Cement Practice Field Calculations

WELL CEMENTING TRAININT- PROJECT WORK

Instructions

The following information was received from the ARAMCO SAUDI representative outlining the
plan for the well Conductor, Surface, Intermediate casing strings and Liner. Study the program
carefully and make the cementing job calculations for each. Record your answers on the Excel
file provided and send the spreadsheet to your trainer. Also remember to include your full‐page
wellbore diagram along with your work.

Currently there are 5 casing strings to set on this well. The first will be a 30 inch, 310 lb/ft casing
with a 1 inch wall thickness. This will be run in a 36 inch open hole. From previous experience
we expect an excess volume equal to 100% of the annulus volume. The second will be a 20 inch,
133 lb/ft. This will be run in a 26 inch open hole, we expect 100% excess on the open‐hole
annulus volume. The third is 13⅜ inch, 72 lb/ft casing. Expected wash out areas will be detailed
later. The fourth string will be a 9⅝ inch, 53.5 lb/ft casing. Expected wash out areas will be
detailed later. The last string will be 7 inch liner, 29 lb/ft, N‐80, Buttress.

30 inch Conductor
TD of casing will be 714 feet. Cement this to the surface with Class "G" + 2% CaCl cement mixed
at 16.0 lb/gal. We have already ordered the float shoe and plug sets for this job. Displace it
leaving 20 feet of cement in the casing. Well fluid and displacement fluid is sea water at 8.5
lb/gal.

20 inch Surface Casing

TD of the 8 round, J‐55 casing will be 3810 feet with a 50 foot shoe joint. Run a float collar and
guide shoe. Cement this using the inner‐string method: the drill pipe is 5 inch, 20.5 lb/ft. Use no
drill pipe plugs and hold no pressure on the annulus (drill pipe to casing). Lead cement will be
class "G" + 7% bentonite (gel) + 0.4% HR‐5 to the surface. The tail cement will be class "G" neat
with an HOC of 700 feet. The well fluid and displacement fluid are 10.4 lb/gal mud.

13⅜ inch Intermediate Casing

TD of the C‐75 Buttress casing will be at 8,283 feet. Use a float shoe and a float collar, with the
collar installed at 8201 feet. The TOC of the class "G" + 9% gel + 0.3% HR‐5 lead cement will be
2810 feet. The HOC of the class "G" + 0.5% HR‐5 + 0.2% CFR‐3 + 35% SAA‐1 tail cement will be
1075 feet. Use 60 barrels of 12.8 lb/gal Dual Spacer ahead of the lead cement.
 Cement Practice Field Calculations

Plan on using the same mud for this section of the well as used on the 20 inch casing section
Estimated hole geometries will be:

 0 to 3,810 feet cased hole

 3,810 to 5,370 feet 17 1/2 inch diameter
 5,370 to 5,992 feet 21 1/2 inch diameter
 5,992 to 8,283 feet 18 1/4 inch diameter

9⅝ inch Long String (Two Stages Cement Job)

Note: with a limitation of frac gradient (15 ppg) two stages cementing is a must.

1st Stage:

We want to set this 53.5 lb/ft, N‐80, 8 round casing at 14341 feet. Use a float collar and a float
shoe. Install the collar at 14251 feet. Use class "G" + 3% gel and 0.4% HR‐5 mixed at 15.0 lb/gal
as the lead slurry. Use class "G" + 47 lb/sk Hi‐Dense #4 + 0.5% HR‐5 mixed at 17.1 lb/gal as the
tail slurry. The TOC for the first stage will be 300 feet above DV Tool (9⅝ inch DV Tool @ 200 ft
inside a previous casing). We want 1,500 feet of tail cement in the annulus. We will be using an
11.6 lb/gal water based mud. Displace the top plug with 9.3 lb/gal production water. Leave no
cement above the top plug.

From past experience we expect a washed out area from 9494 feet to 11,513 feet. It is
projected to be ⅞ inches larger than the bit size of 12¼ inches. The rest of the hole should be
gauge. Use your Halliburton Dual Spacer mixed at 13.0 lb/gal and have enough spacer for 1000
feet of fill in the gauge annulus.

2nd Stage:

For the second stage cementation, opening bomb is dropped; lands on and open the stage
collar. Now circulation starts through ports at stage collar, 2nd stage cementing to surface using
class "G" + 3% gel and 0.4% HR‐5 mixed at 15.0 lb/gal & Halliburton Dual Spacer mixed at 13.0
lb/gal and have enough spacer for 1000 feet of fill in the casing to casing annulus.

NB: For the case of weak formation’s casing point and low frac gradient
(less than 12 ppg), what could be the recommended solution?
 Cement Practice Field Calculations

Note from the Customer:

We’ve unexpectedly encountered a weak formation located at 18400 feet. We will need to drill
deeper and run the liner in order to protect this formation and. We want to try and set the 7”
liner at 18756 feet. We’re currently drilling with an 8‐½” drill bit. The open‐hole annulus is
washed out 30%.

7 inch Production Liner

Liner
o 29 lb/ft, N‐80, Buttress
o Top of liner 13851 feet (MD)
o TD 18756 feet (MD)
o Average Joint length is 38 feet
o Landing Baffle will be installed 1 joint above the float shoe
o Run on 5 inch, 19.5 lb/ft, S‐135 drill pipe
Open Hole
o Annulus is 30% washed out
Equipment
o Float, plugs and surface equipment will be supplied by Halliburton
o Batch mix blender for cement
Temperature Survey
o BHCT = 210°F (From previous data)
o Surface Temperature should be 78°F
Cement Data
o TOC 13551 feet (MD)
o API Class G + 0.4% CFR‐3 + 0.4% HR‐12 + 0.3% HALAD 344
o Density: 16.0 lb/gal
o TT = 4:58 HRS:MIN (this includes 1 hour mix time on surface)
Spacer Data
o 25 bbl of Tuned Spacer III
o Density = 13.0 lb/gal
o PV = 28.0
o YP = 21.6
Well fluid and Displacement Fluid
o After TD is reached density is to be reduced to 12.2 lb/gal
o Thin mud to give:
o PV of 18.0
o YP of 12.0
 Cement Practice Field Calculations

Note from the Customer:

Unfortunately, after logging and completion the decision was made to plug off and abandon the
well. We will need to set 2 balanced cement plugs. We will use 3‐½”, 13.3 lb/ft drill pipe for two
operations and the well fluid is 8.7 lb/gal KCl brine. We will use the well fluid as the
displacement fluid for all three operations

Balanced Plugs

Spacer

 Dual Spacer at 13.0 lb/gal

 Pump 10 bbl ahead of each plug and enough behind to balance

Stinger (use on both plugs)

 500 feet of 2‐3/8”, 4.6 lb/ft tubing

Plug #1

 API Class H cement + 0.2% CFR‐3 + 0.35% HR‐12 mixed at 16.4 lb/gal
 Set at 14050’ (MD)
 Plug length: 400 feet

Plug #2

 API Class G neat cement

 Set at 1500’ (MD)
 Plug length: 400 feet