Innovative Application of Ultra-Lightweight Epoxy Resin-Cement Slurry Mixture Achieved Zonal Isolation Objectives and Secured Well Integrity: Case History From Offshore Gulf of Suez

2015 ◽  
Author(s):  
Devesh Bhaisora ◽  
Ahmed Aly ◽  
Ahmed Morsy ◽  
Hesham Shamma ◽  
Radi El Nashar ◽  
...  
Keyword(s):  
Epoxy Resin ◽  
Case History ◽  
Resin Cement ◽  
Gulf Of Suez ◽  
Cement Slurry ◽  
Well Integrity ◽  
Zonal Isolation

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.

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%.

Successful Single-Stage Cementing in a Weak Formation: A Case History in Spain

2014 ◽  
Author(s):  
A.. Bottiglieri ◽  
A.. Brandl ◽  
R.S.. S. Martin ◽  
R.. Nieto Prieto
Keyword(s):  
Engineering Design ◽  
Case History ◽  
Laboratory Testing ◽  
Single Stage ◽  
Formation Damage ◽  
Cement Slurry ◽  
Integrity Test ◽  
Open Hole ◽  
Zonal Isolation ◽  
Horizontal Wellbore

Abstract Cementing in wellbores with low fracture gradients can be challenging due to the risk of formation breakdowns when exceeding maximum allowable equivalent circulation densities (ECDs). Consequences include severe losses and formation damage, and insufficient placement of the cement slurry that necessitates time-consuming and costly remedial cementing to ensure zonal isolation. In recent cementing operations in Spain, the formation integrity test (FIT) of the open hole section indicated that the formation would have been broken down and losses occurred based on calculated equivalent circulating densities (ECDs) if the cement slurry had been pumped in a single-stage to achieve the operator's top-of-cement goal. As a solution to this problem, cementing was performed in stages, using specialty tools. However, during these operations, the stage tool did not work properly, wasting rig time and resulting in unsuccessful cement placement. To overcome this issue, the operator decided to cement the section in a single stage, preceded by a novel aqueous spacer system that aids in strengthening weak formations and controlling circulation losses. Before the operation, laboratory testing was conducted to ensure the spacer system's performance in weak, porous formations and better understand its mechanism. This paper will outline the laboratory testing, modeling and engineering design that preceded this successful single stage cementing job in a horizontal wellbore, with a final ECD calculated to be 0.12 g/cm3 (1.00 lb/gal) higher than the FIT-estimated figure.

Novel Resin-Cement Blend to Improve Well Integrity

2021 ◽  
Author(s):  
Vikrant Wagle ◽  
Abdullah Saleh Al-Yami ◽  
Sara AlKhalaf ◽  
Khawlah Abdulaziz Alanqari ◽  
Wajid Ali ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
New Technology ◽  
Great Part ◽  
Resin Cement ◽  
Cement Slurry ◽  
Cement System ◽  
Zonal Isolation ◽  
Primary Cementing ◽  
Field Deployment ◽  
The Right

Abstract A good primary cementing job governs in a great part the producing performance of a well. Successful zonal isolation, which is the main objective of any cementing job, primarily depends on the right cement design. The resin-based cement system, which is a relatively new technology within the oil industry has the potential to replace conventional cement in critical primary cementing applications. This paper describes the lab-testing and field deployment of the resin-based cement systems. The resin-based cement systems were deployed in those well sections where a potential high-pressure influx was expected. The resin-based cement system, which was placed as a tail slurry was designed to have better mechanical properties as compared to the conventional cement systems. The paper describes the process used to get the right resin-based cement slurry design and how its application was important to the success of the cementing jobs. The cement job was executed successfully and met all the zonal-isolation objectives. The resin-based cement's increased shear bond strength and better mechanical properties were deemed to be instrumental in providing a reliable barrier that would thwart any future issues arising due to sustained casing pressure (SCP). This paper describes the required lab-testing, lab-evaluation, and the successful field deployment of the resin-based cement systems.

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.

Dual-porosity fractured Miocene syn-rift dolomite reservoir in the Issaran Field (Gulf of Suez, Egypt): a case history of the zonal isolation of highly fractured water carrier bed

2012 ◽  
Vol 374 (1) ◽  
pp. 379-394 ◽  
Author(s):  
Ati Saoudi ◽  
Adel R. Moustafa ◽  
Ramadan I. Farag ◽  
Maher M. Omara ◽  
Hossam Wally ◽  
...  
Keyword(s):  
Case History ◽  
Dual Porosity ◽  
Gulf Of Suez ◽  
History Of ◽  
Zonal Isolation

Epoxy Resin Helps Restore Well Integrity in Offshore Well: Case History

2017 ◽  
Author(s):  
Miguel Vicente Perez ◽  
Jardyson Melo ◽  
Romulo Blanc ◽  
Andre Roncete ◽  
Paul Jones
Keyword(s):  
Epoxy Resin ◽  
Case History ◽  
Well Integrity

First Application of a Lightweight Salt Slurry to Help Cement Longest Intermediate Casing across Salt Section and Improve Well Economics: Case History from the Gulf of Suez

2012 ◽  
Author(s):  
Devesh Bhaisora ◽  
Nestor Paton ◽  
Arshad Waheed ◽  
Radi El Nashar ◽  
Mohamed Farouk ◽  
...  
Keyword(s):  
Case History ◽  
Gulf Of Suez

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.

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