1. Reduction of Remedial Cementation of Production Liners…
…through the use of Equipment, Procedures & People
Nicole Baird: EPW-GOM TLP, Jackup & Platform Wells Team Lead
Loran Galey: SIEP-EPT Well Performance Team – Cementing Expert
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2. Objectives Case for Action – NPT Related Trouble Time / Cost
GOM Production Cementing Staircase – Equipment, Process, People
2007 – 2008 Results
GOM Learnings
Go-Forward Plans& Next Steps for 2008 – 2009+
Conclusions
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3. Case for Action 2004-2005 GOM operations experienced 26 NPT events
Total Days associated with Prod Csg Cmt NPT = 25.2 days
Total Cost (2008$$) associated with Prod Csg Cmt NPT = $4.4 MM
Objective sands becoming depleted, psi (34,475 kPa)
Reduced Margins for cementing ECDs
Max PP – Min FG margins of 0.6 ppg or less common (72 kg/m3)
Compaction-induced wellbore failures
TLP weight / space constraints prohibit use of specialty equipment
Slimhole sidetracks, tighter clearances between csg strings more common
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4. Historical Production Csg Cement NPT
Average reduction in NPT $ of 20% per year
Year 2006 numbers impacted by Ursa A4ST
2008 YTD Numbers (as of June 20, 2008)
NPT Cost associated with Prod Csg Cmt = $624,000: NPT Time = 1.9 days
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5. GOM Approach: What, Where, How & When
Joint development with BTC Experts (Cowan, Galey) and Service Providers (HES, SLB)
Focus on all aspects – Equipment, Slurry Design, Procedures, People
Rotatable Liner Hangers
Remote Plug Dropping Heads
Lightweight Slurries for 14 – 15 ppg environment (1680 – 1800 kg/m3)
Move from “pump to bump” mentality to “theoretical displacement”
Manage the level of change – use small steps versus fundamental movements
It’s about the “small” things that you do while drilling,
post-drilling, and cementing that add up to big results!
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6. Staircase Approach: What, Where, How & When
Integrated Team Effort
Well Engr Staff
Offshore Rig Team
Technology
Service Providers
2008 H2
Clear Fluid Displacement
Technology for “Small Csg & Big Hole”
Slimhole Use of D155 for Light Cmt
2008 H1
Swellables (Zonal Isolation, TOL) = Brutus, Mars, Auger
Use of D155 for Low Cost Lightweight Cmt = Auger A10
2007
Remote Plug Dropping Head = Auger A2
Ream-down systems (hnr, shoe, etc) = Auger A8 & A13
Use of Focused T&D Plots = Auger A10
Swellable Placement = Auger A13
2006
Rotatable Hnrs (TIW) = Brutus A5ST3
LiteCrete Slurry Design = Auger A18
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7. GOM Results to Date
No remedial production cementation jobs since Ursa A4 (2006)
Have experienced problems with equipment (liner hangers) which have caused NPT as a result of altering method of primary cementation (Brutus A7ST2 Versaflex activation, Mars A8 plugging of shoe track)
LiteCrete dry bulk segregation at Auger is predominate cause of NPT in 2007
Drove trial use of D155 with conventional class H on Auger A10 & 2008 Summer Program
Successfully rotated / reamed liners to TD as proactive measure
Allowed rotation at TD
Use of Remote Plug Dropping head enabled full rotation during cementation
Joint Taskforce established to link pre-cementation activities (Hole Cleaning, Liner / Casing Running) and shift operational paradigms
NET RESULTS, Year to date NPT cost = 1.9 days / $624,000
Of this, 1.3 days and $250,000 was due to failure of a TIW Xpak system post cementation on Brutus A1ST3
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8. Auger A10 ST3: Swellable, D155, Depleted Sands
Cmt. Technology Implemented
Swellables for zonal isolation / cmt channeling
Rotatable 7” liner and equipment, for reaming & rotation at TD of 25,000’ MD
Use of D155 as alternative to LiteCrete
Location of Swellable, CBL ran prior to swell time expended
Objective Sand (Perforations):
Depleted from 12.6 ppg to 6.7 ppg (6000 psi depletion)
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9. Brutus A7ST2: SH cementation (5.5”) after reaming to TD
Initial 7 5/8” production liner stuck
Redrilled section below 7 5/8” and ran 5.5” liner
Rotated 5.5” liner from 21,384 to 22,150’ MD
Full rotation while prep for cmt job
No rotation established after stopping to drop Drill pipe dart
Unable to set Versaflex Hanger due to high angles – circulated out primary cmt job during setting process
CBL log of 2nd primary cementation attempt with EZSV – 6 days after liner on bottom.
Successful job attributed to rotation (“smear effect”) of liner to TD & use of RSS system
J2 sand (Objective Interval)
Cemented 6 days after Lnr to TD
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10. Learnings & Continuous Improvement (1)
Utilization of LiteCrete requires careful consideration
Issues of Dry Bulk segregation
Sensitive to mix water volumes & proper slurry recirculation for target density
D155 as alternate to LiteCrete
Advantages:
One dry-blend cement (Class H) for entire job
All liquid additives. Unused additives can be returned
Flexibility to make last-minute slurry density changes
Easier to sample and test
50% cost reduction compared to LiteCRETE
Disadvantages:
Rig space could limit job size. Deck space is needed for liquid tanks.
Liquid additive hoses present additional tripping hazards
More liquid additive volume onboard, therefore more risk of chemical spill (although D155 is non-hazardous)
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11. Learnings & Continuous Improvement (2)
Use of swellables in oversized hole applications
Low side channeling prevention
Added “flow barrier” for multiple intervals (spaceout becomes critical)
Multiple companies distributing product – engineer the design upfront
Don’t overestimate the power of paradigms
“Pump until you bump”
“We’ll establish rotation once we get to TD”
“What’s 0.1 ppg difference in ECD?”
Shift the design one element at a time
Know what you are changing and why  ensure buy-in
Test more than just cement – mud interfaces
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12. Next Steps: Where do we go from here?
Synthetic Based Mud Contamination
New DP Dart & Casing Liner wiper plug designs
Use of Higher Density Slurries (increased contamination resistance)
Depleted Sands in GOM
Use of Managed Pressure Drilling equipment for cementation operations
Use of graphitic carbons (G-seal, vin-seal, etc) to serve as LCM plugging in cementation slurry designs
Hole Cleaning Prior to Cementing / As Part of Cementing
Use of “foamed flushes” ahead of cement slurries
Use of “foamed spaces” as part of clean up cycle
3-Dimensional Modeling for Cement Displacement Efficiency
Standard Use of KCl Additive for Prevention of Shale / Clay Swelling
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13. whereby small changes add up to big results
Conclusions
One of the most common practices, yet it can cause significant problems later in the life of the wells
Sustained Casing Pressure
Micro-annulus
New practices, procedures & combinations can reap great benefits and not necessarily new technology
Remote Plug Dropping Heads
Class H slurries + different additive combinations
Rotation & centralization for displacement efficiency
Performance Improvement is all about doing everything you can right the first time,
whereby small changes add up to big results
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14. Acknowledgements SIEP-EPT Well Performance Team, Fluids & Cementation
Mike Cowan
Loran Galey
Ron Rock
EPW Wells-GOM TLP, Jackup, Platform Drilling Engrs
EPW Wells-GOM TLP, Jackup, Platform Completion Engrs
Service Providers: Halliburton (Cementing, EasyWell), Schlumberger (Cementing), TIW (Liner Hangers), Baker (Liner Hangers), MI (Fluids)
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