Intelligent Iron! A Primer On Casing Equipment - Part 3 (Stage Cementing Tools) - LinkedIn

2/8/2021 Intelligent Iron!
A Primer on Casing Equipment - Part 3 (Stage Cementing Tools) | LinkedIn
Try Premium Free

Search
for 1 Month
Intelligent Iron! A Primer on Casing

Equipment - Part 3 (Stage Cementing
Tools)
Published on October 23, 2018
Alfredo Sanchez, P.E., PMP 6 articles Following

CEO at MorphPackers Limited
This article is the third in a series intended to be a primer on casing equipment (aka primary
cementing equipment, PCE). In addition to providing a fundamental and practical
understanding of equipment specifications and selection criteria, I will attempt to persuade
the reader to think differently about PCE - a paradigm shift. I will do this by showing how
PCE can help the well engineer deliver a quality wellbore, on schedule and on budget, while
meeting productivity objectives and protecting the environment.
The series will consist of the following parts:
Part 1: Introduction (click)
Part 2: Float Equipment (click)
Part 3: Stage Cementing Equipment (this article) Messaging
https://www.linkedin.com/pulse/intelligent-iron-primer-casing-equipment-part-3-sanchez-p-e-/ 1/18
2/8/2021 Intelligent Iron! A Primer on Casing Equipment - Part 3 (Stage Cementing Tools) | LinkedIn
Part 4: Casing Centralizers

Search
Try Premium Free
for 1 Month
Part 5: Applications Engineering
Part 6: Quality
Part 7: Other Considerations
While the reader may find Part 1 (first article) less actionable, I do encourage you to go
through it as I believe it will challenge the “Dumb Iron” perception, and set the stage for
further analysis and discussion. More important, I truly hope I am successful at convincing
the reader
Like thatComment
the concept Share
of continuous improvement, certainly applies to PCE selection as
25 · 6 comments
well.
-------------------
PART 3 CONTENT
Introduction
Applications
Common types of multi-stage cementing tools
Equipment specifications
Quality and testing
Applications engineering
Field practices
Closing remarks
INTRODUCTION
The utilization of stage cementing tools in primary cementing applications has increased in
recent years. Stage cementing tools are arguably one of the most complex downhole tools
used in primary cementing operations. These tools play a crucial role in maintaining long-
Messaging
term wellbore integrity. While stage tools are most commonly used to protect weak zones
from the hydrostatic pressure of a full cement column, other applications include selective
Search
Try Premium Free
for 1 Month
placement of a single cement stage, gas migration risk mitigation, and other.
This article will cover basic concepts in the operation, selection, application, and
manufacturing of stage cementing tools. The article will be limited to plug/pressure-operated
multi-stage cementing tools. Workstring-operated port collars will not be covered.
APPLICATIONS
Multi-stage cementing tools are

installed in the casing string to
allow communication between the
casing and the annular space. The
most common application is
cementing across weak zones in
two stages (Fig 1).
A multi-stage cementing tool

allows the cement job to be conducted in multiple stages, typically two stages. This is most
commonly required in the presence of weak formations that would not support the
hydrostatic pressure of a full column of cement, Figure 2:
Messaging
Try Premium Free

Search
for 1 Month
Figure 2 shows a casing string at the bottom of the well prior to being cemented in place
(a). Note the presence of a weak zone somewhere in the open hole. Prior to pumping
cement, hydrostatic pressure at the weak zone is relatively low and does not break the weak
rock.
In a conventional cement job, cement is pumped behind a bottom plug, typically with some
other fluids ahead of the plug. Once enough cement has been pumped, a top plug is
launched. The bottom plug lands on the float collar and the plug’s burst disc or diaphragm is
ruptured with pressure, allowing cement to flow through the plug’s hollow core, through the
float equipment, and out into the annular space. Generally, pressure at the weak rock will not
increase significantly while cement is still below the weak zone (b).
However, pressure at the weak zone will start to increase faster once cement is pumped
above this zone (c). Pressure will continue to increase as the height of the cement column
above the weak zone increases. Eventually, pressure at the weak zone may be high enough
to fracture the formation (d). Cement will then be lost into the weak zone, making it
impossible to bring top of the cement to surface or desired depth (e).
For more clarity, an animation of the above process is shown below:
Messaging
Try Premium Free

Search
Single Stage Cementing Animation R1 - Potential cement loses in single stage ce…
ce… for 1 Month
As mentioned earlier, cement loses may be avoided by conducting the cement job in two or
more stages. A typical two-stage cement job is illustrated in Figures 3 and 4.
Figure 3 illustrates the first stage of a two-stage cement job:
Messaging
AnSearch
inflatable external casing packer (optional) and a stage cementing tool are installed inTrythe
Premium Free
for 1 Month
casing string (a). Typically, these are installed so that their setting depth is above the weak
zone. A smaller amount of cement is pumped and displaced with a special type of top plug
called the first stage flexible plug (b). The flexible plug will pass through the stage tool
without getting damaged and without damaging the stage tool (c).
As the plug lands on the float collar or landing collar, first stage cement is displaced out into
the annular space and up to the the proximity of the stage tool (d). This concludes the first
stage; note that the smaller amount of cement prevents the pressure at the weak zone from
breaking the formation (e).
The second stage is illustrated in Figure 4:
To conduct the second stage, pressure is applied against the first stage plug to open, inflate
and close the external casing packer (a). At that point, the annular space below the packer is
isolated from further significant pressure increases. If a packer was not used, first stage
cement is allowed to set prior to pumping the second stage.
When using a hydraulic stage cementing tool, pressure in applied again to open the stage
tool and open communication from the inside of the casing to the annular space above the
packer (b). For mechanical stage tools, a dart is dropped from surface and allowed
Messagingto land on
theSearch
tool. Pressured is then applied on the dart to open the tool mechanically. Hydraulic and
Try Premium Free
for 1 Month
mechanical stage tools are described in more detail later in this article.
After opening the stage cementing tool, second stage cement is pumped down the casing and
out the annular space. The second stage cement is displaced with a special cement plug,
called the stage tool closing plug (c). The plug lands on the stage tool as the second stage
cement is displaced into the annular space above the ECP (d).
With the plug on the stage tool, additional pressure is applied to close the stage tool. Cement
has now reached surface or the target depth without fracturing the weak zone (e).
As mentioned earlier, this is the most common application for stage cementing
tools. However, stage tools are used for many other types of applications, including selective
placement of a single stage cement job.
The above process is shown in the below animation:
Two Stage Cementing - Avoiding potential cement loses with two stage cement job
A multi-stage cementing job may also be conducted in three stages. The procedure would be
similar to the above, but utilizing two stage tools and two packers.
Other common applications include:
Discontinuous cement intervals, Figure 5 Messaging
Search
Off-bottom cementing, Figure Try
6. Premium Free
for 1 Month
In some cases, the objectives may

be slightly different, such as:
Breaking the cement column into

two shorter sections to reduce
potential gas migration
Placing other types of fluids in the

annular space.
STAGE TOOL TYPES
The two main types of stage

cementing tools are:
Hydraulic/mechanical
Mechanical only
Hydraulic/mechanical tools are opened through differential pressure (in burst mode) at
the tool. As shown in the above animation, differential pressure is created by applying
pressure against the first stage flexible plug. The plug is landed on float equipment or a
dedicated landing collar.
One advantage of hydraulic tools is that they can be opened almost immediately after
completing the first stage cement. Also, this type of tool is not limited by hole inclination
angle.
One disadvantage is the risk associated with failure to bump the first stage plug. Also, fluid
leaking through the plug. Both can increase the risk of over displacing cement into the
annular space. Fortunately, hydraulic designs will typically allow the tool to be opened by
Messaging
dropping
Search
a dart; this option is limited to lower inclination angles and increases non- Try Premium Free
for 1 Month
productive time.
Another potential limitation is that hydraulic tools tend to open at much higher
pressures. Can the higher pressure surge create formation problems? I’ve heard arguments
both in favor and against this idea.
Figure 7 shows a Rubicon Type

680 Hydraulic/Mechanical stage
tool with standard plug set.
Mechanical tools are opened

utilizing a dart dropped from
surface. Usually, the dart is
dropped soon after completing the
first stage cement job. Sufficient
time is allowed for the dart to
gravitate down to the stage tool
opening seat. Pressure is then
applied to open the tool. The tool
is closed using the second stage
plug in a similar way as with the hydraulic tool as shown in the following animation:
Stage Tool 681 - Rubicon Type 681 mechanical stage cementing tool
Messaging
Figure
Search
8 shows a Rubicon Type 681 Try Premium Free
for 1 Month
Mechanical stage tool with standard plug
set. Note the additional opening dart
included with the standard plug set.
Additional stage tools types and options

commonly used include:
1. Phenolic seats: these tools incorporate

phenolic seats and darts to improve
drillout times and minimize potential bit
damage.
2. Three-stage: three stage cementing

tools allow the cement job to be
conducted in three stages for further
reduction of the cement column height, or for selective placement of cement. Typical
configurations include mechanical-hydraulic and hydraulic-hydraulic.
3. Additional plug sets: some manufacturers offer additional plug sets for further
operating flexibility. Some of these options include, latch down plugs, pump down darts,
and bypass plugs.
4. Cancellation cones: some designs require the tool to always be fully operated, even if a
second stage job was not performed. Cancellation cones are used for this purpose and
should be considered at the time of purchase.
Additional technical information on Rubicon stage cementing tools can be found at:
Multi-Stage Cementing Equipment Archives - Rubicon Oilfield

International
Rubicon Oilfield International
Messaging
Try Premium Free

Search
for 1 Month
QUALITY AND TESTING
No industry standards specific to the manufacturing and testing of stage cementing tools
exist today. However, due to the major impact that stage tools have in ensuring well
integrity, I strongly believe these tools should be manufactured under a Quality Management
System, such as API Q1.
The well engineer or end user should understand the manufacturer’s design and development
verification and validation procedures. These procedures should consider functional
tests. The following video shows an opening test of a hydraulic stage tool (protective guards
are normally used):
Opening R1 - Testing of Rubicon hydraulic stage cementing tool
Stage cementing tools are assembled from multiple components. This may limit the
accuracy of finite element analysis or theoretical calculations. Validating these calculations
through physical tests should be considered.
Other downhole tools, such as external casing packers, may be installed in the casing
string. Precise coordination of operating pressures is critical for successful operations. One
cannot overemphasize the importance of consistency and accuracy in actual operating
pressures. This should be well tested and documented during the design and development
process. Messaging
Try Premium Free

Search
for 1 Month
EQUIPMENT SPECIFICATIONS AND SELECTION CONSIDERATIONS
As with any other equipment that becomes part of the casing string, it is important that the
user has a thorough understanding of all performance and strength specifications. At
minimum, these should include:
Casing specifications: size, weight, grade, connection
Maximum outside diameter
Tool length and weight
Maximum drillout inside diameter
Seat(s) diameter
Operation type (described above)
Differential pressure ratings (in running in and closed positions)
Maximum load below the tool
Temperature ratings
Torque limitations
Operating pressures (nominal and tolerances)
Recommended drillout procedure
Number and size of ports
Description of operating plugs
Recommended operating procedure
Type of seals
Equipment specifications should be evaluated against job requirements. Operating pressures

should be defined based on cement hydraulics calculations and simulations.Messaging
For example,
some tool designs work on differential pressure (between the inside of the casing and theTry Premium Free
Search
for 1 Month
annular space). The fluid column in the annular space may consist of multiple fluids with
different densities. These parameters will have a direct impact on pump operating
pressures. Also, when utilizing hydraulic opening tools, confirm that the opening pressure
can be set higher than the maximum differential pressure at the tool while circulating.
Other important considerations include maximum dog leg severity (passing through or at
setting depth), maximum downhole temperature, and fluid types. Accounting for fluid
compressibility is particularly important when running an inflatable external casing packer.
FIELD PRACTICES
Competent field service is fundamental for successful multi-stage cementing

operations. Field service practices should be defined well ahead of the installation date,
ideally during job planning. Field service activities should include at minimum the
following:
1. Equipment inspection
2. Operations planning
3. Equipment installation and reporting.
Equipment inspection – as soon as possible after arriving to location, the tool and
associated equipment should be inspected and confirmed to be in good condition. At
minimum, these activities should include:
Record manufacturer's tool identification information
Confirm tool description matches casing program
Visually inspect condition of the tool and confirm no visible signs of damage, including
threads and seats
Confirm all accessories and required installation tools and materials arrived with the tool
and are in good condition
Messaging
Visually inspect the inside of the cement head or plug launcher to confirm compatibility
Search
Try Premium Free
for 1 Month
with the plugs.
Operations planning and reporting – ensuring that all relevant field personnel is aware
of and in agreement with the tool operating sequence and critical parameters. The following
information should be reviewed, calculated, and discussed with field personnel:
Confirm required installation depth
Define plug bump and land pressures and rates
Define plug displacement rates and expected free-fall time (when applicable)
Review cementing program
Discuss operating procedure and contingency plans
Confirm compatibility with all other casing accessories, such as float equipment,
crossovers, external casing packers, etc. Including:
- Confirm plugs will pass through all ID restrictions
- Stage tool operating pressures are synchronized with other tools
- Compatibility of operating plugs with landing collars (or float collars)
- Plugs fit the cement head
Discuss relevant safety considerations
Confirm plugs are properly loaded in the cement head
Confirm plugs are launched
Record actual job parameters (setting depth, displacement rates, operating pressures,
etc.)
Record and describe any anomalies, including deviations from cementing program.
Messaging
The above activities should be performed by trained personnel with specific knowledge of
Search
Try Premium Free
for 1 Month
and experience with the equipment being run.
DRILLOUT
Stage cementing tools are typically drilled out after the cement job. This involves drilling
out the tool seats and plugs. Recommended drillout procedures will vary by manufacturer
and drilling practices. When available, specific drillout procedures for different bit types
must be obtained and communicated to the field. These procedures will include a
recommended range for the following parameters: rotation speed, flow rate, weight on
bit. Attention should be given to maximum values, including max drillout torque. Also, care
must be taken to minimize potential damage to the seals.
CLOSING REMARKS
Stage cementing tools are among the most complex downhole tools used for primary
cementing operations
The role of stage tools in long-term wellbore integrity should always be considered
While the most common application for stage tools is two-stage cementing to protect
weak formations, other common applications include discontinuous cement intervals,
off-bottom cementing, and gas migration mitigation
Stage tool selection should consider casing running (torque and drag) operations,
hydraulic simulations and field operating procedures. Attention should also be given to
available plug sets and contingency methods
Stage tools should be manufactured under a Quality Management System
Field practices should cover tool inspection, operations review, installation, and
reporting practices.
Thanks for your time reading this article. I look forward to your comments and stay tuned
for the next article in this series, Part 4: Casing Centralizers.
Messaging
REFERENCES Try Premium Free

Search
for 1 Month
Bonett, A. and Pafitis, D. Getting to the Root of Gas Migration. Oilfield Review. Elsevier.
New York, NY 1996
Nelson, E.B., Guillot, D. (Eds). Well Cementing 2nd Edition. Schlumberger. Sugar Land,
TX 2006
Sanchez, R.A. Intelligent Iron! A Primer on Casing Equipment – Part 1

(Introduction). LinkedIN, March 2018
Sanchez, R.A. Intelligent Iron! A Primer on Casing Equipment – Part 2 (Float

Equipment). LinkedIN, May 2018
Specification for Casing and Tubing, Ninth Edition. American Petroleum Institute,
Washington, 2011
Specification for Quality Management System Requirements for Manufacturing

Organizations for the Petroleum and Natural Gas Industry, Ninth Edition. American
Petroleum Institute, Washington, 2013
Report this
Published by
Alfredo Sanchez, P.E., PMP 6 articles Following
Published • 2y
#Primary Cementing Equipment #Stage Cementing Tools #Casing Hardware
Reactions
+13
6 Comments
Most relevant
Add a comment…
Mark James, PMP RPEQ NER • 3rd+ 2y

Bid Coordinator and Well Cementing Consultant Messaging
Excellent, comprehensive post.
Try Premium Free
Search
for 1 Month
Like · 2 Reply · 1 Reply
Alfredo Sanchez, P.E., PMP • Following 2y

Thanks Mark!
Like Reply
Mohammad Masroor Zia Shaikh, PEng • 2nd 2y

Operations & Sales Manager at Kasab International Energy Services LLC
Thanks! Very informative indeed.
Like Reply · 1 Reply
Alfredo Sanchez, P.E., PMP • Following 2y

Thanks Mohammad.
Like Reply
Load more comments
Alfredo Sanchez, P.E., PMP

Following
m Alfredo Sanchez, P.E., PMP
ron! A Primer on Casing Intelligent Iron! A Primer on Casing Intelligent Iron! A Primer on Casing Improving Cement Placemen
- Part 4 (Casing Equipment - Part 2 (Float Equipment - Part 1 (Introduction) Long-Term Wellbore Integrit
s) Equipment) Through Fit-For-Purpose Cas
Alfredo Sanchez, P.E., PMP on Linke…
chez, P.E., PMP on Linke… Alfredo Sanchez, P.E., PMP on Linke… Alfredo Sanchez, P.E., PMP on
ticles
Messaging
Try Premium Free

Search
for 1 Month
Messaging

Intelligent Iron! A Primer On Casing Equipment - Part 3 (Stage Cementing Tools) - LinkedIn

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Intelligent Iron! A Primer On Casing Equipment - Part 3 (Stage Cementing Tools) - LinkedIn

Uploaded by

Copyright:

Available Formats

2/8/2021 Intelligent Iron!

A Primer on Casing Equipment - Part 3 (Stage Cementing Tools) | LinkedIn

Try Premium Free