Well Cementing Business

Overview

BAYU BUANA NATANAGARA

16 March 2024 1
bayu.natanagara.16@Aberdeen.ac.uk / bayu.Natanagara@gmail.com
Personal Information
Formal Education:
◦ Teknik Fisika, Universitas Gadjah Mada, Indonesia
◦ Oil and Gas Engineering, University of Aberdeen, UK
Experience : 2010 – 2012 SLB Field Engineer (Cementing) – Balikpapan
2012 – 2015 SLB DESC Engineer (Cementing) – Balikpapan
2015 – 2016 SLB Field Service Manager (Cementing) – Balikpapan
2016 – 2017 Educational leave
2017 – 2018 SLB Well Service Coordinator for Indonesia (Pumping) - Indonesia
2018 – 2019 Pertamina Hulu Mahakam Fluid and Cement Engineer – Balikpapan
2019 – 2021 Pertamina Hulu Mahakam Drilling Engineer – Balikpapan
2021 – 2022 Premier Oil/Harbour Energy Drilling Contract Engineer – Jakarta
2022 – 2023 Premier Oil/Harbour Energy Well Intervention Engineer – Jakarta
2023 – Now Premier Oil/Harbour Energy Sr. Drilling Engineer – Jakarta

2
Agenda

•Needs of Well Cementing

•Basic Design of Cementing
•Cementing Execution
•Cementing Evaluation
•Research and Development
•Cementing Business Process
•Supply Chain Management
in Cementing

3
Needs Of Well Cementing
Well Delivery Process in Oil and Gas Business under
Petroleum System Cycle
Mature Explore Appraise Select Define Execute Operate Abandon
SG0 SG1 AFE SG2 AFE SG3 SG4 SG5 SG6 SG7
LL
AFE
AFE

SG
There are various points within the business SG at which a well may be approved and/or drilled

Exploration well WDP is a nested process within the business SG phases

FEL – 0 - 3 Execute

Appraisal well
WDP
FEL – 0-3 Execute

Development well (new project or infill)

FEL 0 - 1 FEL - 2 FEL - 3 Execute

PMP Project
Project Management
FEL 0 - 1 FEL - 2 FEL - 3 Execute
Process
SG3 SG4 SG5

5
Well Integrity Management System Purpose and Scope
Defined in terms of its pressure-containing boundary:
Well • Pressure-containing equipment on top of the well (e.g wellhead, Xmas trees) Xmas tree
• Downhole pressure-containing equipment (e.g casing, cement, tubing, safety valves, packers)

Well integrity in regard to the oil and gas well, is defined by NORSOK D-010 as the:
• Application of technical, operational and organizational solutions to reduce risk of uncontrolled release of Downhole
formation fluids throughout the Petroleum System Cycle. barrier
elements

Well Integrity Management System arises from the safety needs and based on regulations.

Note: Any equipment outside the well boundary, is not considered

as part of the well and is not subject to WIMS, including:
• Equipment downstream of Xmas tree production wing valve Well Cementing is part of
(e.g. production choke)
• Equipment downstream of the Annulus outlet valves
Well Integrity

6
Basic Cementing Design
Well Cementing

Primary Cementing
• Cementing during drilling period
• With drilling rig
Remedial Cementing
• Cement plug
• Remedial squeeze cement

4/23/2020 11
Primary Cementing
How to place the cement?

Protect and support the casing

Isolate production zone from other

permeable zones

Prevent movement of “unwanted” fluid

through annulus (well integrity support)

4/23/2020 12
Cement Placement

13
4/23/2020
 Standards Reference for Cementing
Sharing Knowledge

API 10A

API RP 10B

API RP 65

Well
Cementing,
Nelson, E.B.,
1990

4/23/2020 14
Cement Class as per API 10A
Class
Ordinary (O)
Medium Sulfate Resistant
(MSR)
High Sulfate Resistant (HSR)
4/23/2020
Depth (m) Properties
A 0-2000 General purpose when no special properties are required
B 0-2000 Sulphate Resistance
C 0-2000 Condition when require high early compressive strength
D 2000-3000 Sulphate resistance, intended for deep well as it has a
natural retarded property
E 3000-4000 Sulphate resistance, HPHT well, retarded cement
F 3000-5000 Extreme HPHT, sulphate resistance, retarded cement
G 0-2500 Covering a wide range of depth, temperature and
pressure. Basic well cement. MSR and HSR
H 0-2500 Covering a wide range of depth, temperature and
pressure. Alter with accelerator or retarder. Basic well
cement. MSR and HSR
15
Cement Chemistry Exothermic Reaction
Develop CS Ettringite

Simplified Abbreviation
C3S + H2O → CSH + CH
C2S + H2O → CSH + CH

4/23/2020 16
 Pre-induction
Hydration of Cement
Induction
The hydration of cement is a
function of temperature and
Acceleration pressure. The higher the
pressure and/or temperature,
time of hydration will be shorter
De-acceleration

Diffusion

CSH + CH
H20
C3S H20 C3S H20 C3S
CSH
+CH

4/23/2020 17
General Cement Lab Testing
Density

Rheology

Thickening Time

API RP 10B
Fluid Loss

Sedimentation Test

Compressive Strength

Compatibility

4/23/2020 18
General Cement Additives

Density Control
• Weighting agent
• Extender

Thickening time and setting time control

• Accelerator
• Retarder

Viscosity control

Filtration control

4/23/2020 19
Density Control Additive
Example of Density Hierarchy
Heavy Cement
Cement
Normal class G with 44% BWOC of water will Spacer 2.18 SG
result in 1.9 SG cement slurry Drilling 1.98 SG
fluid 1.80
SG Hematite
Ilmenite
Deep well with high Formation pressure will Sand
require heavy Mud Barite

Requirement of 10% density hierarchy above

the fluid ahead for effective laminar flow
Pressurized Mud Balance
4/23/2020 20
Density Control Additive (Lightweight Cement)
Challenges Solution
Options

Water Extender

Cenosphere
Lightweight
Weak formation
slurry
Slurry density <
fracture gradient
↑ Limitation
water &↓
Able to cement
it’s→
withstand
when
exposedpressure
poor to pressure
strength
Less hydrostatic & Engineered Highly
ECD Crush-Resistant

4/23/2020 21
High Pressure Density Crush
“Novel Cementing Solutions to Impede Lost Circulation with
Light Weight Pressure
Slurry Postapplied
CrushedtoTest
simulate Highly Crush-Resistant Lightweight Cement System and
Density Comparison
downhole condition Engineered Fibers”, SPE Asia Pacific Oil & Gas Conference and
Exhibition, 25-27 October 2016, Perth, Australia
1.540

Cenospheres
Cenosphere-Based Slurry Engineered Highly
1.520 1.520
sample Crush Resistant sample Losses Occurence in Cementing Job
Hollow Glass Sphere-Based Slurry Comparison of Cenosphere-Based Slurry Vs Hollow
1.500 Glass Sphere-Based Slurry
1.495
100%
Slurry Density

1.480 1.480 90% Cenosphere

80%
1.460 1.460
70% 44
57
1.440 1.440 60% 62

50% 39

1.420
40%
1.410 1.410
1.405 1.405 30%
1.400 1.400 1.400 1.400
20% 28
19
1.380 10% 14
14.5 2500 3000 4000 5000 7500
0% 1

Particles 2013 2014 2015 2016

Particles crush Pressure (psi)

Losses

stable No Losses

4/23/2020 22
Thickening Time

Time measure of how long the cement slurry remains pumpable,

stipulated from the cement mixed with water /mix fluid
Defining the thickening time requirement is from the job time + 2 hours, or
Consistometer job time x 1.5. The longest time will be considered in design
Batch Mix Job
Volume Pump Rate time
Sequence
(bbl) (bbl/min) (min)
Batch mix cement 60 116 + 120 = 236 minutes
Pump Spacer 50 5 10 116 x 1.5 = 174 minutes
Drop Bottom Plug 10

Requirement thickening
Pump Cement slurry 100 5 20
Drop Top Plug 10
Displacement 30 5 6 time is 3:56 hr:min
Total Job time 116

Mix on Fly Job

Volume Pump Rate time
116 + 120 = 156 minutes
Sequence
(bbl) (bbl/min) (min)

Cement mixing
Pump Spacer
Drop Bottom Plug
50 5 10
10
116 x 1.5 = 174 minutes
process Mix and Pump Cement slurry 100 5 20
Drop Top Plug 10 Requirement thickening
Displacement
Total Job time
30 5 6
36 time is 2:36 hr:min

4/23/2020 23
Thickening Time

Thickening time parameter is under unit of Boundary Consistency

(BC)
𝑇 − 78.2
𝐵𝐶 =
Where, 20.02
T = Torque measured in paddles (g-cm)
Term of unpumpable as per API is 100 BC. While other companies has stringent
rules, 70 BC or 40 BC

Thickening Time
Alteration Additives Accelerator Retarder

Shorten the Elongate the

hydration hydration
period period

Calcium
CaCl2 Lignosulfonate

4/23/2020 24
 Temperature test at ambient temp and at
BHCT (conditioned to BHCT)

Viscosity Of Cement slurry

Rotational Viscometer
For effective laminar flow, friction API RP 10B, Section 12
pressure hierarchy is 15% above
the fluid ahead PV = 1.5 x (Q300 - Q100)
Ty = Q300 - PV
Rheological Model

Cement Surface Cement Surface

Common Additive - Ca++ - Ca++ -

A
Sulphonate Polymers - Ca++ R - Ca++ -
A
- Ca++ - Ca++ -

A: Attractive Interaction
Polymelamine Sulphonate
Ty Ty B: Repulsive Interaction

4/23/2020 25
 Causes of fluid loss:
Filtration Control (Fluid Loss) 1. Differential pressure in annulus vs
formation
Fluid loss in cement is a term for Filtrate 2. Permeable formation
(Aqueous solution) lost to the formation 3. High water to cement ratio

Stages of fluid loss:

P1 1. Dynamic Fluid Loss
2. Static Fluid Loss
ΔP = 1000 psi ± 50
Common Additive

Latex

Test is performed in 30 minutes, then calculate

P2 the volume of filtrate. If the nitrogen gas is
blown before 30 minutes, then use the ISO Polymers
HTHP Fluid Loss calculation. Unit for API fluid loss is ml/30 min

Solid particle replacing water (microsilica)

4/23/2020 26
Filtration Control (Fluid Loss)
Fluid loss risk associate
4/23/2020
Basic design for FL: (without considering
gas tight design)
1. Surface casing < 500 ml/30 min
2. Intermediate casing < 250 ml/30 min
3. Production casing < 100 ml/30 min
Nevertheless, the lower the better,
depend on your budget!
27
 Cement isolation in potential flow zones (API RP65)
Density • Appropriate ECD

• Effective Laminar Flow Displacement, Ty > 15%

Rheology from displaced fluid

Fluid Loss • ALARP, best practice <50 ml/30 min

Thickening Time • Right Angle Set, no gelation trend

Gel Strength Control • CSGS to 500 lb/100 ft2 below 45 min

Critical Static Gel Strength Mechanical • Young’s Modulus, Poisson Ratio, Tensile strength,
CSGS = (OBP x 300) x (Deff/L) Properties Compressive Strength, Expansion/Shrinkage

[unit in lb/100 ft2]

Where:
OBP Overbalance Pressure
300 conversion factor
L length of cement column (ft)
Deff (Diameter Open hole – Diameter casing) (inch)

4/23/2020 28
Strength Retrogression
At temperature above 230 degF, hydrated cement would change the
structural which leads to strength retrogression

Expansion Crystalline
At 250oF (120oC) - slow decrease
Permeable
Low-compressive strength
At 450oF (232oC) - within a few
days
Prevention: reduce cement C/S ratio by addition of 35 to 40%
BWOC silica
At 600oF (315oC) - within hours

4/23/2020 29
Cementing Execution
Cement Equipment in General
Cement Unit Batch Mixer

Bow type centralizer

Float Collar Float Shoe

4/23/2020 31
Cement Equipment in Drilling Setup
Cementing in Rigless (WO) AWB Deck Platform

Expro Pump
Max =
0.3 BM

Return Sand
Choke
Tank KO DRUM Manifold Filter
300 bbl
Equipment Setup

Production
Line
Batch Mixer 2x75 bbl and 2x50 Flow Cross
ANSI 2”
bbl Batch Mixer 1a Batch Mixer 1b
Water Tank 75 bbls 75 bbls WV
150 bbls Production
Coil
Line
Tubing FLP 350 psi
AW-1 Max 1000 psi
Water Tank 2 x 150 bbl Batch Mixer 2a Batch Mixer 2b
Water Tank
42 bbls 42 bbls
150 bbls

Cement pump 2 ea with 2

x 7.5 bbl displacement
tank each CSP Thai
Wilden Pump Pump
Pump #2 #1
Displacement Tank
Parallel line up after cement 14 bbls
pump (1 with screen and 1 Spacer Fresh Water

without screen)
Surface Screen
33
Cement Slurry Lab Test (Special Consideration)
Time to cut and mix cement Bigbag
Thickening Time
With the non-ideal condition due to high wave on barge, the duration of cutting • Lifting Bigbag
cement onboard will be longer
Main Deck to Batch Mixer

Tank 3 -
BMX-1
Cement
Unit 1
Cement
Unit 2
3.5 Min (BMX)
Tank 1 - single single
75 bbl 50 bbl Pump Pump
Lead Tail

Tank 4 - Tank 2 -
• Cut Cement
Bigbag and
transfer to
BMX-2
5 Min BMX
3.5 Minutes

Tank 5 -
150 bbl
• Lifting Bigbag
Tank 6 -
back to Deck
150 bbl
3.5 Min
3.5 Minutes

12 minutes per
Bigbag
Cement Bigbag

Texas Deck
Cement Evaluation
Cementing Evaluation
AA well

Volumetric
T

Surface Sample Hard Set Timing

3’
Cement Bond Log R
CC well

5’
Post job Playback performed with match pressure R
from design to the actual recorded pressure

Sustain Casing Pressure Monitoring

36
Research And Development
Value Added in All Technology Proposal
• Secure the • Revenue
Well • High IBT
Construction / Value
Value Well Remedial • Recognition
Added to
Added to • Cost saving Service • Green
Customer • Well Integrity Company Money
Lightweight Cement Slurry Case
SCP
Santan

• Weak formation which require

lightweight Tunu
cement slurry system in
Tambora Muara Badak
surface section
Samarinda
Sisi-Nubi
Losses
• Past decade high statistic of cement
Handil

job loss circulation Weak formation

Senipah

Bekapai

• SCP occurrence after cement

Peciko job Shallow Gas
Balikpapan
zones
South MHK 44

44
Density Control Additive (Lightweight Cement)

Challenges Solution
Options

Cenosphere

Lightweight
Weak formation
slurry
Slurry density <
fracture gradient Limitation
Able to withstand
when it’s
exposed
pressure to
to pressure
8000 psi
Less hydrostatic & Hollow Glass
ECD Sphere

16/03/2024 45
Replacement of Cenosphere with HGS History

Light Weight Slurry Post Crushed Test

Losses Occurence in Cementing Job 2nd Stage Cementing Execution
Density Comparison Surface Section
Comparison of Cenosphere-Based Slurry Vs Hollow
Glass Sphere-Based Slurry 100%
1.540
100%
90%
90% Cenosphere Cenosphere-Based Slurry
1.520 1.520
80%
80%
Hollow Glass Sphere-Based Slurry 70%
1.500
70% 44 1.495
60%
57 35
60% 62
Slurry Density (SG)

1.480 1.480 39 30
50% 2
50% 39
40%
40% 1.460Glass Sphere
Hollow 1.460
30%
30%
1.440 1.440
20%
20% 28
19 10%
10% 1.420 14 5
0% 1 1 0
0% 1.4101 1.410
1.405 2013 1.405 2014 2015 2016
2013 2014 1.4002015 2016
1.400 1.400 1.400
Losses
Run 2nd Stage Cementing Number of Well with ECP/DV
No Losses 1.380
14.5 2500 3000 4000 5000 7500

Pressure (psi)
16/03/2024
Shallow Section Cementing Roadmap

Price increase
60%
Optimized 1.4 SG High crush
slurry resistance using HGS

1.4 SG High Crush resistance

slurry using HGS

Single density
slurry 1.4 SG
Cenosphere blend
Moving further backward to the
Taking a backward step to 2010 by
time where Bentonite cement
using Cenosphere system could
system was used will even cut the
Dual density reduce the cost. However, there
cost significantly. Risk of using this
slurry 1.5 SG will be an issue associated such as:
will be: Non-gastight slurry, low
and 1.4 SG with Sustain Casing Pressure, Loss
compressive strength, longer WOC,
Cenosphere Circulation, 2nd Stages cementing,
and intensive monitoring for SCP
blend etc.
issues.

2010 2014 2019

 Do we really
need 8000 psi Maximum BHP
Drilling Cost Good enough
rated light during cement
Optimization Design
weight job is 4000 psi
additive?

Fit for purpose design is required

48
Challenge in Fit for Purpose Design Cement System

Main Objective is to
have low cost Difficulties in If only Cenosphere
cement system with Price wise HGS is could sustain to
sourcing HGS 4000
fit for purpose still relatively costly high pressure
psi
performance

49
 Main Design of the Cement Slurry

Initial cement
Cenosphere The cement
slurry density is
enhancement system is aimed
1.38 SG to
properties for shallow well
overcome crush
option as base with BHP below
of cenosphere in
design 4000 psi
high pressure

Another challenge With lower density,

is how to ensure means require
Is this going to be as simple as the Compressive more cenosphere
that? strength is suitable which increase the
with lower cement risk of crush in
density? downhole?

50
 Crush Test Density test
Cenosphere Slurry Performance (Density after Crushed)
1.425 Max BHP for
1.42 1.42 Surface : 3500
1.415 psi
1.41 1.41
Density, SG

1.405
1.4 Acceptable density
1.4
tolerance is 1.40 SG ±
1.395 1.395 1.395 0.02 SG after slurry is
1.39 subjected to pressure;
1.385 1.38
1.385
1.38
1.375
0 500 1000 1500 2000 2500 3000 3500
Pressure

1.38 SG Cenosphere (27 % BWOC) 1.38 SG Cenosphere (31 % BWOC)

52
Summary Lab Testing
Cenosphere Concentration
Parameter
27% BWOC (A) 31% BWOC (B) 31% BWOC (C)
Cenosphere Density (SG) 0.83 0.83 0.83
BHP (psi) 3500 3500 3500
SVF (%) 37.6 40.62 40.46
Density before crush (SG) 1.38 1.38 1.38
Density at BHP 1.4 1.42 1.42
Microsilica (gps) 2.3 2.3 3
Pv after mixing (cP) 28.3 28.7 31.3
Ty after mixing (lbf/100 ft2) 8.91 12.06 19
Pv after conditioning (cP) 33.9 33.4 39.5
Ty after conditioning (lbf/100 ft2) 15.32 18.74 26.3
Set hard (hrs) 20 20 16
UCA (psi) 1452 psi in 61 hours Over spec 2241 psi in 24 hours

All Parameter has been accepted as per requirement, and slurry cost is 20% reduced from HGS System
3/16/2024 56
Field Implementation
No Well Job Type Final Press Final Press Estimated Designed 1.4 SG
Name (planned) (actual) Annular TOC Cement
psi psi Cavity return
(m3)
1 AA 9-5/8" Surface 541 564 31% Surface 15.43

2 BB 9-5/8" Surface 252 230 62% Surface 2.7

3 CC 9-5/8" Surface 248 257 58% Surface 3.32

4 DD 9-5/8" Surface 780 812 70% Surface 2.0

3/16/2024 57
Other Loss Circulation Technology

C
M
C M C
M M M
M C M
M C
M M

Combination of Fiber σ

and Solid Particle

3/16/2024 58
Self Healing Adaptive Responsive Material

Well Integrity Risk

Flexible Cement

Placement During Set Post-set

Minutes Hours→Days Months → Years Self Healing Cement

Immediate Short-Term Long-Term

Gasintegrity F L Eintegrity Inorganic Scale Utilization
integrity –
Centralization migration XIBLE CEMENT
good stand-off control additives SELF HEALING CEMENT (CaCO3 high mineral)
Fluid displacement
Hydrostatic pressure
during placement Annulus Remedial Intervention
Chemical

3/16/2024 59
 Objective

Annulus Cementing – Future Opportunity

Challenges in Cement Packer

Cement to be placed above production packer

PDHG with lines in the annulus up to surface

Long coverage column with high cement volume required

Unpredicted weather condition on site

QAQC on site to ensure that the cement slurry is as per lab test

High temperature above 230 degF

60
Cementing Business Process
 General Cementing Organization
Cementing Operation Manager

Cementing Technical Manager Cementing Services Manager Support

Sr. Lab Manager Cementing Supervisor Bulk Plant Supervisor Supply Chain

Sr. Technical Engineer Cementing Operators / Asst. Operators Bulk Plant Operators / Asst. Operators
Material Management

DESC Engineer Finance

Field Engineer

Harbour Energy
62
WELL INTEGRITY SHARING SESSION | MARCH 2024
Cementing Manager Roles

Operation Management
Operation • Pre and Post Job Document Review
Management
Profit and Loss Management
• Revenue accrual – DSO
• Clear Dispute – NPT
• Cost management
Profit and
Market Share • PcPr management
Loss
Management
Monitoring
Stakeholders Management
• Customer
• Vendors
• Local Issue

Process Improvement
• Value added – Logistics, Lean Sigma process
Process Stakeholders Market Share Management
Improvement Management
• Short term and long term opportunities

Harbour Energy
63
P&L Components in Cementing Business

Revenues Service Management and Cost Control

NOT COST CUTTING !
COSTS •Controls and monitors operating efficiency of fixed assets and
personnel to optimize return on investment without compromising
• Compensation service quality and safety.
• Material & Supplies (M&S) • Controls and monitors ordering and inventory of products and spare
• Depreciation parts to ensure maximum efficiency and profitability.
• Product Cost •Responsible for reporting & invoicing of services provided using
• Total Field Cost Company processes and systems

• Field Segment Contribution •Organizes, schedules & optimizes maintenance of all equipment as
per Company procedures.
• Shared Cost
• Ensures inventories of supplies & fixed assets are controlled
Net Income (IBT)

Harbour Energy
64
Cementing Supply Chain Management
Cementing Supply Chain Management
◦ Sourcing
Sourcing ◦ Supplier Identification, Evaluation, Selection.
◦ Embargoed countries support
◦ Supplier Base Management
Process
Improvements
Supplier
Management ◦ Contract Agreements, Performance Measurement
and Review
◦ Business Process Improvements
◦ Including coaching and mentoring for local
purchasing
Cementing
Supply
Chain
◦ Cost Savings Initiatives
T&C Regulatory
Field &
Revenue
◦ PC/PR reduction
Compliance Suppo
rt ◦ Inventory Management
◦ T&C and Regulatory Compliance in procurement
activities
◦ Field and Revenue Support
◦ Efficient and effective service levels with key field
Cost Savings
Initiatives
Inventory
Management
customers
◦ Distribution Support
 Commodity Classification
• Manage Inventory

Bottleneck Critical
High Risk Low Value High Risk High Value • Chemicals Forecast
Criticality

Ensure supply Supplier engagement

continuity
• Local Supplier Research

• Customer Engagement – Negotiation

Routine Leverage Skills – i.e Logistics
Low Risk Low Value Low Risk High Value

Simplification of Maximize Sells up

• Maximize the commercial advantages –
process
through PcPr and Value added approach
Value (spend)

67 KS
 • Supplier Performance
− Cost Trends − Product / Job Quality
Supplier Qualification − Safety Record − Environmental Compliance
Criteria − Delivery / Timeliness − Technology Changes

• Supplier Capability
− Capacity − Research & Development
− Financial Strength − Product Lines
− Logistics − Information Systems

• Continuous Improvement Philosophy

− Management Experience − Customer Focus
− Leadership & Vision − SQM Institutionalization
− Growth Plans − Ongoing Measurements

WHAT DO YOUR CUSTOMERS WANT?

Thank You

69