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This paper deals with oil well cementing flash setting problem definition, interpretation and localization via PABM (phenomenon analysis-based method) and Swiss cheese model investigation. Cementing is the most critical job throughout the well realization process; it presents the face of the well during production or abandonment. Within cement job some, problems come out and could lead to lose the well objectives, and it can be classified as cementing program’s awkward or operational hitches. This work is oriented toward operational stage, even if cement program and preparation seem in the rules of the art, the execution stage can interrupt the smooth running of cement job. Flash setting is one of the most critical problems that could be occurred, and it can be recognized by the prior increases in pressure to reach unpumpable stage. Identifying flash setting phenomenon and distinguishing them from other operational comportment stay hard task and present the heart of this work. Consequences could be varied from simple cement left inside casing to total free pipe of the annulus. PABM together with cheese model is proposed to be used for deep analysis of flash setting problems and points out the real causes, if they exist, rather than flash setting. The method proposed includes five steps, description of the operation, phenomenon, assumptions, cheese model and conclusion. The three first steps construct operation scrutiny, and the fourth step represents PABM. In this latter method, assumptions will pass through a selective process made from operation facts, and only the adequate assumption reaches the last layer of the model. Practical cases have been detailed to point out the merit of this method and distinguishing flash setting from other related cement problems.
This paper deals with oil well cementing flash setting problem definition, interpretation and localization via PABM (phenomenon analysis-based method) and Swiss cheese model investigation. Cementing is the most critical job throughout the well realization process; it presents the face of the well during production or abandonment. Within cement job some, problems come out and could lead to lose the well objectives, and it can be classified as cementing program’s awkward or operational hitches. This work is oriented toward operational stage, even if cement program and preparation seem in the rules of the art, the execution stage can interrupt the smooth running of cement job. Flash setting is one of the most critical problems that could be occurred, and it can be recognized by the prior increases in pressure to reach unpumpable stage. Identifying flash setting phenomenon and distinguishing them from other operational comportment stay hard task and present the heart of this work. Consequences could be varied from simple cement left inside casing to total free pipe of the annulus. PABM together with cheese model is proposed to be used for deep analysis of flash setting problems and points out the real causes, if they exist, rather than flash setting. The method proposed includes five steps, description of the operation, phenomenon, assumptions, cheese model and conclusion. The three first steps construct operation scrutiny, and the fourth step represents PABM. In this latter method, assumptions will pass through a selective process made from operation facts, and only the adequate assumption reaches the last layer of the model. Practical cases have been detailed to point out the merit of this method and distinguishing flash setting from other related cement problems.
Achieving well integrity relies on achieving zonal isolation among narrowly separated sublayers of the reservoir throughout a long openhole section. This requires flawless primary cementation with a perfect match of optimized fluid design and placement. In a UAE field, there are several challenges experienced while cementing production sections, predominantly due to long open holes with high deviation, use of nonaqueous fluids (NAF) for shale stability, and loss circulation issues while drilling and cementing. The need to pressure-test casing at high pressures after the cement is set and the change in downhole pressures and temperatures during well completion / production phases result in additional stresses that can further endanger the integrity of the cement. Breaking of the cement sheath would lead to sustained annular pressure and compromise the needed zonal isolation. Hence, the mechanical properties for cement systems must be thoroughly tested and tailored to withstand the downhole stresses. A systematic approach was applied that used standard cementing best practices as a starting point and then identified the key factors in overcoming operation-specific challenges. In addition to the use of engineered trimodal slurry systems, NAF-compatible spacers, and loss-curing fibers, an advanced cement placement software was used to model prejob circulation rates, bottomhole circulating temperatures, centralizer placement, and mud removal. To enhance conventional chemistry-based mud cleaning and to significantly improve cleaning efficiency, an engineered fiber-based scrubbing additive was used in spacers with microemulsion based surfactant. Furthermore, a real-time monitoring software was used to compute and monitor equivalent circulating density (ECD) during the cementing operation and to evaluate cement placement in real time. Results of cement jobs were analyzed to define the minimum standards/criteria and then to verify the efficiency of the applied solutions. The 9 5/8-in. casing / liners were successfully cemented using this methodological approach, and lessons learned were progressively used to improve on subsequent jobs. Advanced ultrasonic cement bond logging tools along with advanced processing and interpretation techniques facilitated making reliable, conclusive, and representative zonal isolation evaluation. The cement bond logs showed significant improvement and increased the confidence level towards well integrity. After establishing field-specific guidelines over 2.5 years, continuous success was replicated in every well for all the rigs operating in this UAE field.
This paper presents a case of study of cementing operations in extended reach drilling (ERD) wells on two artificial islands in UAE. The cementing objectives involved covering and isolating the shallower oil or water-bearing zone, sealing any potential crossflow interval between various reservoirs, and mitigating communication between the 13 3/8-in × 16-in. and 9 5/8-in × 12 ¼-in. annulus. Additionally, the cement will become a secondary barrier planned for the 9 5/8-in. casing to prevent potential exposure of the 13 3/8-in. casing in the event of injection gas percolation. For this case was necessary to design the cement with the necessary mechanical properties to extend the well life expectancy. To accomplish the operation objectives, the formations, well design complexity, and possible complications were considered. Understanding these factors facilitated the improvement in the approach and design to obtain better cementing operations results. To achieve all of the targets, various enhancements were implemented systematically over time, which included adding fiber in the cement spacer to mechanically enhance mud removal, adding corrosion inhibitor and bactericide to protect the casing if fluid remained in the well. Various lead cement slurries were designed with tailored rheology to remain within the established narrow margin between the pore pressure and fracture gradient. A flexible and expandable tail cement slurry system was implemented to increase the likelihood of proper isolation. The expansion of the tail cement slurry after the cement sets and the tailored mechanical properties used to achieve the necessary resilience, provide support for the stresses encountered during the life of the well. Upgraded properties, such as fluid loss, reduced permeability, and static gel strength (SGS) development, were used to mitigate possible influx between formations. Both cement slurries were loaded with resilient fiber to enhance the cement ductility. These strategies combined with software simulations enabled equivalent circulating density (ECD) management, contamination avoidance, friction pressure hierarchy, discernment of the top of cement (TOC), determination of possible channels, and appropriate stand-off design. The application of the solutions combined with outstanding consistent field operational performance enabled the following: Fine-tuning various practices, improving isolation across critical zones, achieving the planned TOC, sealing the formations that could create potential future issues, and reducing the probability of interzonal communication or crossflow. A systematic approach was necessary to achieve all the objectives in these challenging wells and determine which practices and technologies provide the appropriate results. Cementing ERD wells with the challenges previously described is not a standard industry practice. This case study presents the staged application of the enhancements that improved the cementing results. These were inferred by evaluating the operational parameters (density, pumping rate, pressure, volumes, and surface returns) in conjunction with the availability of cement logs (CBL, VDL, ULTRASONIC). The results demonstrated the capability to achieve isolation; Furthermore, the continuous annulus surveillance showed no undesirable sustained casing pressure.
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