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Summary. A laboratory study has been conducted to identify the various mechanisms involved in the invasion and migration of
formation gas in cemented annuli and to develop procedures to stop this process. Mechanisms operate differently in different
circumstances, and it is important for the zonal-isolation characteristics of the cement that the preventive procedures used are the
appropriate ones.
Introduction
The drilling industry has paid much attention to gas-well zonal- A cement slurry was pumped into a 12-m [39-ft] vertical steel
isolation problems, and there is extensive literature on the subject. 1 column. The column was sealed and a gas pressure, Pro was ap-
However, many of the possible solutions referred to in the publi- plied at the top of the column with nitrogen. A transducer meas-
cations reviewed in Ref. 1 were found to work only under specific ured the pressure exerted on the bottom of the column, Pb, as a
field conditions. function of time. Fig. 3 compares typical depressurization, Pb/Pr-
A number of projects were undertaken by Koninklijke/Shell E&P ratio, curves for neat and foamed cement slurries. The gas pressures,
Laboratorium in the late 1970's and early 1980's to attempt to over- Pro were kept constant for the duration of the tests. The minimum
come these limitations. This paper summarizes that work. Empha- in the neat cement curve corresponds to the time at which gas from
sis is placed on laboratory investigations, and only superficial the top of the column started to break through to the pressure trans-
reference is made to field results, which will be published later in ducer at the bottom of the column.
more detail. The increase in the depressurization rate after 5 to 6 hours cor-
responds to the cement reaching initial set-i.e., the start of the
Investigations Into the Causes of the Problem exothermic hydration reactions. Initial set was determined by meas-
Zonal Isolation. Mud Displacement. Laboratory tests showed that uring the temperature of the setting slurry. Depressurization also
certain proprietary anti~gas-migration cements had excellent zonal- occurred in foamed cement columns but gas breakthrough never
isolation characteristics. It was hoped that these cements could pro- occurred.
vide adequate zonal isolation in situations where mud-displacement Foam cements are used successfully for gas-well zonal-isolation
practices were poor-i.e., good mud displacement occurred only purposes but their use has the following limitations.
over short annular sections. These hopes proved unfounded. Field 1. Service- and operating-company foam-cementing expertise is
experience showed that, irrespective of how good a particular ce- not available in all operating areas.
ment type was at resisting gas invasion and/or migration, reliable 2. Foam-cement rheologies cause too much shear thinning for
zonal isolations could be obtained only if effective mud-displacement efficient mud displacement. This disadvantage is often overcome
practices were used. Consequently, it was decided that any reliable by the use of preflushes, scavenger slurries, etc. Relying on these
system must ensure both good mud displacement and the prevention techniques, however, to give adequate high-velocity contact times,
of gas migration after placement. and thereby ensuring efficient mud displacement, can be a problem.
No laboratory mud-displacement research was included in these 3. Foam cement may not prevent annular gas migration through
studies. Mud-displacement practices adopted by Shell in the late the microannuli.
1970's2 were confirmed to be reliable, and much operational effort Pressure Transmission. Gels developed by a cement slurry soon
has been spent on increasing their applicability to a wider range after placement restrict pressure transmission through the slurry. 5
of field conditions. Such equations as Eq. 1 are used to calculate the effect of a given
Gas Invasion/Migration After Placement. Good displacement gel on pressure transmission.
practices coupled with the use of stable, fast-setting, low-fluid-loss
slurries were found to solve gas zonal-isolation problems in many p=4GLld, ....................................... (1)
(but not all) operational circumstances. More effective and univer-
sally applicable techniques were therefore required. where
An analysis of field data showed that gas could migrate vertically P = axial pressure differential required to initiate axial
through the cement, the inner cement/casing microannulus, the outer . movement of cement slurry,
cement/formation microannulus, or through all three (Fig. 1). G = static gel strength at a given time,
Migration through the microannuli did not occur under all field cir- L = length of cement column, and
cumstances (see the Discussion), but failure to take precautions to d = diameter of cement column.
prevent such migration resulted in numerous zonal-isolation failures.
The most common use of such an equation is to determine the
Depressurization Phenomena. Neat Cement and Foam Cement. maximum time for which a cement-pumping operation can be in-
Depressurization of the annular cement column 3 was understood terrupted and the slurry still be moved again after the interruption.
to be partly responsible for gas invasion. One of the justifications Eq. 1, however, assumes that the slurry is acting as a coherent "one-
for developing a foam cement 4 was to obtain slurries that would phase body. " This may be a valid assumption for pumping appli-
depressurize less than conventional ones. cations, bilt it may be less valid in certain other applications. Eq.
The differences in depressurization behavior of neat and foamed 1 is not valid for a situation in which a slurry is depressurized in-
slurries were demonstrated in tests with the apparatus shown in ternally, owing to fluid loss or hydration, and subsequently repres-
Fig. 2. surized by the water phase within the "slurry gel matrix." How
'Now at Nederlandse Aardolie Maatschappij. pressure transmission occurs in a setting cement slurry needed to
Copyright 1988 SOCiety of Petroleum Engineers be understood.
SPE Drilling Engineering, March 1988 77
================~~~~~~~~~~GAS CHANNELS IN
CEMENT MA-TRIX
MICRO-ANNULUS
BETWEEN CASING
AND CEMENT (DUE
A f - - - TO PRESSURE REDUCTION
INSIDE CASING)
,
NITROGEN LOOP 2
I
g~~~;J :::():1t: PRESSURE
SEE I
PRESSURE ENLARGED
DIAGRAM I
I T I'
P __ 6
DESIGNA TlON
.~n .-n
1 ,MIXER
2 ECCENTRIC SCREW PUMP
p
3 MAGNETIC FLOW METER
• SAMPLE/FLUSH POINT
5 MEASURING COLUMN
, PRESSURE TRANSDUCER
7 THERMO COUPLE
I
70
II
Q. I
!II:
~
0
II:
60 6, I
0 I
III 50
II: I
::I
III I
40
,
III
III 51
II:
Q. 4
:I 30 ~
::I
CEMENT-FILLED - - f - - - - i WATER-FILLED 0
COILED COPPER TUBE THERMOSTATED 0 2 3 4 5 6 7 8
(1.50m LONG 6mm 1.0.' BATH
TIME (hours)
Fig. 4-Apparatus for measuring pore pressure in setting Fig. 6-Maximum differential pressures observed with con-
cement. secutive cycles.
RECORDERS
450
400
.• PRESSURE TRANSDUCER __~~~--lIl!
CONSTANT
NITROGEN --M~-l><l-4'1l-lXl
'"
iii
II: 350
PRESSURE
::>
...
"'"' PIPE NIPPLE WITH CAPS --~~<-
II: THERMOCOUPLE
..;:
..J
300
CEMENT SLURRY __ ----<-
....
BAROID HEATING JACKET
z OR THERMOSTATIC BATH
II: 250
......
0
200
1-7 COOLING CYCLES
INITIAL SET
HYDRAULIC HAND PUMP
0 FOR PRESSURIZING WITH WATER
0 4 8 12
TIME (hours)
Fig. 7-Cement set monitoring apparatus.
Fig. 5-Pressure transmission capability of pore fluid in ce-
ment during setting.
100 5. 1
structure has been allowed to develop before the fluid loss is meas- Q.
ured. To demonstrate this, Table 1 contains the fluid-loss results O+--~ __ ~~ ____ ____ ~ ~~- __r---io
of a slurry with poor fluid-loss control, which was tested in various o 10 15 20
ways. Such a slurry would never be used in the field for zonal- TIME (hourw) tEXCL. 20 min STtRIIING IN CONSISTOMETfRJ
1 920'
2 810" CEMENT
3 130"
4 1050 t
2.5 em 'U·TUBE'
5 1050* IN CNEN AT
2O-100"C
For slurries with good initial API fluid-loss control [API high- Note that the time at which initial set occurs is very dependent,
pressure/high-temperature (HP/HT) < 50 cm 3], the fluid losses de- among other factors, on how the slurry is sheared. 2 Our records
termined after they have been allowed to remain static for a few show that in extreme cases, initial set in the field can occur up to
minutes after initial set often approached zero-Le., after initial 6 hours later than in a consistometer simulation. It is important that
set, their fluid losses are not considered to contribute significantly the correct initial set is used in the cementation design.
to slurry depressurization.
Stability. Little work was done on slurry stability. It was assumed V-Tube Gas Suction Tests. Given the above hypothesis, it was
that the free-water content of slurries under downhole conditions assumed that gas invasion/migration caused by hydration shrinkage
should be less than 1.0% after placement to prevent the formation of the cement was of prime concern. The V-tube apparatus 8 was
of water pockets and channels through which gas could migrate. developed specifically to investigate this phenomenon. The apparatus
Similarly, it was considered that column depressurization caused (Fig. 9) allows the other depressurization mechanisms to be
by the vertical movement of water through the static cement neglected.
gels 6 ,7 -Le., phase segregation-should be minimized, e.g., The V-tube was filled with a cement s"iurry, and gas pressure
through the use of fluid-loss additives. 5 was applied to the top of one of the legs. The cement was allowed
Working Hypothesis on Cement Depressurization. On the basis to set and the gas pressure was monitored continuously throughout
of the above, a working hypothesis was formulated to explain the the process. As expected, gas was not sucked into the cement until
mechanisms by which an API cement slurry depressurized. This after initial set (see V-Tube Anti-Gas-Migration Tests). The gas
hypothesis was subsequently used as a basis for developing solutions flow rates through the cemented V-tubes were subsequently meas-
to the gas invasion problems. It can be summarized as follows. ured by increasing the pressure differential across the V-tube (usual-
I. When a stable cement slurry is placed in the wellbore, it begins ly up to 4 to 20 MPa [580 to 2,900 psi]) and measuring the resultant
to gel, and the hydrostatic pressure it exerts tends to fall from that flow rates.
of the slurry to that of the water phase within the slurry. This tran-
sition is interrupted by initial set. At initial set, the exothermic hydra- Gas Migration Tests. Vertical gas-bubbleigas-stream flow through
tion reactions start, pore water begins to be converted into hydrates cement columns was studied as part of a more comprehensive in-
(resulting in a net volume reduction), and the pore pressure of the vestigation of vertical gas flow in non-Newtonian fluids. For cement
cement starts to fall to below that of the water-phase gradient. slurries and other opaque slurries, 2-m [6.6-ft]-high columns fitted
2. Depressurization can be further aggravated by fluid loss. How- with electrodes to measure gas movement were used (Fig. 10). It
ever, iflow-fluid-Ioss (API HP/HT<50 cm 3 ) cement slurries are was found that as gel values increased, gas migration rates decreased
used and the slurries are not placed until or after initial set, depres- until a critical gel value was obtained. Above this value, no further
surization caused by fluid loss is not considered to be a problem. gas movement occurred (Fig. 11). From the results, it was con-
3. Because slurries are designed to be placed at initial set, their cluded that, if gas should invade a cement before initial set as a
dominant depressurization mechanism is considered to be that result- result of depressurization caused by cement gelation, the gel that
ing from hydration shrinkage. had caused the depressurization in the first place would almost cer-
200 25
SLURRY
. .
_,
20
E
E
150
...
GLASS TUBE ,: "'-"._ ... -.... ... ... :z:
t- t-
CONDUCTIVITY
ELECTRODES
U
..
0
.J
100 ~'"
15
"z.
0:
BUBBLE
..
>
.J
II
10
t-
'".
.J
II
:>
II
50
"
O+---~-----r----~--~----~~~r----+O
o 10 15 20 25 30 35
l.
".
u,j600
a:
:::l
tJ)
tJ)
w
a:
WATERI II.
PRESSURE CEMENT TRAP .... 400
REDUCING VALVE
"j:z
w
a:
w
1::200
Q
[ NO FOAMING AGENT
Fig. 12-Apparatus for measuring gas injection pressures in
setting cement.
o+-~~~~~~--~--~
o 5 10 15 20
tainly be strong enough to prevent invasion of seepage bubbles. TIME (hou's)
In these experiments, gels of 20 Pa [0.003 psi] were usually strong
enough to stop small gas bubbles from migrating, and such gels Fig. 13-lnfluence of foam formation on gas injection pres-
are usually formed by most slurries soon after placement. This rein- sure during gas flow into a setting cement column.
forced our opinion that the main gas invasion/migration problem
was after initial set, not before it.
leakage rates were still unacceptably high. When the V-tube was
Investigations To Find Solutions to the Problem cooled rapidly after the leakage rates had stabilized, however, it
In line with the comments made in Zonal Isolation, solutions to was found that gas flow in the surfactant-containing cement virtu-
the problem necessarily require reliable hydraulic sealing of the ally stopped, while the flow rate in the cement without the surfac-
cement, of the cement/casing bond, and of the cement/formation tant did not. For a lO-MPa [1,450-psi] pressure differential across
bond. Failure to achieve anyone of these seals may lead to failure the V-tube, the gas flow rate for the surfactant-containing slurry
of the cementation. The sealing problem within the cement will be reduced from 1200xlO- 1O to 43xlO- 10 m 3 /s [4.2xlO- 6 to
considered first. 152x 10- 9 ft 3 /sec] while for the slurry without surfactant, the
The chances of developing an unfoamed cement system that was flow rate remained almost constant (i.e., it "increased" from
44 800 x 10- 10 to 45 500 x 10- 10 m 3 /s [158xlO- 6 to 161x
capable of stopping formation gas invasion were not considered to
be good. Efforts were therefore concentrated on developing systems 10 -6 ft 3 /secD. Thus, it was concluded that gas was migrating
that would give zonal isolation by prevention of gas migration. A through both the slurry and the outer microannulus formed by bulk
number of anti-gas-migration systems were investigated (some of cement shrinkage. Cooling the V-tube sealed the microannulus and
al~owed the rates of migration through the cement and through the
which performed well), but only the system that was chosen for
further development is discussed here. mlCfoannulus to be determined independently. In this way, it was
The selected system simply involved the incorporation of a foam- shown that the only significant gas leakage with the surfactant ce-
ing surfactant (same type as that used in foamed cements) in an ment had been through the microannulus. The microannulus flow
u?foamed cement slurry. The purpose of the surfactant was spe- in the surfactant-free cement was insignificant compared with the
CIfically to generate a foam cement with invading formation gas flow through the slurry proper.
instead of gas added to the slurry at surface or generated by chem- Attention was now concentrated on practical field solutions to
ical reaction downhole. Surfactants have been added to cements the problem of microannulus flow. Inert fillers (silica flour, sand,
since the earliest days of oilwell cementing. To the best of our latex, etc.) were incorporated in the cement-slurry formulations to
knowledge, however, Marrast et ai. 9 were the first to recognize reduce the extent by which they shrank. Fig. 14 shows that in the
t?e potential of certain types of surfactants to inhibit gas migra- V-tube tests, annular gas leakage problems were significantly less
tIOn. They showed that the use of surfactant-containing cements, when a filler was used.
whic~ w~re capable of forming stable foams when invaded by gas,
The biggest reduction in microannulus leakage rates was obtained,
had slgmficantly less gas zonal-isolation problems than cements however, by internally lining a 2.54-cm [I-in.] section of each of
without this capability. the V-tube legs with a thin, compressible material (a seal ring).
The hydraulic seal obtained with the seal-ring/surfactant cement
Vse of a Foaming Surfactant To Increase Resistance to Gas
Migration. It became apparent from the previously described and
subse~uent scouting studies that if a gas stream were forced through
a gellIng surfactant-containing slurry, the gas would be changed
3.5j
3.0
~
",.".. .... - .- - -
_____________ .
from a fingering low-viscosity fluid into a viscous foam with con-
siderably more resistance to migration. 2.5 /
/
LEGEND
These observations were quantified with the apparatus shown in A - _ NEAT CEMENT
O.Oi---..,..-----
Fig. 12. The injection pressures required to flow gas at a controlled
,'/\
0-----
X - - - NlAT CEIlENT*SURfACTANT
NUT CEIlENT* SURFACTANT* 35'10 SAND
0-------· NEAT CEMENT .. SURfACTANT .. SEAL RING
rate through a cement column were measured. Gas injection was 0.5
: I \
started at initial set. In Fig. 13, typical injection pressures are given 0.' :j \
for two cements that were identical except that one contained a foam- 0.3 /l \"
ing surfactant and the other did not. Note that the incorporation :1:1 \/r-:....--------------
,IE "'-"-.........
0.2
of a surfactant increases the resistance to flow six-fold.
0.1