Geothermal Drilling and Well Design (SE-830-DR2) : Cementing

GEOTHERMAL DRILLING AND WELL DESIGN
(SE-830-DR2)
Cementing
Sverrir Thorhallsson
sverrir.thorhallsson@gmail.com
ISE Geothermal Drilling and Well Design March 2019 Sverrir Thorhallsson 1
CASING AND CEMENTING
After drilling each section of a well a new casing is run and then cemented full
length. The casing design was described in another lecture, but here the
running of the casing and cementing will be described.
The casing in lengths of 10-13 m is added one by one, by screwing the
threaded connections together and lowering the pipe by pipe.
The casing cementing is one of the most critical operations of the drilling
operation, because:
• The cement has to support the casing uniformly as the thermal expansion stresses
the steel beyond the yield point. Poor cementing is a leading cause of casing failures.
• There can be now water pockets in the annulus between two casing strings as it will
most likely cause a collapse in the casing at startup due to the expansion of the water
which has no place to go.
• The cementing has to block any fluid movement up the annulus, be it from the
formation or through a casing leak.
• Cementing is one of the most critical operations of the drilling to get right.
API COLOR CODING OF CASING STEEL GRADES
API markings are stenciled on every pipe
•J-55 One bright green band

•K-55 Two bright green bands
•L-80 One red band and one brown band
•C-75 One blue band
•N-80 One red band
NOTE:
If the API monogram is missing from the stenciled markings, the casing may
be produced under the works specifications.
CASING A WELL (1 OF 2)
1. Inspect well casing in stock:

Color band coding reveals steel grade. Most common API K55, C75 and L80.
Higher grades may not be suitable due to inadequate H2S resistance, e.g. N80.
Stenciled markings show diameter (“) and weight (fb/ft), grade of steel,
connection, length.
Loosen thread protector and inspect.
Measure the length of each casing - casing tally.
2. Install casing hardware:
Float shoe on bottom + two centralizers. (Float = Float valve = check valve)
Float collar at second joint + cent. every three.
3. Put “Baker-Lock” on lowest three joints or tag weld to prevent unscrewing.
4. Re-grease each casing thread before joining with Kopr-Kote Geothermal
(thermal grade) compound (or equivalent).
CASING A WELL (2 OF 2)
5. Tighten each buttress joint until the casing coupling with reference to the
triangular stamp mark on the upper casing. If the triangle mark is not
reached or has disappeared, reject the pipe. Record the torque reading.
6. Fill-up the casing with water as the casing job progresses.
7. For cementing:
- Inner string method: Land casing off bottom and connect inner string (drill
pipes) to float shoe for cementing.
- Plug method: Install the cementing head.
8. Strap down the casing to the rig floor with chains. This is for large casing
that can “float” in the heavy cement slurry.
9. Circulate cold water to condition and cool the well prior to cementing.
CASING CONNECTIONS
•Buttress threads are most common.

•VAM threads are sometimes used.
•API round threads are seldom used.
•Hydril (now Tenaris) or special threads are sometimes used to reduce
clearance between casing OD and well ID e.g. for slotted liners.
•Surface casings are sometimes butt welded. In Iceland also the anchor
casing to ~350 m. Requires certified welders.
•Welding is used for casing heads. Requires heating and post weld
treatment. Note: Most high-grade casing steels can not be welded >K55.
BUTTRESS THREADED CONNECTION
casing
casing
being
being Triangular
screwed Triangular
screwed mark stamped
mark stamped
on the casing
Re-grease
Re-grease by
onpipe
themfg.
casing
treads by D
treads by thermal
applying D to
byguide
pipe mfg..
applying tightening and
grade thermal to guide
control thread
grade
compound
to inside of
compound
coupling
coupling tightening
engagement. and
control thread
coupling.
to inside of Min. to base
engagement.
coupling. casing
of triangle,
in slips max. to apex.
Reject casing
not properly
engaged.
CASING CENTRALIZER SPACING
60 Centalizer placement:
50 -Two on bottom
For 9 5/8” and 10 3/4” - One on first joint
Hole deviation (°)
40 -One every third joint
30 Selection – two types:

• Spring in open hole
20 • Rigid in casing annulus
10
Note:
Consider not having
0
centralizers in top 200 m
0 10 20 30 40
in case that “spagetti”
Centralizer spacing (m )
string fill-up is required.
LINER HANGER
MAIN REASONS FOR CEMENTING
•Casing cementing:
Hold the casing in the well.
Prevent fluid migration outside the casing.
Corrosion protection.
•Hole conditions:
For sealing loss of circulation zones.
For stabilizing weak zones (washouts, collapses).
To plug a well for abandonment or for repair.
To kick-off sidetracking in an open hole or to pass junk.
To plug a well temporary before being re-cased.
TYPES OF CEMENTING OPERATIONS
– Casing
• Each casing string, full length
• Cemented liners
• For plugging and abandonment
– Open hole
• Loss zones
• Collapses
• Plugs
– Materials
• HT cement mix with 40% silica flour. w/wo microspheres and expanded perlite
– Methods
• Pumping on casing through a cementing head, using plugs
• Inner-string cementing method
• Reverse circulation cementing
• Cementing up to a loss zone and then immediately reverse circulation
CASING CEMENTING - PLANNING
• Calculate the annulus volume to be cemented, preferably from caliper logs

and add some for losses. If logs are not available use theoretical volume *2.2
(commonly referred to as 120% excess). Volumes (L/m) are found in the DDH.
•Calculate material requirements and determine yield (L slurry/100 kg dry
cement), cement slurry density (g/cm3).
• Make cement lab tests for thickening time, based on expected bottom hole
circulation temperature (BHCT).
• Plan the cementing operation:
• Material requirements on site. Cement (kg), water (m3), additives.
• How long to condition the hole and cool just before cementing
• Slurry pumping rate (L/s), calculate pumping time.
• Displacement volume of water (m3) to clean out casing or drill string.
• Contingency plan e.g if no cement returns are obtained or the cement
becomes hard and can not be pumped..
EXCESS CEMENT REQUIREMENTS FOR CASING CEMENTING – HELLISHEIÐI
For ancor casing ~300 m For production casing ~900m
Ref. Björn M. Sveinbjörnsson, Sverrir Thorhallsson
CEMENTING CONSIDERATIONS
•In most countries the cementing jobs are carried out by specialist cementing
service companies.
•Some drilling contractors also cement. By adding cement tanks, pneumatic
transport system and receiving tanks to the rig the cement mix can be
prepared on site. The rig crew can also complete the cementing job, either by
special cementing equipment or by using the rig pumps and a jet mixer.
•Maintain high pumping rates (17-20 L/s) and plan for < 90 minutes of total
pumping time (cementing + displacement).
•Rubber plugs or spacers are not really required. Many prefer to run the top
plug to insure that the cement is not flushed from the shoe.
LOGS BEFORE RUNNING CSG
Caliper X-Y
to estimate
required
slurry volume (m3)
Fluid gain (inflow)
Fluid loss zones
VOLUME FROM CALIPER LOG
CALCULATION OF SLURRY REQUIREMENTS FROM CALLIPER LOG 12 ¼“ HOLE
Theoretical volume 22 m3
Calculated volume 50 m3
from caliper measuerments
CALCULATION OF MATERIAL REQUIREMENTS – 9 5/8“ CASING CEMENTING
Depth Volume Total volume DDH Pumping time

Item Description m l/m l 20 l/s
1 Casing/Casing Annulus, 9-5/8" x 13-3/8" 68 lb/ft 350 31,16 10.906 D18
2 Casing/Open hole, 9-5/8" x 12-1/4" 1000 29,1 29.100 D16
3 Rat hole, 12-1/4" hole 2 76,04 152 D4
4 Volume in Shoe track, 9-5/8" 47 lb/ft 12 38,19 458 D10
Answer 1 Theoretical Slurry Volume [l] 40.616
5 Excess Quantity of 100 % for item 2 and 3 29.252
Answer 2 Estimated Total Slurry Volume 69.868 58,2 minutes
Ratio Volume
Estimated material requirements kg/m3 m3 Total
Answer 3 Cement (Dry) for SG 1,9 1319 69,9 92.156 kg I7
Answer 4 Water 581 69,9 40.594 l I7
Depth Volume Total volume

Displacement vol. for inner-string cementing m l/m l
Answer 5 Displacement inside 5"x19.5 lb/ft drill pipe 975 9,05 8.824 D8 7,4 minutes
Total 65,6 minutes
CASING PROGRAM:
• Anchor casing: 350 m 13 ⅜" x 68 lb/ft
• Production casing: 1000 m 9 ⅝" x 47 lb/ft
• Well depth for this section: 1002 m drilled with 12 ¼" drill bit
CEMENING UNIT AND CBL PROBE
MAIN METHODS OF CASING CEMENTING
Inner string cementing

method is commonly used for
geothermal wells.
Note:
-Shorter pumping time.
-Can pump until
cement returns are
obtained.
-Especially useful for
large diameter casings and
long strings.
-Check collapse resistance of
casing as the weight of the
cement has to be supported
with water on the inside of
the casing and no extra
pressure.
NOVEL METHODS OF CEMENTING WHEN THERE ARE BIG LOSSES
INNER STRING CEMENTING – FLOAT COLLAR
CEMENTING CASING – LOSS ZONE
It is a common problem
that cement is not returned
to surface
If a loss zone is at the top

of cement it is possible to
do a “top-job”
(ANIMATION)
CEMENTING – “SPAGETTI” STRING
If top of cement is
in the annulus between
two casing strings a
small pipe is lowered
down and cement
squeezed through it
to fill up the annulus.
(ANIMATION)
2-STAGE CEMENTING
2. stage
Open/close ports
1. stage
Less hydrostatic
pressure against the
formation and lower
collapse pressure
exerted on the casing
Ref.: Halliburton
CEMENTING SMALL WELLS AND IN LARGE LOSSES WITH CEMENT+SAND
LOSS OF CIRCULATION POLICY (ICEL.)
1. Losses while drilling for casing frequently heal by themselves while drilling.
(e.g. Krafla, Iceland)
2. Large loss zones >10 L/s are cemented after drilling a ~30 m rat hole, if they
do not heal.
3. Loss of circulation material, mica flakes wood shavings and sawdust, is used
if cuttings do not do the job.
4. Cementing is done through the drill pipe and topping up until the loss is
covered. Having the lowest most 100 m of the cementing string from
fiberglass tubing is to reduce the risk should the cementing string get stuck
and have to be reamed out.
5. If the loss is way above the bottom of the hole, frequently the well is filled
up with sand to the loss zone and then cemented.
6. Large loss zones can be cemented with sand and cement from a ready mix
truck, delivered by concrete pumps (mainly low temp wells).
LOSS ZONES – OPTIMUM PLACEMENT TECHNIQUE FOR CEMENT PLUGS
LOSS ZONE CEMENTING (ANIMATION)
CEMENTING LOSS ZONES
Cementing Loss Zones

Well TR-4a, Berlin
-10
By ready-mix
truck and pumping
sand+cement
0 Ground level
10
Loss req.
Depth (m)
Hand mix
two jobs
sand+cem
20
Major loss
at 13 m
Req. seven
30 cem. jobs
Big loss at 16 m
Req. three cem. jobs
Legend
Reach of plug
in case of no loss
40 to the formation
Top of cement (TOC)

Big loss at 37 m
Bottom of cement plug 12 - 50 m3/hr
Sverrir 30.05.97
Req. two jobs
50
0 1 2 3 4 5 6 7 8 9 1011121314151617181920
Cement job #
HT CEMENT (1 OF 2)
•Normal cement exhibits strength retrogression.

Add 30-40% silica flour (-325 mesh quartz).
Use high-temperature well cement (API G or H).
Brands of Portland have been found to be OK for geothermal wells.
•Typical composition of HT cement mix by contractor:

Cement (API G and H, local brands-tested) 100 kg
Silica flour, for temperature resistance 40 kg
Expanded perlite, for lower density, plugging 2 kg
Bentonite, for holding perlite, pumpability 2 kg
Water loss additive 0.5 kg
Retarder, for longer pumping time when hot » 0.5 kg
•Neat cement is used for cementing losses (Portland)
•Commercial blends with silica flour are available from cement manufacturers:
Dyckerhoff (DE)
Italcementi (IT)
HT CEMENT (2 OF 2)
•The pervious cement formulation with silica flour has been used for decades
in geothermal drilling around the world and also the use of perlite to reduce
the density and plug small fissures.
•It is common practice to add mica flakes to the cement slurry in the mixing
tank as a loss of circulation material (LCM) to block any leaks from the well.
•Some cementing companies are also adding filtrate reducers to their mix,
silica microspheres (very expensive), foamers or friction reducers.
•Another common practice is to mix the last 4 m3 of the slurry going into the
well extra thick to insure that the segment around the casing shoe is good.
TECHNICAL STANDARDS FOR CEMENT TESTING AND OILWELL CEMENT
Standards API:
• API Recommended Practice 10B Recommended Practice for Testing Well
• Cements API Specification 10A – Specification for Cements and Materials
for Well Cementing
NOTE:
At Aluto Langano there is a well equipped cement testing laboratory with the
latest equipment that confirms to the API standards.
SEE company catalogs for the testing equipment:

http://www.ofite.com/products/cement-testing
http://www.fann.com/fann/products/oil-well-cement-testing/owcement-testing.page
http://www.chandlerengineering.com/Products/OilWellCementing/index.aspx
http://pdf.directindustry.com/pdf/rigchina-group-company/rigchina-hthp-
consistermeter-single-cell-model-rchcm-8020-to-condition-cement-slurries-as-
specified-within-api-specification-10/39431-523755.html
CEMENT TESTING – CEMENT LAB
Types of testing, using actual material for the cement job and even the water source:
• Density of cement slurry (g/cm3).
The density is measured by a mud balace. It is either with simple lid or has a pressurized lid
that compresses any air bubbles (TruWate – type) to provide a more accurated density
reading.
• Determination of water requirements and cement yield (L/100kg dry cement).
Based on the cement mix the water requirements and yield can be calculated based on the
density or it can be measured directly in the laboratory. It is suggested that the most reliable
results are made by direct lab mearsurements. The reulsts show how much water and dry
materials are requied to prepare a certain volume of slurry – the yield.
• Thickening time test.
A temperature bomb (HPHT consistometer) with a stirrer whose torque is measured (Bc) vs.
time to see when the cement becomes too thick for pumping. The „temperture ramp“ is
ajusted to simulate the pumping time and bottom hole circulation temperature (BHCT).
• Viscosity.
Determined with a rotating viscosimeter at two speeds. Also by a Marsh funnel.
• Fluid loss.
Determined with a filter press. (ml/30 min)
• Compressive strength.
Ultrasonic Cement Testing
SLURRY DENSITY, WATER REQUIREMENTS AND THE YIELD (SLURRY VOLUME)
Ref.:DDH table I6
PORTLAND CEMENT AND 0.2% RETARDER (1 OF 3)
CEMENT STRENGTH RETROGRESSION
Test @ 150°C and 105 bar

600
Compressive strength (kg/cm2)
500
400
Portland cement + silica flour
300
200
Portland cement
100
0
0 5 10 15 20 25 30
Curing time (days)

Ref. Italian paper
REFERENCES
• GEOTHERMAL WELL CEMENTING, Hagen Hole (2008)

https://pangea.stanford.edu/ERE/pdf/IGAstandard/ISS/2008Croatia/Hole0
6.pdf
• GEOTHERMAL WELL CEMENTING, MATERIALS AND PLACEMENT
TECHNIQUES, Evans Kiprotich Bett (UNU-GTP 2010)
http://www.os.is/gogn/unu-gtp-report/UNU-GTP-2010-10.pdf
• SLURRIES FOR GEOTHERMAL WELLS CEMENTINGS, Nediljka GAURINA
(1994)
http://rgnzborad.rgn.hr/6_CEMENT_SLURRIES_FOR_GEOTHERMAL_WELLS
.pdf
CASING TOOLS FOR CEMENTING
•Buttress threaded cementing head w/ valve. Plug container for releasing

rubber wipers.
•Casing shoe - float shoe (w. non-return valve).
•Float collar for inner-string cementing (w. non-return valve). Stab-in adapter
on the end of the drill pipes for inner string cementing.
•Casing centralizers. Leaf spring type in open hole or rigid in casing/casing
annulus.
•2-stage cementing collar, for long casing strings.
Required for casing strings longer than ~1100 m as the high pressure fractures
the formation.
CEMENT BOND LOGS (CBL)
After cementing the casing the following questions will arise:

Where is the top of cement (TOC), if the cement does not reach the surface - no
returns?
Has the cement become hard?
Is the cement everywhere around the casing?
Is the casing bonded to the casing and formation?
These questions can be answered in part by running a Cement Bond Log
(CBL).
Ref. Benedikt Steingrímsson
USE OF CBL-LOGS IN ICELAND
Determine the cement bond to the

casing and the rate at which the
cement behind the casing sets.
Determine the top of cement if

cement did not reach surface.
Determine if there are water pockets

in the annulus behind the casing (no
Cement Bond)
Can assist in casing failure analysis.
Quality control to demonstrate that

the job was sucsessful.
Ref. B. Steingrímsson

Geothermal Drilling and Well Design (SE-830-DR2) : Cementing

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GEOTHERMAL DRILLING AND WELL DESIGN

API markings are stenciled on every pipe

•J-55 One bright green band

1. Inspect well casing in stock:

•Buttress threads are most common.

40 -One every third joint

30 Selection – two types:

• Calculate the annulus volume to be cemented, preferably from caliper logs

For ancor casing ~300 m For production casing ~900m

Ref. Björn M. Sveinbjörnsson, Sverrir Thorhallsson

Fluid gain (inflow)

Fluid loss zones

Depth Volume Total volume DDH Pumping time

Depth Volume Total volume

Inner string cementing

If a loss zone is at the top

Cementing Loss Zones

Top of cement (TOC)

•Normal cement exhibits strength retrogression.

•Typical composition of HT cement mix by contractor:

•Neat cement is used for cementing losses (Portland)

SEE company catalogs for the testing equipment:

Test @ 150°C and 105 bar

Curing time (days)

• GEOTHERMAL WELL CEMENTING, Hagen Hole (2008)

•Buttress threaded cementing head w/ valve. Plug container for releasing

After cementing the casing the following questions will arise:

Determine the cement bond to the

Determine the top of cement if

Determine if there are water pockets

Can assist in casing failure analysis.

Quality control to demonstrate that

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