Reverse circulation cementing is a placement technique that reduces bottomhole equivalent circulating densities (ECDs) and reduces lost circulation risk in wells in which conventional circulation pressures would break down formations. Until now, reverse circulation cementing has been performed only on land or in shallow-water wells in which the annulus was accessible from the surface to pump down. This paper describes the design, development, and validation of technology that enables subsurface reverse circulation. Gaps in technology have made it challenging to transfer reverse-cementing-placement techniques to primary cementing operations in deepwater. To reverse cement a liner, fluids must be pumped down the work string to prevent potential contact inside the riser and blowout preventer (BOP), and then fluids must be injected into the annulus downhole while full circulation continues. A tool system was developed to facilitate this unique flow path, provide alternative methods to set liner hangers, and provide flexibility for contingencies and other operational requirements. The developed subsurface reverse circulation tool system uses radio frequency identification (RFID) technology so that the tools can be operated remotely and repeatedly either by RFID tags or through surface-pressure pulse sequences. Three RFID-activated tools were designed: a circulation tool, a crossover tool, and a downhole flapper. The prototype tool system was first evaluated through bench testing of individual components and then through large-scale rig testing. During the rig trials, the entire system was run into a test well, and a multiday sequence of flow testing validated the function and performance of each tool. After successful testing in rig trials, the subsurface reverse circulation tools (RCT) were deployed in the Appalachia basin field, located in the Northeastern United States. This paper discusses the requirements of a subsurface reverse-circulation-cementing system. It describes the design, development, and validation of technology that enables subsurface reverse circulation. It also describes the prototype system that was built and the field testing results. This new capability enables the cement to be pumped down the work string and then to exit to the annulus at a point above the liner string.
This paper covers the development and validation of a hydraulic simulator for subsurface reverse cementing placement in which fluids are placed down drillpipe and diverted into the annulus through a crossover tool above a liner hanger. Returns are taken up the liner inner diameter and are re-diverted through the crossover tool back to surface. Since commercially available cementing simulators are unable to model cement placement through this flow path with a crossover tool, a simulator was developed and validated using downhole pressure data collected during large-scale flow testing and a reverse cementing field trial. Development of this simulator is a major step forward to implementing a subsurface reverse cementing system in deep water. This custom simulator determines the magnitude of equivalent circulating density (ECD) reductions and identifies opportunities in which subsurface reverse cementing is advantageous with regard to pressure. Traditionally, placement through reverse cementing results in reduced bottomhole ECDs compared to conventional cementing. This pressure reduction is not uniform throughout the annulus, and a placement simulator that takes into account wellbore geometry, a crossover tool, fluid properties, and cementing hydraulics is required to assess viability of reverse cementing for specific deepwater wells. Computational fluid dynamics (CFD) modeling was conducted using specific crossover tool geometry and various fluid properties to develop a lumped-pressure loss model mimicking local pressure drops. This lumped model was incorporated into a hydraulics system-level solver to estimate surface and downhole pressures. The hydraulics solver was initially validated by comparing model output with downhole pressure data collected from large-scale flow testing and a field trial in which a liner was cemented using the crossover tool. The resulting subsurface reverse cementing simulator is able to simulate incompressible, multi-fluid placement through a crossover tool. Current capabilities of the simulator include incorporation of a crossover tool to divert flow into the annulus directly above the liner hanger in a deepwater well; estimation of surface pressures, bottomhole pressures, and downhole ECDs at any specified depth; and estimation of u-tubing effect from free fall of fluids. During a large-scale closed-system flow test, model output matched pressure gauge readings to within 11%. Comparisons of field trial surface and downhole pressures correlated with model output for cement placement. This paper will present comparisons of simulator pressure output and collected downhole data used for validation, along with simulator output for an example subsurface reverse cementing job for a deepwater liner.
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