SPE/IADC 130313

Managed Pressure Drilling Brings Added Value to Production Casings

Cementing Operations Increasing Success Rates and Quality in HPHT
Fractured Narrow Window Wells
Juan Carlos Beltran, SPE, Corrado Lupo, SPE, Fernando Gallo, SPE, Hermogenes Duno, SPE, and
Leiro Medina, SPE, Schlumberger

Copyright 2010, SPE/IADC Managed Pressure Drilling and Underbalanced Operations Conference and Exhibition

This paper was prepared for presentation at the 2010 SPE/IADC Managed Pressure Drilling and Underbalanced Operations Conference and Exhibition held in Kuala Lumpur, Malaysia, 24–25 February 2010.

This paper was selected for presentation by an SPE/IADC program committee following review of information contained in an abstract submitted by the author(s). Contents of the paper have not been reviewed
by the Society of Petroleum Engineers or the International Association of Drilling Contractors and are subject to correction by the author(s). The material does not necessarily reflect any position of the Society of
Petroleum Engineers or the International Association of Drilling Contractors, its officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written consent of the
Society of Petroleum Engineers or the International Association of Drilling Contractors is prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300 words; illustrations may not
be copied. The abstract must contain conspicuous acknowledgment of SPE/IADC copyright.

Abstract

The oilfields in study are important assets for the National Oil Company and represent 14% of the total oil production of the
country. Two wide different and drastically challenging scenarios can be found: HPHT wells with a narrow mud weight
window; and highly depleted wells in fractured carbonates. In both cases, the cementing job in production casings is
historically classified as very difficult as a direct consequence of high frictional pressure losses due to the small annulus and
deep wells configuration which causes loss circulation problems. A close analysis of the offset wells identified the use of
MPD as a possible partial solution to mitigate the usual loss circulation scenario.
This document describes the successful implementation of the MPD technique as a supplemental aid for cementing jobs,
eliminating cement losses, avoiding formation damage, reducing mud losses by also offering additional safety to this kind of
operations. In the last two years MPD has been used in a number of cementing jobs in HPHT wells and also in low pressure
wells; with equivalent circulating densities as high as 1.65 sg. in both single phase and multiphase drilling fluids MPD
applications as low as 0.29 specific gravity.
Paper will also detail recommended operational procedures and recommended practices to integrate the MPD technique along
with conventional cementing operations. The annulus between the 5” liner and the 7” liner 38# is very small, this condition
associated with a narrow mud weight window, makes quite impossible to do a successful cementing job without the aid of the
MPD technique.

Introduction

Each time MPD is widely implemented and its advances and successful applications are known.
The field is composed by highly fractured carbonates and produces light crude and gas.
This field is characterized for a very narrow mud weight window in production zone.
Main operational issues while drilling these wells are related to 5 5/8” section:

• Mud losses,
• Hydrocarbon influxes,
• Low ROP
• Formation damage.
• NPT associated with constant mud density modifications

In this well a proactive MPD was implemented to drill all the section between 5645 m (18515 ft) and 6020 (19745 ft). At the
end no kicks were observed and just 47 m3 of mud were lost associated mainly with a fishing operation.
After the drilling, the final big challenges were to RIH and cement the 5” liner: a combination of a narrow mud weight
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window, a liner 7” of 38 lb/ft ID: 5.92” and a slim hole of 5 5/8”. Frequently the cement jobs are unsuccessful in this field,
most of the cement is lost to the formation, and formation damage is high especially because these wells produce through
secondary porosity (fractures). Normally the wells in the zone are cemented in overbalance, no matter the formation damage
and the unsuccessful cementing jobs. In this well by the first time in the field, it was used the MPD technique to RIH the
liner and to make the cement job.

The Challenge

To RIH and cement one production liner in a slim hole with a very narrow mud weight Window.
The general Industry definition of slim hole is a bore hole which has a drill string / annulus ratio > 0.7, although for others it
means drilling hole sizes smaller than 6” in diameter. However, it is more appropriate to refer to slim hole as bore holes with
small annular clearances, because the commonality of the problems associated with slim hole drilling arises from the small
annular clearances rather than the hole size itself. See Fig. 1, showing the mechanical status of the well previous to the job.
Due to the small annular clearance, the drilling envelope is reduced and in turn well control is more critical, specifically:
• High ECD can fracture weak formations.
• High ECD can mask over pressured formations (due to large gap between ECD and drilling fluid equivalent density
in static conditions).
• Much smaller kick tolerances compared with conventional wells, hence early kick detection is paramount.
• A small kick will result in significantly longer influx height; therefore a large hydrostatic pressure reduction takes
place, which leads to substantially higher annular pressures when compared to conventional wells.
• Larger swabbing / surging effects, with higher likelihood of kicks / losses occurring.
• The magnitude of the annular pressure losses affects the selection of the circulating rate (during kick control) and
the actual well control method(s).

The Solution
A proactive MPD application was analyzed and planned between a multidisciplinary team; clear procedures and risk analysis
were created and implemented. People in the field made the final effort for the success of the operation.

• Wiper trip
• RIH the BHA with the liner
• Previous Circulating
• Cementing Job
• Setting the Packer and tripping out the setting tool

1. Wiper trip
Previous to the liner running, it was done a conditioning trip until 6020 m MD (19745 ft). To POOH the BHA, after de pump
was stopped, it was stripped through the rotary head with 550 Psi. With the bit at the 7” shoe, it was pumped a balanced
heavy pill off 10 m3 to compensate a total pressure of 750 Psi, equivalent to the friction losses plus the natural pressure of
the MPD surface equipment and one trip margin to compensate any swab effect, then it was POOH the bit to the top of the
heavy pill, a flow check was done, observing normal conditions it was removed the bearing assembly of the rotary head and
the BHA was POOH at a controlled speed to avoid any swab effect.

2. RIH the BHA with the liner

Casing running was treated the same as per MPD tripping practices. No design consideration for the liner centralization was
made to ensure compatibility with the RCD.
The liner was run at a controlled speed until the shoe track was in the middle of the heavy pill. At this depth it was displaced
50% of the heavy pill, once complete the lap time, it was RIH the liner until the base of the heavy pill (shoe track of the 7”
casing), at this depth it was circulated the other 50% of the heavy pill. The reason to circulate the heavy pill in to sections
was to avoid the overbalance associated with the small annulus and with the friction losses of the fluid while circulating.
After the first circulating it was applied 375 psi at the MPD choke and after the second circulation, it was replaced all of the
overbalance generated by the heavy pill (750 Psi were applied).
SPE/IADC 130313 3

It was continued RIH the liner maintaining the backpressure and a controlled speed to avoid any surgency effect.

3. Previous Circulating
Once on bottom, it was circulated the well starting at a low rate to evaluate the cementing rates for losses or influxes. Each
time the pump was stopped or the mud rate reduced, backpressure was applied with the MPD choke manifold to compensate
the reduction in the BHP. The backpressure was the necessary to maintain an ECD of 1.17 g/cc.

4. Cementing Job
Finishing the circulation, it was dropped the ball, after the ball was seated, the pump backpressure was maintained in the
MPD choke until the liner hanger was seated, and with 2900 Psi pump pressure. The back pressure was released to reduce
the surge pressure to the formation while the shearing of the ball seat with a maximum pump pressure of 3950 psi. The
cementing was done as follows: pumped 23 bbls of Mud Push II, followed by 18 bbls of cement liteCrete dropped the dart
plus 37 bbls of Mud Push II plus 310 bbl of mud. Pumping pressure 500 to 900 Psi, it was observed plug setting with 1300
psi. The ECD calculated was 1.17 g/cc (9.75 ppg), this ECD was maintained during all of the job, backpressure was applied
with the MPD choke each time the pumping rate was reduced, and when the heavier fluids started to raise through the
annulus the back pressure was reduced according with the calculations of ECD done with the hydraulic simulator. When the
cement was pumped the backpressure was totally removed from the MPD choke manifold. See Fig. 2, showing the
schematic of the well with the liner and cementing job.

5. Setting the Packer and tripping out the setting tool

With the cement on position, it was activated the packer with 35 tons of weight. The setting tool is lifted 10 stands (271 m)
from 5448 m to 5171 m and pump is started at a rate of 220 gpm. Once the bottoms up, it was observed mud contaminated
with mud push and only a maximum reading of gas of 190 units. Completed the circulation, lifted the string from 5171 m to
4814 m, it was done a flow check, the bearing assembly was removed and continued POOH the setting tool. The cement and
spacers were calculated with a density enough to set the well overbalanced, as a contingency in case of the packer do not
give hermeticity to the system, it was designed to replace the heavy pill used in the Wiper trip.

Operations Troubles

1. Choke plugging with rubber of the hydrill element. See Fig. 3, showing rubbers used during cementing job.
2. Float valves leaking. As a lesson learnt, it was established to install two float valves in the BHA to reduce the fail
probability, commonly due to the high BHT (close to 180ºC). As a best practice it was implemented during the
drilling operation to maintain on location one NRV to be installed at anytime in case of fail of the float valves
3. There was some confusion of the liner hanger technician during the process to set the top packer with bearing
assemble of the rotary head. The packer has been designed to be set with weight, in spite of the weight tests done
before the cementing operation.
4. Miss alignment of the BOP stack, lead to the damage of the seal elements of the rotary head. It was necessary to
pump a heavy pill to make the well under control and trip to the shoe to install a new one bearing assembly in the
rotary head. See Fig. 7, shows the eccentricity of the drilling string and the damage to the seal elements of the
rotary head.

MPD Equipment

Minor modifications to the conventional drilling equipment are required to implement the MPD techniques: Basically the rig
up of the rotary head is the only equipment which requires rig modification; the float line must be conditioned to allow the 7
1/6” outlet of the rotary head. See Fig. 5, where shows the P&ID of the MPD equipment and the Fig. 6, shows the equipment
used to control the fluids at surface (Separator, Choke manifold and main flow lines). In other hand, to achieve the best
performance of a rotary head, it is necessary to have a well alignment BOP. The main equipment in a MPD operation, is the
rotary head, if it fails the operation cannot continue, particularly in a proactive MPD, where a release of the backpressure will
lead to an influx if the response is not fast.
4 SPE/IADC 130313

Conclusions

¾ The MPD has shown to be a helpful tool for the cementing jobs.
¾ MPD technique, properly applied and managed, can produce significant cost and uncertainty reduction benefits to
produce step wise changes in drilling economic performance. The versatility, accuracy and flexibility of adjusting
wellbore pressures with an MPD system have changed the face of conventional well control.
¾ There were no mud losses during the cement job the cement job was successful. Normally the logs show a low
cement quality in this small annulus. See the figure 4, showing the cement logs.
¾ Effective communication was a key element in the success of the operation. Too many people was involved in the
operation, the risk of mistakes associated with bad communication was higher.
¾ The leadership of the drilling WSS was one of the main elements of the operation linked with the success.
¾ The HSE procedures and policies had a very important role in the success of the job. The reservoir produces low
gravity condensate, flammable gas and H2S in low concentrations, a closed circulation system at surface, increased
the safety conditions for the personnel at the rig site.
¾ It was run a cementing log CBL-VDL observing good isolation in the entire cemented zone. The zone objective to
be shut has an excellent isolation according to the cementing log.

References

Well Control Manual, Schlumberger, 2006

Sjors Jansen, SPE, Peter Brett, SPE, and Jorg Kohnert, SPE, Shell Expro, and Roger Catchpole, Amey Vectra Ltd. “Safety
Critical Learnings in Underbalanced Well Operations” , SPE/IADC 67688, Drilling Conference held in Amsterdam, The
Netherlands, 27 February–1 March 2001.

PhD C.P. Tellez, SPE, PEMEX; H. Duno, SPE, O. Casanova, and W. Colombine, SPE, Schlumberger; C. Lupo,
SPE, J.R. Palacios, SPE, and L. Medina, SPE, Optimal Pressure Drilling Services. “Successful Application of MPD
Technique in a HP/HT Well Focused on Performance Drilling in Southern Mexico Deep Fractured Carbonates Reservoirs”,
Paper presented at the IADC/SPE Managed Pressure Drilling and Underbalanced Operations Conference and Exhibition held
in San Antonio, Texas, 12–13 February 2009

Nomenclature / Acronyms

CBHP = Constant Bottom Hole Pressure

BHP = Bottom Hole Pressure
NPT = Non Productive Time
WOB = Weight on Bit
ROP = Rate of Penetration
ECD = Equivalent Circulating Density
ESD = Equivalent Estatic Density
BHA = Bottom Hole Assembly
OSC = Operating Support Center
WITSML = Wellsite Information Transfer Standard Markup Language
APWD = Annular Pressure While Drilling
HSE = Quality Health Safety and Environment
SPE/IADC 130313 5

Figures

Figure 1. Mechanical Status

20” x 13 3/8” x 9 5/8” x 7 5/8”

Well type “J”

AGUJERO 26” @ 1000 mv

Lodo (Programa Tentativo) m TVD:
Agujero 26”:
Intervalo 50 - 1000 mv: Calcico: 1.10 - 1.25 gr/cc
Agujero 17 1/2”:
Intervalo 1000 - 2698 mv: EI: 1.35 – 1.65 gr/cc
Agujero 12 1/4”:
Intervalo 2698 - 4889 mv : EI: 1.85 – 2.10 gr/cc
Agujero 8 1/2”:
Intervalo 4889 - 5541 mv: EI: 1.85 – 1.95 gr/cc
Agujero 5 5/8”:
Intervalo 5541 – 5857 mv: EI: 1.10 – 1.15 gr/cc
AGUJERO 17 1/2” 2700 mv

AGUJERO 12 1/4” @ 4876 mv / 5010 md

AGUJERO 8 1/2” @ 5475 mv / 5645 md

Liner: 7” 38 lb/ft, 4780-5675 m
Stub: 7 5/8” 39 lb/ft, 2500-4780 m
Comp: 75/8” 39 lb/ft, 0-2300 m
7 5/8” 39 lb/ft, TRC-110, 2300-2500 m

Etapa MPD
AGUJERO 5 5/8” @ 5857mv / 6012md
Liner 5” 18 lb/ft, TAC-140, 5475-6020 m

Figure 2. Cement Schematic

Oil Based Mud

23 Bbls Mud Push

II Spacer

Top of 5" Liner @ 5443 m

7" shoe @ 5645 m

18 Bbls Cement liteCrete
37 Bbls Mud Push II
spacer

TD 6020 m
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Figure 3. Hydrill Elastomers Damaged

Life of the elastomers

is reduced by the
aromatic components
of the oil based mud.
It was frecuent choke
plugging.

Figure 4. Cement Log

SPE/IADC 130313 7

Figure 5. MPD Equipment Layout

P&ID WELL-1

Figure 6. MPD Equipment

MPD Secondary
Separator Line
Rig Choke

MPD Choke
Command Manifold
Center

Pumping
Skid Cementing
Equipment

Primary Line
Shipping
Lines
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Figure 7. Rotary Head Rubbers Failure due to the BOP missalignment

Miss a lignment of the BOP leads to a TP excentric. This is one of the biggest
enemies of the sealing elements of the RCH

In the left pictures is shown the excentricity of the drilling string

In pictures at the bottom are shown the seal elements of the rotary head
damaged.