SPE DISTINGUISHEDis funded

through a gthrough a g

SPE FOUThe Society gratef

those companies thatby allowing the

to participate

And special thanks to The Americapand Petroleum Engineers (AIME) fo

D LECTURER SERIESprincipallygrant of thegrant of the

NDATIONfully acknowledgest support the programir professionalsas Lecturers.

an Institute of Mining, Metallurgical,g gor their contribution to the program.

Cementing PaA Local Solution to

SPSPInternat

David J. Mack, MaraDavid J. Mack, Mara

aradigm Shift: a Global Problem

EEtional

athon Oil Co., SPEathon Oil Co., SPE

Out

Introduction Introduction Cement strength requCement strength requCement strength requCement strength requSolving a consequentSolving a consequentL b kL b kLab workupLab workupField examplesField examplesEconomicsEconomicsConclusionsConclusionsConclusionsConclusions

tline

uirementsuirementsuirementsuirementstial problemtial problem

IntrodIntrodArea of

uctionuctionInterest

IntrodIntrodCement Job

Cement across low frCement across low frProvide zonal isolatioProvide zonal isolatioProvide zonal isolatioProvide zonal isolatiozoneszonesStand up to stresses inStand up to stresses inStand up to stresses inStand up to stresses inhydraulic fracturinghydraulic fracturingE i lE i lEconomicalEconomical

uctionuctionb Objectivesrac gradient shalesrac gradient shaleson for multiple payon for multiple payon for multiple pay on for multiple pay

ncurred duringncurred duringncurred during ncurred during

IntrodIntrodHistory of Gas Sha

TwoTwo--stage jobsstage jobsThixotropic slurriesThixotropic slurriesThixotropic slurriesThixotropic slurriesMicrospheresMicrospheresFFFoamFoamSilicateSilicate--extendedextended

uctionuctionale Well Cementing

IntrodIntrodLightweight Silicat

Original Lightweight S

Density (ppg) Yield (ft3/11.5 2.91

12.0 2.48

12.5 2.15

13.0 1.91

13 5 1 7113.5 1.71

uctionuctionte-Based Cement

Silicate Cement (80°F)72-Hour Compressive Strength

/sk)72 Hour Compressive Strength

(psi)470

700

1,050

1,550

1 9411,941

Cement StrengtCement StrengtNormally consider onNormally consider onNormally consider onNormally consider oncompressive strengthcompressive strength2,000 to 5,000 psi is t2,000 to 5,000 psi is t, , p, , pTensile and flexural sTensile and flexural s8 psi tensile strength 8 psi tensile strength p gp gcasing string (equatescasing string (equatespsi compressive strenpsi compressive strenC ki f ilC ki f ilCracking failures are Cracking failures are the use of lowthe use of low--densitydensitystrength cementstrength cementstrength cement strength cement

h Requirementsh Requirementsnly unconfinednly unconfinednly unconfined nly unconfined

typical requirementtypical requirementyp qyp qstrength also importantstrength also importantrequired to support a required to support a q ppq pps to approximately 100 s to approximately 100 ngth)ngth)

ll b li i d i hll b li i d i hall but eliminated with all but eliminated with y and lowy and low--compressive compressive

IntroduIntroduLightweight Silicat

12 ppg density12 ppg density12 ppg density12 ppg densityCement 4,000 feet plus iCement 4,000 feet plus iV i lV i lVery economical versus Very economical versus other cement blendsother cement blendsUsed on over 2000 wellsUsed on over 2000 wells

uctionuctionte-Based Cement

in single stagein single stagej b dj b dtwotwo--stage cement jobs and stage cement jobs and

s since 1998s since 1998

Consequent

The problem:The problem:–– Cement sheath with 7Cement sheath with 7

strength can’t be “seestrength can’t be “seelogging equipment avlogging equipment avBasinBasinBasinBasin

–– Longer waitingLonger waiting--onon--ceceadditional strength deadditional strength degg

–– Result is several daysResult is several dayswellwell

tial Problem

700 psi compressive 700 psi compressive en” with conventional CBL en” with conventional CBL vailable in the Appalachian vailable in the Appalachian

ement time required for ement time required for evelopmentevelopmentpps of lost production per s of lost production per

Free

PipePipe

Channel - ?

Good BondBond

How Can WCem

Compressive strengCompressive strengCompressive strengCompressive strengattenuation relationattenuation relation

G l 1 000 iG l 1 000 i–– Goal: 1,000 psi comGoal: 1,000 psi comshould yield enougshould yield enoug

hi ihi ito achieve attenuatito achieve attenuati

We See The ment?

gth and acousticgth and acousticgth and acoustic gth and acoustic nshipnship

i hi hmpressive strength mpressive strength gh acoustic impedance gh acoustic impedance iiionion

How Can We Se

Compressive strength anCompressive strength anCompressive strength anCompressive strength anrelationship.relationship.

1 000 i i t1 000 i i t1,000 psi compressive str1,000 psi compressive strenough acoustic impedanenough acoustic impedan

e The Cement?

nd acoustic attenuationnd acoustic attenuationnd acoustic attenuation nd acoustic attenuation

th h ld i ldth h ld i ldrength should yield rength should yield nce to achieve attenuationnce to achieve attenuation

Lab WLab WObjectives For

1,000 psi compressiv1,000 psi compressivCBL must “see” it in CBL must “see” it in 12 ppg density12 ppg densityppg yppg yNormal thickening timNormal thickening timEasy to mix and pumEasy to mix and pumEasy to mix and pumEasy to mix and pum

WorkupWorkupr New Cement

e strengthe strength72 hours72 hours

memempmpmpmp

Lab WLab WChem

Compressive strengthCompressive strengthusing Class A/Type I using Class A/Type I

Pozzolan powder discPozzolan powder discppat concentration up toat concentration up to

Changing portland ceChanging portland ceIII cement played a laIII cement played a lap yp ycompressive strength compressive strength

WorkupWorkupmistryh hurdle tough at first h hurdle tough at first

cement @ 12 ppgcement @ 12 ppg

covered to be effective covered to be effective o 10%o 10%

ements to ASTM Type ements to ASTM Type arge role in achieving arge role in achieving g gg ggoalgoal

Lab WLab WNew Blend Slu

WorkupWorkupurry Properties

Lab WNew SlurryNew Slurry

Thickening Time, HrThickening Time, Hrg ,g ,Temperature, Temperature, 00FFPressure psiPressure psiPressure, psiPressure, psiFree Water @ 90Free Water @ 9000, m, mTime to 50 psi, Hr:MTime to 50 psi, Hr:MTime to 500 psi, Hr:MTime to 500 psi, Hr:Mpp24 Hr Strength, psi24 Hr Strength, psi48 Hr Strength psi48 Hr Strength psi48 Hr Strength, psi48 Hr Strength, psi72 Hr Strength, psi72 Hr Strength, psi

Workupy Propertiesy Propertiesr:Minr:Min 2:412:41

80801000100010001000

mlml 00MinMin 1:451:45MinMin 8:518:51

63063090190190190110101010

Lab WoNew Slurry ComprNew Slurry Compr

1400

1600

1800

sisi

1300

1185

1000

1200

1400

tren

gth,

ps

tren

gth,

ps

630

875880 901

600

800

1000

pres

sive

St

pres

sive

St

387

567

200

400Com

pC

omp

00 24 48

Tim

orkuppressive Strengthsressive Strengths

1625

1345

1057

12761307

10431010

700

1010

50:50:2 14.5 ppg

Corporate Lab

Region Lab

Original LWSC

72 96 120 144

me, hr

Field ExamField ExamKanawha C

Good bond log according to CBL/VDL over this intervalover this interval toward the bottom of the hole. The log was run about 96 hours after the plug was down on the 4-1/2 production casing cement jobcement job.

mple WV-1mple WV 1County, WV

195 sacks

TD = 5,750 ft.

Fill = 3 230 ftFill = 3,230 ft.

Field ExamField ExamKanawha C

Fair to good bond log according to CBL/VDL over this intervalover this interval toward the bottom of the hole. The log was run about 80 hours after the plug was down.

mple WV-2mple WV 2County, WV

184 sacks

TD = 5,499 ft.

Fill = 3 549 ftFill = 3,549 ft.

EconomEconomCycle Time

100 well program, IF100 well program, IFGas sells for $5 00/MGas sells for $5 00/MGas sells for $5.00/MGas sells for $5.00/MLost production days Lost production days 5 d ll 5005 d ll 5005 days per well = 5005 days per well = 500500 days x $1000/we500 days x $1000/we

ics Ofics Of…e Reduction

P = 200 MSCFP = 200 MSCFMSCFMSCFMSCFMSCF

= ($1000)/day cash flow= ($1000)/day cash flow0 d /0 d /0 days/year0 days/yearell = ($500,000)ell = ($500,000)

EconomEconomCycle Time

New slurry costs $1,5New slurry costs $1,5100 wells x $1,500 = 100 wells x $1,500 = Reduce WOC time byReduce WOC time byReduce WOC time byReduce WOC time byNet value = $500k Net value = $500k -- $$

ics Ofics Of…e Reduction

500 more500 more$150,000$150,000

y 5 days per welly 5 days per welly 5 days per welly 5 days per well$150k = $350k$150k = $350k

ConcluConclu

Cement does not need seCement does not need secompressive strengthcompressive strength

usionsusions

everal thousand psi everal thousand psi

ConcluConclu

Cement does not need seCement does not need secompressive strengthcompressive strengthCement blend @ 12 ppgCement blend @ 12 ppghourshours

usionsusions

everal thousand psi everal thousand psi

g achieved 1,000 psi in 72 g achieved 1,000 psi in 72

ConcluConclu

Cement does not need seCement does not need secompressive strengthcompressive strengthCement blend @ 12 ppgCement blend @ 12 ppghourshoursNew Pozzolan powder aNew Pozzolan powder aIII cement proved to be eIII cement proved to be eppcompressive strength of compressive strength of

usionsusions

everal thousand psi everal thousand psi

g achieved 1,000 psi in 72 g achieved 1,000 psi in 72

and switch to ASTM Type and switch to ASTM Type effective in improving effective in improving p gp gsystemsystem

ConcluConclu

Oilfield casing need not Oilfield casing need not with API cementswith API cementswith API cementswith API cements

usionsusions

be cemented exclusively be cemented exclusively

ConcluConclu

Oilfield casing need not Oilfield casing need not with API cementswith API cementswith API cementswith API cementsField application successField application success

usionsusions

be cemented exclusively be cemented exclusively

sfulsful

ConcluConclu

Oilfield casing need not Oilfield casing need not with API cementswith API cementswith API cementswith API cementsField application successField application success

h fl i d fh fl i d fCash flow improved for Cash flow improved for

usionsusions

be cemented exclusively be cemented exclusively

sfulsfullllarge programlarge program

Thi P i tThis Point

API class cement mayAPI class cement mayavailableavailable

t F dt Forward

y no longer be y no longer be

Thi P i tThis Point

API class cement mayAPI class cement mayavailableavailableMust develop cementMust develop cementconstruction type cemconstruction type cemypyp

t F dt Forward

y no longer be y no longer be

t blends using ASTM t blends using ASTM ment.ment.

Thi P i tThis Point

API class cement mayAPI class cement mayavailableavailableMust develop cementMust develop cementconstruction type cemconstruction type cemypypLook to other industriLook to other industrisolutionssolutionssolutionssolutions

t F dt Forward

y no longer be y no longer be

t blends using ASTM t blends using ASTM ment.ment.ies for potential ies for potential

Thi P i tThis Point

API class cement mayAPI class cement mayavailableavailableMust develop cementMust develop cementconstruction type cemconstruction type cemypypLook to other industriLook to other industrisolutionssolutionssolutionssolutionsChange our paradigmChange our paradigm

t F dt Forward

y no longer be y no longer be

t blends using ASTM t blends using ASTM ment.ment.ies for potential ies for potential

mm

Thankk You