate Comparison

Vacuum
8,------------------------------------,
1=2
7 Well: Simulated Job
Casing: 9 5/8"
Displacement
Fluid c 6
~5
.0
.0

~4
Lead Cement iii
0:
Slurry 3
1=,5 ~ Pump Rate In
U:: 2
Spacer Flow Rate Out - Wahlmeier & Lam
1=6
Washer
- - Flow Rate Out - Proposed Model
1=7 O+-~~==~==~==~==~--~
Drilling Flui o 20 40 60 80 100 120
1=8
Time- min

Fig. 3-Comparison of SIMENT AR results with Wahlmeier

Fig. 2-Schematic representation of the well system. Lam's3 results.

176 SPE Drilling & Completion, September 1993

 TABLE 1-INPUT DATA
Flow Rate Comparison
14
Data Specifications Cases Field: Fazenda Balsamo
Pump Rate In
Well 7-FBM-39-BA 3-RNS-125 12
Casing: 951S"
Field Fazenda Balsamo Flow Rate Out Country: Brazil
Company A Model
Inclination vertical vertical
.S 10
Shoe depth, ft 4,265.09 12,408.14
Well depth, ft 4,265.09 12,450.79

.0
Casing type production intermediate .0 8
Bit diameter, in. 8.75 12.25 Q)

Casing diameter, in. 5.50 9.53 1ii

a: 6
Water depth, ft 0.00 167.32 ~
Collar depth, ft 4,166.67 12,290.03 0

Concerned depth, ft 3,280.84 9,842.52

u: 4
Leading slurry top, ft 1,640.42 8,202.10
2
Tail slurry top, ft 0.00 11,318.90
Nominal diameter, in.
Previous casing 9.625 13.375 0
Riser 20.00 0 5 10 15 20 25 30 35 40 45
Casing 5.50 9.625 Time-min
Previous liner
Liner Fig. 4-Comparison to a service company model.
Landing string
Landing string
Openhole 8.75 12.25
Depth, ft
Previous casing 328.08 7,450.79 Flow Rate Comparison
Riser 167.33 16
)
Casing 4,265.09 12,408.14
Previous liner 14 - -. Pump Rate In
)

Liner Flow Rate Out

Landing string c: 12
x Company B Model
Landing string
Openhole 4,265.09 12,450.79
'E
:s 10
:B, - - - Flow Rate Out
Proposed Model
:f
I
\'I
I"'"

*-
Displacement fluid
I
Weight, Ibm/ft 8.33 11.60
Well: 3RN8-125 'I(
Viscosity, cp 1.00 a: 86 Casing: 9 5IS"
Plastic viscosity, cp 42.00
Yield point, Ibf/l00 ft2 30.00 ~ Country: Brazil ~
u. 4
Volume, bbl 99.12 20.00
800.00
88.20
2 - - - r\ - I',
x"/

Tail cement slurry

Weight, Ibm/ft 16.00
o t 1 t I'

Plastic viscosity, cp 28.00

o 50 100 150 200 250
Yield point, Ibf/l00 ft2 4.00 Time- min
Volume, bbl 69.40
Landing cement slurry Fig. 5-Comparison to another service company model.
Weight, Ibmlft 15.90 16.00
Plastic viscosity, cp 28.40 28.00
Yield point, Ibf/l00 ft 2 4.00 4.00 t = time, t
Volume, bbl 118.00 173.40 p = density, m/L3
Drilling fluid {j = + 1 if j is in the column, or -1 if j is in the
Weight, Ibm/ft 10.50 11.60
Plastic viscosity, cp 30.00 42.00 annulus
Yield point, Ibf/l00 ft2 5.0 30.00
Spacer Subscripts
Weight, Ibm/ft 12.70 a = atmospheric
Viscosity, cp 1.00
Volume, bbl 30.00
f = friction
Washer i = fluid type
Weight, Ibm/ft 8.33 8.50 inj = injection
Viscosity, cp 1.00 1.00 j = constant-diameter section number
Volume, bbl 30.00 30.00 k = constant-diameter section interface
I = fluid interface
rigues, and Cleide Cavalheiro for their contributions. Special thanks v = vapor
also go to Petrobnis, which supported the research.
References
Nomenclature I. Arnold, E.S.: "Cementing: Bridging the Gap From Laboratory Research
A = area, L2 to Field Operation," JPT (Feb. 1983) 2843.
g = acceleration of gravity, Llt 2 2. Beirute, R.M.: "The Phenomenon of Free Fall During Primary Cement-
h = fluid-column height in a constant-diameter section, L ing," paper SPE 13045 presented at the 1984 SPE Annual Technical
Conference and Exhibition, Houston, Sept. 16-19.
L = fluid-column length in a constant-diameter section, L
3. Wahlmeier, M. and Lam, S.: "Mathematical algorithm aids analysis of
p = pressure, m/U 2 V-tubing during slurry placement," Oil & Gas J. (Jan. 7, 1985) 80.
q = flow rate, L3 It 4. Ishii, M.: Thermo-Fluid Dynnmic Theory of Two-Phase Flow, Eyrolles,
s = coordinate Direction des Etudes et Recherches d'Electricite de France, France (1975).

SPE Drilling & Completion, September 1993 177

 5. Campos, W., Lage, A.C.V.M., and Poggio, A. Jr.: "A Transient Model
Authors To Simulate the Free Fall Effect During Cement Operation in Oil Wells,"
Proc., 10th Brazilian Congo of Mechanical Engineering, Rio de Janeiro
(Dec. 1989) 2, 423.
6. Campos, W. and Lage, A.C.V.M.: "Varia9ao de pressao ocasionada
por movimento de coluna considerando 0 fluido incompressfvel," Mesa
Redanda Sabre Fluidos de Perjura,ilo (Nov. 1987) 1.
7. Silva, M.G.P. and Martins, A.L.: "Estimativa da perda de carga no
escoamento anular turbulento de fluidos de perfura9ao," Proc., 10th
Brazilian Congo of Mechanical Engineering, Rio de Janeiro (Dec. 1989)
2,9.
8. Sarmento, A.H.V.: Multiview user's guide, CENPES/Petrobnls (avail
able only by special request to A.C.V.M. Lage) (1988).
Campos Lage Poggio 9. Restum, MJ.L. and Campos, C.H.C.: "Minimiza9ao do Efeito Tubo
em "U" no Campo da Fazenda Balsamo," Mesa Redanda Sabre Reves
Wellington Campos has worked for Petrobras as a drilling timenta e Cimenta,ilo (Oct. 1986) 3, 2.
engineer since 1980. He worked in the field until 1984, when
he joined .Petrobras Research Center. Campos holds a BS SI Metric Conversion Factors
degree in civil engineering from Uberlandia Federal U. and bbl x 1.589873 E-Ol m3
an MS degree in petroleum engineering from Ouro Preto Fed-
ep x 1.0* E-03 Pa's
eral U. He currently is a PhD-degree candidate in petroleum
engineering at the U. of Tulsa. Antonio Carlos V.M. Lage ft x 3.048* E-Ol m
has worked for the Petrobras Research Center since 1986. ft2 x 9.290304* E-02 m2
Before working in research, he was a drilling engineer in in. x 2.54* E+OO em
charge of offshore field operations at the Campos basin. Lage Ibf x 4.448222 E+OO N
holds a BS degree in mechanical engineering from the Mili- Ibm x 4.535924 E-Ol kg
tary Inst. of Engineering and an MS degree in mechanical en
gineering from Rio de Janeiro Federal U. Ademar Pogglo * Conversion factor is exact. SPEDC
Jr. is the section head of software development for the Drill Original SPE manuscript received for review Oct. 14, 1990. Revised manuscript received
ing Sector at the Petrobras Research Center. He holds a BS Nov. 14, 1992. Paper accepted for publication March 1, 1993. Paper (SPE 21107) first
degree in mechanical engineering from Guaratingueta State U. presented at the 1990 SPE Latin American Petroleum Engineering Conference held in Rio
de Janeiro, Oct. 14-19.

178 SPE Drilling & Completion, September 1993

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