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SPE 24976
New Approach to High-Density Cement Slurries for Cementing
High-Pressure, High-Temperature Wells
N,C, Johnston, BJ Services Italia, and Maurizio Senese, AGIP SpA
SPE Members
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- All of these problems can be addressed by a new
A new tschnique has been developed for densified
slurry cementing operations employing a new
mix-water dispersible weighting agent, Ibis approach
has overcome many logistical, quality control and
slurry design problems encountered with conventional
dry-blended weighting agents.
Wells in the Po Valley of Nort!!ern Italy encounter
bottom hole pressures over t SO MPa and temperatures
to 190° C. Such conditions dictate the use of weighted
cement slurries with controlled thickening time, fluid
loss, slurry stability and acceptable theologies at both
surface and downhole conditions,
Historically, weighting agents such as barite, or
haematite, have been used to densify the slurries, the
materials being dry-blended into the cement at the bulk
plant.1’hese Mends, however, require considerable time
and expense prior to the job for preparation,
verification and transportation to rig site,
Despite such rigorous controls, some authors 1 have
reportw! problems caused by density segregation of the
weighting agent in the dry blend during tvmsportation
and storage,
Three additional factors must be considered when
using dry blends, Firstly, any changm in slurry design
afler initial blending are time consuming and costly
since they involve returning the material to the supply
bue for re-blending. Secondly, additional quantities of
material must be blended and tested, if field logs
indicate that the hole is larger than anticipated,
Thirdly, excess blend causes complications for storage,
and disposal poses environmental prcblems, In
ofl%horeor remote locations these three factors are af
even greater Comern,
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technique that uses a novel water dispersible weighting
agent. ‘This material allows great flexibility to
accommodate last minute design changes as there is no
pm-blending and the weighting agent is not added until
the slurry mix water is prepared. ‘l%is is particularly
beneficial in Italy since a proprietary blend of Class
“G” cement plus 40% silica flour is supplied dhct
from the manufacturers, All the rementing additivt%
can, therefore, be added to the mix water eliminating
the nwd to dry blend cement fbr these wells.
This paper describes the new technique and its field
application. It includes slurry properties and cost
comparisons between the new weighting agent and
traditional desigrs.
-t irw A-
Barite was the original weighting agent used in this
area, It has a moderate density (approximately ?,2
g/cm3) but requires significant amounts of water to wet
the partic!e surfaces. J.arge quantities of barite must,
therefore, be used in high density slurries, and this
leads to fir rheoiogies ad reduced compressive
strength, ~ From job experience the pm’ rheologicaJ
characteristics of barite slurries have resulted in
surface mixing problems, high displacement pressures
and loss of returns due to formation breakdown.
Haematite has a density of approximately 4,9 g/cm3
and was introduced to overcome many of the
shortcomings of barite, It has become the most
commonly used slurry weighting agent, Like barite,
haematite is formed by the milling of mineral ore and
is, therefore, subject to natural variationa in the raw
material and particle size distribution during the
manufacturing process. This can lead to difficulties in
designing an easily mixable slurry that is also stable
under well conditions,
143
-.
SPE 24976- NEW APPROACH ‘IO HN2H DENSXTYCEMENT SLURRIES FOR CEMEIWING
HIGIi PRESSURE HIGH TEMPERATURE WELLS
The new waterdispersible weighting agent is 96-98%
composed of a stable oxide of manganese, and has a
density of around 4.9 g/cm3 (similar .to that of
hamnatite).
The material is a secmdary product of
ferro-manganese manufacture, produced following
reaction at extreme temperatures (1000 - 1750°C).
Ninety-eight percent of the particles have diameters
less than 10 micron, co pared with haematite in the 20
- 100 micron range $’. The spherical form of the
particles is shown in Figure 1, and a typicaI particle
size analysis, by laser diffraction technique, is seen in
Figure 2.
The surface ar~ of the weighting agent is
approximately 3 m /g, ten times greater than typical
API cement, and it is this large surface which
contributes to its unique ability to remain suspended in
mix water.
It is supplied in “Big Bagsw of approx 1000 kg
capacity, or in 25 kg sacks, is easily handled following
normal health and safety procedures and produces less
dust during handling than either cement or haematite.
An illustration of the usual slurry densities achieved is
shown in Figure 3.
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The new weighting agent was extensively tested, both
in tk? laboratory and in field-scale trials, prior to its 07:00 Prepare 15 m sp cer @ 1950 kg/m3
use in the field. Testa include those described in API
Spec. 105, supplemented by tests for slurry stab~l~ty
(surfiice, and downhole 6), mix-water stabihty
(suspension characteristics) and mix water aging, T%e 15:40 Test lines, Pump 14 m9 spacer.
latter was investigated to ensure that job delays
involving prolonged storage of prepared mix-water did
not adversely affect slurry performance (thickening
time, etc.)
As can be seen from the results in table 1, the slurries 17:58 Displace w“ 1 m3 spacer, then 98,5 m3 mud,
were inherently stable with nc evidence of density
segregation. The prepared mix-water was also stable,
with no indication of weighting agent settling-out even
under static conditions, (’fable 2). Aging of prepared
mix water did show some evolution of properties with
time, but this effect was minor, even after 48 hours,
and probably within the bounds of experimental error,
(Table 4).
Taking job #5 in Table 1 as an example, this WMone
of the largest 9 5/8” liner jobs performed in Northern
Italy as the hole was washed out from 12 1/4” gauge to
an aver ge of 16 5/8”, r quiring a slurry volume of
160 mf at 2000 kglm-, f See figure 4 for well
“l%& $
schematic: depth 5382 m, top of liner 3379 m, BHCT:
132°C!,
.
.
$~
Class “G” silica flour blend: 188 rolls
New Weighting Agent: 39Tns
Mix Water (fresh): 78 m5
Total mix water: 100 m3
(Including weighting agent and all additives)
Calculated Mix Water Density 1363 kg/m3
Ed12m!w
The equipment required for cementing operations using
the new weighting agent is basically the same as fix
conventional weighting agents. The total storage
capacity for cement can be reduced by the vohme of
dry blended weighting agent, conversely the prepared
mix water storage capacity must be increased by the
absolute volume of the new weighting agent. A crane,
or fork lift truck, is sufficient fix handling the
weighting agent bags; some extra time should be
allowed for their addition to the mix water.
Se&figure 5 for equipment layout schematic.
,.. .
Ceme~
00:00 Spot equipme t and hookup lines.
08:00 Prepare 100‘f m mix water containing new
weighting agent and cement additivm. Check
water density against eoretical value
15:45 Commence mixing cement slurry, pumping into
intermediate tank
16:08 Pu p slurry downhole, average rate 1,46
mFhnin Pressure around 20 ME~
17:S6 Drop wiper plug
riite 1.6 m?’, pressure rising horn 20.8 to 24.
MPa. Rate reduced after 26-30 m!
displacement, as wiper plug exits drill pipe.
19:07 Bump plug, pressure up to 28 MPa.
19:11 Bleed pressure
19:20 Reverse circulate.
Observ@ s.
The new weighting agent was added quickly and was
rapidly dispersed in the mix water producing an
increase in density similar to the cahdated value,
After being pumped to the storage tanks virtually no
material was left in the bottom of the batch mixer tank.
Similarly, after the job was finished, the water storage
144
tanks and the slurry intermediate tank were free from
weighting agent deposit.
The slurry itself was fluid, stabie and easy to biend,
the density being easiiy maintained, Tabie 5 illustrates
an exampie of the consistency in siurry surface
rheoiogica.iproperties.
Pmt ~
Cement jobs in the Po Vaiiey are generaiiy evaluated
on the basis of cased hoie logs. CBL/VDL is the
normal iog combination, as high mud weights preciude
the use of ultrasonic toois, Whiie recognizing the
difficulty in comparing results from jobs where the
new weighting agent was used, with those where other
weighting materials were used, some striking
improvements have been s-en. Log sections shown in
Figurea 7, (obtained after J lb #3, Tabie i) and Figure
8, (a haematite design) illustrate a typical comparison.
Reasons for the improved CBL resuits in Fig 7 are
probabiy not due to a direct effect of the new material
itseif on tooi response. The acoustic impedance of
cement formulations containing the new weighting
agent are very simiiar to those containing haematite.
The most iikeiy reascn for the CBL improvements is
enhanced mud dispiacemeitt due to the superior
rheoiogicai propetiies of siurries containing the new
weighting agent. Newer ultrasonic toois capabie of
providing spatial resolution in high mud weights couid,
in future, resoive this issue.
L
145
1 The new water dispersible weighting agent has
eliminated many of the probiems associated with
conventional dry-biended materials.
2 Cement siurries using the new material are easiiy
designed and exhibit exceiient properties (good
rheoiogy, no sedimentation, etc.)
Last minute design changes due to weii conditions
have been made without probiem.
3 The new weighting agent is quickiy dispersed in
the cement mix water; there hss twen no
settiingaut of the material.
4 In ltaiy it has been used on sixteen cementing
operations to date. In ail cases the siurries were
fluid and prepared with ease. Post-job evaluation
resuits have been encouraging.
The material has also been used successthliy in
other countries.
5 The direct material cost per cubic metre of siurry
is simiiar to that of a conventional design.
However, when consideration is given to the
additional iogistics rwd haiidiing costs of haematite
systems, the new weighting agent can significantly
reduce costs,
 t
●
SPE 24976- NEW APPROACH TO HIGH DENSITY CEMENT SLURRIES FOR CEMENTING
HIGH PRESStJREHIGH TEMPERATUREWELLS Page 4

Figure 1
New Weighting Agent Mlcrograph

Particle Size Distribution Slurry Density Using

New Weighting Agent New Weighting Agent

25
‘OOT---- s1
3000~—
f

1
C 80,
:
u
I
I T i’ 20 u
?
2760 ~

; 60 1s v
I o
v I
a u

“ 40 10 !
0
I
u
: 20 6

0 0
0,1 1 10 100
Microns

— thmuldlve Volums - Volum6

Figure ?,
SPE 24976 -By Nell Johnston and Maurizio Senese Page 5

Case History, 9 5/8” Liner @6382 m, Trecate 19x,

-41A
(;-’) (“;’)
(“”6-’)
(“”~)
1.p
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“1
- ..

.—
-
‘“’- “’ Cle&_@* iha” Blend”-”A’
i
--.
+-,d
: —.— N 6 Bulk Silos 7--

r . . ..-. “;:::::::1----
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.- [1 J
iiud LlrIo
High Preoeu

Ma Itor
Se ,ofe
~ Slurry E23 ! I Slurry E3Zl I
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...._T ------- -J r
n ,1

,l.+Ijij~-~jii;hi[AddltWes
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.- ] T..lr-
Used As Into?mcdlatc
(Aloe tl.rry
L______ 1

7 $ ! __, __q__ ______, _

Figure 4 Figure 5

Case History, 9–5/8” !,iner ot 5382 m, Trecate 19x

Slurry Density 2(200 Kg/m3 using New Weightirq Agent
.51-- -1-3000
— DENSllY, Kg/m3 $
------ FLOW RATE, m3/min 1’
----- PRESSURE, MPo/t O 1
4

@~f+’r r’frrv-r-p ~=-v~+f I I 8 1 I r7-m-p-

85 110 125 160 185 210 235 ’260 285
EIAPSED TIME, MIN

Ffgure 6

147
 ●
1 ●

SIPE 24976- NEW APPROACH TO HIGH DENSITY CEMENT SLURRIES FOR CEMENTING
HlGH PRESSURE HIGH TEMPERATUREWELLS Page 6

Figure 7 Figure 8
New Weighting Agent iiaemetite Slurry

148
~= , . .:

●
✎☛

SPE 24976 -By Neil Johnston and Maurizio Semse Page 7

WEK3HTED SLURRY COMPARATIVE LABORATORY HEWJLTS

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I SLURRY No. 11$1 2 3 4 5

WEIGHTINQ AC3ENT ame Haofnalts Naw A@d !+asfnano Ndw ~sd

mm 1*2 *889 1aQl 1 eel 1981
Ma TwE ; t--- 7’Lknf s-we” Ltw D-a/r Lilw s-w )Linar @-u@’ Lhlw

A ?! &
NIA o NIA o
NIA o NIA o
(*$E~NtJ ME)
MUID L088 @ BNCT -G- 76 a16 m
c,
RWEOLO~Y. FA#lN W I m“ 27 I u“ w I 88” 1 w I 88”
800 mm >4w/>wO leO\14Q s3001NIA 1 lis/@
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>300/188 116/80 me/8e i se/48
a481~40 _ele8 180180 4a/2a
t=+=+
144177 48/40 e71aa WI*4
E 1618 10/4 $1s 8/4
101s $/3 *la eta
IWA ./a N/A 7/a
NIA wila NJA 16t8
P!
0.6 1.0 0.6 0.0 e.e
0.8 1.0 i 1.0
3.0 $0
— T- 0.6 I O,e 0.6 / 0.3-
!

r----+%

-IL- J I I 5% LEss
I

NOTE8 :
-—. NIA : NOT AVAkBAlJ5
awa : DY WEWIT OF CU88 WLICA PROPW7ARY BLEND
● 8W t4ffER&NeE 6
$Lt#)RY COST 18 %l@8@”@ COST, INCLWD!NQ MNDUNQ

149
 ●
b
SPE 24~6 APPROACH ‘X) HIGH DENSITY CEMENT SLURRIES FXXtCEMENTING
- NEW
HIGH PRESSURE HIGH TEMPERATURE WELLS Page 8

.
U?nwQos Mix wat@r
DWWL BHCT Bottom hole circulating temperature
BHST Bottom hole static temperature
After addition of 70% of New BWOC by weight of cement
Weighting Agent During agitation 1430 BWOB by weight of cement.kilica blend
PPg: pounds per gallon
After 14 min static 1430
(sampled off tank bottom)

After 30 min static 1430 psi * 6.894757 E-03 = MPa

(sampled from fluid surface) “F (“F-32)/l.8 =
0

BPM * 2.649780 E-03 = m5 /rein

After 30 min static 1430 8 * 0,3048 = m
(sampled off tank bottom)
l@lQM%@Qf@i
Aiter addition of all weighting
agent during agitation 1600 The authors extend their thanks to the managementof
AGIP S,p.A., Italy and IN Services for permission to
pttblish this paper. The assistance of G. Romano of
AGIP I&bOratoryand Phil Rae of BJ Services are
particularly appreciated.
e mixed water prepared above was used to make 6
9
m of slurry at density 2130 kg/m3

1 Pace, R.S., McEitlesh, P. M., Cobb, J.A.,

Olsberg, M.A.: “Improved Bulk Blending
150 ii5 Techniques for Accurate and Unifbrm Cement
;:: 104 82 Blends”, SPE 13041 (1984),
100: 58 49
6: 10 10 2 Nelson, E,B., Baret, J, F., Michaux, M,: “Well
3: 6 8 Cementing”, ed E,B. Nelson, Elsevier Science
Publishing Co., New York, NY (1990). Chapter 3.
Field rheology readings are higher than those reported
in the lab, although this could be due to differences in 3 Carter, G,, Smith, D,K,: “Properties of Cementing
mixing energy and slurry temperature (11” vs 27°C), Composition at Elevated Temperatures and
Pressures”, SPE 892 (1957).

XiiMM, Mix YWL4AIS 4 Anderstm, C, and Wilson, S,: Personal

Communications (192),

62 0 C 5 Spec 10, “API Specifications for Materials and

0 320 Testing for Well Cements”, fifth edition, API,
8 325 Washington D,c,, (July 1 1990),
295
;: 301 6 Greaves, C,, and Hibbert, A.: “Test lmprovea
48 282 Measurernsnt of Cement-Slurry Stability’, Oil &
Gas Journal, (Feb 1990), 35-40,
Table 5. ~
Obtained when cementingjob no #3 (see Tab!e 1)

3QJki2f!QJ’Yu&Mi
200 135 135 136
100 76 76 74
6 14 13 14
3 10 9 10
150