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Case Studies of Expanding Cement To Improve Wellbore Sealing
Case Studies of Expanding Cement To Improve Wellbore Sealing
Amanmammet Bugrayev, Svetlana Nafikova, Salim Taoutaou, Andrey Timonin, Guvanch Gurbanov, Alexander
Burkenya, and Irina Amanova, Schlumberger; Mahomud Hegab, Dragon Oil
This paper was prepared for presentation at the SPE Gas & Oil Technology Showcase and Conference held in Dubai, UAE, 21 - 23 October 2019.
This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents
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Abstract
Good cement bond at the casing-cement and cement-formation interfaces is essential for effective zonal
isolation. Poor bonding can lead to underground fluids and gases to enter the annulus and create sustained
casing pressure (SCP), jeopardising the working envelope of the well and limiting its production. One of
the causes of a poor cement-formation bonding is attributed to a cement shrinkage. Cement systems that
expand after setting can help improve primary cementing job results by sealing microannulus. The enhanced
bonding is the result of enhanced shear bond and adhesion of the cement against the pipe and formation.
Cement expansion is achieved by addition of the expanding additives into cement system. The mechanism
of expansion is based on set cement volume growth over initial volume post setting. This is driven either
by gas bubbles created during chemical reaction or by crystal growth within set cement matrix. Careful
optimization of the cement slurry designs with an addition of the expansion additives to conventional
and complex blend systems allowed greatly improving the cement bond evaluation log results without
compromising other mechanical properties of cement.
This paper outlines the successful application of expanding cement to seal different sizes of wellbore;
the study evaluates the effect of the expansion by comparing the cement evaluation log from numerous
cementing jobs. Examples included in the comparison are cemented production strings (casings and liners)
with different types of cement systems used across 9 5/8-in. production casings and 7-in. and 4 1/2-in.
production liners.
Introduction
Downhole well integrity is one of the most important aspects in the well lifecycle due to the high remedial
cost for well repair should the annulus seal fail. Therefore, significant effort is being made to achieve
annulus zonal isolation. The quality of zonal isolation of the primary cement job is verified using sonic and
ultrasonic tools. Despite the application of good cementing practices, the cement evaluation logs are not
always satisfying and sometimes cause debates on whether sufficient coverage and isolation were provided.
In the worst-case scenario, annulus remediation is needed to repair the defects.
These ambiguous results from cement evaluation logs could be driven by several factors that could
include, but are not limited to, poor mud removal and/or cementing practices, debonding due to well fluids
2 SPE-198630-MS
change, pressure tests, fluid loss after placement until the cement hardens, and cement shrinkage (Parcevaux
and Sault 1984). In this paper, we discuss the cement shrinkage and the impact of its elimination on cement
evaluation log results.
Cement shrinkage is a natural process that all cement systems undergo. The cement volume reduction
can be due to moisture loss, chemical reactions, and hydration processes. To overcome this phenomenon,
expanding additives are added to cement slurry formulations.
Figure 1—Comparison of recorded ultrasonic logs of the production string at the same
interval in a well A: a, 9 days after the cement job and b, 43 days after the cement job.
Although expansion additives improve cement bonding, these results may not be seen due to other
cementing job factors. The most common negatively affecting factors are mud removal, poor pipe standoff,
hole washouts, or simply insufficient time for crystal growth within the cement matrix. Therefore, expanding
additives should not be taken as the sole solution but should be combined with a good cementing engineering
approach and industry practices.
Typical conventional cement slurry formulation and properties are shown in Table 1, and Fig. 2 represents
the results of the expansion test results. Conventional cement slurry had 5% by weight of cement (BWOC)
of low temperature expanding additive. As can be seen in Fig. 2, a linear expansion reached up to 1% within
10 days, and 1.5 % linear expansion after 34 days.
Table 1—Conventional cement slurry with expanding agent recipe and properties
Expanding agent 5.000 % BWOC Compressive strength, [psi]/ [hr:mn] 2022 / 17:55
Fluid loss control 0.350 % BWOC Plastic viscosity Pv [cP] 101.4 102.5
10/34 days expansion test result [%] 1.0 / 1.5 % @ 50°C, 3000 psi
The expanding additives were also used in the high solid volume fraction (SVF) slurries as well. These
slurries have an SVF exceeding 50%. Slurry formulation and properties of high SVF slurry are summarized
in Table 2. This slurry recipe was designed with 1% by weight of blend (BWOB) of high-temperature
expanding agent. The expansion test results are shown in Fig. 3. This formulation of cement slurry resulted
in 0.31% liner expansion within 2 days and 0.37% after 15 days of testing.
SPE-198630-MS 5
Table 2—High SVF cement slurry with expanding agent recipe and properties
Fresh water 1.659 gal/sack Compressive strength 500 psi, [hr:mn] 11:26
Expanding agent 1.000 % BWOB Compressive strength, [psi]/ [hr:mn] 2670 / 14:00
Fluid loss control 0.150 % BWOB Yield point Ty [lbf/100ft2] 27.37 20.76
Retarder 0.065 gal/sack 2/15 days expansion test result [%] 0.31 / 0.37 % @ 85°C, 3000 psi
Figure 3—Expansion graph of high SVF cement slurry with expansion additive.
Case Studies
Case Study 1: Cementing 9 5/8-in. casing
An openhole section of well B was drilled with a 12 1/4-in. bit from previous casing shoe at 2424 m down
to 3698 m measured depth (MD) with a maximum inclination of 50.4°. A 12.7 ppg [1.52 SG] density water-
based mud (WBM) was used for this section.
The openhole section crossed five gas-bearing formations—CH-4, CH-5, CH-6, CH-7, and CH-8. The 9
5/8-in. (53.5lbf/ft) was run and cemented using 15.2 ppg [1.82 SG] lead and 17.0 ppg [2.04 SG] gas-tight
tail slurry to provide zonal isolation between these formations behind 9 5/8-in. casing.
An engineered approach was required to meet job objectives. Analysis of the cement evaluation logs
from the offset wells led to a conclusion that the application of the standard and local best practices to ensure
effective mud removal is obtained are not sufficient, and further improvement is required. The decision
was made to focus on overcoming the cement shrinkage issue by addition of the expansion additive to the
cement slurries. Cement job execution was performed successfully, and the pressure signature suggested
6 SPE-198630-MS
that top of cement (TOC) is higher than initially planned (Fig. 4). Consequently, 8 1/2-in. and 6-in. openhole
sections were drilled, and 7-in. and 4 1/2-in. liners were successfully cemented.
Figure 4—Top of cement matching from pressure signature of the 9 5/8-in. casing cementing job in well B.
Cement quality evaluation was done with ultrasonic tool run 34 days after cementing the 9 5/8-in. casing
in well B (Fig. 5b). The ultrasonic tool measures acoustic impedance of annular material and attenuation of
the flexural wave with good azimuthal and vertical resolution. Measurements are combined to derive the
SLG map. On the log (Fig. 5), the first column on the left is depth track; this is followed by the acoustic
impedance map (second column), the flexural attenuation map (third column), SLG map (fourth column),
and fractions of solid, liquid and gas (fifth column).
SPE-198630-MS 7
The log on the left (Fig. 5a) shows cement evaluation log in the reference well C, where similar
conventional class G cement systems were used with no addition of the expansion agent. The SLG map on
this left log shows the presence of poor-quality cement in the annulus as indicated by the predominantly
liquid (blue in colour). Measured average acoustic impedance is relatively low, being around 3 MRayls
confirming presence of poor-quality cement. Gas (red in colour) present on SLG map across the 1850 to
2050-m interval shows presence of debonded cement that created a gas-filled (or dry) microannulus.
The log on the right (Fig. 5b) shows the latest cement evaluation log results for well B where expanding
cement was pumped. The SLG map on the log shows the presence of good cement in the annulus. Quality
of the cement deteriorates from bottom of well B towards surface, and cement gets contaminated with
liquid above 2600 m. Also considering that presented data (i.e., maps) are oriented, we see the presence
of a narrow channel at the high side of the casing starting from approximately 3300 m. Most probably,
both facts indicate that cement got contaminated due to incomplete mud removal or/and excessive fluids
intermixing at interfaces during cementing operation. At the same time, across entire logging interval, there
is no debonded cement, thanks to expansion agent in cement slurry.
Comparison of the log on the left with one on the right shows significant improvement in cement quality
for 9 5/8-in. section for well B where the expanding agent was used with the cement slurry.
8 SPE-198630-MS
The cement job was executed as per design. Cement quality evaluation was done with an ultrasonic tool
run 2 days after the cement job. The log was analysed and plotted in Fig. 7 against the zone of interest
(CH-2) from similar well E where expanding agent was not used. The log on left (Fig. 7a) was from well
E where conventional class "G" cement without expanding agent was used, whereas the log on right (Fig.
7b) was from well D where liner was cemented using conventional cement slurry with expanding additive.
Comparison of the SLG maps on both logs, across the CH-2 sand, shows that cement on the left log is of
poor-quality cement and might be debonded from liner, resulting in absence of zonal isolation across CH-2
sand. At the same time, on the right log, the SLG map shows the presence of good cement in the annulus
SPE-198630-MS 9
across the 1490 to 1625 m interval resulting in good zonal isolation across this zone. As the result, well D
was completed successfully and handed to production. Liquid channel, present below 1625 m at the low
side of the 7-in. liner, was formed in the deviated section of the well as the result of poor liner centralization.
Figure 7—Ultrasonic evaluation logs of cemented 7-in. liner across CH-2: a, well E, conventional
cement slurry without expanding agent and b, well D, cement slurry with expanding agent.
with expanding agent. The objective of the job was to ensure a good zonal isolation across the CH-4 gas
formation. The job was challenging because of the small liner size, which meant small cement slurry volume
of 86.1 bbl [13.69 m3], deep liner setting depth, and capability to utilize only single wiper plug, which
complicates the mud removal strategy. The liner cementing job was executed successfully as per the job
design.
Cement bond quality evaluation was done with a slim sonic tool, run 6 days after cement placement,
confirming a good zonal isolation (Fig. 8b). The slim sonic tool measures the amplitude of a sonic signal
produced by a transmitter and after it has travelled through a short section of the casing as an extension
mode. Measured cement bond log (CBL) amplitude in column 2 from left indicates quality of cement
bonding to outer liner walls; low CBL amplitude corresponds to good cement bond, and high CBL amplitude
corresponds to absence of cement bond. The slim sonic tool also uses eight azimuthal receivers to plot
azimuthal variations in CBL amplitude and derive the amplitude map. Black and dark brown colour on the
amplitude map corresponds to low CBL amplitudes measured azimuthally, hence indicating good bond in
between cement and liner. White and light-yellow colour on the amplitude map corresponds to high CBL
amplitudes measured azimuthally, hence indicating poor cement bond to liner walls, as shown on the log
in column 4 from left. The slim sonic tool also provides a qualitative indication of cement bond to the
formation using a variable density log (VDL) waveform, as shown on the log in column 3 from the left.
Analysis of data acquired with the slim sonic tool in well F cemented with slurry having expanding agent
(Fig. 8b) showed a good cement bond to the liner (low CBL amplitude, azimuthal CBL image dark in colour,
and almost invisible first arrivals on VDL) as well as good cement bond to the formation (clear formation
arrivals on VDL) confirming good zonal isolation across the entire 4 1/2-in. liner.
At the same time, analysis of data acquired with slim sonic tool in the 4 1/2-in. liner of well G cemented
with a conventional cement slurry (Fig. 8a) showed a poor cement bond to the liner (high CBL amplitude,
azimuthal CBL image light in colour, and visible first arrivals on VDL) as well as a relatively poor cement
bond to the formation (absent formation arrivals on VDL across almost the entire log) confirming poor
zonal isolation behind the 4 1/2-in. liner in this well.
A comparison of logs showed significant improvement in cement to liner and cement to formation
bonding and thus again demonstrated the positive impact of approach taken to improve wellbore sealing.
SPE-198630-MS 11
in deep lower sections of the well is challenging because they have narrow annuli. These narrow annuli
bring high friction during fluid pumping. Additional friction is created by liner hanger restrictions. These
conditions are getting more challenging with high-SVF fluids due to density requirements. The flow of
high-SVF fluids in narrow annuli increases friction significantly. The combination of all above-mentioned
factors increases the risk of losses. Effective mud removal is also a challenge in cementing job with close
densities of fluids.
In addition to increasing friction, narrow annuli have another drawback in cement slurry placement. This
is related to small annular volume requirement for the cementing jobs. Delivering a small volume of fluid
uncontaminated to a deep well TD is a challenge in every cementing job. A good practice is to separate
fluids by mechanical barriers such as a wiper plug. However, this is not feasible on every cementing job to
various factors governed by operator's planning.
The job in well H involved careful consideration of all aspects for an effective placement. First, 200
bbl [31.8 m3] of low-viscosity mud were pumped ahead of spacer, and sufficient spacer volume (100 bbl
[15.9 m3]) treated with scrubbing technology fibers was utilized for optimum placement. Cement slurry was
batch mixed to ensure a good slurry homogeneity. During the cement job execution, 60 bbl [9.54 m3] of
losses were observed, resulting in a low top of cement (TOC) in the annulus, as estimated from the analysis
performed on the surface pressure data recorded during cementing operation (Fig. 9).
Figure 9—Top of cement matching from pressure signature of the 4 1/2-in. liner cementing job.
The cement bond evaluation log in well H was run 8 days after cement placement (Fig. 10b). Despite the
lost circulation event and estimate of low TOC, zonal isolation was achieved across the required intervals.
SPE-198630-MS 13
Figure 10—Cement evaluation logs of 4 1/2-in. liner where high-SVF heavyweight cement slurries were
used: a, well I, cement slurry without expansion and b, well H, cement slurry with expanding additive.
Cement bond evaluation log results of well H were then compared to the sister-well I with the similar
casings configuration, where high-SVF cement slurry was pumped but no expanding agents added into
14 SPE-198630-MS
slurry recipe (Fig. 10a). Comparison analysis showed significant improvement in the quality of the cement-
to-liner bond because measured CBL amplitude was lower than in reference well H and the azimuthal
CBL map image was darker in colour. At the same time, formation arrivals, visible on VDL waveforms,
showed improvement in the quality of cement-to-formation bonding compared to reference well I. These
log comparisons confirm that expanding agents are beneficial in high-SVF cement slurries.
Conclusions
Cement shrinkage is one of the factors affecting the zonal isolation, and it can be indicated by sonic and
ultrasonic cement log responses. This study confirmed that the use of expanding agents can mitigate the
cement shrinkage, and this was verified by the improvement in the cement evaluation log response.
Acknowledgments
Special thanks go to Schlumberger and Dragon Oil drilling department management and team for their
support and permission to publish this work. Without their support this work would not be performed,
and paper conclusions would not be achieved. Also, the authors would like acknowledge assistance and
contributions done by Schlumberger Balkanabad laboratory and logging department team.
Nomenclature
API – American Petroleum Institute
bbl – barrel
BWOB – by weight of blend
BWOC – by weight of cement
CBL – cement bond log
CH – Cheleken
SLG map – solid/liquid/gas map
SVF – solid volume fraction
TD – total depth
TOC – top of cement
VDL – variable density log
WBM – water-based mud
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