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