COST EFFECTIVE CEMENT PLANNING PART OF WELL PLANNING

Cost Effective Cement Planning
Institute of Drilling Technology, Dehradun

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FIRST IT IS NECESSARY TO BE AWARE OF

THE COST IMPLICATION RELATED TO
CEMENTING OPERATION

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BRIEF CEMENTING REVIEW
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Requirement For a Cementing Operation
1. CEMENTING EQUIPMENT
2. CEMENTING TOOLS / ACCESSORIES
3. CEMENT : Class G OWC
4. CEMENT CHEMICALS
5. PLANNING / DESIGNING
6. EVALUATION
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Cementation Job for a WELL

• Planned Job :
 Primary Casing Cementation
 BOP Test / Hermetical Test
• Non-Planned Job :
 Secondary Cementations
 Plug job
 Squeeze job
 Allied Jobs
 Oil spot
 Pressure test
 Other Misc.
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What is Cementing cost
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PLANNED COST
Primary Casing Cementation
Fixed cost : Cementing Equipment Expenses

Cementing Service Cost
Variable cost : Cementing Accessories

 Cement & Additives
 Floating Equipment
 Cementing Plugs
 Stage collars
 Centralizers & scratchers
 Liner hangers etc.
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How does the Cementing

Cost get escalated?
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SINGLE MAJOR FACTOR:

POOR PRIMARY CEMENTATION
Unsuccessful Primary Cementation
Sick Well
1. Low production/Poor Reservoir

Evaluation
2. Repair and Work over Operation–

Recurring Expenditure
10
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REASONS FOR POOR PRIMARY CEMENTATION

• HOLE IS NOT PROPERLY GAUGED, CLEANED OR
CONDITIONED
• LACK OF PROPER CENTRALISATION
• CEMENTATION IS NOT PLANNED & EXECUTED

PROPERLY.
• VITAL EQUIPMENT FAILED DURING

CEMENTATION.
• POOR QUALITY & POOR EVALUATION OF CEMENT

BOND
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OTHER THAN POOR PRIMARY CEMENTATION
Non-planned Secondary jobs

1. Plug/Squeeze Jobs during drilling for
- Fishing – Side Track
- Mud loss
- Well head repair
- Cellar pit seepage
- Formation/ shoe integrity
- Temporary suspension
REMARK : NOT DESIRED BUT ESSENTIAL SOMETIMES
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Non-planned Secondary jobs contd….

2. Cement repair as a consequence of
- Mud pump problem
- Inability to reciprocate casing
- Faulty pressure gauges.
- Inaccurate stroke counter
- Improper mud properties
- Inadequate centralizers
- Excessive caving
- Poor slurry design
- Unable to maintain designed slurry wt.
REMARK: NOT DESIRED & ALSO AVOIDABLE
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Non-planned Secondary jobs contd….
3. Others
 Cement squeeze for casing pipe failure
 Squeeze job failure

- Improper design
- Non- availability of required
additives.
- Improper execution
- Inadequate WOC.
 Avoidable allied job

- Misc. pumping /pressure testing
REMARK: NOT DESIRED & ALSO AVOIDABLE
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4. Improper evaluation of cement bond
A good bond or bad bond may be misleading if properly

not evaluated
Often it is found that there is no INJECTIVITY during

squeeze job
IMPORTANT to avoid unnecessary cement repair job

based on wrong evaluation as it leads to RIGTIME
WASTAGE AND DAMAGE OF CASING.
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Who can Contribute to Cost Reduction?
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CEMENTATION IS A SMALL BUT VERY

SIGNIFICANT PART TO ENSURE
LONG LIFE OF WELL FOR WHICH IT
IS NECESSARY FOR ALL
ASSOCIATED TO PLAY A ROLE FOR
COST REDUCTION
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COST ESTIMATE :
A GENERAL QUANTIFICATION
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Know the basic cost

Item UOM Approx. Cost
(Rs.)
Neat cement Per MT 8,000
Chemical slurry Per M3 41,000
Gas tight slurry Per M3 53,000
HPHT slurry Per M3 75,000
Deepwater slurry Per M3 130,000
Light weight slurry (< 1.5) Per M3 100,000
Cementing cost (onshore) Per job 5,00,000
Cementing cost (offshore) Per job 15,00,000
Onshore operating rate Per day 15,00,000
Offshore operating rate Per day 150,00,000
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NOW WITH THE UNDERSTANDING OF

COST IMPLICATION
Next Logical Step is the Cost

Reduction in Cementing Operation

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Cost Reduction – Possibilities
PURPOSE OF COST AWARENESS IN

CEMENTING MOSTLY MEANS TO
AFFECT SAVINGS IN TERMS OF
RIGTIME THROUGH BETTER
PRIMARY CEMENTATION AS COST
OF CEMENTING OPERATION &
MATERIALS ARE PEANUTS
COMPARED TO RIG COST
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Cost Reduction – Possibilities
1. SELECTION OF PROPER EQUIPMENT

2. SELECTION OF PROPER CEMENTING TOOLS &
MATERIALS
3. PROPER PLANNING AND DESIGNING
4. CO-ORDINATION TO ENSURE SMOOTH JOB
EXECUTION
5. A GOOD PRIMARY CEMENTATION
6. OPTIMISATION OF WOC
7. PROPER EVALUATION OF CEMENTATION
8. TO AVOID UNNECESSARY PRESSURE STRESS
ON CASING
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SELECTION OF PROPER
CEMENTING EQUIPMENT
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SELECTION OF PROPER CAPACITY EQUIPMENT
1. WHILE SELECTING, EQUIPMENT SYSTEM

SHOULD HAVE THE FOLLOWING
• INTEGRATED MIXING CUM PUMPING UNIT WITH
A PRECISION SLURRY MIXER OR RECIRCULATING
MIXER OR AUTOMATIC DENSITY CONTROL
UNIT
• ADEQUATE CEMENT BULK HANDLING
CAPACITY
• ADEQUATE ADDITIVE HANDLING CAPACITY
REMARK: THIS IS REQUIRED TO ACHIEVE APPROPRIATE

DESIGNED UNIFORM CEMENT SLURRY DENSITY AND
SLURRY QUANTITY AT LEAST POSSIBLE TIME.
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SELECTION OF PROPER
CEMENTING TOOLS
& MATERIALS
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SELECTION OF PROPER C/TOOLS
1. GUIDE SHOE WITH FLOAT FUNCTION
• ADDITIONAL FLOAT FUNCTION FOR A BACK

UP TO FLOAT COLLAR IN CASE F/C FAILS
SAVES CASING FROM ‘WOC UNDER

PRESSURE’ AND THEREBY THE QUALITY
OF CEMENT BOND IS NOT AFFECTED
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2. STAB-IN-SHOE FOR SURFACE CASING
• ENSURES POSITIVE CEMENT RISE

• ELIMINATION OF TOP UP JOB
• ENSURES ACTUAL CEMENT QUANTITY PUMPING
• SAVES DISPLACEMENT TIME
• OCCASIONAL CHANNELING INSIDE CASING IS
ELIMINATED
• ALL ABOVE SAVES RIGTIME
• ADDITIONAL COST IS INSIGNIFICANT
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3. LINER SHOE WITH SIDEPORTS
ENSURES CIRCULATION, CEMENT PUMPING

AND DISPLACEMENT EVEN WHEN HANGER
FAILS RESULTING IN RESTING OF SHOE AT
BOTTOM
• ELIMINATION OF FAILURE OF LINER

CEMENTATION & SAVES RIGTIME
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4. LINER HANGER WITH PACKER
ENSURES SEALING OF LINER HANGER AFTER

CEMENTATION AND ELIMINATES CHANCES OF
SQUEEZE JOB AGAINST HANGER TOP
LEAKAGE
• CONSIDERABLE SAVINGS IN RIGTIME

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5. EXPANDABLE LINER HANGER
ENSURES POSITIVE SEALING OF LINER

HANGER AFTER CEMENTATION AND
ELIMINATES NECESSITY TO DRILL CEMENT
WITH TWO BITS OF DIFFERENT SIZE
• CONSIDERABLE SAVINGS IN RIGTIME

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6. NON-ROTATING CEMENTING PLUGS

(WITH FLOAT COLLAR)
IMPROVES QUICK DRILLING OF CEMENTING

PLUGS WHEN OPERATION FOR NEXT PHASE
STARTS
• SAVINGS IN RIGTIME
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7. HYDRAULIC STAGE COLLAR
ENSURES OPENING OF STAGE COLLAR

HYDRAULICALLY ELIMINATING NEED FOR
TIME REQUIRED FOR OPENING PLUG
MOVEMENT.
FURTHER IT IS MUST FOR DEVIATED HOLE
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8. MECHANICAL AIDS (CENTRALISER)
 ENSURES CENTERING OF CASING AND

ALLOWS MAX STAND OFF
 WITH PROPER STAND 0FF, CEMENT SLURRY
COVERS ENTIRE CSG CIRCUMFERENTIALLY
 VERY IMPORTANT FOR DEVIATED WELL
• ELIMINATES REPAIR JOB

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9 MECHANICAL AIDS (TURBO/SPIROLISER)
 ENSURES ADDITIONAL LOCALISED

TURBULENCE
 EFFECTIVE FOR GOOD BOND THROUGH
LOCALISED ZONE ISOLATION WHEN
TURBULENCE CANNOT BE ACHIEVED DUE TO
PRESSURE LIMITATION
• ELIMINATES REPAIR JOB & THEREFORE SAVES RIGTIME

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SELECTION OF PROPER C/MATERIALS
10.PREFLUSH / WASH / SPACER
 NEEDS TO BE USED FOR EFFECTIVE MUD

CAKE REMOVAL & MUD REPLACEMENT
BY
CEMENT SLURRY
 VERY EFFECTIVE WHEN TURBULENCE
CAN NOT BE ACHIEVED IN CEMENT SLURRY
• RESULTS IMPROVEMENT IN CEMENT BOND

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PROPER DESIGNING OF
CEMENT SLURRY
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Types of slurry –
Essential to meet WELL REQUIREMENT
Conventional slurry
Light weight slurry
Loss control slurry
Heavy weight slurry
Engineered cement slurry
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PROPER JOB PLANNING
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THERE IS NO SUBSTITUTION
FOR A GOOD PRIMARY
CEMENTATION JOB
FIRST TIME EVERYTIME
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PLANNING OF A PRIMARY JOB
 IS CEMENT RISE SUFFICIENT?

 IS TURBULENCE ACHIEVABLE?
 IS CRITICAL CONTACT TIME ACHIEVABLE?
 DOES CEMENT RISE & DYNAMIC FORCE
CAUSE FORMATION FRACTURE?
o MULTISTAGE IS RQUIRED?
o LIGHTWEIGHT CEMENT IS
REQUIRED?
 IS SUFFICIENT STANDOFF MAINTAINED?
 SUFFICIENT STRENGTH DEVELOPED?
 IS SIMULATION RUN REQUIRED FOR
OPTIMISATION OF JOB PARAMETER?
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HOW POOR PRIMARY JOB HAS MAJOR

CONSEQUENCES?
(STUDY OF MACONDO WELL BY DEEPWATER HORIZON)
 AT TD, CMTG SERVICE PROVIDER RECOMMENDED FOR 7”
LINER CEMENTATION FOLLOWED BY 7” TIE-BACK
CEMENTATION (FOR FOUR TIER SAFETY).
 OPERATOR LOWERED 7”X9 7/8” COMBINATION CASING
TO SAVE RIGTIME & EXPENSES
 CENTRALISER USED 6 Vs RECOMMENDED 21 NOS
 PRIOR TO CEMENTATION, MUD WAS NOT CIRCULATED &
CONDITIONED PROPERLY
 TOP OBJECT WAS NOT COVERED BY CEMENT
 DESPITE PRESSURE TEST PROBLEM DURING POSITIVE &
NEGATIVE TEST, OPERATOR PLACED 1ST A/PLUG.
 BEFORE 2ND A/PLUG, DURING RISER VOL DISPLACEMENT
WITH WATER, BLOWOUT OCCURRED
 ALL ABOVE WITHIN 20 HRS OF PRIMARY CEMENTATION
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HOW POOR PLANNING & CMT SLURRY

DESIGN FOR A SECONDARY JOB HAS
MAJOR CONSEQUENCES?
(CASE STUDY OF A WELL IN INDIA)
WELL REQUIREMENT :
AFTER REACHING TD, OPEN HOLE WAS

REQUIRED TO BE ABANDONED BY
CEMENT PLUG AT 7” LINER SHOE TO
FACILITATE TESTING OF UPPER ZONES
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HOW POOR PLANNING & CMT SLURRY DESIGN FOR A

SECONDARY JOB HAS MAJOR CONSEQUENCES?
 COMBINATION STRING OF 5” X 3 ½” DP WAS USED FOR PLUG

JOB IN THE WELL (5 7/8”OHX7”LX9 5/8“Csg)
 200M OF CEMENT PLUG WAS PLANNED
 AFTER P/O WELL COULD NOT BE CIRCULATED OUT AND

FINALLY CEMENT WAS FOUND TO BE SET AT 2 ½ HRS TIME
AGAINST DESIGNED 6 HRS THICKENING TIME
 EXCESS LENGTH OF C/PLUG COUPLED WITH RESTRICTED

ANNULUS RESULTED IN A STUCK UP OF THE STRING
 NUMBER OF DAYS WERE LOST IN FISHING OPERATION
 WELL WAS FINALLY ABANDONED W/O TESTING
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OPTIMISATION OF WOC
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WAITING ON CEMENTATION
ONCE CEMENTATION IS COMPLETE, WOC IS REQUIRED

FOR SUFFICIENT COMPRESSIVE STRENGTH
DEVELOPMENT IN CEMENT SLURRY TO START NEXT
OPERATION
WOC TIME IS REQUIRED TO BE GIVEN FOR

COMPRESSIVE STRENGTH DEVELOPMENT
•For Resuming drilling (500 PSI)
•For Recording CBL & VDL/PERFORATION
(2000 PSI)
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WAITING ON CEMENTATION –cost reduction possibilities
In addition to all desired parameter, IDT

developed slurries have very early strength
development characteristics which can result in
considerable reduction of WOC.
Recently WOC has been reduced from 72 hrs to
48 hrs as proved in well PDEE in Cambay. Plan
is to reduce it further to 36 hrs

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OTHER FACTORS
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WELL HEAD SELECTION

(TO SAVE WOC)
SELECTION OF TAILOR MADE

WELLHEAD LIKE SSMC (STANDARD
SNAP RING MODULAR COMPACT)
SAVES WELL TIME ON WOC
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OTHER FACTORS
o DISPLACEMENT OF CEMENT SLURRY BY

WATER (IF FEASIBLE) TO PREVENT
MICROANNULUS
o COMBINING HERMATICAL TEST DURING

BUMPING OF TOP PLUG TO PREVENT DAMAGE
TO SET CEMENT
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PROPER EVALUATION OF
CEMENT BOND
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CEMENT JOB EVALUATION
QUALITY OF CEMENT BOND IS AFFECTED BY
•TOOL & CASING ECCENTRICITY
•CYCLE SKIPPING / TRAVEL TIME STRETCH
•WASH OUT OF FORMATION
•FAST FORMATION ARRIVAL
•DIFFERENCE IN SLURRY DENSITY
•DIFFERENCE IN CASING WEIGHT
•PRESENCE OF GAS / NON HOMOGENOUS FLUID

Institute of Drilling Technology, Dehradun 51
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PROPER EVALUATION OF CEMENT QUALITY
•Understanding of strength and limitations of

cement bond log
•Basic principles of cement evaluation devices
TWO MAIN STEPS
•Recording of quality log
•Proper interpretation

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CEMENT JOB EVALUATION
LIMITATION OF CBL/VDL
Cement bond log measurement does not represent
3600 average of the sonic signals
Improper knowledge leads to wrong interpretation

Leads to unnecessary squeeze decisions
No CBL/VDL tool can identify a channel within a

cement sheath

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NEW TOOLS ARE AVAILABLE FOR

CEMENT BOND EVALUATION
CET : CEMENT EVALUATION TOOL

(THROUGH 6/8 SEGMENTS)
USIT : ULTRA SONIC IMAGING TOOL

(THROUGH 360D ROTATION)
HIGHER COST IS INSIGNIFICANT CONSIDERING

BENEFIT OF PROPER INTERPRETATION AND THERBY
REDUCING CHANCES OF UNWANTED REPAIR
54
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THANK YOU
55

COST EFFECTIVE CEMENT PLANNING PART OF WELL PLANNING

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COST EFFECTIVE CEMENT PLANNING PART OF WELL PLANNING

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Cost Effective Cement Planning

Institute of Drilling Technology, Dehradun

FIRST IT IS NECESSARY TO BE AWARE OF

Institute of Drilling Technology, Dehradun

BRIEF CEMENTING REVIEW

Requirement For a Cementing Operation

2. CEMENTING TOOLS / ACCESSORIES

3. CEMENT : Class G OWC

Cementation Job for a WELL

What is Cementing cost

Fixed cost : Cementing Equipment Expenses

Variable cost : Cementing Accessories

How does the Cementing

SINGLE MAJOR FACTOR:

Unsuccessful Primary Cementation

1. Low production/Poor Reservoir

2. Repair and Work over Operation–

REASONS FOR POOR PRIMARY CEMENTATION

• LACK OF PROPER CENTRALISATION

• CEMENTATION IS NOT PLANNED & EXECUTED

• VITAL EQUIPMENT FAILED DURING

• POOR QUALITY & POOR EVALUATION OF CEMENT

OTHER THAN POOR PRIMARY CEMENTATION

Non-planned Secondary jobs

REMARK : NOT DESIRED BUT ESSENTIAL SOMETIMES

Non-planned Secondary jobs contd….

REMARK: NOT DESIRED & ALSO AVOIDABLE

Non-planned Secondary jobs contd….

 Squeeze job failure

 Avoidable allied job

REMARK: NOT DESIRED & ALSO AVOIDABLE

4. Improper evaluation of cement bond

A good bond or bad bond may be misleading if properly

Often it is found that there is no INJECTIVITY during

IMPORTANT to avoid unnecessary cement repair job

Who can Contribute to Cost Reduction?

CEMENTATION IS A SMALL BUT VERY

Know the basic cost

NOW WITH THE UNDERSTANDING OF

Next Logical Step is the Cost

Institute of Drilling Technology, Dehradun

Cost Reduction – Possibilities

PURPOSE OF COST AWARENESS IN

Cost Reduction – Possibilities

1. SELECTION OF PROPER EQUIPMENT

SELECTION OF PROPER CAPACITY EQUIPMENT

1. WHILE SELECTING, EQUIPMENT SYSTEM

REMARK: THIS IS REQUIRED TO ACHIEVE APPROPRIATE

SELECTION OF PROPER C/TOOLS

1. GUIDE SHOE WITH FLOAT FUNCTION

• ADDITIONAL FLOAT FUNCTION FOR A BACK

SAVES CASING FROM ‘WOC UNDER

SELECTION OF PROPER C/TOOLS

2. STAB-IN-SHOE FOR SURFACE CASING

• ENSURES POSITIVE CEMENT RISE

SELECTION OF PROPER C/TOOLS

3. LINER SHOE WITH SIDEPORTS

ENSURES CIRCULATION, CEMENT PUMPING

• ELIMINATION OF FAILURE OF LINER

SELECTION OF PROPER C/TOOLS

4. LINER HANGER WITH PACKER

ENSURES SEALING OF LINER HANGER AFTER

• CONSIDERABLE SAVINGS IN RIGTIME

SELECTION OF PROPER C/TOOLS