Isolating Gulailah High Pressure High Temperature Water Zone Using New Heavy
Weight Slurry
Said Zaki El zeghaty-ADMA-OPCO, Amjad Babasheikh - Schlumberger, Abdulhameed Mohsen - Schlumberger
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Abstract
The well (A) is a planned 16, 315 ft gas well targeting the
Lower Khuff gas bearing formation. The 12-¼ inch hole
section is drilled from 11,667 ft MD (10,500 ft TVD)
throughout Gulailah high-pressure water formation and finally
the 9 5/8 inch casing is landed at 13,722 ft MD (12,080 ft
TVD) in Sudair formation. While drilling nearby wells,
inconsistent formation pressure was experienced in Gulailah.
This varied from 1.32 SG EMW (Equivalent Mud Density) up
to as high as 1.95 SG EMW. The large variation in pressure
has led to poor cementing results and even to water flow up
the 9 5/8” casing annulus in some of the nearby wells.
One of the main objectives of the cementation of the 9 5/8”
casing was to maintain the integrity of the well by isolating
the intermediate high pressure water bearing Gulailah
formation from other formations and by creating a positive
seal around the 9 5/8” casing shoe and inside the 9 5/8” – 13
3/8” casing annulus to prevent any water flow up to surface.
It was then mandatory to set a work plan to improve the hole
condition, the well stability as well as the cementing
parameters and technique in order to meet the above
objectives and to prevent expensive remedial work. Moreover,
heavy weight slurry having the ability to be mixed at a wide
range of density was highly required in order to provide
enough flexibility for the design to match the actual well
condition.
. remedial work.
Introduction
Cementing any annulus when high pressure zone exist
requires heavy weight slurry, which should provide enough
hydro static pressure to control the formation pressure and
isolate it from upper zones later on.
Traditionally, heavy weight slurry used to be obtained either
by reducing mixing water in the slurry to favor of cement in
the ratio between water and cement, which is considered the
drive for any slurry final density up to certain range.
The other way to increase slurry density is by adding
weighting agent materials, which have some negative effects
on the slurry and set cement properties.
The drawbacks of the conventional heavy weight slurry
(which are discussed in this paper), plus the need for a cement
which can provide this deep costly offshore well with
extended producing life, lead to looking for a new technology
which can over come all the challenges a real need.
Here for this job, a new high density high performance slurry
used at density of 20.83 ppg (2.5 SG), which is utilizing a
totally new technology not based on chemistry, but on
PHYSICS to overcome the problem of obtaining a very low or
very high density slurries with out sacrificing the slurry or the
set cement properties.
Past Experience
In some near by wells which drilled in the past, poor
cementing results has been experienced due to under
estimating Gulailah water pressure and using conventional
cement slurries, even annulus pressure build up between 9
5/8” and 13 3/8” annulus occurred, and led to very expensive
High press. formation Gulailah
2 Saeed ZAKI, Amjad BABASHEIKH, and Abdul hameed. MOHSEN
Few wells drilled in this offshore filed so far, Gulailah water
pressure was ranging from 1.32 SG EMW up to more than
1.95 SG EMW, and the formation pressure could change
dramatically from one well to another which are just around.
Conventional high density slurry
In conventional slurry systems, the cement slurry density can
be increased by reducing mixing water, and more dispersing
is required to insure mixability, but reduced water slurry has
some disadvantages such as difficulty to maintain good fluid
loss, solid settling and high rheology, on the other hand the
main limitation of reduced mixing water system , is that the
slurry can not go beyond density of 18.0 ppg (2.16 SG)
If higher density (more than 18.0 ppg) slurry is required,
heavy weight materials (weighting agents); like Hematite,
Barite, or Illuminate can be added to the slurry to increase it’s
density without reducing mixing water, this requires that dry
cement with weighting agent to be blended (dry mixed)
together at certain ratio for the desired density then to be
transported to the rig site.
Segregation of cement and heavy materials during
transportation to the rig site is another challenge beside the
settling down of the heavy materials when the cement is in
liquid phase, also the final compressive strength and the
tensile strength of the cement will be dropped due to less
amount of cement in the system.
Both liquid slurry and set cement properties of conventional
slurry is mainly a function of water to cement ratio.
Mixability, pumpability, satiability, plastic viscosity, and yield
point of any given conventional slurry is directly affected by
water to cement ratio.
In neat conventional slurry at 15.8 ppg (1.9 SG) for example;
44% water by weight of cement is API standard required
water to cement ratio, but in fact only about half of this
amount is necessary for cement hydration process, the other
half is added just to overcome pumpability problem by
covering the surface area around cement particles to enable
these particles to slide on each other, as all the spaces between
cement particles has to be filled with water to make it
pumpable.
However this excess amount of water will negatively affect
early building of compressive strength , and final compressive
strength which the set cement will reach, also it increases
permeability and porosity.
Chemical additives are aiding in minimizing the effect of
water to cement ratio on some slurry properties but only up to
a limit.
New high density high performance slurry:
In this new high performance slurries both in it is light
density (ranging from 8.0 to 12.0 ppg) version and high
density version (up to 24 ppg) , performance of the slurry is
dependent on optimization of packing volume fraction –PVF-
which is a function of the shape, size, and the amount of solids
per given volume. In this system, there is much more solids
per unit volume than conventional slurry, the higher
percentage of solids is resulting from having three or four
different size particles based on (granulometry theory) –fig.1-
which enable better packing for solids in the same volume
than if we have only one size particles.
The small and medium particles which their size are
accurately engineered will fill the voids around the bigger
size particles, and provide a bearing surface for different
particles to slide on each other easier, and relatively at low
rheological values, and final desired density is controlled by
the weight of the different particles not by water to cement
ratio.
In other words; the different properties of the slurry and later;
the mechanical properties of set cement is driven by the dry
blend design , which means; it is been disconnected from
water to cement ratio, and this enable us to maintain
plus/minus certain slurry properties regardless the final
density of the slurry, as these properties are function of the
packing volume fraction, i.e. size, shape, and amount of
particles not water to cement ratio.
Also, this new slurry will build earlier compressive strength,
has higher final compressive strength with much lower
permeability and porosity, and does not require any special
equipment or special mixing procedure, also it’s density can
be adjusted by more than +/- 1.0 ppg at any time as quick as
adding an additive to the slurry.
The operation
BHCT prediction
The simulation of the Cementing software used to
predict the cooling effect of mud circulation on BHCT
(Bottom hole static temperature, and compared to API
BHCT (Bottom hole circulating temperature) – fig. 2.
The simulated BHCT is a function of down hole static
temperature, mud circulation flow rate, circulation
duration, mud surface temperature, well deviation and
annular geometry.
In the lab, the slurry thickening time tested with
maximum value between Cementing software simulated
BHCT and the API BHCT.
Quality check
As it is known QC (quality check ) is key factor of the
success of any cementing operation and especially for
3 Isolating Gulailah High Pressure High Temperature Water Zone Using New Heavy Weight Slurry
such a critical operation, thus; three samples taken from
the dry blend after the last transfer between bulk silos,
the samples taken from the beginning, middle, and end
of each batch while transferring to the bulker trucks,
before delivering it to supply boats, and the homogeneity
of the blend confirmed by checking the samples
specific gravity in the laboratory.
Another blend sample has been sent to the base
laboratory after it arrived to the rig site along with mixing
water sample and final mud sample.
Thickening time test, rheological readings, free water
test, fluid loss test, settling test, compatibility tests with
mud and spacer, and finally the compressive strength
test has been repeated on the rig’s samples and all the
tests results confirmed matching with the original blend
results.
Execution
9 5/8” Liner shoe was set at 13,722 ft (12,080ft TVD) with
maximum deviation of 40 deg, estimated job volume was 460
bbls of slurry at density of 20.83 ppg (2.5 SG).
Proper and effective mud removal was one of the main
factors in success of this critical operation , for this the
rheology of the mud planned to be dropped to the minimum
possible values with out inducing any settling of the mud
weighting agents, then the rheology and density of the spacer
ahead of the slurry and the slurry it self carefully engineered
to fulfill the criteria’s required for effective laminar placement
technique and to insure well control during and after the
cement operation fig. 3-.
Cementing computer aided design software used to optimize
the densities, rheologies, placement techniques, pumping
rates, and spacer volumes and types to improve mud removal,
also the software used for optimizing the centralizes
placement to achieve more than 86 % stand off ratio
between casing and formation annulus. fig. 4
The slurry designed to have very good fluid loss control with
zero operational free water (at bottom hole condition), and 24
hours compressive strength of 7000 psi
The job executed in very complex environment, six upgraded
slurry batch mixers has to be set up on the offshore rig
platform which is known by it is space limitation –fig. 5-, and
in order to minimize the time required to mix 460 bbl of slurry
in the batch mixers, additional bulk plant mobilized to the rig
platform to enable parallel bulk supply , and this reduced time
required for mixing by 50%.
And for QC reasons on actual mixed slurry, the density of the
slurry measured by two pre-calibrated pressurized mud
balances, and the rheology of the slurry measured at the rig
laboratory and showed similar readings to lab mixing.
Structured pre-job meetings both in town office and on the rig
site held , and comprehensive contingency plans prepared to
solve any un-expected events, the job performed smoothly in
6 hours with out any problems, the U-tube effect and surface
pressure during execution was matching what has been
predicted by cementing simulation software.
Job Evaluation
Very hard cement found at top of liner about the expected
height, positive and negative pressure tests performed to
check for any leak in liner over lap and both proved good
sealing, USIT (Ultra Sonic Imager Tool) cement logs results
showed good to excellent bond with acoustic impedance
values similar to what been predicted by the simulation
software, and it proved good zonal isolation for the different
formations including Gulailah High water pressure formation,
No annular pressure exists, and no remedial work required.
Conclusion:
Based on optimized packing volume fraction theory, this new
high density high performance system, has got many superior
advantageous over conventional slurry systems.
Both liquid slurry and set cement properties helped in
achieving the objectives of cementing the 9 5/8” liner from the
first time and with excellent results, the density flexibility of
this new system mitigated the risk of needing to change the
blend due to required density variation thus; saved rig time,
and the very early and high compressive strength (7000 psi in
24 hrs) exceeded the requirements, also the low permeability
and porosity will provide more protection to the casing from
abrasive fluids and will extended the life of the well more and
more before any need for remedial work.
Later, on another nearby well, the same system used for
similar condition, and the same level of success repeated
again.
References
1- Erik B. Nelson “Well Cementing” 1990.
2- Bipin Jain, A.M.P. Raiturkar, Chris Holmes, Andrew
Dahlin “Using ParticleSize Distribution Technology for
Designing high-Density, High -Performance Cement
slurries in Demanding Fortier Exploration Wells in South
Oman” Paper SPE/IADC 59134 presented at the 2000
IADC/SPE Drilling conference held in new Orleans,
Louisiana, 23-25 February.
3- Eric Moulin, Philippe Revil and Bipin Jain, : ‘’ Using
4 Saeed ZAKI, Amjad BABASHEIKH, and Abdul hameed. MOHSEN

Concrete Technology to improve the performance of 2. Amjad Babasheikh is Cementing Technical Engineer,
Lightweight Cement” Paper SPE/IADC 39276 presented at working in Abu Dhabi-UAE.
the 1997 SPE/IADC Middle East Oil Technical – Schlumberger Dowell
Conference , Manama, Bahrain, November 23-25. – He is a SPE member.
Authors:
1. Mr. S. Zaki El – Zeghaty is the cement engineering 3. Abdulhameed Mohsen, is senior Lab Engineer.
section leader with ADMA-OPCO drilling division. In – Schlumberger Dowell
his capacity Mr. El – Zeghaty is fully responsible for all – He is SPE member
operational and technical aspects of the cementing
processes in ADMA-OPCO drilling operation. Mr. El-
Zeghaty has 36 years of experience with ZADCO,
Dowell Schlumberger, Halliburton and Eygptian
Petroleum Cooperation.
- He is a SPE member and has published numerous
SPE papers
5 Isolating Gulailah High Pressure High Temperature Water Zone Using New Heavy Weight Slurry

Fig.1, Showing packing volume fraction optimized by using different particle size
6 Saeed ZAKI, Amjad BABASHEIKH, and Abdul hameed. MOHSEN

D epth = 13730 ft
275

A PI BHCT
Geoth.Prof ile
A nnulus
Tubular Fluids
Mud Tem p. History (degF)
225 200 250

0 25 50 75 100 125
Time (min)

Fig. 2, Showing API BHCT, and cementing software simulated BHCT

7 Isolating Gulailah High Pressure High Temperature Water Zone Using New Heavy Weight Slurry

(x 1000) psi
ft
0 2 4 6 8 10 12
0

Hydrostatic
Min. Hydrostatic
Max. Dynamic
Min. Dynamic
Frac
Pore
5000
10000
15000

Fluid Sequence Dynamic Well Security

Fig. 3 Dynamic Well Security Graph, showing max. and min. dynamic pressures
8 Saeed ZAKI, Amjad BABASHEIKH, and Abdul hameed. MOHSEN

% ton
ft
0 50 100 0 50 100 150

0
Betw een Cent. Hookload Up
At Cent. Hookload Dow n
Weight
Drag Force

5000

Fig. 4

The Liner
standoff
ratio and
the
Running
10000

forces
15000

Pipe Standoff Running Forces

Additional
Silo

Fig. 5 The offshore platform, showing the layout of the 6 batch mixers and extra bulk plan
9 Isolating Gulailah High Pressure High Temperature Water Zone Using New Heavy Weight Slurry