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Cement Quality Assurance in FactoryCement Quality Assurance in Factory--StyleStyleWells in the Haynesville ShaleWells in the Haynesville Shale
Authors:
Eric Perner Petrohawk Ener
Corporation; Anthony Febbraro, Eric Evans,Jeff Watters, CSI Technologies LLC
Speaker: Eric Evans, CSI Technologies
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Agenda
Project Team
Haynesville Region/Wells Overview
Problems/Issues
QA/QC Program Solutions
Conclusion
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Project Team
Petrohawk Energy Corp.
Founded In 2003
Over 200 Wells Drilled In Haynesville To Date
Recentl Mer ed With BHP
CSI Technologies LLC
Founded In 1990
Independent Laboratory/Consulting Company
Focus on Field Operations And R&D
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Haynesville Region/Wells Overview
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Haynesville Region/Wells Overview
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Problems/Issues
Slurry Stability
Gas Migration
Placement And ECDs
Measured TOC Variation
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QA/QC Program
Analysis
Bulk Plant Loading
Laboratory Testing
Outcome
Operation Standardization
Helped Identify Ongoing Issues Solutions were proposed
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Slurry Stability
Issues
HPHT Zones Horizontal Sections
Hole Eccentricity
Risk Of Major Operational Failure Completion (Fracturing Treatments)
Solutions
New Laboratory Tests Modified Schedule
Cement Blend Standardization
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Settling
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Settling
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Settling
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Settling
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Settling
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Gas Migration Issues
Overburden Pressure Hydrostatic
Dynamic
Hole/Pipe Geometry
Displacement Efficiency
Solutions
Accurate Temperature Estimations
Slurry Design Modification
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Temperature Simulation
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Compressive Strength Development50 psi 500 psi 12 hr 24 hr 36 hr 48 hr
310F 6:31 7:58 2208 3793 - -
275F 7:00 8:20 1564 2604 - -
250F 21:36 24:30 0 0 1825 2050
225F 25:15 35:04 0 0 560 1200
50 psi 500 psi 12 hr 24 hr 36 hr 48 hr
310F 9:36 11:48 570 3370 3630 3700
275F 10:50 16:04 110 1330 2570 3230
250F 39:25 45:43 0 0 0 660
225F 48:10 57:23 0 0 0 30
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Placement And ECDs
Issues
High Pump Pressures
Lost Circulation
o u ons Crossover Location
Rheology
Improved Conditioning Techniques
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Losses Due to ECDs
Losses During
Displacement
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Crossover Location
5000
6000
7000
8000
ure(psi)
Surface Pressure vs. Casing Crossover Location
0
1000
2000
3000
4000
0 20 40 60 80 100 120 140 160 180 200
SurfacePress
Time (min)
XO as Run
XO at 9,500 ft
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Losses Due to ECDs
Losses During
Displacement
20
21
22
23
W)
ECD's at Shoe vs Cement Rheology
Baseline:
Pv=200, Yp=15;
Pv2=150, Yp2=14
Half Rheology:Pv=100, Yp=8;
Pv2=75, Yp2=7Double Rheology:
Pv=400, Yp=30;
Pv2=300, Yp2=28
17
18
19
0 20 40 60 80 100 120 140 160 180 200
ECD's(ppgE
Time (min)
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Rheology
Plastic Viscosity (cP) Yeild Point (lbf/100ft^2)
Before
After QC
Program Before
After QC
Program
80F 358 318 72 58
190F 324 227 55 33
190F CUP 351 138 62 19
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Measured TOC Variation Issues
Displacement Efficiency Cement Contamination
Improper Mud Removal/Cleaning
Drilling Stricter Back-Reaming
Pipe Rotation
Cementing Cement/Spacer Design Standardization
Pump Rate Control
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Standardization of Cementing
OperationsIntermediate Production
System Lead Tail Cement
Density (lb/gal) 12.6 - 13 14.6 - 15 17
Initial Bc
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Conclusion Implemented QA/QC Program
Bulk Plant Observation
Laboratory Testing/Confirmation
On-Site Observation
Testing Procedures New ett ng Tests
Compressive Strength Development
Standardized Cement Slurries Base Compositions
Performance Requirements
Reduction In Failure Costs No Cementing Related Major Operational Failures To Date
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Questions/Comments