SPE 123085

Water-Gas Migration Control and Mechanical Properties Comparison With a

Quick-Setting Slurry Design (QSSD) to Be Applied in a Production
Cementing Job for Ecuador
H.B. Ramirez, A. Santra, C. Martinez, Halliburton; X. Ramos, Petroamazonas

Copyright 2009, Society of Petroleum Engineers

This paper was prepared for presentation at the 2009 SPE Latin American and Caribbean Petroleum Engineering Conference held in Cartagena, Colombia, 31 May–3 June 2009.

This paper was selected for presentation by an SPE 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 and are subject to correction by the author(s). The material does not necessarily reflect any position of the Society of Petroleum Engineers, its
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Abstract
A slurry design based on Sorel cement technology with a median particle size of 5 to 10 microns has been optimized without
using Portland cement. This mechanically modified slurry with quick-setting technology is designed to withstand the
operational changes that may play a crucial role in the performance of the cement sheath once the well is drilled, completed,
and in production. Two additional mechanically modified slurries were designed using local Class “G” cement for
comparison.
The control of gas migration can be enhanced by obtaining a transition time value of less than 30 minutes. Transition time
is defined as the length of time it takes for the static gel strength (SGS) to change from 100 lb/100 ft2 to 500 lb/100 ft2. The
SGS tests were performed under simulated downhole pressure and temperature conditions. A value of 10 minutes for
transition time was obtained. SGS tests were carried out with a static gel strength measuring device (SGSMD). It is important
to mention that the zero gel time (ZGT), is defined as the amount of time the slurry can remain static after placement time
and still transfer almost full hydrostatic-pressure from fluids before reaching an SGS of 100 lb/100 ft2; it can also be adjusted
in regards to the cementing job.
The mechanical properties of this quick-setting slurry design (QSSD) were comparable and in some aspects were
improved. The results included a Young’s modulus around 5E+05-psi, Poisson ratio of 0.23, and a tensile strength of 250-psi.
The bottomhole circulating temperature (BHCT) was 172°F and bottomhole static temperature (BHST) at MD was 208°F.
Cylindrical samples were cured at 208°F and 2,000-psi for seven days and were used for measurement of mechanical
properties.
This slurry design was developed for Ecuador to solve three major problems on production liners:
• Water-gas migration throughout the annulus
• Long waiting-on-cement time (WOC) to develop compressive strength
• Improvement of the mechanical properties to minimize the effect of failure mechanisms on the cement (cracking,
debonding, shear failure) that can result in poor cement bond logs and remedial cementing jobs

Introduction
Issues associated with water and gas influx while drilling have faced operators creating challenges of safe and efficient
drilling, optimum influx control, and long-term well integrity in almost every area of the world. Many companies, research
institutions, and universities have been studying water and gas influx controllers and developed chemicals and mechanical
products that could overcome these problems (Zaitoun, A. et al.1992; Griffith, J. 1996).
These challenges can substantially impact well economics by adding cost for lost rig time and extra materials. These
conditions can result in poor primary cementing that potentially jeopardizing well integrity above the producing reservoir.
Cement bond logs (CBL) have resulted in poor amplitude in thousands of wells with water/gas influx. Many of these negative
conditions that later affect the production can be prevented during drilling by the use of this QSSD which provides essentially
a short value for transition time and optimizes the mechanical properties to better withstand future operational charges (Ravi,
K. et al. 2002; Ravi, K. et al. 2008).
The purpose of this paper is to describe the advantages this new material, its enhanced mechanical properties, and
possible applications. This QSSD is based on a rigid-setting-fluid (RSF) system used to minimize lost circulation while
drilling a pay zone with oil/water-based mud, allowing the operator to complete a prolific well rather than having to abandon
the prospect (Tirado et.al. 2008). RSF has been developed using Sorel cement based technology. Advantages of Sorel cement
2 SPE 123085

when applied downhole are: low waiting on cement (WOC), Right angle set, lean rheology to access narrow annulus, and
lower thermal conductivity to name a few. However, in general Sorel cement based systems are often expensive and
mechanically brittle in nature. In this work we have tried to address the cost by incorporating inert low cost filler material (for
example Fly Ash) while the mechanical properties were optimized by incorporating additives like elastomers and fibers.
Understanding which system is suitable for an application can be confusing because of the many systems and chemicals
available. Differences in terminology and interpretations of the performance of certain chemicals can add to the confusion.
When more than one method is available to solve a problem, a particular method’s reliability, pricing, and convenience as
well as the experience of the user, can determine the method of choice.
There are other techniques to minimize water and gas influx, such as conformance while drilling (CWD) which has been
applied in only a relatively small number of wells (Sweatman, R. 1999; Soliman, M. et al. 2000). The use of this QSSD
technology helps minimize alternative interventions and also helps reduce cost.
The cost of RSF technology has limited its application so far, but the QSSD that is proposed in this paper could solve this
problem without sacrificing good performance. Substantial reduction in rig-time due to shortened WOC time of the proposed
system may offset the cost of the system.
Initial lab tests show encouraging trends toward a favorable impact on drilling operations. Although a chemical can
perform well under reservoir conditions in a laboratory test, successful performance during an operation cannot be
guaranteed. A primary reason for the relatively low rate of success in water and gas influx control is the use of an incorrect
candidate-selection process. Several authors have suggested procedures and guidelines for water and gas-influx control
(Sutton, D. and Sabins, F. 1984; Santra, A. et al. 2007).

Experimental
All the slurries were mixed in accordance to API RP 10B procedure. The only exception occurs when fibers are used. Fiber
integrity is thought to be susceptible to the high shear induced by the laboratory blender. Therefore, they are added to the
slurry after it has already been mixed at a blender speed no greater than 4,000 RPM.
An ultrasonic cement analyzer test is performed at a downhole pressure and temperature which should end at the bottom
hole static conditions (sources could include temperature simulations with specialized software or API scheduling). The test
is monitored until a plateau in the transient time signal has been reached, then the slurry is considered to be at or near
ultimate strength. This procedure helps ensure that samples tested for mechanical properties have reached stable properties,
as would be experienced in downhole conditions.
Simultaneously to this test, samples are placed in an autoclave-curing chamber under similar conditions (usually with a
limit on pressure) and cured under the same temperature and pressure. As much time as reasonably possible is used when
relieving the curing-chamber pressure and temperature. This is an attempt to mitigate any sample deterioration that may
occur caused by changes in the loading condition. Typically, a linear ramp is used over a 12-hr period during the night.
The compressive strength is defined as the maximum resistance of a material to an axial force. Beyond the limit of the
compressive strength, the material may become irreversibly deformed and no longer provides structural support and/or zonal
isolation.
Thickening time measurements were carried out using a HPHT consistometer. Thickening time refers to the time required
for the composition to achieve 70 Bc after contacting of the slurry components. At about 70 Bc, the slurry undergoes a
conversion from a pumpable fluid state to a non-pumpable paste.
The SGS test determines the gel-strength development characteristics of a static fluid under temperature and pressure
conditions. The SGSMD can be used to perform this test. This equipment measures the shear resistance of a slurry under
downhole temperature and pressure while the slurry remains essentially static. The shear resistance is correlated to the SGS
(units are lb/100 ft2) and a plot of SGS development is made as a function of time.
All samples, when removed from the curing chamber and before testing, are kept in a moist environment to prevent the
samples from drying out and cracking. Such environments can include storing in humidity-controlled cabinets. Each sample
is then prepared in accordance to ASTM D 4543-04, which specifies requirements on the samples dimensions, surface
smoothness, and parallel testing surfaces. Prepared samples are used to determine the mechanical properties of the slurry
design from the tests described below.
Unconfined compression testing is used to determine material characteristics, such as Young’s modulus and Poisson’s
ratio. The testing apparatus is a 500,000-lb load frame using axial and radial extensometers. Compressive-testing follows
ASTM D 2938-95.
Young’s modulus, also termed elastic modulus, λ, is indicative of the elasticity of a material or the tendency of the
material to reversibly or to resiliently deform under an applied force. Poisson’s Ratio refers to the ratio of transverse-
contraction strain to longitudinal strain in the direction of stretching force.
Young’s modulus and Poisson’s ratio are mathematically determined by following ASTM D 3148-02. An average
modulus of a linear portion of the stress-strain curve is used to obtain this value. Also, the ratio of radial-strain-to-axial-strain
is averaged on the same portion of the strain curves and results in a calculated Poisson’s ratio.
Confined compression testing is generally used to characterize a materials shear failure. Confined testing is performed
according to ASTM D 2664-04 and is conducted in a similar manner as unconfined compressional tests, but with the addition
SPE 123085

of a hydraulic fluid applying stress on the curved sides of the sample, which is separated from the fluid by a rubber sleeve.
These tests are run in a drained condition. Fluid contained with the sample is allowed to escape to the atmosphere.
The confined pressure raises the stress state of the material and the net stress to failure is often a function of the confining
load. Statistical averages of sample failures at two confining pressures and the unconfined tests are used to calculate the
Mohr-Coulomb shear-failure criteria consisting of cohesion and friction angle.
Tensile strength is defined as the maximum longitudinal stress a material can withstand before tearing. Typically, the
tensile strength is envisioned as the forces required to pull apart the cement composition, while the compressive strength can
be envisioned as the force required to crush the cement composition. Tensile strength can be determined by the Brazilian
tensile-strength test where a line-load is applied to a 1-in. wide by 2-in. diameter sample, giving an indirect measurement of
this property. The testing procedures are in accordance with ASTM D 3967-05. “Dog bone” tests can also be performed,
resulting in a direct measurement of tensile strength.

Results and Discussion

Basic requirements for QSSD. This slurry was designed to initially meet the basic requirements, such as free water, settling,
fluid loss, thickening time, and compressive strength. The results are summarized in Table 1. The tests were performed at a
BHCT of 172°F.

Table 1—Results for Basic Requirements on QSSD.

Density, Free Settling Fluid Thickening Compressive

(lb/gal) Water, (cc) Loss, Time, strength after
(cc) (cc) (hr:min) 24hrs, (psi)
QSSD 16.50 0 Nil 18 02:20 1,087

Free water is an indicator of settling and the static stability of the slurry. Zero to trace-free water indicates a stable slurry.
Fluid loss is a measure of the amount of water that can be lost from the slurry to the formation. It is desirable to limit fluid
loss to inhibit alteration of the desired hydration of the cement and performance properties. Additionally, a loss of fluid will
result in a more viscous slurry, which in turn can affect the ability to properly place the slurry in the wellbore. Settling data is
collected to investigate the rheological behavior of the slurry. Generally, solid particles in slurry tend to settle towards the
lower portion over time. No settling indicates that the slurry is able to suspend those solid particles over time. The above
results demonstrate that QSSD can be designed to control the basic requirements, which could also be controlled with the
Portland cements.

Thickening Time. A desirable thickening time allows the composition to remain pumpable without gelling during downhole
placement before setting. Fig. 1 shows the right-angle-set characteristic for this fluid. The solid green curve is the fluid
consistency. The solid blue curve is the BHCT control in the consistometer; the test involves a simulated batch mixing time
of 45 min, then 45 min later the BHCT (172°F) is reached and the right-angle-set with 70 Bc is reached at 2:20 hr.

Waiting On Cement. A more rapid onset of compressive strength development, WOC time, when compared to an otherwise
similar composition comprising a Portland cement, is obtained. WOC time refers to the amount of time for cement to develop
compressive strength after placement as the cement transitions from a fluid to a solid form. Typically, the time to reach 50-
psi and 500-psi compressive strength after placement is measured and recorded and is referred to as WOC50 and WOC500,
respectively. At WOC500, the cement exhibits a compressive strength where the majority of drilling-rig operations can
recommence.
Two mechanically modified Portland cement (MMPC) slurry designs were compared versus the QSSD regarding
compressive-strength at the BHST calculated at the top of the liner (189°F); the results are presented in Table 2. Altogether,
Figs. 2-4 show that the WOC time for the QSSD could be at least 50% less than either MMPC-1 or MMPC-2 to reinitiate
drilling-rig operation or completion as discussed above.
4 SPE 123085

Fig. 1—Thickening time chart for the QSSD.

Table 2—WOC Comparisons for Three 16.50-lb/gal Slurry Designs.

Slurry Design, 16.50 lb/gal WOC50 (hr:min) WOC500 (hr:min)

MMPC-1 21:42 24:05
2 0:52 13:48
QSSD 0:16 7:23

Fig. 2—Compressive-strength result for 16.50-lb/gal MMPC-1 slurry design.

SPE 123085

Fig. 3—Compressive-strength result for 16.50-lb/gal MMPC-2 slurry design.

Fig. 4—Compressive-strength result for 16.50-lb/gal QSSD.

Static Gel Strength. The SGS tests were performed using the static gel strength measurement device. Zero gel time and
transition time can be obtained from the SGS chart. Transition time reflects the ability of the slurry to minimize water/gas
influx while the hydrostatic-pressure applied from the slurry will decrease and could allow this influx through the cement.
The desired range of transit time is between 0 and 30 min. Consequently, a slurry with a longer zero gel time and shorter
transition time more effectively controls water/gas influx, which helps limit migration channels in the set slurry sheath. When
the SGS value reaches 500 lb/100 ft2, the fluid no longer transfers full hydrostatic-pressure from the fluid (or the fluids above
it) but has sufficient gel-strength to block the water/gas influx through the slurry.
The SGS chart on this slurry (Fig. 5) meets the accepted range of transition time that was discussed above. The numerical
results are presented in Table 3.
6 SPE 123085

Fig. 5—SGS result for 16.50-lb/gal QSSD.

Table 3—SGS Numerical Results for 16.50 lb/gal QSSD.

ZGT, min TT, min
QSSD

Mechanical-Properties Testing. The mechanical properties of the QSSD were investigated and compared with MMPC-1 and
2 defined before. All cylinders were cured for 7 days at BHST of 208°F and a pressure of 2,000-psi. Compressive strengths,
cohesions, friction angles, Brazilian tensile strengths, Young’s modulus, and Poisson’s ratio were determined. The MP
measurements were performed according to the experimental section and the results are summarized in Table 4.

Table 4—Summary of Mechanical Properties for Three 16.50-lb/gal Slurry Designs.

Brazilian
Slurry Friction Young’s
Compressive Cohesion,* Tensile Poisson’s
Design, Angle, Modulus*
Strength, psi psi Strength, Ratio*
16.50 lb/gal degrees psi
psi
MMPC-1 2,129 660 27.7 205 7.05x105 0.182
1,180 471 19.36 176 4.96x105 0.175
1,519 464 27.88 250 5.06x105 0.231
* Averaged results from unconfined tests.

The results demonstrate that the mechanical properties of the QSSD were comparable with the mechanically modified
Portland cement slurries.

Conclusions
There were several notable advantages of the newly designed QSSD:
• The thickening time and other basic requirements are easily designed for this QSSD in parallel with the Portland-
cement slurries.
• WOC was much shorter for QSSD in comparison with mechanically modified Portland-cement designs.
• As desired, a very short transition time (10 min) and a controlled value for ZGT (57 min) were obtained on the
QSSD without much slurry adjustment. However, it is not the same for the Portland cement based systems tested
(either MMPC-1 or MMPC-2).
• The mechanical properties for the QSSD was comparable to a suitably mechanically modified Portland-cement-
based design.
SPE 123085

Acknowledgements
The authors of this paper thank PetroAmazonas-Ecuador and the management of Halliburton Energy Services for the support
and permission to prepare and present this paper.

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