Special Cement Systems

Foamed Cement

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 Foamed Cement

A stable matrix of gas (air or nitrogen) contained in a cement slurry.

Gas Bubbles

Cement Matrix

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 Foamed Cement

Slurry
Mixer

Batch Foamer
Mixer Pump

Slurry
Pumper

Nitrogen
Pumper WELL

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 Foamed Cement

Disadvantages :

Difficult to design

Complex Execution
− Personnel
Advantages − Equipment

Easily variable density range − Procedure
650 to 1750 kg/m3 (6 to 14.5 ppg) − Back Pressure

No blending
Availability of gas

Good mud removal
Availability of equipment

Elasticity to absorb stresses
Stringent safety requirements

Relatively high strength, (higher tensile)

Low thermal conductivity

Thixotropic behavior

Two phase ( FL)
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 Applications

Weak and fractured formations

Losses to vugs

Geothermal and steam injection wells

Casings in permafrost

Alternative to stage cementing

Air-drilled wells

Improved bonding across salt

Gas and water flow control

Squeezing depleted zones

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 Properties

Mechanical properties:
− Dependent on foam Quality (porosity)
• Ratio of gas to slurry
• 15 to 30 % for improved properties

Pore size distribution

– Quality
– Stability
– Mixing Conditions

Physico-chemical properties:
− Dependent of base slurry density
• Cement
• Additives
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 Mixing Stable Slurry

Foaming agent and stabilizer

Foam generator
− Disperser disk with adequate pressure drop

Base slurry
− Mixed at optimum water ratio
− Uniform slurry mixing (density control)

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 Design Properties

Density
– Foam quality

Mechanical properties
– Base slurry density
– Compressive Strength
– Young modulus

Foamability
– Poisson coefficient

Rheology – Tensile strength

Free Fluid
Shear bonding

Fluid loss control
Permeability

Compatibility

Durability

Thickening time

Thermal conductivity
• LAB mixing at ambient conditions API / ISO 10426-3
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 Rheology

Foams are different from other fluids

– Compressible
– Bubble structure changes
– Dynamically unstable

Rheology measurement
– Viscometers are not suitable
• Shear changes bubble network
• Foam decays while testing
– Pipe rheometers
• Foam is compressible
• Non-Newtonian behavior

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 Compressive Strength

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 Thermal Conductivity

Density (g/cc)

Conventional
Lightweight
Slurries
Btu/hr-ft-oF

W/moK
Foamed Cement

Density (lb/gal)

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 Job Design

Wellbore fluids Well conditions

Drilling fluid
Low fracture gradients

Pre-flush
Losses

Cap slurry
Hole condition and geometry

Foamed cement slurries
Intervals to cover

Tail slurry
Potential for flow

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 Constant Nitrogen Ratio

Easy design

Hole size independent

Simplified execution

Varying cement properties

No flowing zones

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 Constant Density Method

Spacer

Multiple stages

Hole size dependent

Complex execution

Constant cement properties

Difficult with small volumes

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 Design Guidelines

2 Goals
– Control hydrostatic during placement
– Good density profile in annulus at end

3 Rules :
– Make operation as easy as possible
– Put as much cement in well as possible
– Put minimum amount of nitrogen in well

4 Parameters
– Number of stages
– Nitrogen ratio for each stage
– Back pressure
– Cap slurry
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 Number of Stages

Sensitive to
– Hole geometry
– Hole condition
– Leak off

Multiple stages make execution difficult
– Rate and volume schedules
– Difficult to run excess
– Risk of formation breakdown

One stage treatment
– Always try first
– Easier to design and execute
– Good slurry profile (density/strength)
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 Foamed Cement Process Control

Meters N2 & surfactant rates from

slurry rate
– Foam quality delivered as designed
– Ensures well control
– Slurry properties delivered as designed
Process control cement unit ( 3 controls) – Mass flow meters for mass balance
1600
guarantee 5

4 .5
1400
B a s e S lu r r y r a te
4
1200
3 .5 s c f/ m in
Foam er
s c f/ b b l
1000
3 s c f/ b b l
N 2 s tr o k e r a te b b l/m in
800 2 .5
J .Y . F M

2 fo a m e r
600 g a l/b b l
1 .5
400
F o a m e r r a tio
1
200 N 2 r a tio 0 .5

0 0
0

108

216

324

432

540

648

756

864

972

1080

1188

1296

1404

1512

1620

1728

1836

1944

2052

2160

2268

2376

2484

2592

2700

2808

2916

3024

3132

3240

3348

3456

3564

3672

3780

T im e (s e c )
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 Foamed Cement Process Control

Wellhead
Bleedoff w/Choke

Cement Unit
Foam
Generator

Densitometer

Check Valve
N2 Isolation
Foamer Recirc. Valve
Pump Tub

N2 Mixer Check Valve

Bleedoff
Tank w/ N2 Choke
2000 gals Popoff Valve
180 MSCF

Flowmeter
N2
Pump Restricted Area
N2
Tank
2000 gals Process
180 MSCF Control
Computer

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 Evaluation

Temperature survey
– WOC 8-24 hr
– Less change than conventional cements
– ID tops of tail and cap

CBL- Azimuthal sonic tool
– Low acoustic impedance -> high amplitude
– Use acoustic impedance charts

Ultrasonic tool (USIT™)
– Calibrate for low acoustic impedance (IMAU, IMAL)
– Compressive Strength is not valid
– Affected by gas -> but uniformly

Schlumberger Isolation Scanner®
– USIT + Flexural wave attenuation
– Solid, Liquid or Gas
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 CBL Interpretation Chart

CBL Advisor
7

Acoustic Impedance (Mrayl)

6
Amplitude (mV)

Density (lb/gal)
3-ft Spacing CBL

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