Nov Nov 2008 2008

Advanced Cementing to Increase Well Productivity

November 12 14, 2008
The University of Oklahoma Norman, Oklahoma

Nov Nov 2008 2008

Drilling Ahead (Concept & Applications)

Nov Nov 2008 2008

Long Term Compressive and Shear Strength

Shear strength not measured Compressive strength specified High temperatures, long term stability, add Silica Flour 35% BWOC 500 psi to support casing 2000 psi for perforating & around shoe To prevent long term strength loss, a large percentage of silica flour is added.
5000
Compressive strength (psi) at 3,000 psi UCA 4000 3000 2000 1000 0
Thickenin g time at 350F (5hr, 27min) Compressive strength at 320F Compressive strength at 350F

10

15

20

25

30

35

40

Time (hr)

Shoe Depth - Other Considerations

Nov Nov 2008 2008

Pressure transition zones Competent formations Isolating mutually exclusive trouble zones Once the depth of the next casing is known, then the formations at and below that depth are examined. Ideally, the shoe should be set in a pressure transition zone, where the pore pressure gradient increases with depth. This is because the fracture pressure also increases in a transition zone, so a casing set in a transition zone normally can withstand more pressure at the shoe than a casing set above it. Casing should not be set in a weak formation where losses are more likely, such as in a fractured limestone or unconsolidated sandstone (occurrence of losses and a kick difficult to control)

US Minerals Management Service (MMS) Requirement

Pore pressures, frac gradients prediction
Nov Nov 2008 2008
0 1000

2000

Fracture gradient Fracture gradient 0.5

3000

Mud weight

t f , D V T pressure Pore
4000 5000 6000 7000

8000

Fracture gradient in ppg must - 0.5 ppg (MMS requirement) How do we get FG? Easy to determine shoe depth (min. setting depth) Does not account for different factors for kick tolerance

9000 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Pressure gradients in mud weight form, ppg equivalent Normal pressure

Pore pressure Mud weight prediction

Fracture pressure

Fracture - 0.5 ppg

Cement Impermeability Gas Influx

Nov Nov 2008 2008

The graph shows a plot of the pressure transmitted in the cement slurry vs. time. Gas flow in the annulus will start once pressure drops below pore pressure. Problem; gas entering the cement during setting. Cause: loss of hydrostatic during transition phase. Solutions: RAS (right-angle set) cement, gas blocking additives to prevent the movement of gas through the set cement. Bc = Beardon consistency unit

Principal Rock Stresses

Nov Nov 2008 2008

Within a body of rock, there will be present compressive and

shear stresses and, rarely, tensile stresses. Tensile and compressive stresses are termed axial stresses. Axial stresses only (no shear) Vertical stress = overburden stress. Horizontal stresses arise due to rock elasticity. Fracture pressure = lowest horizontal stress.

Well Design Data Requirements All Wells

Nov Nov 2008 2008

Pore and fracture pressure prognosis Full completion details Expected lithology, in-situ stresses, temperature gradient Well objectives, targets, depths, logs and other evaluation requirements and required final hole size at TD Site survey and shallow gas survey Local infrastructure and inhabited areas Environmental impact assessment Seasonal weather information As much offset data as possible

8 2000

10

11

Pressure Gradient (ppg) 12 13 14 15

16

17

18

3000

Overburden FG Shale FG Sand Pore Pressure Flow Zone Sand Zone 2 PL1:50 PP Gas PL1:50 PP H20 Max. Mud Wt.

4000

5000

6000
TVDrkb (ft)

7000

8000

9000

10000

11000

12000

Primary Well Control During Cementing

Nov Nov 2008 2008

Hydrostatic pressure must exceed all exposed pore pressures throughout the displacement.

Overburden Stress (Eatons Correlation)

Nov Nov 2008 2008

Overburden; weight of rock above the depth of interest. Gradient increases with depth (compaction). Overburden stress at 10,000 = 10,000 x 0.945 = 9450 psi. Overburden stress at 4,000?

Overburden Stress
Nov Nov 2008 2008

Overburden; weight of rock above the depth of interest. Gradient increases with depth (compaction). Overburden stress at 10,000 = 10,000 x 0.945 = 9450 psi. Overburden stress at 4,000? 4000 x 0.895 = 3580 psi.

Formation Integrity Testing - Procedure

Nov Nov 2008 2008

Once a casing is cemented in the well, rock above the casing shoe is protected from pressures generated during drilling deeper. We need to know the rock strength just below the casing shoe. To measure formation fracture pressure at the shoe fracture it! How? 1. Drill out of the shoe (about 10-ft). 2. Close the BOP. 3. Pump slowly into the well. 4. Measure pressure vs.. volume pumped.

Formation Integrity Testing Full Leak Off Test

Nov Nov 2008 2008

Formation Integrity Testing Limit Test

Nov Nov 2008 2008

In development wells where the rock stresses are well known and the casing points to reach total depth are known by experience, sometimes a limit test is done. The well is tested to a pressure where the Drilling team can be certain that the shoe strength is sufficient to make the next casing point. Unfortunately these limit tests limit the information available.

Formation Integrity Testing - Uses

Nov Nov 2008 2008

Limit Test Used while drilling development wells, confirm sufficient shoe strength to reach the next planned casing point. Limit test limits the information gained.

Leak off test - Determines actual shoe strength. Gain information on in-situ rock stresses. Actually gives the least minimum stress

Well Planning Pressure & Stress Profiles

Nov Nov 2008 2008

These pressure/stress profiles are important in well design. What happens to the pore pressure below 9,200?

Well Planning Pressure & Stress Profiles

Nov Nov 2008 2008

Drilling at 13,600 with mud shown. What will happen when pore pressure > mud hydrostatic? The well will kick, that is flow.

What is Drill-Ahead?
Nov Nov 2008 2008

To put things in perspective, "Drill-Ahead" is more of an engineering process than any specific material. The word Process may be added to better represent what is involved and to help explain the business case. The key idea for the Drill-Ahead Process (DAP) is to design treatments that increase frac-gradients (FG) or borehole pressure containment, "decrease" (isolate) pore pressures, or "lower" hole collapse pressures.

DAP's objective is to save major well construction costs.

What is Drill-Ahead?
Nov Nov 2008 2008

One of the main reasons for calling DAP a process is the analysis needed to determine if it is the correct solution with a high chance for success Analysis defines the problem and identifies key parameters needed to design a DAP treatment. Analysis includes determination of the formation leak-off path geometry, the pore pressure, the hole-collapse pressure profile, and other formation characteristics. Definitely, a multi-discipline team may be needed for this part of the process

Drill-Ahead Process
Nov Nov 2008 2008

How to Achieve Drill-Ahead

Several different Baroid and Cementing PSL products have been successfully applied for DAP

Drill-Ahead Process
Nov Nov 2008 2008

Treatments to Achieve Drill-Ahead

Cement Squeezes LCM Pills Polymer Gel Pills Experimental Systems

Resins & Monomers Mud Reactive Plugs Combinations (DAP)

Drill-Ahead Process
Nov Nov 2008 2008

Treatments to Achieve Drill-Ahead

FlexPlug reactive pills that rapidly give moderate increases (~1ppg) in FG
Concentrated FlexPlug reactive pills for rapid, large increases (up to 5.2 ppg) in FG Some of these jobs are reported in SPE 68946 & 71390

Drill-Ahead Process
Nov Nov 2008 2008

Treatments to Achieve Drill-Ahead

DrillAhead ShoePro - For improving LOT at the shoe DrillAhead Target For improving LOT for a weak zone to ensure drilling to target DrillAhead X-Flo For curing cross-flows / underground blowouts and obtaining well control DrillAhead FlexPlug For curing severe to lost circulations All these products are designed to be pumped through bit and no waiting time

Drill-Ahead Process
Nov Nov 2008 2008

Treatments to Achieve Drill-Ahead

SteelSeal in the circulating fluid incorporated slowly during several days of drilling deeper makes moderate FG increases in the upper hole sections. The lower sections may also need several days of continuous hole circulation to get FG increases.

Drill-Ahead Process
Nov Nov 2008 2008

Treatments to Achieve Drill-Ahead

Permseal pills after a few hours waiting time decreases or totally blocks pore pressures to prevent severe gas, water, and fines influx. Some small degree of consolidation is also achieved in permeable, friable formations
Reference: SPE 36482

Drill-Ahead Process
Nov Nov 2008 2008

Treatments to Achieve Drill-Ahead Injectrol pills after several hours provide low cost prevention of moderate influxes of water Foam cement squeezes to seal large, cavernous leak-off pathways and give some degree of pressure containment

Drill-Ahead Process
Nov Nov 2008 2008

Treatments to Achieve Drill-Ahead Baroid LCM products that work slowly (like SteelSeal) to build moderate degrees of hole pressure containment

Industry Drilling Cost of Wellbore Instability

Nov Nov 2008 2008

AMOCO: ARCO:

$600MM to $1 Billion per Year 17% of Total Well Cost

MOBIL:
Western-Atlas: HES & Shell:

Min. 10% of Total Well Cost

>$6.4 Billion per Year ~$8 Bil. 96 & ~30% Total Budget

API Survey:
GRI & OGS: SHELL: BP(123 GOM):

19-24% Holes w/ Sig. Mud Loss

$500-750MM/year in Shales >$500MM/year in Shales $167.6MM 1985-97 DS-DW-SWF

Nov Nov 2008 2008

Balancing Pore Pressure and Fracture Gradient

Need 3 casings to TD

PP

FG

Nov Nov 2008 2008

Balancing Pore Pressure with New Fracture Gradient

Treatments new FG limit

Saves setting one casing

PP

FG

Nov Nov 2008 2008

Lets review some application techniques

Nov Nov 2008 2008

Application Techniques
After Primary Cementing - Pressure Test Casing - Then WOC Drill Out Float Collar and/or Float Shoe Clean the Rat hole Start Leak Off Test (LOT)

Nov Nov 2008 2008

Application Techniques

Leaking Off

LOT not sufficient -- fractures in formation and channel in cement suspected

Nov Nov 2008 2008

Application Techniques
Low psi

Bit placed one DAP & mud reacted volume above shoe Treatment begins as DAP pumped down drill pipe

Nov Nov 2008 2008

Application Techniques
Diverting with psi up and down

Fracture zone and channel being treated

Nov Nov 2008 2008

Application Techniques

Treatment ends as maximum squeeze pressure indicates system is forming a dehydrated plug

Nov Nov 2008 2008

Application Techniques
Dehydrating plug with psi up to max & slow decrease

Pack and Bleed Off Repeated until less than 50-100 psi bleed off

Nov Nov 2008 2008

Application Techniques
Wash psi

Well recirculated as rat hole slowly cleaned

Nov Nov 2008 2008

Application Techniques
Wash psi

Bit run slowly down through the treated interval

Nov Nov 2008 2008

Application Techniques

FIT confirms higher pressure integrity Process completed Ready to DrillAhead

Nov Nov 2008 2008

Application Techniques
DAP resists swab/surge as drilling resumes DAP may be repeated if needed at deeper depths

Nov Nov 2008 2008

DAP Well C: LOT & FIT Enhancement

Ann. Press. Before F.P #1 (psi) Ann. Press. After F.P. #1 (psi) Ann. Press. After F.P. #2 (psi)

1400

1200

LOT Before Treatment (ann. psi) ________

1000

LOT After 1st Treatment (ann. psi) _______

800

600

FIT After 2nd Treatment (ann. psi) _______

400

200

0 14:20 14:30 14:40 14:50 15:00 15:10 15:20 15:30 15:40

Time
Customer: BERKLEY PETRO. Well Description: Well #EAST LOST HILLS #1 Job Date: 09-JAN-2000 UWI: Ticket #: FLEXPLUG
HTG Version G3.1.2 12-Jan-00 18:32