Classification – Additives – Calculation Well Design - PE 413 Classification – Additives – Calculation of Drilling Cements

Classification of Drilling Cements API has defined: Eight standard classes designated class A to class H. Three standard types of cement for use in wells. Three types specified are: Ordinary O, Moderate sulfate-resistant MSR, And high sulfate-resistant HSR.

Classification of Drilling Cements

Classification of Drilling Cements

Classification of Drilling Cements

Classification of Drilling Cements

Classification of Drilling Cements

Cement Additives For the slurry: Thickening time (acceleration, retardation) Density (extenders, weight increase/reduction) Friction during pumping Fluid loss (by filtrate) Lost-circulation resistance (whole slurry loss) For set cement: Compressive strength Strength retrogression (loss with time) Expansion/contraction

Cement Additives

Cement Additives Accelerators Cement-setting time is accelerated to reduce WOC time and to increase early strength. This is desirable for surface pipe, in shallow (cooler) wells, and for setting plugs. The most common accelerators are calcium chloride, sodium silicate, sodium chloride (low concentrations), seawater, hemihydrate forms of gypsum, and ammonium chloride. Type: Accelerators Amount used per sack (% by weight) Calcium Chloride (CaCl2) (flake, powder) 2 - 4  Sodium Chloride (NaCl) 3 - 10 (water)  Sodium Silicate (Na2SiO3) 1.5 - 5 (cement)

Cement Additives Retarders Cement-thickening time is slowed primarily to allow the slurry to be pumped and displaced into position before setting. Retarders Amount used per sack (% by weight) Calcium-Sodium Lignosulfonate 0.1 - 1.0 Calcium Lignosulfonate 0.1 to 1.0 Saturated Salt Solutions -

Temperature Effect on the Thickening Time Cement Additives Temperature Effect on the Thickening Time Thickening time is a function of both temperature and pressure, and these effects must be predicted before additives are selected

Density Reducing Additives - Extenders Cement Additives Density Reducing Additives - Extenders Slurry density may be reduced with extenders such as bentonite, pozzolan, diatomaceous earth, and anhydrous sodium metasilicate. Low-density slurry is frequently preferred, to decrease the likelihood of breaking down the formation and causing lost circulation. In addition, low- density slurries cost less per cubic foot because yield per sack is increased. Density decrease results in large part from increased water content. Extenders, with their high surface area to "tie up" water, permit water addition without separation. Cement strength is reduced approximately in proportion to water-content increase. However, we shall see later that high strength is not always required

Density Reducing Additives - Extenders Cement Additives Density Reducing Additives - Extenders Type: Density reducers/extenders Amount used per sack (% by weight) Bentonite 2 to 16 Attapulgite 1/2 to 4 Diatomaceous Earth (Diacel D) 10, 20, 30 or 40 Pozzolan, Artificial (fly ash) 74 lb/sk

Density Increasing Additives Cement Additives Density Increasing Additives High density cement sluries are often necessary to offset the high pressures that are frequently encountered in deep or abnormally pressured fromations. Density may be increased with weight material such as sand, barite, hematite or ilmenite, and/or salt dissolved in the mix water. Density increasers Amount used per sack (% by weight) Sand 5 to 25 Barites 10 to 108 Ilmenite (iron-titanium oxide) 5 to 100 Hematite 4 to 104 Salt 5 to 16

Filtration Control Additives Cement Additives Filtration Control Additives Fluid loss, or the premature escape of mix water from the slurry before chemical reaction occurs, can cause many downhole problems, including Differential sticking of casing and decentralization Formation damage by filtrate (if not controlled by mud cake) Loss of pumpability Cement bridging above gas zones and gas cutting from hydrostatic pressure loss Improper or premature dehydration during squeezing

Filtration Control Additives Cement Additives Filtration Control Additives Materials to reduce filtrate loss and friction Amount used per sack (% by weight) Fluid-loss additives 0.5 -1.5% Organic polymers (cellulose) 0.5 – 1.5%  Carboxymethyl hydroxyethyl cellulose (CMHEC) 0.3 - 1.0% Latex additives, form films 1.0 gal/sk Bentonite cement with dispersant 12-16% gel

Amount used per sack (% by weight) Cement Additives Friction Reducer Friction reducers or dispersants are commonly used to lower viscosity, yield point and gel strength of the slurry to reduce friction in pipe, and thus allow turbulent flow to occur at reduced pump rates. These additives also permit slurries to be mixed at lower water/cement ratios so that higher densities may be achieved. Type: Friction reducer Amount used per sack (% by weight) Polymer: blend 0.5 to 0.3 lb/sk Polymer: long chain 0.5 to 1.5 lb/sk Calcium lignosulfonate Sodium Chloride 1 to 16 lb/sk Organic acid 0.1 to 0.3 lb/sk

Lost Circulation Materials Cement Additives Lost Circulation Materials "Lost circulation" or "lost returns" refers to the loss to formation voids of either whole drilling fluid or cement slurry used during the course of drilling or completing a well. Cement, with its larger particle size is less susceptible to loss in permeable formations. Types of lost-circulation additives available for cement are blocky- granular materials (walnut shells, gilsonite, crushed coal, perlite- expanded and perlite-semiexpanded) which form bridges, and laminated materials (cellophane flakes) which form flake-type mats.

Lost Circulation Materials Volumes used, typical range Cement Additives Lost Circulation Materials Type material Generic name Type particle Volumes used, typical range Granular   Gilsonite Graded 5-50 lb/sk Perlite Expanded 1/2-1 cu ft/sk Walnut shells 1-5 lb/sk Coal 1-10 lb/sk Lamellated Cellophane Flakes 1/8-2 lb/sk Fibrous Nylon Short fibers 1/8-1/4 lb/sk

Lost Circulation Materials Cement Additives Lost Circulation Materials

Cement Additives Summary

Calculation Basic Calculations When the concentration of an additive is expressed as a weight percent, the intended meaning is usually that the weight of the additive put in the cement mixture is computed by multiplying the weight of cement in the mixture by the weight percent given by 100%. Percent mix = water weight x 100/cement weight The volume of slurry obtained per sack of cement used is called the yield of the cement. 1 sack = 94 lbm.

Calculation Basic Calculations

Calculation Basic Calculations Note 1: The addition of bentonite to cement requires that the amount of water be increased. It is recommended, for testing purposes, that 5.3% water be added for each 1% bentonite in all API classes of cement. Note 2: The addition of barite to cement generally requires that the amount of water be increased. It is recommended, for testing purposes, that 0.2% water be added for each 1% barite.

Calculation Basic Calculations Example 1: A class A cement slurry having a water/cement ratio of 0.46 will be added 3% of bentonite. What is the required increase in water/cement ratio? Answer: 46% + 5.3% x 3 = 61.9% Example 2: A cement slurry having a normal water/cement ratio of 0.38 and weighted to 18 lbm/gal by addition of 60% of barite. What will be the required increase in water/cement ratio? Answer: 38% + 0.2% x 60 = 50%

Calculation Basic Calculations

Water Requirements of Cement Materials Calculation Water Requirements of Cement Materials

Water Requirements of Cement Materials Calculation Water Requirements of Cement Materials

Calculation Basic Calculations Example 1: it is desired to mixed a slurry of class A cement containing 3% bentonite, using the normal mixing water as specified by API. Determine the weight of bentonite and volume of water to be mixed with one 94-lbm sack of cement. Also compute the percent mix, yield, and density of the slurry.

Calculation Basic Calculations The weight of bentonite to be blended with one sack of class A cement: 94(lbm)0.03 = 2.82 lbm/sack The normal water content for class A cement is 46%. 5.3% water must be added for each percent bentonite. Thus, the percent mix is: 46 + 5.3 x 3 = 61.9% The weight of water to be added per sack 0.619 x 94 = 58.186 lbm/sack The volume of water to be added for one sack 58.186(lbm) / 8.33 (lbm/gal) = 6.98 gal/sack

Calculation Basic Calculations Yield = total volume of slurry in one sack Yield = Vcement per sack + Vbentonite per sack + Vwater per sack Yield = 94(lbm) x 0.0382(gal/lbm) + 2.82 (lbm) x 0.0453 (gal/lbm) + 6.98 (gal) Yield = 10.69 gal/sack Density of the slurry = total mass of slurry / total volume of slurry Density of the slurry = (94 + 2.82 + 58.186) / 10.69 = 14.48 lbm/gal

Calculation Density Calculations Example 2: It is desired to increase the density of a class H cement slurry to 17.5 lbm/gal. Compute the amount of hematite that should be blended with each sack of cement. The water requirements are 4.5 gal/94 lbm class H cement and 0.36 gal/100 lbm hematite.

Water Requirements of Cement Materials Calculation Water Requirements of Cement Materials

Calculation Density Calculations Let x represent the mass of hematite per sack needed to bring the slurry cement density up to 17.5 lbm/gal. The slurry includes: 94-lbm cement, x-lbm hematite, and y-lbm water. The volume of water needed for mixing 1 sack of cement and x-lbm of hematite: Vwater = 4.3 + 0.36(x)/100 = 4.3 + 0.0036x (gal) The weight of water needed for mixing 1 sack of cement and x-lbm of hematite mwater = (4.3 + 0.0036x)8.33 (lbm)

Calculation Density Calculations x = 18.3 lbm hematite per 94 lbm cement.