Halliburton Cementing Psl: Liner Cementing Best Practices
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Halliburton Cementing PSL Liner Cementing Best Practices Conventional and Tack-and-Squeeze Methods
All information contained in this publication is confidential and proprietary property of Halliburton Energy Services, Inc. Any reproduction or use of these instructions, drawings, or photographs without the express written permission of an officer of Halliburton is forbidden. © Copyright 2006 Halliburton All Rights Reserved. Printed in the United States of America.
Contents Conventional Liner Cementing and Slurry Design Best Practices Introduction .............................................................................................. 1 Conventional Liner Best Practices ........................................................... Use of Software ................................................................................. Determining BHCT ............................................................................ Zero Free Water ................................................................................ Slurry Sedimentation ......................................................................... Fluid Loss .......................................................................................... Rheologies ........................................................................................ Spacer Compatibility ......................................................................... Wettability Testing .............................................................................
2 2 2 2 2 2 2 2 3
Liner Cementing Recommendations ....................................................... 3 Tack-and-Squeeze Liner Job (With Service Tool) Slurry Placement Best Practices ............................................................. 5 Tack-and-Squeeze Liner Job (Without Service Tool) Slurry Placement Best Practices ............................................................. 8 Example Job Chart for a Hesitation Squeeze .......................................... 10
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Halliburton Cementing PSL
Conventional Liner Cementing and Slurry Design Best Practices Introduction In well completions, it often becomes economically prudent to run a liner rather than a full string of casing. The liner must then be cemented. The end product of an effective liner program is the isolation of each zone behind the liner to create a seal between the liner and the previously run string of casing. Several factors enter into the planning and performance of a liner job: • Geometries—pipe and hole sizes, deviation, and azimuth. • Liner hardware—hanger and packer geometries and flow restrictions, centralizers, operating darts, and plugs. • Hydraulics—equivalent circulating density, fluid densities, and mud removal parameters. • Slurry design—formation flow potential prevention, mud removal, stability, and adequate set properties. • Spacer design—compatibility, wettability, solids support, and mud removal. • Operational issues—pressure and rate limitations, pipe movement (if applicable), and order/timing of operations. In the most common method of liner cementing, the liner is joined to the bottom of the previously installed casing string by overlapping inside the existing cemented casing. The cement for the liner is circulated down the drillpipe and liner string, out the liner shoe, and up the outside of the liner through the overlapped section. With the cementing operations completed, the excess cement may be either reversed out and the drillpipe pulled, or the drillpipe is pulled and the excess cement allowed to harden above the liner and drilled out later. Some formations will break down if excess cement is reversed out.
March 2006
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Halliburton Cementing PSL
Conventional Liner Best Practices The following best practices will help ensure the performance of a good liner cement job.
Use of Software Include OptiCem™ software to predict accurate mud removal to aid in determining erodibility and improve predicting top of cement. Calculate the gas-flow potential (GFP) and use it in determining final slurry design. Import caliper LAS files and directional survey into the OptiCem software design to further exploit the effectiveness of the software and aid in determining centralizer placement and top of cement.
Determining BHCT Use locally accepted practices, including API schedules, local schedules, or WellCat™ software simulation schedules, as applicable, to determine bottomhole circulating temperature (BHCT).
Zero Free Water Keep free water at zero level in the slurry design in all situations. Use the free-water test procedure appropriate for the well conditions as specified in the Halliburton Global Lab Best Practice (GLBP) Manual or API RP 10B. A 45-degree angle free-water test is the most severe and should be used for critical applications regardless of the wellbore angle. Free water for the liner-top squeeze slurry is not usually a vital concern but still should be maintained at less than 1% and discussed with the customer so that more stringent requirements are noted and met.
Slurry Sedimentation Tendencies of the slurry to settle can be observed during the free-water test. However, critical applications should specifically examine sedimentation. A maximum allowable density variance of ±0.5 lb/gal between top and bottom of the set sample is usually applied, but critical situations may warrant tightening this range.
Fluid Loss Fluid loss for liner applications should be less than 100 ml unless otherwise specified by the customer. Testing on a stirring fluid-loss cell is the preferred method. Fluid-loss control is typically not a monitored or a tested parameter for the liner-top squeeze slurry, but this should be discussed with the customer.
Rheologies Run rheologies at a minimum of three different temperatures for each fluid (mud, spacers, and cement slurries) used on a liner cement job for entry in OptiCem software.
Spacer Compatibility Test between spacers, cements, and drilling fluids in accordance with local practices and API RP 10B, as applicable.
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Halliburton Cementing PSL
Wettability Testing Incorporate wettability testing into spacer design when any nonaqueous (oil or syntheticbased) drilling fluid is encountered. Follow local practices and API RP 10B, as applicable.
Liner Cementing Recommendations The following recommendations can help ensure effective liner cementing: 1.
Proper displacement volumes are critical in liner tack-and-squeeze cementing. Include tool joint inside diameter (ID) in landing string displacement volume calculation; and tool joint ID changes among different grades of drillpipe. Caliper drillpipe tool joints, regardless of grade, to confirm the values used for volume calculations and to help ensure tool (plugs and dart) passage through the landing string. Drift the drillpipe as each stand is picked up while running in the hole to further ensure dart passage. Excessive scale in the drillpipe can also hinder dart displacement.
2.
Calculate liner displacement volume based on a caliper. Caliper a minimum of 20% or 20 joints (whichever is less) on location. Use the average for the volume calculation.
3.
Before coming out of the hole with the drilling assembly, condition the drilling mud to properties conducive to cementing the liner. These properties may vary depending on well conditions. Consultation among Halliburton, the mud company, and the operator is required.
4.
Extend the liner lap, at a minimum, above the top of the previous shoe track, float collar, and top of cement recorded when drilling out the previous casing.
5.
Be sure the OptiCem software design is current for the well and includes the centralization recommendation. A minimum of 70% standoff is normally recommended, but this value should be determined for the specific application. Include all geometries, especially restrictions, in OptiCem software. Model fluid compressibility for nonaqueous mud systems. Consider centralization in the lap.
6.
Based on the GFP provided by OptiCem software, provide a slurry design that is adequate to help prevent annular gas flow after cement placement.
7.
The spacer design should incorporate compatibility, settling, and wettability testing as required. The spacer volume should provide a minimum of 1,000 ft or 10 minute contact time. Spacer volume for a liner-top squeeze should be adequate to help ensure fluid separation in the drillpipe and casing below, the minimum generally being the greater of 10 bbl or 200 ft.
8.
Calculate cement slurry volumes for a "tack-and-squeeze" procedure based on no more than 75% of the annular gauge hole volume, i.e. the gauge hole annular volume less 25% (to help ensure that no cement is circulated above the top of the liner).
9.
Use OptiCem software to determine the maximum height cement may attain due to annular gauge hole volume displacement and/or channeling using erodibility modeling. Import the caliper LAS file into OptiCem software if said log has been run to improve volume, placement, and centralizer calculations.
March 2006
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Halliburton Cementing PSL
10. Break circulation before the liner enters open hole to reduce surge and swab pressures and to lessen the risks of channeling and building excessive equivalent circulating densities (ECD) after the liner is on bottom. 11. Stage circulation rates up slowly after liner is at total depth. Monitor surface pressures and annular returns for indications of annular bridging. Monitor returns closely for rate, formation gas/fluid influx, and excessive solids loadings. Adjust the conditioning plan accordingly. 12. Hold a safety meeting with all involved personnel before operations begin. Assign and clearly communicate roles and responsibilities throughout the operation to all parties. The liner tool representative must describe the procedure and expectations for setting and testing of the liner, including anticipated pressures associated with darts and wiper plugs, rate limitations, and the length of time required for all liner tool operating events. Establish all pressure limitations. Set pop-offs and/or pump kick-outs before the job accordingly. Discuss and agree on maximum pull and torque allowances before the job begins. 13. Halliburton strongly recommends hanging the liner before commencing cementing pumping operations. 14. Monitor rates and pressures during the job and compare to the values predicted by OptiCem software to help ensure that maximum rates are achieved and that maximum ECDs are not exceeded. 15. When using darts or plugs (single- or dual-plug set), adjust the rates for displacement as recommended by the liner company and plug supplier to launch and land plugs. Perform all rate changes gradually and avoid abrupt changes to help ensure continued dart displacement through the landing string. Avoid rate changes just prior to landing string ID changes. If the cement volume is greater than the landing string volume, make plans to decrease the cementing rate to allow launching of the bottom plug in dual-plug scenarios. Record volumes and annotate job charts to show darts landing and pressure responses for launching plugs. 16. Slow rate down as recommended by the liner provider and plug provider as the top plug lands in the float collar or landing collar. Record volume for final displacement and pressure. Do not over-displace the liner. Release pressure slowly to check floats. 17. Set the liner packer if appropriate and pull at least 10 stands before reversing out. If a "tack-and-squeeze" method is to be used, continue to the next section on tool operation and subsequent squeeze procedures.
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Halliburton Cementing PSL
Tack-and-Squeeze Liner Job (With Service Tool) Slurry Placement Best Practices The following best practices can help ensure effective slurry placement: 1.
Measure, caliper, and verify all tools for correct size and type immediately after arriving on location. Verify that all tool IDs will allow all liner plugs to freely pass through. Ensure that the left hand-set squeeze packer is the correct size for the casing in which it will be run and set it. Drift all tools and crossovers before making up tools on the rig floor. Ensure that the packer rubbers are of the correct durometer rating for the job.
2.
Have all parties involved review and agree upon all documentation and procedures involving the running, cementing, and squeezing operations of the liner.
3.
Perform a job safety analysis (JSA) and hold a prejob safety meeting with all parties involved before picking up any tools.
4.
Hydraulic jars are not recommended to be run in the tool string. The tool could possibly be damaged if the tool string is jarred should it become stuck. Should the liner company and/or customer insist on jars, note this requirement on the work order and locate the jars above the left hand-set squeeze packer.
Important—Meter the jars on the rig floor before pulling the slips to help prevent any accidental jarring. 5.
Run a minimum of two joints of drillpipe between the liner hanger and the left hand-set squeeze packer unless a liner-top packer will be engaged.
6.
On jobs where a liner-top packer is to be engaged, run a minimum of three stands of drillpipe between the liner hanger and the left hand-set squeeze packer. This will reduce the risk of cement slurry being lifted up to the left hand-set squeeze packer during slurry placement.
7.
Run a bumper sub below the left hand-set squeeze tool. This will aid in determining if the packer is free should the tool string become stuck.
8.
Make up all tools with correct torque before running the liner. If this is not possible, use the mouse hole or have a section of the rig floor removed. Use a backup when making up all tools to help prevent any damage caused by bending. Torque straight threads to maximum recommended values and check mechanical slips for full travel.
Important—Never set slips on the left hand-set squeeze packer with weight hanging below. 9.
March 2006
Discuss the packer and other tool operations with the driller and be sure the driller fully understands the expectations of the role. Stay on the rig floor if conditions warrant and always use a drillpipe wiper rubber when going in and out of the hole.
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Halliburton Cementing PSL
10. On reaching bottom, record the pickup and slack off weight indicator readings. The service tool operator is to remain on the rig floor while the liner is being set. 11. Caution the floor personnel about pipe torque and possible backlash. The block should always be locked and, for top drives, be sure that both locks are locked. 12. Be extremely cautious of left hand backlash of the drillpipe when rotating off the liner. Caution—Do not slack off if backlash occurs while picking up. Apply right hand torque and continue picking up, holding the torque, and working the lug back onto the short side of the jay-slot. 13. After running the bottom liner "tack" cement job, release from the liner and pull up the hole a distance equivalent to that listed in Table 1, depending on the packer size. Table 1—Pulling Distance Based on Packer Size Packer Size in.
Pulling Distance
(cm)
16
(41)
13 3/8
(33.97)
11 3/4
(29.85)
10 3/4
(27.31)
9 5/8
(24.45)
8 5/8
(21.91)
7 5/8
(19.37)
7
(17.78)
ft
(m)
± 150
(± 46)
± 200
(± 61)
± 400
(± 122)
14. If the top plug bumps, seals, and the floats hold, reverse out 1 ½ drillpipe volumes, set the packer, and wait a minimum of 8 hours to give the cement in the annulus time to reach initial set as determined by the appropriate lab test (UCA). 15. If the top plug did not bump after the liner "tack" cement job, reciprocate the drillpipe for approximately 30 minutes, then wait a minimum of 12 hours or until a minimum compressive strength of 500 psi has been developed before running the liner-top squeeze cement job to keep from pumping cement down into the liner. (Confirm this compressive strength with the liner "tack" lab test results before commencing squeeze operations.) 16. Test the casing and packer, then establish an injection rate and pressure. When circulating the squeeze cement down the drillpipe, close the circulating ports on the packer 10 bbl or 10% of the drillpipe volume (whichever is greater) before the spacer gets to the packer. 17. Precede the cement with a volume of spacer weighted to a minimum of 0.5 lb/gal above the mud weight and a minimum volume equivalent to ± 200 ft of separation in the largest size casing that it will be passing through.
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Halliburton Cementing PSL
18. Follow the cement with a volume of spacer weighted to a minimum of 0.5 lb/gal above the mud weight and a minimum volume equivalent of the larger of 5 bbl or ± 100 ft of separation in the largest size drillpipe that it will be passing through. 19. Clear the tool and leave 50–100 ft of cement on top of the liner. Exact volume and length will depend on the casing size and customer preference. Be cautious of the displacement volume accuracy measurements if the mud is aerated and/or if there is excessive displacement. 20. If the maximum allowable squeeze pressure is reached and holds and there is no flow back prior to clearing the packer by the recommended distances, pull the packer free and reverse out 1 ½ drillpipe volumes. 21. Minimize and equalize pressure before pulling the packer free with the annular preventer closed and a minimum pressure on the accumulator. Set the liner-top packer, if one is present, according to the liner tool service operator's instructions. This might require slacking off. 22. After setting and testing the liner-top packer, pick up and reverse out 1 ½ drillpipe volumes. 23. Pull out of hole and lay tool assembly down. Note—A hesitation squeeze may be run to help ensure that the entire liner top receives cement. For an example of a hesitation squeeze job log and details, see Pages 10 and 11. This procedure sometimes incorporates a lead and tail cement. The lead cement should have adequate fluid-loss control to help ensure that it achieves the best displacement through the liner lap. The tail cement can be designed to have a higher fluid-loss value to try and initiate slurry dehydration and bridging, thus a "squeeze." The tail may also be designed to have a shorter transition time and/or thickening time as an attempt to effect better displacement of gelled mud in the lap. Testing should be done on the lap squeeze slurry to ensure that it has a delayed gel period appropriate for the planned operation.
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Halliburton Cementing PSL
Tack-and-Squeeze Liner Job (Without Service Tool) Slurry Placement Best Practices When the tack-and-squeeze operation is performed without a service tool, the following best practices can help ensure effective slurry placement. It is also common practice to run the tack-and-squeeze operation without the use of a squeeze packer. This is possible in applications when the injection pressure at the top of the liner is low (especially in deep water). In this case, the annular preventors are closed to enable injection into the liner top. Perform the tack cementing job in the usual manner, then resume with the following procedure. 1.
After running the bottom liner "tack" cementing job, release from the liner and pull up the hole a distance of ±200 feet (61 m).
2.
If the top plug bumps and seals and the floats hold, reverse-out 1 ½ drillpipe volumes, and wait a minimum of 8 hours. Allow the cement in the annulus to reach initial set as determined by the appropriate lab test (UCA).
3.
If the top plug did not bump after the liner "tack" cementing job, reciprocate the drillpipe for approximately 30 minutes. Wait a minimum of 12 hours—or until a minimum compressive strength of 500 psi has developed—before running the liner top squeeze cementing job to keep from pumping cement down into the liner. Important—Confirm the compressive strength with the liner "tack" lab test results before commencing squeeze operations.
4.
Close the annulars and establish an injection rate and pressure. When circulating the squeeze cement down the drillpipe, close the annular 10 bbl or 10% of the drillpipe volume (whichever is greater) before the spacer gets to the bottom of the drillpipe.
5.
Precede the cement with a volume of spacer weighted to a minimum of 0.5 lb/gal above the mud weight and a minimum volume equivalent to ±200 ft of separation in the largest size casing that it will be passing through.
6.
Follow the cement with a volume of spacer weighted to a minimum of 0.5 lb/gal above the mud weight and a minimum volume equivalent of the larger of 5 bbl or ±100 ft of separation in the largest size drillpipe that it will be passing through.
7.
Clear the end of the drillpipe and leave 50–100 ft of cement on top of the liner (do not overdisplace). Exact volume and length will depend on the casing size and customer preference. Be cautious of the displacement volume accuracy measurements if the mud is aerated and/or if there is excessive displacement.
8.
If the maximum allowable squeeze pressure is reached and holds and there is no flowback prior to clearing the end of the drillpipe by the recommended distances, reverse-out 1 ½ drillpipe volumes. Pull out of hole.
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Halliburton Cementing PSL
Note—A hesitation squeeze may be run to help ensure that the entire liner top receives cement. For an example of a hesitation squeeze job log and details, see Pages 10 and 11. This procedure sometimes incorporates a lead and tail cement. The lead cement should have adequate fluid-loss control to help ensure that it achieves the best displacement through the liner lap. The tail cement can be designed to have a higher fluid-loss value to try and initiate slurry dehydration and bridging, thus a "squeeze." The tail may also be designed to have a shorter transition time and/or thickening time as an attempt to effect better displacement of gelled mud in the lap. Testing should be done on the lap squeeze slurry to ensure that it has a delayed gel period appropriate for the planned operation.
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Halliburton Cementing PSL
Example Job Chart for a Hesitation Squeeze Figure 1 is an example of a hesitation squeeze job chart. Table 2 (on the following page) provides the corresponding details for this sample job.
Hesitation Squeeze 2500 Final Pressure from Squeeze Job. 2370
PRESSURE, psi
2000
1500
1000
500
0 0.00
5.00
10.00
15.00
20.00
25.00
30.00
35.00
VOLUME PUMPED, bbl
Figure 1—Example of a job chart for a hesitation squeeze
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Halliburton Cementing PSL
Table 2—Hesitation Squeeze, 13 5/8-in. Shoe Vol., bbl
Press, psi CASING TEST
Remarks Mix and pump 800 sacks cement at 16.4 lb/gal Cement in place at 04:00 hr
March 2006
0.00 0.00 0.00 1.00
840 835 32 860
Final pump pressure ISIP First 15-minute waiting period
2.00
1060
3.00
1125
4.00
1190
5.00 5.00 5.00 6.00
1240 1200 127 510
7.00
1250
8.00
1370
9.00
1410
10.00 10.00 10.00 11.00
1500 1450 260 1090
12.00
1550
13.00
1665
14.00
1820
15.00 15.00 15.00
1850 1830 1820
Final pressure on third stage ISIP
16.00 17.00
410 1325
Fourth 15-minute waiting period
18.00
1780
19.00
1990
20.00
2100
21.00 21.00 21.00 22.00
2120 2100 589 1330
23.00
1830
24.00
2110
25.00
2200
26.00 26.00 26.00 27.00
2220 2200 794 1680
28.00
2200
29.00
2380
30.00
2360
30.00
2370
Final pressure on first stage ISIP Second 15-minute waiting period
Final pressure on second stage ISIP Third 15-minute waiting period
Final pressure on third stage ISIP Fifth 15-minute waiting period
Final pressure on fourth stage ISIP Sixth 15-minute waiting period
Final pressure on fifth stage Page 11 of 12
Halliburton Cementing PSL
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All information contained in this publication is confidential and proprietary property of Halliburton Energy Services, Inc. Any reproduction or use of these instructions, drawings, or photographs without the express written permission of an officer of Halliburton is forbidden. © Copyright 2006 Halliburton All Rights Reserved. Printed in the United States of America.
Contents Conventional Liner Cementing and Slurry Design Best Practices Introduction .............................................................................................. 1 Conventional Liner Best Practices ........................................................... Use of Software ................................................................................. Determining BHCT ............................................................................ Zero Free Water ................................................................................ Slurry Sedimentation ......................................................................... Fluid Loss .......................................................................................... Rheologies ........................................................................................ Spacer Compatibility ......................................................................... Wettability Testing .............................................................................
2 2 2 2 2 2 2 2 3
Liner Cementing Recommendations ....................................................... 3 Tack-and-Squeeze Liner Job (With Service Tool) Slurry Placement Best Practices ............................................................. 5 Tack-and-Squeeze Liner Job (Without Service Tool) Slurry Placement Best Practices ............................................................. 8 Example Job Chart for a Hesitation Squeeze .......................................... 10
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Halliburton Cementing PSL
Conventional Liner Cementing and Slurry Design Best Practices Introduction In well completions, it often becomes economically prudent to run a liner rather than a full string of casing. The liner must then be cemented. The end product of an effective liner program is the isolation of each zone behind the liner to create a seal between the liner and the previously run string of casing. Several factors enter into the planning and performance of a liner job: • Geometries—pipe and hole sizes, deviation, and azimuth. • Liner hardware—hanger and packer geometries and flow restrictions, centralizers, operating darts, and plugs. • Hydraulics—equivalent circulating density, fluid densities, and mud removal parameters. • Slurry design—formation flow potential prevention, mud removal, stability, and adequate set properties. • Spacer design—compatibility, wettability, solids support, and mud removal. • Operational issues—pressure and rate limitations, pipe movement (if applicable), and order/timing of operations. In the most common method of liner cementing, the liner is joined to the bottom of the previously installed casing string by overlapping inside the existing cemented casing. The cement for the liner is circulated down the drillpipe and liner string, out the liner shoe, and up the outside of the liner through the overlapped section. With the cementing operations completed, the excess cement may be either reversed out and the drillpipe pulled, or the drillpipe is pulled and the excess cement allowed to harden above the liner and drilled out later. Some formations will break down if excess cement is reversed out.
March 2006
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Halliburton Cementing PSL
Conventional Liner Best Practices The following best practices will help ensure the performance of a good liner cement job.
Use of Software Include OptiCem™ software to predict accurate mud removal to aid in determining erodibility and improve predicting top of cement. Calculate the gas-flow potential (GFP) and use it in determining final slurry design. Import caliper LAS files and directional survey into the OptiCem software design to further exploit the effectiveness of the software and aid in determining centralizer placement and top of cement.
Determining BHCT Use locally accepted practices, including API schedules, local schedules, or WellCat™ software simulation schedules, as applicable, to determine bottomhole circulating temperature (BHCT).
Zero Free Water Keep free water at zero level in the slurry design in all situations. Use the free-water test procedure appropriate for the well conditions as specified in the Halliburton Global Lab Best Practice (GLBP) Manual or API RP 10B. A 45-degree angle free-water test is the most severe and should be used for critical applications regardless of the wellbore angle. Free water for the liner-top squeeze slurry is not usually a vital concern but still should be maintained at less than 1% and discussed with the customer so that more stringent requirements are noted and met.
Slurry Sedimentation Tendencies of the slurry to settle can be observed during the free-water test. However, critical applications should specifically examine sedimentation. A maximum allowable density variance of ±0.5 lb/gal between top and bottom of the set sample is usually applied, but critical situations may warrant tightening this range.
Fluid Loss Fluid loss for liner applications should be less than 100 ml unless otherwise specified by the customer. Testing on a stirring fluid-loss cell is the preferred method. Fluid-loss control is typically not a monitored or a tested parameter for the liner-top squeeze slurry, but this should be discussed with the customer.
Rheologies Run rheologies at a minimum of three different temperatures for each fluid (mud, spacers, and cement slurries) used on a liner cement job for entry in OptiCem software.
Spacer Compatibility Test between spacers, cements, and drilling fluids in accordance with local practices and API RP 10B, as applicable.
Page 2 of 12
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Halliburton Cementing PSL
Wettability Testing Incorporate wettability testing into spacer design when any nonaqueous (oil or syntheticbased) drilling fluid is encountered. Follow local practices and API RP 10B, as applicable.
Liner Cementing Recommendations The following recommendations can help ensure effective liner cementing: 1.
Proper displacement volumes are critical in liner tack-and-squeeze cementing. Include tool joint inside diameter (ID) in landing string displacement volume calculation; and tool joint ID changes among different grades of drillpipe. Caliper drillpipe tool joints, regardless of grade, to confirm the values used for volume calculations and to help ensure tool (plugs and dart) passage through the landing string. Drift the drillpipe as each stand is picked up while running in the hole to further ensure dart passage. Excessive scale in the drillpipe can also hinder dart displacement.
2.
Calculate liner displacement volume based on a caliper. Caliper a minimum of 20% or 20 joints (whichever is less) on location. Use the average for the volume calculation.
3.
Before coming out of the hole with the drilling assembly, condition the drilling mud to properties conducive to cementing the liner. These properties may vary depending on well conditions. Consultation among Halliburton, the mud company, and the operator is required.
4.
Extend the liner lap, at a minimum, above the top of the previous shoe track, float collar, and top of cement recorded when drilling out the previous casing.
5.
Be sure the OptiCem software design is current for the well and includes the centralization recommendation. A minimum of 70% standoff is normally recommended, but this value should be determined for the specific application. Include all geometries, especially restrictions, in OptiCem software. Model fluid compressibility for nonaqueous mud systems. Consider centralization in the lap.
6.
Based on the GFP provided by OptiCem software, provide a slurry design that is adequate to help prevent annular gas flow after cement placement.
7.
The spacer design should incorporate compatibility, settling, and wettability testing as required. The spacer volume should provide a minimum of 1,000 ft or 10 minute contact time. Spacer volume for a liner-top squeeze should be adequate to help ensure fluid separation in the drillpipe and casing below, the minimum generally being the greater of 10 bbl or 200 ft.
8.
Calculate cement slurry volumes for a "tack-and-squeeze" procedure based on no more than 75% of the annular gauge hole volume, i.e. the gauge hole annular volume less 25% (to help ensure that no cement is circulated above the top of the liner).
9.
Use OptiCem software to determine the maximum height cement may attain due to annular gauge hole volume displacement and/or channeling using erodibility modeling. Import the caliper LAS file into OptiCem software if said log has been run to improve volume, placement, and centralizer calculations.
March 2006
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Halliburton Cementing PSL
10. Break circulation before the liner enters open hole to reduce surge and swab pressures and to lessen the risks of channeling and building excessive equivalent circulating densities (ECD) after the liner is on bottom. 11. Stage circulation rates up slowly after liner is at total depth. Monitor surface pressures and annular returns for indications of annular bridging. Monitor returns closely for rate, formation gas/fluid influx, and excessive solids loadings. Adjust the conditioning plan accordingly. 12. Hold a safety meeting with all involved personnel before operations begin. Assign and clearly communicate roles and responsibilities throughout the operation to all parties. The liner tool representative must describe the procedure and expectations for setting and testing of the liner, including anticipated pressures associated with darts and wiper plugs, rate limitations, and the length of time required for all liner tool operating events. Establish all pressure limitations. Set pop-offs and/or pump kick-outs before the job accordingly. Discuss and agree on maximum pull and torque allowances before the job begins. 13. Halliburton strongly recommends hanging the liner before commencing cementing pumping operations. 14. Monitor rates and pressures during the job and compare to the values predicted by OptiCem software to help ensure that maximum rates are achieved and that maximum ECDs are not exceeded. 15. When using darts or plugs (single- or dual-plug set), adjust the rates for displacement as recommended by the liner company and plug supplier to launch and land plugs. Perform all rate changes gradually and avoid abrupt changes to help ensure continued dart displacement through the landing string. Avoid rate changes just prior to landing string ID changes. If the cement volume is greater than the landing string volume, make plans to decrease the cementing rate to allow launching of the bottom plug in dual-plug scenarios. Record volumes and annotate job charts to show darts landing and pressure responses for launching plugs. 16. Slow rate down as recommended by the liner provider and plug provider as the top plug lands in the float collar or landing collar. Record volume for final displacement and pressure. Do not over-displace the liner. Release pressure slowly to check floats. 17. Set the liner packer if appropriate and pull at least 10 stands before reversing out. If a "tack-and-squeeze" method is to be used, continue to the next section on tool operation and subsequent squeeze procedures.
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Halliburton Cementing PSL
Tack-and-Squeeze Liner Job (With Service Tool) Slurry Placement Best Practices The following best practices can help ensure effective slurry placement: 1.
Measure, caliper, and verify all tools for correct size and type immediately after arriving on location. Verify that all tool IDs will allow all liner plugs to freely pass through. Ensure that the left hand-set squeeze packer is the correct size for the casing in which it will be run and set it. Drift all tools and crossovers before making up tools on the rig floor. Ensure that the packer rubbers are of the correct durometer rating for the job.
2.
Have all parties involved review and agree upon all documentation and procedures involving the running, cementing, and squeezing operations of the liner.
3.
Perform a job safety analysis (JSA) and hold a prejob safety meeting with all parties involved before picking up any tools.
4.
Hydraulic jars are not recommended to be run in the tool string. The tool could possibly be damaged if the tool string is jarred should it become stuck. Should the liner company and/or customer insist on jars, note this requirement on the work order and locate the jars above the left hand-set squeeze packer.
Important—Meter the jars on the rig floor before pulling the slips to help prevent any accidental jarring. 5.
Run a minimum of two joints of drillpipe between the liner hanger and the left hand-set squeeze packer unless a liner-top packer will be engaged.
6.
On jobs where a liner-top packer is to be engaged, run a minimum of three stands of drillpipe between the liner hanger and the left hand-set squeeze packer. This will reduce the risk of cement slurry being lifted up to the left hand-set squeeze packer during slurry placement.
7.
Run a bumper sub below the left hand-set squeeze tool. This will aid in determining if the packer is free should the tool string become stuck.
8.
Make up all tools with correct torque before running the liner. If this is not possible, use the mouse hole or have a section of the rig floor removed. Use a backup when making up all tools to help prevent any damage caused by bending. Torque straight threads to maximum recommended values and check mechanical slips for full travel.
Important—Never set slips on the left hand-set squeeze packer with weight hanging below. 9.
March 2006
Discuss the packer and other tool operations with the driller and be sure the driller fully understands the expectations of the role. Stay on the rig floor if conditions warrant and always use a drillpipe wiper rubber when going in and out of the hole.
Page 5 of 12
Halliburton Cementing PSL
10. On reaching bottom, record the pickup and slack off weight indicator readings. The service tool operator is to remain on the rig floor while the liner is being set. 11. Caution the floor personnel about pipe torque and possible backlash. The block should always be locked and, for top drives, be sure that both locks are locked. 12. Be extremely cautious of left hand backlash of the drillpipe when rotating off the liner. Caution—Do not slack off if backlash occurs while picking up. Apply right hand torque and continue picking up, holding the torque, and working the lug back onto the short side of the jay-slot. 13. After running the bottom liner "tack" cement job, release from the liner and pull up the hole a distance equivalent to that listed in Table 1, depending on the packer size. Table 1—Pulling Distance Based on Packer Size Packer Size in.
Pulling Distance
(cm)
16
(41)
13 3/8
(33.97)
11 3/4
(29.85)
10 3/4
(27.31)
9 5/8
(24.45)
8 5/8
(21.91)
7 5/8
(19.37)
7
(17.78)
ft
(m)
± 150
(± 46)
± 200
(± 61)
± 400
(± 122)
14. If the top plug bumps, seals, and the floats hold, reverse out 1 ½ drillpipe volumes, set the packer, and wait a minimum of 8 hours to give the cement in the annulus time to reach initial set as determined by the appropriate lab test (UCA). 15. If the top plug did not bump after the liner "tack" cement job, reciprocate the drillpipe for approximately 30 minutes, then wait a minimum of 12 hours or until a minimum compressive strength of 500 psi has been developed before running the liner-top squeeze cement job to keep from pumping cement down into the liner. (Confirm this compressive strength with the liner "tack" lab test results before commencing squeeze operations.) 16. Test the casing and packer, then establish an injection rate and pressure. When circulating the squeeze cement down the drillpipe, close the circulating ports on the packer 10 bbl or 10% of the drillpipe volume (whichever is greater) before the spacer gets to the packer. 17. Precede the cement with a volume of spacer weighted to a minimum of 0.5 lb/gal above the mud weight and a minimum volume equivalent to ± 200 ft of separation in the largest size casing that it will be passing through.
Page 6 of 12
March 2006
Halliburton Cementing PSL
18. Follow the cement with a volume of spacer weighted to a minimum of 0.5 lb/gal above the mud weight and a minimum volume equivalent of the larger of 5 bbl or ± 100 ft of separation in the largest size drillpipe that it will be passing through. 19. Clear the tool and leave 50–100 ft of cement on top of the liner. Exact volume and length will depend on the casing size and customer preference. Be cautious of the displacement volume accuracy measurements if the mud is aerated and/or if there is excessive displacement. 20. If the maximum allowable squeeze pressure is reached and holds and there is no flow back prior to clearing the packer by the recommended distances, pull the packer free and reverse out 1 ½ drillpipe volumes. 21. Minimize and equalize pressure before pulling the packer free with the annular preventer closed and a minimum pressure on the accumulator. Set the liner-top packer, if one is present, according to the liner tool service operator's instructions. This might require slacking off. 22. After setting and testing the liner-top packer, pick up and reverse out 1 ½ drillpipe volumes. 23. Pull out of hole and lay tool assembly down. Note—A hesitation squeeze may be run to help ensure that the entire liner top receives cement. For an example of a hesitation squeeze job log and details, see Pages 10 and 11. This procedure sometimes incorporates a lead and tail cement. The lead cement should have adequate fluid-loss control to help ensure that it achieves the best displacement through the liner lap. The tail cement can be designed to have a higher fluid-loss value to try and initiate slurry dehydration and bridging, thus a "squeeze." The tail may also be designed to have a shorter transition time and/or thickening time as an attempt to effect better displacement of gelled mud in the lap. Testing should be done on the lap squeeze slurry to ensure that it has a delayed gel period appropriate for the planned operation.
March 2006
Page 7 of 12
Halliburton Cementing PSL
Tack-and-Squeeze Liner Job (Without Service Tool) Slurry Placement Best Practices When the tack-and-squeeze operation is performed without a service tool, the following best practices can help ensure effective slurry placement. It is also common practice to run the tack-and-squeeze operation without the use of a squeeze packer. This is possible in applications when the injection pressure at the top of the liner is low (especially in deep water). In this case, the annular preventors are closed to enable injection into the liner top. Perform the tack cementing job in the usual manner, then resume with the following procedure. 1.
After running the bottom liner "tack" cementing job, release from the liner and pull up the hole a distance of ±200 feet (61 m).
2.
If the top plug bumps and seals and the floats hold, reverse-out 1 ½ drillpipe volumes, and wait a minimum of 8 hours. Allow the cement in the annulus to reach initial set as determined by the appropriate lab test (UCA).
3.
If the top plug did not bump after the liner "tack" cementing job, reciprocate the drillpipe for approximately 30 minutes. Wait a minimum of 12 hours—or until a minimum compressive strength of 500 psi has developed—before running the liner top squeeze cementing job to keep from pumping cement down into the liner. Important—Confirm the compressive strength with the liner "tack" lab test results before commencing squeeze operations.
4.
Close the annulars and establish an injection rate and pressure. When circulating the squeeze cement down the drillpipe, close the annular 10 bbl or 10% of the drillpipe volume (whichever is greater) before the spacer gets to the bottom of the drillpipe.
5.
Precede the cement with a volume of spacer weighted to a minimum of 0.5 lb/gal above the mud weight and a minimum volume equivalent to ±200 ft of separation in the largest size casing that it will be passing through.
6.
Follow the cement with a volume of spacer weighted to a minimum of 0.5 lb/gal above the mud weight and a minimum volume equivalent of the larger of 5 bbl or ±100 ft of separation in the largest size drillpipe that it will be passing through.
7.
Clear the end of the drillpipe and leave 50–100 ft of cement on top of the liner (do not overdisplace). Exact volume and length will depend on the casing size and customer preference. Be cautious of the displacement volume accuracy measurements if the mud is aerated and/or if there is excessive displacement.
8.
If the maximum allowable squeeze pressure is reached and holds and there is no flowback prior to clearing the end of the drillpipe by the recommended distances, reverse-out 1 ½ drillpipe volumes. Pull out of hole.
Page 8 of 12
March 2006
Halliburton Cementing PSL
Note—A hesitation squeeze may be run to help ensure that the entire liner top receives cement. For an example of a hesitation squeeze job log and details, see Pages 10 and 11. This procedure sometimes incorporates a lead and tail cement. The lead cement should have adequate fluid-loss control to help ensure that it achieves the best displacement through the liner lap. The tail cement can be designed to have a higher fluid-loss value to try and initiate slurry dehydration and bridging, thus a "squeeze." The tail may also be designed to have a shorter transition time and/or thickening time as an attempt to effect better displacement of gelled mud in the lap. Testing should be done on the lap squeeze slurry to ensure that it has a delayed gel period appropriate for the planned operation.
March 2006
Page 9 of 12
Halliburton Cementing PSL
Example Job Chart for a Hesitation Squeeze Figure 1 is an example of a hesitation squeeze job chart. Table 2 (on the following page) provides the corresponding details for this sample job.
Hesitation Squeeze 2500 Final Pressure from Squeeze Job. 2370
PRESSURE, psi
2000
1500
1000
500
0 0.00
5.00
10.00
15.00
20.00
25.00
30.00
35.00
VOLUME PUMPED, bbl
Figure 1—Example of a job chart for a hesitation squeeze
Page 10 of 12
March 2006
Halliburton Cementing PSL
Table 2—Hesitation Squeeze, 13 5/8-in. Shoe Vol., bbl
Press, psi CASING TEST
Remarks Mix and pump 800 sacks cement at 16.4 lb/gal Cement in place at 04:00 hr
March 2006
0.00 0.00 0.00 1.00
840 835 32 860
Final pump pressure ISIP First 15-minute waiting period
2.00
1060
3.00
1125
4.00
1190
5.00 5.00 5.00 6.00
1240 1200 127 510
7.00
1250
8.00
1370
9.00
1410
10.00 10.00 10.00 11.00
1500 1450 260 1090
12.00
1550
13.00
1665
14.00
1820
15.00 15.00 15.00
1850 1830 1820
Final pressure on third stage ISIP
16.00 17.00
410 1325
Fourth 15-minute waiting period
18.00
1780
19.00
1990
20.00
2100
21.00 21.00 21.00 22.00
2120 2100 589 1330
23.00
1830
24.00
2110
25.00
2200
26.00 26.00 26.00 27.00
2220 2200 794 1680
28.00
2200
29.00
2380
30.00
2360
30.00
2370
Final pressure on first stage ISIP Second 15-minute waiting period
Final pressure on second stage ISIP Third 15-minute waiting period
Final pressure on third stage ISIP Fifth 15-minute waiting period
Final pressure on fourth stage ISIP Sixth 15-minute waiting period
Final pressure on fifth stage Page 11 of 12
Halliburton Cementing PSL
Page 12 of 12
March 2006
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