Overview
EnsurSet Cement System
Maintain long-term well integrity with self-sealing cement
system providing enhanced mechanical properties
The Baker Hughes EnsurSet™ self-sealing
cement system provides a durable cement
sheath to help ensure well integrity and
zonal isolation for the life of the well.
Because of changes in pressure and
temperature to the cement sheath over the
life of the well, the cement sheath may fail
or crack and allow annular pressure to build
up. This cracking and pressure build-up can
result in
„„Sustained casing pressure
„„Cross flow
„„Lost production
„„Collapsed casing
„„Contaminated water zones
„„Increased workover costs
By sealing cracks up to 0.009 in.
(0.2286 mm), the Baker Hughes EnsurSet
self-sealing cement system helps address
these problems. EnsureSet cement swells
in the presence of hydrocarbons to shut
off the flow through the cement matrix
and micro-annulus.
The cement system improves the ductility of
the cement and the tensile to compressive
strength ratio, and it lowers Young’s
Modulus and provides a higher Poisson’s
ratio. It can self-seal multiple times and
delivers a durable cement sheath in a wide
variety of field conditions. The hydrophilic
EnsurSet cement easily mixes in the field
and its mechanical properties can be
customized to meet specific well challenges.
The cement system is thoroughly tested
with a custom-engineered and patented
test device that quantifies the limits of
the crack size and helps ensure that the
cement system maintains long-term zonal
isolation. This cement system can
„„Be mixed and pumped using
conventional cement equipment
„„Work in slurry densities from 12.4 to
17.5-ppg at temperatures up to 325°F
(163°C) without any negative impacts
on the slurry
„„Reduce flow within 24 hr and seal
cracks in 48 hr
„„Seal same crack multiple times
„„Seal cracks up to 0.009 in (0.2286 mm)
Wellbore isolation is becoming increasingly
more important to both regulatory agencies
and the public. No matter how good the
Applications
„„Cementing in fields with a history of
sustained casing pressure
„„High tectonic stress areas
„„Hydraulic fracture areas
„„Risk mitigation
–– Unable to follow all of best practices
–– Less than optimal centralization,
no pipe movement
„„Plug and abandonment
Features and Benefits
„„Self-sealing properties
–– Swells in the presence of liquid
hydrocarbons and/or condensates
–– Shuts off liquid hydrocarbon flow
through the cement matrix or
micro-annulus
„„Improved ductility of cement, lower
Young’s modulus, higher Poisson’s ratio
–– Makes cement more resilient to stress
–– Enhances durability of cement
–– Improves tensile to compressive
strength ratio
„„Hydrophilic
–– Provides better and easier mixing
than hydrophobic materials
„„Sealingcracks in the matrix and the
micro-annulus
–– Address and mitigate risks associated
with sustained casing pressure
„„Environmental Compliance
–– Member of SmartCare Family Products
 cement design, external factors—tectonic stresses, changes to Enhanced mechanical properties
temperatures or pressures other than anticipated, unknown rock Conventional Cement EnsurSet Cement
and reservoir properties, hole and placement issues—can result in slurry slurry

failed cement and a buildup of sustained annular pressure, either Compressive strength 2300 psi 2350 psi

through the cement matrix or a micro-annulus. Recent studies have Tensile strength 235 psi 350 psi

found that more than 50% of the wells that are 15 years old or Young’s modulus 1.6 x 106 7 x 105

older have at least one casing string with sustained casing pressure. Poisson’s ration 0.18 0.30

Remedial operations in these cases are both difficult and Test apparatus capabilities
expensive. Today, US federal regulation does not allow wells with „„Cures cement under temperature and pressure
sustained annular pressure to be plugged and abandoned. „„Adjustable desired crack or micro-annulus width

The Baker Hughes EnsurSet self-sealing cement system alleviates „„Hydraulically cracks cement under temperature

this problem with a cement system that reduces remediation costs „„Controls, measures, and records developed crack size

and maximizes the integrity of the well over its entire life. „„Tests flows through cracked cement matrix or induced micro-annulus

„„Measures and records flow and pressure

A self-sealing cement additive is blended with the cement and „„Tests with gas, oil, or other fluids

when it is pumped into the well. The additive remains inactive until
hydrocarbon contacts the material. Upon contact, the self-sealing Self-sealing test apparatus
material absorbs the hydrocarbon and swells the material to plug
the gap and shut off and seal the hydrocarbon flow.

To find out how the Baker Hughes EnsurSet self-sealing cement

system can help you achieve long-term well integrity contact your
Baker Hughes representative or visit BakerHughes.com.
Fracturing - Break and Seal Test
Controlled crack width = 0.003 in., curing time = 96 hrs, Seal Time = 24 hrs
1200

979
1000
894 880
791
Test Pressure (psi)

800
Crack
Initiation
600 Pressure Break-
Seal #1
Break-
400 Seal #2 357
Break-
Seal #3
250
200 Break-
Seal #4 Break-
Seal #5
0
0 1 2 3 4 5 6 7
Ageing Time (days)

EnsurSet Cement system system capable of sealing same crack multiples times.

www.bakerhughes.com
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© 2013 Baker Hughes Incorporated. All rights reserved. 38278. Rev 12/2014