Primary Cementing

WATHIK MOHAMMAD ALHASHIMI, P.ENG

 PRIMARY CEMENTING
Sealing annular space: Wellbore-Casing
❖ Isolate/contain productive/problematic /weak intervals

❖ Support & protect Casing Strings

Well Casing Strings

o Conductor

o Surface
o Intermediate
o Production
o Liners
o Tie-back
 Conductor Casing
Purpose:
o Confines circulating fluids

o Prevents washing out under rig

o Provides elevation for flow nipple and bell nipple

o Ground level support/protection.

Characteristics:
(Set from 40 to 1500 feet)
Casing is large ; OD 16”- 60”
Surface Hole may eroded severely.
May Pumped out easily (to be tied down to rg floor).

Considerations
Casing Attachments
Cement Properties
Pumping Rates
Slurry Volumes (Excess)
Unique Placement Considerations
 SURFACE CASING
Purpose
➢ Protect underground water sands.
➢ Case unconsolidated formations.
➢ Primary pressure control (BOP nippled-up)
➢ Supports subsequent casings.
➢ Case off loss circulation zones.
Characteristics
❖ (Set depth:40 - 4500’)

❖ Stick in unconsolidated formations.

❖ Circulation Loss.

❖ Guide shoe GS)/Float shoe(FS)/FC Float collar(FC)/Differential Float Collar (DFC).

Considerations:
o Casing sizes
o Casing Attachments
o Cement Properties
o Pumping Rates
o Slurry Volumes (Excess)
o Unique Placement Considerations
Remarks:
❑ Inner cementin technique {Thru Drill Pipe(DP)}
❑ Bottom &Top Cement plugs (For displacement)
❑ Bottom casing joints centralized/thread locked (for drill-out)
 INTERMEDIATE CASING
Purpose:
➢ Cases off loss circulation zones, water flows, etc.
➢ Isolates salt/Fault/HPHT/ sections

➢ Protects open hole from subsequent increase in mud weight

➢ Prevents flow from high-pressure zones if mud weight must be reduced

➢ BOP installed
➢ Supports subsequent casings

Characteristics:
❖ Setting depth varies with hole conditions
❖ Guide shoe, or float shoe, and float collar commonly used.

❖ Cement volumes usually largest in well.

❖ Often cemented in stages.

❖ Prolonged drilling may cause damage.
Remarks
❑ Stage Collar {Differential Valve(DV)}
 MULTIPLE STAGE CEMENTING TOOL

Why?
o Potential Casing Collapse (Cement Slurry Hydrostatic Pressure )
o Cover Weak Zones (First Stage )
o Deep Surface Holes (Cement to Surface)
 PRODUCTION CASING
Purpose:
➢ Conduit for Completion String

➢ Provides pressure control

➢ Cover intermediate casing

Characteristics:
❖ Setting depth through producing zone-Total Depth(TD)

❖ Common sizes 4 ½ “-95/8”casing

❖ Conditioned Drilling
❖ Cemented back (200”) into intermediate casing
❖ Good cement job for completion.
❖ May be run as liner (?)
DRILLING LINER
Short String of casing pipe having Liner hanger on its top, Run and suspended( 200’) in the
previous casing set
Purpose
➢ Casing sizes

➢ Casing Attachments

➢ Cement Properties

➢ Pumping Rates

➢ Slurry Volumes (Excess)

➢ Unique Placement Considerations

Remarks
➢ LH Top (TOL) may be fitted with packer (Seal off TOL upon cementing)
• Set by surface manipulation (rotating to disengage J-slot and • Preferred if one liner is already in well
slacking off weight to engage slips) • Designed to prevent premature setting of slips going into well
• To unseat, drillpipe picked up and rotated to get J-slot to • Hydraulic pressure required to set slips (unseat by picking up
“running in” position drillpipe)
• Most widely used • Designs vary, some tools can also be set with ball plug or
rotation.
• Not as widely used as mechanical set hangers
Setting-tool Shear Screws
Releasing-nut Threads
Sizing Ring Tie-back Receptacle

Pack-off Element Releasing-nut Threads

Plain-Action Setting Collar

Cone

Slips
Upper-Tapered Cones
Automatic J-Latch Cage Upper Slips

Drag Springs
Lower-Tapered Cones
Lower Slips

Mechanical-Set Liner Hanger Hydraulic-Set Liner Hanger

LH Packer (on top of LH optional (weight/hydraulically set)
 LH Plug during Cement job

1. RIH with liner string,

2. Continue RIH with DP to LH setting depth,
3. Liner circulated (Hole/mud conditioning),
4. Set LH,
5. Drop Dart
6. Pump Cement slurry thru cement head
7. Dart displaced (Capacity of running string)
8. Dart Latches into cement plug.
9. Cement plug bumps on FC.
10. Pressure running string (End of displacement)
11. Set LH packer (by weight or hydraulically).
12. Pressure test annulus.
 TIE-BACK CASING
1. Tie- Back stinger run on designed string of casing pipes to TOL,
2. Tie-Back string circulated for condition hole/mud,
3. Calculated volume of Cement slurry pumped,
4. Displacement plug dropped,
5. Cement slurry displace by drilling fluid to LOT,
6. Tie-Back string (tie-back stinger) stung (Lowered) into TOL,
7. Tie-Back string pressure tested for integrity
Purpose:
❖ Extend Production casing to surface (pressure control)

❖ Serves as production casing.

❖ Covers worn/damaged sections of intermediate casing.

❖ Inadequate liner cement job (Bad cement).

 API CEMENT CLASSIFICATION

 API Classes A, G, H, and C (high-early-strength cement).

 API Classes D, E, and F are intended for high-temperature applications (Contain
organic retarder may not be compatible site materials).
 BULK VS ABSOLUTE (YIELD)

1CuFt of dry cement

Pour water into cement

1CuFt slurry
0.66 CuFt of water

To obtain One CuFt of slurry requires One CuFt

of Bulk Cement mixed with 0.66 CuFt of Water

Yield function of slurry weight,

Slurry Volume/Cement bulk volume = Yield.
 CEMENT CALCULATIONS

Given:
1. Diameter of open hole (Bit Size/CL)= OD
2. Casing Shoe setting depth (FT)
3. Float Collar setting Depth (FT)
VOLUME[CuFt]
4. Previous Casing setting depth (Ft) = Sacks
5. Previous Casing ID.
YIELD [CuFt/sacks]
6. New Casing OD
7. New Casing ID
8. Calculate the annular capacity of OH
9. Calculate the annular capacity in-between the two strings of casing and rat hole.
10. Calculate the Tail-in (Rat hole volume required to be left inside new casing)
11. Add 5 + 6+ 7 = total volume of Slurry required for the job
12. Divide 8 / Y Volume of bulk cement required ( Cu Ft-English system)
13. Multiply 9 x Water Ratio = Volume of mix water required for the job.
14. Displacement volume = the volume of the new casing down to Float Collar (FC) FC

SHOE
Lead volume : 240.2 cuft EXAMPLE
Tail volume : 367.05 cuft
: + 18.2 cuft
385.35 cuft
Lead Slurry:- Class G + 6% D20 at 13.9 ppg
Tail Slurry Neat:- Class G at 15.8 ppg
Cement volume Lead: 240.2 cuft = 145.2 sacks
Yield 1.655 cuft/sack
Cement Volume Tail 385.25 cuft = 335.0 sacks
Yield 1.15 cuft/sack
Lead mix water 145sx x 8.56 gal/sx = 1241.2 gal = 29.55 bbls
42 gal/bbl
Tail mix water 335sx x 4.97 gal/sx = 1664.95 gal = 39.64 bbls
42 gal/bbl
Total mix water = 69.19 bbls
20% safety margin : 66.19 bbl x 20/100 = 13.84 bbls
No water ahead, behind, CW, spacer 0 bbls
Priming, washing u= 20 bbls
Total water needed =103 bbls
➢ Solid Additives
➢ Calculated as % by weight of dry cement.
o Except: Salt
o Small amounts will not affect calculation
Liquid Additives
➢ Calculated as gallons of additives per sack of bulk cement
➢ Subtract total amount of liquid additives from amount of mix fluid to have real amount of mix water.

Lead:-6% Bentonite BWOC (145 sks)

Tail:-0.2 gal/sack of Dispersant (335 sks)

Solid Additives

145 sacks x 94 lbs/sack x 6/100 = 817.8 lbs

Liquid Additives
335 sacks x 0.2 gal/sack= 67 gal

Note : Mix water of tail slurry will change

Mix fluid: 335sx x 4.97 gal/sk =1664.95 gal

Mix water= Mix fluid - liquid additives

1664.95 gal - 67 gal = 38.1 bbl

42 gal/bbl
 DISPLACEMENT

➢ To FLOAT COLLAR
Remarks
➢ 1. STAB-IN CEMENTING:

o Displacement to 10-15’ before stab-in shoe

o Check returns - OK - pull out and circulate

➢ 2. GUIDE SHOE:

o Displace to 20-30’ before shoe

➢ Do NOT OVERDISPLACE
 ESTIMATED JOB TIME

MIXING TIME + DISPLACEMENT TIME+10 MINUTES (DROP PLUGS)= ESTIMATION

OF JOB TIME +1 HOUR (SAFETY) = MINIMUM THICKENING TIME
❖ Mixing time + Displacement time + Plugs mixing time:
Lead 42.8 BBls: 4 bpm:-10.5 mins 11mins
Tail 68.6 BBls : 8bpm:- 8.5 mins 9 mins
Displacement:- 4510ft x 0.0361 bbl/ft = 162.8 bbl @
12 bpm 13.6 mins 14 mins
Plugs Dropping :10 mins
Total :44 mins
❖ Allow safe margin :- add 1 hr. (cement still pumpable at end of displacement).
❖ T0toal:- 1hrs 44 mins
EXAMPLES - EXAMPLE 1
Calculate : Slurry Volumes, Cement Volumes,
Mix Water, Additives, Displacement
Job Time
Well Data: 9 5/8” 53.5 lb./ft casing, shoe at 9800’,
collar at 9760’, OH 12 1/4” + 25% excess (No CL), 13 3/8" , 68 lbs/ft
previous casing 13 3/8” 68 lb./ft at 2900’
Slurries: Lead: 5 bpm 9300’ - surface 1
Class “G” @ 12.8 ppg
12% BWOC Bentonite
0.3% BWOC D13
Tail: 3 bpm 9800’ - 9300’
Class “G” Neat @ 15.8 ppg
0.05% BWOC D28 2900'
0.5% BWOC D65
Displacement: 8 bpm 2 9 5/8", 53.5 lbs/ft
❖ Capacities 2
12 1/4" OH
o CAS/CAS : 0.3354 cuft/ft 9300'
o CAS OH : 0.3132 cuft/ft 9760'
3
4 3
o CAS : 0.3973 cuft/ft , 0.0708 bbl/ft 9800'
 Lead Tail
(1) 2900ft x 0.3354 cuft/ft = 972.7 cuft (3) 9800ft - 9300ft x 0.3132 cuft/ft = 156.cuft
(2) 9300ft - 2900ft x 0.3132 = 2004 cuft (4) 40ft x 0.3973 cuft/ft = 15.9 cuft

Excess = 2004 cuft x 0.25 = 501 cuft Excess 156.6 cuft x 0.25 = 39.2 cuft
Total = 3477 cuft Total = 211.7 cuft

2. Yield
Handbook 700.013 2.165 cuft/sk (lead)
700.006 1.15 cuft/sk (tail)

3. Cement
Lead : 3477 cuft = 1606 sacks
2.165 cuft/sk
Tail : 211.7 cuft = 184 sacks
1.15 cuft/sk
4. Mix Fluid
Lead : 1606sk x 12.15 gals/sk = 464.5 bbls
42 gal/bbl
Tail : 184sk x 4.97 gals/sk = 21.8 bbls
42 gal/bbl
5. Additives
Lead : D20 : 1606sk x 94lbs/sk x 0.12 = 18116 lbs
D13 : 1606sk x 94lbs/sk x 0.003 = 453 lbs
Tail : D28 : 184sk x 94lbs/sk x 0.0005 = 8.6 lbs
D65 : 184sk x 94lbs/sk x 0.005 = 86 lbs 6. Displacement
9760ft x 0.0708 bbl/ft = 691 bbls

7. Job Thickening Time

Lead 3477 cuft = 124 min
5.6146 cuft/bbl x 5 bpm
Tail : 211.7 cuft = 13 min
5.6146 cuft/bbl x 3 bpm
Displacement: 691 bbls = 86 min
8 bpm
Drop Plugs= 10 min
Safety = 60 min
298 min
Minimum TT :- 4 hrs 53 min
EXAMPLE 2
Data :
Casing:9 5/8”, 53.5 lbs/ft, 8600’
7”, 29 lbs/ft, 14300’ 9 5/8" , 53.5 lbs/ft
Float collar - 14230’ 1
Open hole: 8 1/2”
Section from 10200’ - 10800’ : 9”
Cement
Lead : - Top surface @ 7 bpm
- “G” at 13.5 ppg
- 0.05 gals/sk D109 8600'
- 0.1 gals/sk D80 8.5" OH
- 8% BWOC - D20 2 7", 29 lbs/ft
Tail : - 250 sacks @ 5 bpm 2 10200'
3 9" OH
- Class “G” @ 15.7 ppg 10800'
- 30% BWOC D66 44
- 0.1 gals/sk D81 3 11507'
- 0.5 gals/sk D603 14230'
Calculate :Slurry Volume, Cement Volume, Mix water &Additives 5
6
Displacement @ 7 bpm Job Time 14300'
Capacities
o CAS/CAS: 0.1301 cuft/ft CAS OH : 0.1268 cuft/ft
o CAS/OHX: 0.1745 cuft/ft CAS : 0.2086 cuft/ft , 0.0371 bbl/ft
1. Volumes
Tail : Yield is 1.475 cuft/sk
250 sacks
---> 250 x 1.475 = 368.75 cuft
Volume (5) + (6) = 368.75 cuft
(6) = 70 x 0.2086 = 14.6 cuft
(5) = 368.75 - 14.6 = 354.15 cuft
Height in annulus 354.15 cuft. = 2793’
0.1268 cuft/ft
14300 - 2793' = 11, 507'
Lead: Surface - 11, 507'
(1) 8600 x 0.1301 = 1118.86 cuft
(2) (10200 - 8600) x 0.1268 = 202.88 cuft
(3) (10800 - 10200) x 0.1745 = 104.70 cuft
(4) (11507 - 10800) x 0.1268 = 89.64 cuft
Total Lead = 1516.1 cu ft
2. Cement sacks
Lead : Handbook : 13.5 ppg
Class "G”+ 8% D20
Yield = 1.825 cuft/Sk
1516.1 cuft = 830.7 = 831 sacks
1.825 cuft/sack
Tail : 250 sacks

3. Mix fluid
Lead : 831sk x 9.76 gal/s = 193.1 bbls
42 gal/bbl
Tail : 250 sks x 6.15 gals/sk = 36.6 bbls
42 gal/bbl
4. Additives
5.
Lead:D20: 831 sks x 94 x 0.08 = 6249 lbs
D109 : 831 sks x 0.05 gals/sk = 41.5 gals
D80 : 831 sks x 0.1 gals/sk = 83.1 gals
Total fluid = 124.6 gals
Tail: D66 : 250 sks x 94 x 0.3 = 7050 lbs
D81 : 250 sks x 0.1 gals/sk = 25 gals
D603: 250 sks x 0.5 gals/sk = 125 gals
Total fluid = 150 gals
5. Mix water
Lead: 193.bbls - 124.6gal = 190.1 bbls
42gal/bbl
Tail: 36.6bbls - 150gal = 33.0 bbls
42gal/bbl
6. Displacement
14230ft' x 0.0371 bbl/ft = 527.9 bbl

7. Job Thickening Time

Lead : 270 bbls: 7 bpm = 38.5 min
Tail : 65.7 bbls: 5 bpm = 13.1min
Plugs: =10min
Displacement 527.9 bbls: 7 bpm = 75min
Safety Margin:= 60 min
TT is 3 hrs.16 min
PRESSURES
Example
Tail Slurry at 15.8 ppg
Top of Tail at 9300 Ft
Lead slurry at 12.8 ppg to surface
Displace with 11.5 ppg Mud
Find differential pressure at end of Job 13 3/8" , 68 lbs/ft

Hydrostatic 1
Casing Hydrostatic
Pmud = 11.5 x 9760 x 0.052
Pmud = 5836 psi
Annular Hydrostatic
Tail Slurry Hydrostatic 2900'
PTail = 15.8 x(9760 - 9300)x 0.052
PTail = 378 psi 2 9 5/8", 53.5 lbs/ft
2
Lead Slurry Hydrostatic 12 1/4" OH
PLead = 12.8 x 9300 x 0.052 9300'
PLead = 6190 psi 9760'
Differential pressure 3
4 3
9800'
PDiff= Annular Hyd. - Tubing Hyd.
 = (6190 +378) - 5836
PDiff = 732 psi = Surface pump pressure
 LONG CASING STRING CEMENTING

Primary Cement Job

9 5/8” Csg , 40 lbs/ft
Shoe @ 9980’ - Collar @ 9900’
Tail slurry @ 15.8 ppg to 9480’
Lead slurry @ 12.8 ppg to 2100’ 13 3/8" , 77 lbs/ft
Mud @ 11.3 ppg
50 Bbls Chemical Wash ahead. 1
Previous Casing 2100’ Chemical wash @ 8.4 ppg
13 3/8“ Csg ,77 lbs/ft
Shoe @ 3150’ Lead Slurry @ 12.8 ppg
12 1/4” OH - Assume 10% Excess.
3150'
Find Lead, Tail and Displacement Volumes required.
9 5/8", 40 lbs/ft
Calculate Differential pressure at the end of the job 2
2
(ignore friction). 12 1/4" OH
9480'
Capacities
9900'
Csg/OH Ann = 0.0558 bbls/ft 3
4 3 Tail Slurry @ 15.8 ppg
Csg/Csg Ann = 0.0564 bbls/ft 9980'

9 5/8” Csg cap (40 #/ft) = 0.0758 bbls/ft

Tail volume = Vol of Shoe track + Vol outside csg (with XS)
= 0.0758 x (9980 - 9900 + 0.0558 x (9980 - 9480) x 1.10
= 6.06 + 30.69 = 36.75 = 37 Bbl = 206.3 cuft
Lead volume = Vol in Csg/OH Ann (with XS)+ Vol in Csg/Csg Ann
= 0.0558 x (9480 - 3150) x 1.10 + 0.0564 x (3150 - 2100)
= 388.53 + 59.22 = 447.75 = 448 Bbls = 2514.04 cuft

Displacement volume = Csg Vol to float collar = 0.0758 x 9900 = 750 Bbls

Differential pressure at end of Job = Hydrostatic of Lead and tail cement columns + Hydrostatic
of wash + Hydrostatic of remaining mud in annulus LESS Hydrostatic of displacing fluid +
Hydrostatic of Tail cement in shoe joint

Height of Chemical wash in Csg/Csg Ann= 50 / 0.0564= 886 ft

Height of Tail = 9980 - 9480 = 500 ft
Height of Lead = 9480 - 2100 = 7380 ft
Height of Chem Wash = 886 ft

Remainder is Mud behind casing = 9900 - (420 + 7380 + 886) = 1214 ft

Annulus hydrostatic= total of Cement slurries + Chem Wash + Mud :
= 15.8 x 500 x 0.052 ( =Tail slurry)+ 12.8 x 7380 x 0.052 ( = Lead slurry)
+ 8.4 x 886 x 0.052 (= Chem Wash)+ 11.3 x 1214 x 0.052 ( Mud in Ann)
= 410 + 4912 + 387 + 713= 6423 psi

Hydrostatic inside casing :

= 11.3 x 9900 x 0.052 (=Mud, disp.)+ 15.8 x 80 x 0.052 (=Tail slurry)
= 5817 + 65.7 = 5883 psi

Differential pressure at float collar :

= psi outside csg - psi inside csg
= 6423 – 5883 = 540 psi
Thank you