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Summary
The exploration and development of deepwater hydrocarbon
resources necessitate the fast evolution of drilling and completion
technologies for deepwater wells. To drill and complete deepwater
wells successfully, sophisticated technologies need to be developed
to solve various problems arising from low temperature, weak
formations, shallow water/gas flow, environmental protection, and
high deepwater rig rate.
It is a challenge to develop a good cement slurry that can be
used successfully for deepwater wells under low-temperature
environment. Such cement slurry should have several distinct
properties, such as a short thickening time, a fast transition from
liquid to solid, a rapid development of compressive strength,
and environmental friendliness. It usually takes a long time for
conventional cement slurry to set and only limited compressive
strength can be achieved at low temperatures. In addition, most
additives used for the conventional cement have adverse effects on
the environment. Therefore, it is of upmost importance to design
an environmentally friendly and low-density cement slurry that is
appropriate for deepwater wells.
In this paper, a new deepwater cement [sulfur polymer cement
(SP-C)] was designed and tested for the first time. This new deepwater cement combines the advantages of the sulfoaluminate cement
and Class G oilwell cement. Green cement additives including
cement dispersant, fluid-loss-control agent, and accelerator were
also developed. Consequently, a unique low-density cement slurry
was obtained for deepwater-well applications. Laboratory tests
showed that the low-density slurry exhibited favorable properties
including the nonexistence of free fluid, an excellent fluid-loss-control capability, a short waiting-on-cement time at low temperatures,
and a shortened transition time of critical gel strength. This new
cement slurry can be easily prepared and applied in deepwater wells
without adverse impacts on the marine environment.
Introduction
The deepwater region in the oil and gas industry usually refers to
the sea area with a water depth of more than 500 m. The earliest
deepwater well operations in the Gulf of Mexico, Brazil, and West
Africa date back to late 1970s (Shirley 2002). At present, the hydrocarbon reserves in deepwater are estimated to be 57 billion BOE,
while undiscovered hydrocarbons of 85100 billion BOE are probably buried in deepwater reservoirs (Pettingill and Weimei 2002;
Rae and Di Lullo 2004). The exploitation of deepwater resources
is inevitable because onshore oil production is diminishing gradually. There are abundant oil and gas resources located in deepwater
regions of the South China Sea. Part of Chinas future energy supply will depend on deepwater hydrocarbon resources in this area.
China National Petroleum Corporation has developed the deepwater
reservoirs in the South China Sea since 2006.
Deepwater cementing is one of the key techniques that ensure
successful drilling and completion of deepwater wells. Compared
220
with conventional cementing, however, deepwater cementing (especially for surface casing) presents many challenges because of the
unfavorable conditions associated with deepwater operations, such
as low temperature, shallow water/gas flow, weak formations, high
rig rate, and stringent environmental requirements. Accordingly, a
good deepwater cement slurry is required to solve these problems.
Design of Deepwater Cement and Its Additives
Deepwater Cement. The temperature at the deepwater seafloor
is around 4C, which varies slightly with different geographical
locations. The circulating temperature of deepwater cement slurry
usually ranges between 10 and 15C, and thickening time can be
quite sensitive at such temperature. Low temperature considerably
slows down the cement-hydration process and has an adverse affect
on the thickening time and compressive-strength development of
the cement slurry. Thus, the cement must set and provide sufficient
compressive strength to proceed with drilling without long waiting-on-cement time, preferably less than 24 hours. And the cement
slurry must have relatively long thickening time that allows it to
be placed successfully in the desired location. Table 1 shows
the effect of temperature on the compressive strength of Class G
cement and microfine oilwell cement (D50 = 3.67 m). It can be
seen that the conventional cement slurry develops no compressive
strength when cured for 12 hours at 4C and at 10C. A similar
observation is also found for the microfine oilwell cement slurry.
Therefore, the conventional cement systems are not suitable for
deepwater drilling and completion operations.
Many deepwater cement systems have been developed; they can
be classified as high-alumina cement system (Brothers and Palmer
2001), fast-setting gypsum cement (Carre et al. 2002), particlesize-distribution cement system with Class G cement and microfine
cement (Piot et al. 2001), and mixed system of Class G cement (or
Class H) and accelerator (Mohammedi et al. 2001; OLeary et al.
2004). The high-alumina cement can achieve rapid strength development under low temperatures, but is incompatible with many
cement additives. One disadvantage of fast-setting gypsum cement
is that each blend must be rigorously tested before cementing
operations because the gypsum quality is highly variable. With the
latter two systems, it is fairly difficult to prevent gas migration and
develop high early strength under low-temperature and low-density
conditions. Therefore, it is necessary to develop a new deepwater
cement system with desirable properties of low-temperature tolerance, low density, and good gas-migration control.
Calcium sulfoaluminate cements, with tetracalcium trialuminate
sulfate (C4 3 S ) phase as their main constituent, were developed
in China in the 1970s, and China is the main world producer of
such cement. Calcium sulfoaluminate cements are characterized
by many advantageous properties, such as high early compressive
strength, compatibility with different additives, high corrosion
resistance, and good expandability. Moreover, their production
requires a lower clinker burning temperature (approximately
1250C) and gives rise to lower emissions of CO2 compared with
ordinary Portland cements (Pra and Ambroise 2004). Ettringite
(AFt) and alumina gel are formed when C4 3 S hydrates, which
makes the calcium sulfoaluminate cement set quickly and develop
a high early strength at temperatures lower than 0C. Thereby,
C4 3 S has been widely used as the main component of cements
for low-temperature applications.
June 2011 SPE Drilling & Completion
Compressive Strength
at 4C (psi)
at 10C (psi)
Sample
W/C
12 hr
0.44
N/A
0.50
N/A
24 hr
Compressive Strength
at 20C (psi)
12 hr
24 hr
12 hr
24 hr
36.23
N/A
120.29
75.36
744.93
333.33
31.88
785.50
455.07
2415.94
product of C3S and C2S, to form AFt (Gastaldi et al. 2007). The
consumption of Al(OH)3 and Ca(OH)2 is able to further accelerate
the hydration rate of Class G cement and sulfoaluminate cement.
The XRD analyses of hydrated SP-C slurry (Fig. 2) also reveal that
AFt is formed with anhydrate and C4 3 S being consumed during
the hydration process.
Properties of the cement slurry (SP-C with fresh water, water/
cement = 0.50), including thickening time, compressive strength,
and volume expansion of set cement, were also measured. A
pressurized consistometer (Model OWC-2000A, Shenyang Oilwell Cementing/Logging Instrumentation Institute) was used to
measure the thickening time of SP-C slurry (Fig. 3). Fig. 4 shows
the compressive-strength development of SP-C slurry at 4C and
atmospheric pressure. These measurements clearly demonstrate
that the SP-C presents desirable physical properties of high early
strength at low temperatures, appropriate thickening time, and
small (but positive) expansion of set cement.
Environmentally Friendly Accelerator. Currently, offshore
drilling rigs are fully used, and rig rate has increased greatly.
For instance, the daily cost in the Gulf of Mexico in May 2006
reached USD 500,000. Shortening the waiting-on-cement time of
cement slurry can undoubtedly reduce the oilwell-construction
cost. Addition of accelerator is a conventional method to shorten
the waiting-on-cement time of cement slurry and enhance the early
strength of cement. Although calcium chloride is the most common accelerator for Portland cement, it does have some secondary
effects on cements properties, including heat of hydration, rheology, compressive strength, and permeability. Organic accelerators such as triethanolamine [N(C2H4OH)3] is not biodegradable,
though it is capable of enhancing the compressive strength when
mixed with other additives.
The calcium sulfoaluminate (C4 3 S ) phase, a principal constituent of sulfoaluminate cement, is most reactive within short
hydration time. It reacts with water to form ettringite (3CaO
Al2O33CaSO432H2O, AFt) and alumina gel [Al(OH)3]. With the
presence of anhydrite, Al(OH)3 reacts with Ca(OH)2, the hydration
C
DB
C
C D
C
D
C
D
B
A
B
A
4000
AB
E
DB
B
A
B E 40C
A
C3S+C2S
C3S+C2S
C4 A 3S
C2S
C4A 3S
C3S+C2S
4C
C2S
C4A 3S
CaSO4
C3S
C4A 3S
1000
0
20
20C
C3S
C4A 3S
2000
CaSO4
Intensity
3000
5
25
30
35
40
2 /
45
10
15
20
25
30
35
40
45
50
55
2 /
1800
SP-C Cement, W/C=0.50
Class-G Cement, W/C=0.44
135
270
(Thickening Time): 186 min
1500
120
(Temperature): 10C
240
210
105
180
90
150
75
120
60
90
45
60
30
30
15
C (Bc)
T (C) / P (MPa)
Cured at 4C
1200
900
600
300
0
30
60
90
120
150
180
Time (min)
12 h
48 h
24 h
Curing Time (Hours)
72 h
Fig. 3Thickening time of the SP-C slurry at 10C and 725 psi.
Fig. 4Compressive strength of SP-C slurry at 4C and atmospheric pressure.
O
O
Na2S2O5,NaOH
HCH+CH3CCH3
30-40
fluid-loss-control agent is mainly composed of low-molecularweight hydroxyethylcellulose with 8000 mPas viscosity (2%
solution, 25C). BD-L is capable of controlling the API fluid-loss
content of freshwater cement slurry within 50 mL/30 min. In
addition, it exhibits favorable biodegradation rate and shows only
a slight retardation effect.
Results and Discussion
Cement Slurry. According to API standard 10B-3-2004, the new
deepwater cement slurries are prepared as per the compositions
given by Table 4. The microsphere (product code: CP-52, Weihui
Chemical Limited Company) with density 0.70.9 g/cm3 is used as
an additive for reducing density of the cement slurries. Low densities of the cement slurries ranging from 1.30 to 1.56 g/cm3 can be
achieved by adding varying amounts of microsphere CP-52.
Fluid-Loss and Free-Fluid Control. It is well known that both
fluid loss from the cement slurry into formation and free fluid of the
cement slurry contribute to water/gas migration in a wellbore. To
minimize their impact on water/gas migration, excessive fluid loss
must be maintained at low levels approximately between 20 and
50 mL/30 min and free fluid is not allowed (OLeary et al. 2004).
The newly developed deepwater cement slurries do not contain free
fluid and maintain API fluid loss less than 45 mL/30 min.
Rheology. A proper understanding of cement-slurry rheology is of
great importance for the design, implementation, and evaluation
of deepwater cementing operations. The rheological properties of
deepwater cement slurries with four different densities are shown
in Table 5.
CH3
O
60-65 , 1.5 h
CH3C-OH + HO-CH2CH2CCH3
CH3
O
HCHO, Gelatin
NaSO3-COCH2CH2CCH3
CH3
-H2O
SO3Na
pH=6-7, 85 , 3 h
O
CH3
NHCH2CH2CCH2CH2OC(CH3)-SO3Na
NHCH2CH2CCH2CH2OC(CH3)-SO3Na
O
CH3
1.90
6.25
10
15.83
14
19.37
28
63.74
NaCl
Concentration (wt%)
61
50
1.0% GSP
31
1.0% SFA
30
18
1.0% GSP
K (Pas )
11
0.430
2.134
1.124
0.014
1.146
0.012
27
10
0.679
0.422
26
13
1.0
0.5
1.021
0.035
39
26
12
1.071
0.025
67
48
31
11
10
0.700
0.435
37
43
27
13
0.5
1.087
0.025
37
41
26
12
1.116
0.020
300
200
100
38
18
20
19
8.5
57
42
18
40
1.0% SFA
18
37
1.0% GSP
1.0% SFA
Cement
Microsphere
CP-52 (wt%)
BD-L (wt%)
GSP (wt%)
LS-A (wt%)
Defoamer
SWX-1 (wt%)
Water
(wt%)
Density
3
(g/cm )
SP-C
60
2.2
0.8
3.0
2.5
90.0
1.30
SP-C
40
2.0
0.6
3.0
2.5
80.0
1.35
SP-C
30
2.0
0.5
2.5
2.2
73.0
1.45
SP-C
15
2.0
0.5
2.0
2.2
61.6
1.56
300
200
100
K (Pas )
n
141
95
55
0.855
0.348
135
93
50
0.902
0.249
132
91
49
0.900
0.246
118
86
44
0.896
0.226
223
60
3000
100
2700
90
2400
80
2100
70
50
1800
1500
1200
Consistency (Bc)
30
Pressure (psi)
Temperature ()
40
60
50
20
900
30
600
20
300
10
10
0
0:00
1:00
2:00
3:00
4:00
5:00
Time (HH:MM)
Fig. 6Thickening time of cement-slurry Sample 1 at 15C and pressure of 1,000 psi.
20
2500
180
45
9000
1350
18
2250
160
40
8000
1200
16
2000
140
35
7000
1050
14
1750
120
30
6000
100
25
5000
900
750
600
12
10
C o mpr es s ivStrength
e S tr ength(psi)
( ps i)
Compressive
1500
T r ans itTime
T im e ((m
ic r os ec /in)
Transit
microsec/in)
10000
StaticGel
G elStrength
Str ength (lbf/100ft
( lb/100ft2)2)
Static
50
G el Value
Value
Gel
200
Pr es s ur e (M
Pa)
Pressure
(MPa)
Temperature (C)
cement and casing after setting. Expansion of cement can help to seal
small fissures between the cement sheath and casing or formation.
Expanding cement has been proved to be both an economical and
effective means for eliminating gas migration because of a microannulus (Seidel and Greene 1985; Jennings et al. 2003). Expansion of
1500
1250
80
20
4000
1000
60
15
3000
450
750
40
10
2000
300
500
20
1000
150
250
0
0:00
0:15
0:30
0:45
1:00
1:15
1:30
1:45
2:00
2:15
2:30
2:45
3:00
Time (HH:MM )
Fig. 7SGS of cement-slurry Sample 1 at 20C and 1,450 psi.
224
2500
180
90
18
2250
160
80
16
2000
140
70
14
100
60
50
12
10
Compressive
Strength
(psi)
Compressive
Strength
120
(psi)
20
Transit
Time
( microsec/in)
Transit Time
(microsec/in)
100
Pressure (MPa)
(MPa)
Pressure
Temperature (C)
200
1750
1500
1250
80
40
1000
60
30
750
40
20
500
20
10
250
0
0:00
1:25
2:50
4:15
5:40
7:05
8:30
9:55
11:20
12:45
14:10
15:35
17:00
Time (HH:MM )
510.14
817.40
1571.00
12 hr
543.48
668.12
1066.67
1274.00
24 hr
1015.94
1142.02
1460.87
1804.35
463
750
914
3 months
5,527
1,012
6 months
5,794
998
12 months
5,908
1,061
18 months
6,012
1,072
1.56
1229.00
1,245
956
1.45
414.50
1 day
5,130
1.35
1031.88
Flexural
Strength (psi)
1 month
1.30
362.32
Compressive
Strength (psi)
4,518
968.11
Duration
of Curing
3,750
12 hr
7 days
24 hr
15 days
Conclusions
A unique deepwater cement slurry was investigated extensively in
the laboratory. The following conclusions were obtained.
1. A new deepwater cement, SP-C, which combines sulfoaluminate cement and Class G cement, was developed. Laboratory
tests demonstrated that the SP-C meets the following key
requirements for deepwater cement at low temperatures: early
development of high strength, appropriate thickening time, and
small (but positive) expansion of set cement.
2. Environmentally friendly additives for the base SP-C, such as
LS-A accelerator, GSP dispersant and BD-L fluid-loss-control
agent, were also developed. These additives were tested and
were shown to be able to enhance the function of the base SP-C
without adverse effect on the environment.
3. The novel deepwater cement-slurry system, mainly composed
of the SP-C, environmentally friendly additives, and hollow
microspheres, exhibits high early strength under low temperatures,
short transition time of critical gel strength from 100 to 500 lbf/100
ft2, and small expansion of set cement. These desirable properties
of the deepwater cement slurries provide practical solutions to the
various problems caused by unfavorable deepwater conditions.
Acknowledgments
The financial support provided by the National High Technology
Research and Development Program of China (863 program,
grant No. 2006AA09Z340) and the PhD Programs Foundation of
225
Percentage Variation
of Volume (%)
4C
0.02
0.05
0.07
0.13
5.88
15C
0.04
0.06
0.14
0.22
4.97
25C
0.07
0.12
0.25
0.34
4.59
226
Conventional
Cement Slurry
SPE Annual Technical Conference and Exhibition, Houston, 36 October. doi: 10.2118/56534-MS.
Seidel, F.A. and Greene, T.G. 1985. Use of Expanding Cement Improves
Bonding and Aids in Eliminating Annular Gas Migration in Hobbs
Grayburg-San Andres Wells. Paper SPE 14434 presented at the SPE
Annual Technical Conference and Exhibition, Las Vegas, Nevada,
USA, 2225 September. doi: 10.2118/14434-MS.
Shirley, K. 2002. Global Depths Have Great Potential. AAPG Explorer
23 (10): 1635.
Ward, M., Granberry, V., Campos, G., Rausis, M., Sledz, M., Weber, L.,
Guillot, D., Naziri, I., and Romero, J. 2003. A Joint Industry Project
to Assess Circulating Temperatures in Deepwater Wells. SPE Drill &
Compl 18 (2): 133137. SPE-83725-PA. doi: 10.2118/83725-PA.
Chengwen Wang is an associate professor in petroleum
engineering at China University of Petroleum (East China). He
holds several patents and has published more than 20 papers
related to drilling and completion engineering.Wangs research
interests include cementing, drilling fluids, formation damage,
and oilfield chemistry. He graduated from the Sichuan Normal
University at Chengdu, China, with a BS degree in chemistry
in 1999. Wang earned his MS degree in oilfield chemistry from
Southwest Petroleum University at Chengdu, China, in 2004 and
his PhD degree in petroleum engineering from China University
of Petroleum (East China). Ruihe Wang is a professor and the
vice-president of China University of Petroleum (East China). He
has 30 years of experience in the field of petroleum engineering.
Wangs research interests include high-pressure water-jet
technology, rheology, cementing, rock mechanics, drilling
equipment, drilling fluids, formation damage, and enhanced
oil recovery. He holds more than 20 patents and has published
more than 150 technical papers. Wang has supervised many
MS degree and PhD degree students. He has received
many awards for his significant contributions to petroleum
engineering technologies and for his work in teaching and
mentoring. Wang holds BS, MS, and PhD degrees from China
University of Petroleum (East China). He serves as a vice-director in both the Petroleum Engineering Education Committee of
China Ministry and the Rock Mechanics Committee of China.
Wang is also a technical editor of Journal of Hydrodynamics
and Acta Petroleum Sinica. Huazhou Li is a PhD degree candidate in petroleum engineering at the University of Regina. His
research interests include thermodynamics and phase behavior in oil-recovery processes, well-cementing techniques, and
application of abrasive-jet technology in petroleum engineering. Li holds a BS degree and an MS degree, both from China
University of Petroleum (East China). Yuhuan Bu is a professor at
China University of Petroleum (East China) in petroleum engineering. Her research interests include cementing, completion,
rheology, drilling fluids, and rock mechanics. Bu holds BS, MS, and
PhD degrees from China University of Petroleum (East China).
Weidong Zhou is an associate professor at China University of
Petroleum (East China) in petroleum engineering. His research
interests include water jet, cementing, enhanced oil recovery,
drilling equipment, and drilling fluids. Zhou holds BS, MS, and
PhD degrees from China University of Petroleum (East China).