Академический Документы
Профессиональный Документы
Культура Документы
Cement System
Foam Quality
Quality (expressed in %) of the foam cement slurry is the % of the total volume occupied by the Nitrogen. For example: A bbl of foam cement slurry of 30% quality consists of 0.70 bbls of solids and liquids (water, additives) and 0.30% Nitrogen.
Other Benefits
Elastic Cement System Resilient / Withstands Pressure Cycling Help Maintain Zonal Isolation Help Prevent Gas Migration Compressibility Fluid Loss Control Improved Mud Displacement Help Prevent Long Term Gas Migration Minimize Remedial Cementing to Repair Casing
Ultra-Lightweight Cement System High Strength / Low Density Help Prevent Lost Circulation Economic saving Eliminate Stage Tool Save Rig Time
Physical Properties
Elasticity
High
Strength
Fluid Loss
Compressibility Low
Physical Properties
High
Viscosity
Low
Low
Permeability
Thermal Conductivity
Water Cap
Water Cap
Strain Gauge
Strain Gauge
54 in. 48 in.
9 5/ 8-in., 10 3 /4 -in.,
5/ 8-in., /8 -in Outer Casing 913 10 3 / 4 -in., 13 3/8 -in Outer Casing
3
Permeability Inlet
Permeability Inlet
6 in.
6 in.
Inlet 6Permeability in. of 20/40 Mesh Sand Pack 3 in. 5 / 2-in., 7-in., Permeability Inlet 9 5/ 8-in Inner Casing
1
3 in.
Foamed cements (Q = 0.18 - 0.38) prevent shear failure during internal casing pressurization Can withstand internal casing pressures up to 10,000 psi without shear failure Compressibility Can withstand mechanical cycling up to 100 times @ 90% of shear failure index Foamed cement generally exhibited no signs of matrix failure, either radially or circumferentially
Compressive Strength
Standard Cement @ 100 F
2000
Strength (psi)
Compressive Strength
Premium Plus Cement @ 100 F
2000
Strength (psi)
Compressive Strength
Premium (fine) Cement @ 100 F
1200 1000 800 600 400 200 0 6 lb/gal 12 Hour 8 lb/gal 24 Hour 10 lb/gal 72 Hour
Strength (psi)
Compressive Strength
Premium (coarse) Cement @ 100 F
800
Strength (psi)
Low Permeability
Low Permeability
From this scanning electron microscope slide you can visualize how to achieve low permeability even at densities of 8 lbs/gal. The low permeability is achieved because high compressive strength, low permeable cement will provide a barrier between the various bubbles inside the matrix of a foam cement so that anything passing through the overall matrix of the foam cement will have to pass through that low permeability cement in between the bubbles (bubbles are not connected!). When the foam quality rises above 50 percent, these bubbles start to interconnect and then you have a flow path through the matrix of the foam and you see the permeability increasing.
Foam Cement
Density (lb/gal)
Thermal Conductivity
Thermal conductivity of foam cement is fairly low. As can seen from this data of dried foam cerment at 230 degrees, thermal conductivities as low as 0.15 BTU degrees Fahrenheit. Thermal conductivity decreases as foam density decreases.
Single stage cement job across weak formation Prevent lost circulation Saves rig time Deep Water Shallow Flow Control Surface Casing Jobs In Deep Water Applications Helps Prevent Water/gas Influx After Placement
Prevent lost circulation during squeeze Maintain surface pressure indication throughout job
Job Design
Static Model Determine unfoamed slurry volume Calculate initial nitrogen concentrations
Job Design
When designing a foam cement job, two computer models are used. First, the static model is used to determine the volume of unfoamed slurry needed for the job and the initial nitrogen concentrations to generate foam slurry of a desired specified density. Then a cement job simulator is used to determine nitrogen needed for dynamic placement. When foam is pumped into place, you have additional pressure on the system due to friction. This additional pressure compresses the foam and increases its density, therefore, you need to add additional nitrogen to expand the foam to the desired slurry density and to fill the entire annulus. The simulator is also used to optimize the pump rates to insure good displacement throughout the job without exceeding the fracture gradient of the open hole.
In the next figure we see an example of a foam cement job. We have a 5 1/2 casing set in an 8 1/2 hole at a depth of 6400 feet. Fracture gradient of 10.7 lbs/gal exists at 5800 feet. Normally several stages of foam cement are pumped followed by a tail cement that is unfoamed. After the plug is bumped, the annulus is closed and an unfoamed cap cement slurry is pumped at the surface to compress the foam to the desired density and cause the cement to set up quickly at the surface conditions. This has several advantages. It is possible to accelerate the cap slurry so that it will set up within 4-6 hours after placement allowing the operator to continuew well operations in a short period of time.
4000 5000
12.5
6400
The base slurry consists of cement mixed at its normal mixing water requirement. If the cement slurry needs to be accelerated for application in cool temperatures, calcium chloride can be added to the base formulation. For deeper hotter applications, if the slurry needs to be retarded, a non-dispersing retarder can be used. This is not a typical lignosulfanate retarder which affect the stability of the foam. For some applications, fluid loss additives are added to the base slurry To the slurry, 1.5% by volume of foaming agent and 0.75% of foam stabilizer are injected through the suction side of the downhole pump These surfactants are used to generate and maintain a stable foam. Foam slurry stability is tested in the lab
Tests conducted with unfoamed base slurry: Thickening time Rheology (simulators use it to predict foam rheology) Fluid loss
Compressive Strength
Foam stability
Free fluid
Performing a Job
Cement Pump Truck
Injection Unit
Pump Foam Chemical
Nitrogen Unit
Foam Generator
Performing a Job
Typically the layout of the job consists of a cement pump truck to mix the base cement slurry Next, an injection unit to inject the foamer and stabilizer into the suction side of the downhole pump. The cement slurry is then pumped to the foam generator. In the nitrogen unit, the nitrogen is vaporized and metered as specified for the job. The nitrogen is also pumped to the foam generator. The generated foam cement slurry is then pumped to the well.
Recent technology includes automation of the nitrogen rate control, base cement density control and surfactant injection control. It is possible to automate the nitrogen rate to proportion a specified amount of nitrogen from the nitrogen pump truck. This eliminates any operator error that could be encountered when relying on simple verbal communication during the job. It is also possible now to automate the cement slurry density control. This regulates bulk cement delivery and mix water rates and eliminates operator error. Also automated is the amount and rate of injection of surfactants into the unfoamed slurry.
Offshore Capability
Self-contained
Automatic rate control 8 x 8 x 10 3000 scf/min max rate 17,000 psi max pressure 100 scf/min minimum rate
Backpressure Control
When conducting a cement job, one thing that needs to be controlled is back pressure, even if foam cement is not expected to return to surface. Without back pressure control, uncontrolled expansion of the foam at the surface can cause whats known as a cement blowout. The highly energized foam cement under pressure can expand quite a bit when it encounters atmospheric pressures. This must be prevented and in order to do that, it is important to maintain back pressure control.
Backpressure Control
Must be able to control the annular flow of a foam cement job Without backpressure uncontrolled expansion of foam at surface will cause Cement Blowout Subsea use can be controlled at seabed by hydrostatics
Backpressure control
Annulus chocking Cement slurry cap pumped after the job Offshore, water hydrostatic is often enough
Nitrogen
Metering
Generator
Density Measurement