Technology Update: Flexible, Single-Skin Completion Concept Meets Well Integrity, Zonal Isolation Needs

2015 ◽  
Vol 67 (11) ◽  
pp. 32-34 ◽  
Author(s):  
Brian Sidle
Keyword(s):  
Well Integrity ◽  
Zonal Isolation

Well Integrity Catastrophe Avoided Through Advanced Well Integrity and Reservoir Monitoring Analysis, a Case Study

2021 ◽  
Author(s):  
Mohamed Elyas ◽  
Sherif Aly ◽  
Uche Achinanya ◽  
Sergey Prosvirkin ◽  
Shayma AlSaffar ◽  
...  
Keyword(s):  
Geothermal Gradient ◽  
Root Cause ◽  
Well Integrity ◽  
Reservoir Monitoring ◽  
Precision Temperature ◽  
Zonal Isolation ◽  
Potential Failure ◽  
Corrective Actions ◽  
Thickness Measurements ◽  
Pulsed Neutron

Abstract Well integrity is one of the main challenges that are facing operators, finding the source of the well problem and isolating it before a catastrophic event occurs. This study demonstrates the power of integrating different reservoir monitoring and well integrity logs to evaluate well integrity, identify the underlying cause of the potential failure, and providing a potential corrective solution. Recently, some Injector/producer wells reported migration of injection fluids/gas into shallower sections, charging these formations and increasing the risk of compromised well integrity. Characterization of the well issues required integration of multi-detector pulsed-neutron, well integrity (multi finger caliper, multi-barrier corrosion, cement evaluation, and casing thickness measurements), high precision temperature logs and spectral noise logs. After data integration, detailed analysis was performed to specifically find the unique issues in each well and assess possible corrective actions. The integrated well integrity logs clearly showed different 9.625-inch and 13.375-inch casings leak points. The reservoir monitoring logs showed lateral and vertical gas and water movements across Wara, Tayarat, Rus, and Radhuma formations. Cement evaluation loges showed no primary cement behind the first barrier casing which was the root cause of the problem. Therefore, the proposed solution, was a cement squeeze. Post squeeze, re-logging occurred, validating zonal isolation and a return of a standard geothermal gradient across the Tayarat formation. Most importantly, the cement evaluation identified good bond from the squeeze point clear to surface, isolating all formations. All these wells were returned to service (injector/producer), daily annular pressure monitoring confirmed that no further pressure build up was seen. Kuwait Oil Company managed to avoid a catastrophic well integrity event on these wells and utilized the approach presented to take the proper corrective actions, and validate that the action taken resolved the initial well integrity issues. Consequently, the wells were returned to service, and the company avoided a costly high probability blowout.

Implementation of Factory Cementing Concept in the High-Intensity Drilling Environment of Khazzan, Sultanate of Oman

2021 ◽  
Author(s):  
Emmanuel Therond ◽  
Yaseen Najwani ◽  
Mohamed Al Alawi ◽  
Muneer Hamood Al Noumani ◽  
Yaqdhan Khalfan Al Rawahi ◽  
...  
Keyword(s):  
Shallow Water ◽  
High Intensity ◽  
Sultanate Of Oman ◽  
Cement Slurry ◽  
Short Term ◽  
Lost Circulation ◽  
Well Integrity ◽  
Sustained Casing Pressure ◽  
Zonal Isolation ◽  
Casing Pressure

Abstract The Khazzan and Ghazeer gas fields in the Sultanate of Oman are projected to deliver production of gas and condensate for decades to come. Over the life of the project, around 300 wells will be drilled, with a target drilling and completion time of 42 days for a vertical well. The high intensity of the well construction requires a standardized and robust approach for well cementing to deliver high-quality well integrity and zonal isolation. The wells are designed with a surface casing, an intermediate casing, a production casing or production liner, and a cemented completion. Most sections are challenging in terms of zonal isolation. The surface casing is set across a shallow-water carbonate formation, prone to lost circulation and shallow water flow. The production casing or production liner is set across fractured limestones and gas-bearing zones that can cause A- and B-Annulus sustained casing pressure if not properly isolated. The cemented completion is set across a high-temperature sandstone reservoir with depletion and the cement sheath is subjected to very high pressure and temperature variations during the fracturing treatment. A standardized cement blend is implemented for the entire field from the top section down to the reservoir. This blend works over a wide slurry density and temperature range, has expanding properties, and can sustain the high temperature of the reservoir section. For all wells, the shallow-water flow zone on the surface casing is isolated by a conventional 11.9 ppg lightweight lead slurry, capped with a reactive sodium silicate gel, and a 15.8 ppg cement slurry pumped through a system of one-inch flexible pipes inserted in the casing/conductor annulus. The long intermediate casing is cemented in one stage using a conventional lightweight slurry containing a high-performance lost circulation material to seal the carbonate microfractures. The excess cement volume is based on loss volume calculated from a lift pressure analysis. The cemented completion uses a conventional 13.7 - 14.5 ppg cement slurry; the cement is pre-stressed in situ with an expanding agent to prevent cement failure when fracturing the tight sandstone reservoir with high-pressure treatment. Zonal isolation success in a high-intensity drilling environment is assessed through key performance zonal isolation indicators. Short-term zonal isolation indicators are systematically used to evaluate cement barrier placement before proceeding with installing the next casing string. Long-term zonal isolation indicators are used to evaluate well integrity over the life of the field. A-Annulus and B-Annulus well pressures are monitored through a network of sensors transmitting data in real time. Since the standardization of cementing practices in the Khazzan field short-term job objectives met have increased from 76% to 92 % and the wells with sustained casing pressure have decreased from 22 % to 0%.

scholarly journals Numerical Modeling of Radial Fracturing of Cement Sheath Caused by Pressure Tests

2019 ◽  
Author(s):  
Sohrab Gheibi ◽  
Sigbjørn Sangesland ◽  
Torbjørn Vrålstad
Keyword(s):  
Numerical Code ◽  
Hydrocarbon Production ◽  
Well Integrity ◽  
Pressure Tests ◽  
Pressure Test ◽  
Zonal Isolation ◽  
Tensile Fractures ◽  
Fracture Opening ◽  
Cement Sheath ◽  
Geological Co2 Sequestration

Abstract To achieve an acceptable level of zonal isolation, well integrity should be guaranteed in hydrocarbon production and geological CO2 sequestration. Well pressure test can cause different types of failures in the well system leading to leakages through these failures. Laboratory evidences have revealed that occurrence of radial tensile fractures is likely during pressure tests. In this paper, we use a numerical code call MDEM which was formulated based on discrete element method. The code can model discontinuum feature of fractures. A model of a lab-sized pressure test was built and compared to an experiment previously published. The model was tested under different confinement levels and effect of the tensile strength of rock on the radial fracture was investigated at the same lab-scale. Fracture opening profiles are also presented showing the leakage potential of these fractures under different pressure level.

Application of Resin-Cement Blend to Prevent Pressure Build-Up in Casing to Casing Annulus CCA: A Novel Approach to Improve Well Integrity

2021 ◽  
Author(s):  
Wajid Ali ◽  
Freddy Jose Mata ◽  
Ahmed Atef Hashmi ◽  
Abdullah Saleh Al-Yami
Keyword(s):  
High Pressure ◽  
Shear Bond Strength ◽  
Resin Cement ◽  
Cement Slurry ◽  
Well Integrity ◽  
Cement System ◽  
Zonal Isolation ◽  
Primary Cementing ◽  
Cement Sheath

Abstract Assurance of well integrity is critical and important throughout the entire well's life cycle. Pressure build-up between cemented casings annuli has been a major challenge all around the world. Cement is the main element that provides isolation and protection for the well. The cause for pressure build-up in most cases is a compromise of cement sheath integrity that allows fluids to migrate through micro-channels from the formation all the way to the surface. These problems prompt cementing technologists to explore new cementing solutions, to achieve reliable long-term zonal isolation in these extreme conditions by elevating shear bond strength along-with minimal shrinkage. The resin-cement system can be regarded as a novel technology to assure long term zonal isolation. This paper presents case histories to support the efficiency and reliability of the resin-cement system to avoid casing to casing annulus (CCA) pressure build-up. This paper presents lab testing and application of the resin-cement system, where potential high-pressure influx was expected across a water-bearing formation. The resin-cement system was designed to be placed as a tail slurry to provide a better set of mechanical properties in comparison to a conventional slurry. The combined mixture of resin and cement slurry provided all the necessary properties of the desired product. The slurry was batch-mixed to ensure the homogeneity of resin-cement slurry mixture. The cement treatment was performed as designed and met all zonal isolation objectives. Resin-cement’s increased compressive strength, ductility, and enhanced shear bond strength helped to provide a dependable barrier that would help prevent future sustained casing pressure (SCP). The producing performance of a well depends in great part on a good primary cementing job. The success of achieving zonal isolation, which is the main objective of cementing, is mainly attributed to the cement design. The resin-cement system is evolving as a new solution within the industry, replacing conventional cement in many crucial primary cementing applications. This paper highlights the necessary laboratory testing, field execution procedures, and treatment evaluation methods so that this technology can be a key resource for such operations in the future. The paper describes the process used to design the resin-cement system and how its application was significant to the success of the jobs. By keeping adequate strength and flexibility, this new cement system mitigates the risk of cement sheath failure throughout the life of well. It provides a long-term well integrity solution for any well exposed to a high-pressure environment.

Case Study in Well Integrity Assurance with Enhanced Ultrasonic Technology for a Highly Attenuative Environment

2021 ◽  
Author(s):  
Batakrishna Mandal ◽  
Xiang Wu ◽  
Sadig Huseynov ◽  
Adesoji Adedamola ◽  
Teles Huanga ◽  
...  
Keyword(s):  
High Pressure ◽  
Acoustic Impedance ◽  
Field Measurements ◽  
Low Noise ◽  
The Caspian Sea ◽  
Low Contrast ◽  
Well Integrity ◽  
Ultrasonic Technology ◽  
Zonal Isolation ◽  
Integrity Tests

Abstract While applying acoustics is not a new science, inherent uncertainties with these techniques are still not addressing challenges that limit confidence in well integrity programs. The Caspian region's significant challenges for cement evaluations include heavy mud and thick casing, as well as the high-pressure/high-temperature (HP/HT) nature of gas condensate wells, which reduces the contrast in acoustic impedance. Accordingly, difficulties have remained in the interpretation of conventional cement bond logs, which has led many operators to be suspicious of well integrity technologies. This paper focuses on the application of ultrasonic cement evaluation technology in the Caspian Sea, and compares results between advanced ultrasonic applications and traditional cement bond logs in heavy mud. The workflow is presented to integrate the advancement of this technology and to eliminate the uncertainties in well integrity analysis. Increasing confidence for further drilling of a high-pressure gas reservoir has been achieved by combining these various measurements that enable a definitive analysis of zonal isolation. The main objective of this well assurance program was to ensure zonal isolation and shoe integrity in order to drill ahead to perform formation integrity tests (FITs). However, obtaining high-resolution cement data in heavy, 2.16-sg, oil-based mud (OBM) was the biggest concern due to the limitations of standard ultrasonic technology. The wide disparity in acoustic impedance, combined with the low contrast between heavy mud and the cemented section, makes evaluation of cement quality and zonal isolation doubtful. Although well conditions challenged the standard measurements, the cement evaluation objective was achieved with the new technology by ensuring 360° azimuthal coverage in permeable sand zones capable of unwanted hydrocarbon production – i.e., preventing sustained casing pressure (SCP). Moreover, a strong and continuous 40-m cement bond prevented crossflow from charging zones through the wellbore and also acted as a barrier against corrosion. Enhancement of pulse-echo technology has proved that it can be applied in a highly attenuative environment to achieve high-fidelity data. Highly acoustic attenuative mud is a major challenge for acoustic ultrasonic technology to achieve a quality answer product for well integrity. To mitigate this problem, a new tool was developed with a highly sensitive low-noise transducer, and with special programmable (both voltage and frequency) firing circuitry, to enhance the transducer signal at the resonance frequency of the casing. The various features of the processing algorithm are also improved, based on the numerous laboratory and field measurements.

Improving Cement-to-Pipe Bonding Evaluation on Coated Casing

2021 ◽  
Author(s):  
Barry Albert Lumankun ◽  
Diyah Ayu Adiningtyas ◽  
Cinto Azwar ◽  
Ahmed Osman ◽  
Rudi Hartanto ◽  
...  
Keyword(s):  
Oil And Gas ◽  
Weight Ratio ◽  
Fundamental Aspect ◽  
Evaluation Tool ◽  
Bond Quality ◽  
Cement Slurry ◽  
Well Integrity ◽  
Zonal Isolation ◽  
Bond Evaluation ◽  
Construction Operation

ABSTRACT In the Oil and Gas industries, drilling a well in both exploration and development operations is becoming more challenging due to the reservoir location and complex reservoir system. A sophisticated high-cost well structure with complex trajectory, subsea system, or even operating in deep water is sometimes unavoidable. One of the crucial factors for a successful well construction operation is to achieve excellent well integrity by having good zonal isolation throughout the target reservoir section. This requires flawless primary cementation from cement job planning, design, and up to execution. The cement bond quality will need to be evaluated by performing the post job cement execution evaluation and wireline logging cement bond log survey. Supported with more stringent regulations, well integrity is becoming a fundamental aspect in drilling and production operations. This brings new challenges to cementing operations and subsequent cement evaluation. Flawless primary cementation is of great importance, from the job planning, design, to the execution. Post-job cement evaluations are needed by performing Pressure Match Post-Job Analysis and Wireline Logging Cement Bond Log Survey. Key parameters in designing optimum zonal isolation cement slurry is good understanding of the wellbore technical challenges and mitigating all geological and formation-related risks, such as narrow pressure margin, gas migration risk, etc. Light cement, complicated cement composition recipes, small cement - mud weight ratio are more common these days, supported with the developing technology in cementing. These, on the other side, would impact the cement bond evaluation. Good cement bond is crucial to ensure good zonal isolation across the reservoir intervals. Casing external coating, applied to protect casing strings from rusts, is another aspect affecting the cement bond, especially cement-to-casing bond. A more advanced cement bond evaluation tool will be required to cope with variety of cementing conditions, to enable producing undoubted log results. Thus, helping Operator in making decisions of subsequent well operations. This paper shows and presents different cement bond log interpretation results from four wells executed with a different method of implementations, performed in a development drilling campaign in Natuna Sea, offshore Indonesia in year 2019. The paper will focus on the 9-5/8" casing cementation, on which the cement bond evaluation became one of the main attentions.

Delivering Zonal Isolation between Reservoir Sublayers in Long, Horizontal 12 ¼-in. Hole Sections in Extended Reach Wells

2021 ◽  
Author(s):  
Azza Elhassan ◽  
Ahmedagha Eldaniz Hamidzada ◽  
Toki Takahiro ◽  
Toma Motohiro ◽  
Mohd Waheed Orfali ◽  
...  
Keyword(s):  
High Pressures ◽  
Lessons Learned ◽  
Measurement Tool ◽  
Persistent Problem ◽  
Lost Circulation ◽  
Well Integrity ◽  
Starting Point ◽  
Discharge Policy ◽  
Zonal Isolation ◽  
Fluid Design

Abstract Good cementing practices are required to achieve effective zonal isolation and provide long-term well integrity for uninterrupted safe production and subsequent abandonment. Zonal isolation can be attained by paying close attention to optimizing the drilling parameters, hole cleaning, fluid design, cement placement, and monitoring. In challenging extended reach wells in the UAE, different methods were employed to deliver progressive improvement in zonal isolation. Cementing the intermediate and production sections in the UAE field is challenging because of the highly deviated, long, open holes; use of nonaqueous fluids (NAFs); and the persistent problem of lost circulation. Compounding the problem are the multiple potential reservoirs; the pressure testing of the casing at high pressures after cement is set; and the change in downhole pressures and temperatures during production phases, which results in additional stresses. Hence, the mechanical properties for cement systems must be customized to withstand the downhole stresses. The requirement of spacer fluids with nonaqueous compatible properties adds complexity. Lessons learned from prior operations were applied sequentially to produce fit-for-purpose solutions in the UAE field. Standard cement practices were taken as a starting point, and subsequent changes were introduced to overcome specific challenges. These challenges included deeper 12 ¼-in. sections, which made it difficult to manage equivalent circulating densities (ECDs), and a stricter requirement of zonal isolation across sublayers in addition to required top of cement at surface. To satisfy these requirements, several measures were taken gradually: applying engineered trimodal blend systems to remain under ECD limits; pumping a lower-viscosity fluid ahead of the spacer; using NAF-compatible spacers for effective mud removal; employing flexible cement systems to withstand downhole stresses; and modeling the cement job with an advanced cement placement software to simulate displacement rates, bottomhole circulating temperatures, centralizer placement, mud removal and comply with a zero discharge policy that restricts the extra slurry volume to reach surface. To enhance conventional chemistry-based mud cleaning, an engineered scrubbing additive was included in the spacers with a microemulsion-based surfactant. The results of cement jobs were analyzed by playback in advanced evaluation software to verify the efficiency of the applied solutions. This continuous improvement response to changes in well design has resulted in a significant positive change in cement bond logs; a flexural attenuation measurement tool has been used to evaluate the lightweight slurry quality behind the casing, which has helped in enhancing the confidence level in well integrity in these challenging wells. The results highlight the benefit of developing engineering solutions that can be adapted to respond to radical changes in conditions or requirements.

Mud-Removal Efficiency Boost by Engineered Scrubbing Spacer in Cementing Operations at Caspian Sea

2021 ◽  
Author(s):  
Amanmammet Bugrayev ◽  
Ravindra Kumar Singh ◽  
Svetlana Nafikova ◽  
Ilshat Akhmetzianov ◽  
Guvanch Gurbanov ◽  
...  
Keyword(s):  
Removal Efficiency ◽  
Successful Implementation ◽  
Gas Migration ◽  
Negative Consequences ◽  
Well Integrity ◽  
Annular Gap ◽  
Challenging Environment ◽  
Zonal Isolation ◽  
Cement Sheath

Abstract Long-term well integrity and zonal isolation are the ultimate objectives for cementing in the well construction process. Effective mud removal plays an essential role in obtaining competent zonal isolation and hence should not be overlooked and underestimated. The negative consequences of poor mud removal can lead to microannulus, channeling, or gas migration, which might require costly time-consuming remediation. The conventional approach of optimizing spacers based on chemical interactions with the mud layer does not always yield desired results and, thus, demanding further improvement. In this paper we discuss the approach taken to boost the mud removal efficiency by implementing an innovative engineered scrubbing spacer containing fibers in a challenging environment, resulting in notable improvement in long-term cement sheath integrity. The engineered scrubbing fibers were thoroughly tested in the laboratory to ensure spacer stability and efficiency. The new spacer with an additional scrubbing capability was introduced to one of the major operators on the Caspian shelf and after successful implementation, it has now been used on more than 20 cementing operations. Scrubbing fibers concentration was optimized through thorough laboratory testing covering flowability, dispersibility, and mud removal efficiency; later, it was applied on most of the cement operations, including 4½-in. liners characterized by a very narrow annular gap across the hanger sections. Cement evaluation log results from those cementing operations demonstrated an improvement in mud removal efficiency, suggesting no issues associated with microannulus, channeling, or gas migration, thus confirming the effectiveness of the newly implemented engineered scrubbing spacer. The typical challenges associated with meeting the zonal isolation requirement on one of the offshore fields of the Caspian shelf, and the success of the approach taken to overcome those challenges by implementing the new engineered scrubbing spacer are discussed. The comparison of cement bond evaluation log results of the jobs where conventional spacer systems were used vs. those where the spacer with scrubbing capability was used are also presented, demonstrating the clear difference and improvement.

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