iptc 18151-ms first application of thermal activated resin ... lcm_presentation 10-12 december...

IPTC 18151-MS

First Application of Thermal Activated Resin as

Unconventional LCM in the Middle East

K. Knudsen, G.A. Leon, A.E. Sanabria, WellCem AS; A. Ansari, R.M.

Pino, Saudi Aramco

CONTENT

1. INTRODUCTION

2. LOSS CIRCULATION

3. LOST CIRCULATION MATERIAL (LCM)

4. NEW MATERIAL: THERMAL ACTIVATED RESIN

5. CASE HISTORY

6. CONCLUSIONS

Slide 2

IPTC 18151-MS • First Application of Thermal Activated Resin as Unconventional LCM in the Middle East

• Kristen Knudsen

INTRODUCTION

• Why loss of circulation occurs?

• How to solve it during drilling and/or cementing?

• Loss of circulation treatments: addition of solid materials to the drilling

mud or use of a non-mud system.

• Loss of circulation, Unsafe operation, Hi potential risk for personal and

material injury, well integrity and time consumming operation.

• This paper presents: Thermal Activated Resin solution. Challenging

field cases in the Middle East.

Slide 3


• Kristen Knudsen

LOST OF CIRCULATION

• Partial or complete loss of drilling

fluid or cement.

• Four types of formation are

responsible for loss of circulation

(Figure).

• Consequences: increased cost, loss

of time, plugging of productive

zones, blowouts, etc.

• Essential part of drilling engineering.

Slide 4


• Kristen Knudsen

LOST CIRCULATION MATERIAL (LCM)

• Fiber Additive to drilling fluids, cement slurry or frack fluid penetrating

a formation.

• Insoluble or water soluble.

• Pumped down a well and spotted to build up an impermeable layer /

filter cake.

• Sometimes two or three pills are used to stop losses / reduce losses.

• In most cases, cement or viscous mud pills with LCM allow to

temporarily reducing the losses but do not guarantee a durable

plugging of the formation.

Slide 5


• Kristen Knudsen

NEW MATERIAL: THERMAL ACTIVATED RESIN

Slide 6


• Kristen Knudsen

• Multi component polymer based liquid resin with a right angle

curing process activated by temperature.

• New cementing technology has overcome a lot of traditional cement

problems.

Property Range

Specific Gravity (SG) 1.03 – 1.05

Density 0.75 – 2.5 g/cc (44 – 156 pcf)

Viscosity 10 – 2000 cP

Setting time 3 min to as long as required

Right angle set Yes

Miscible with water or well fluids No

Pumpable through Tubing / Drill Pipe / BHA

/ Bit Yes

Target Temperature 9 – 135 C (48 – 275 F)

Resistant up to (Temperature) 480 C (896 F)


Slide 7


• Kristen Knudsen

• It acts as fluid and has a variety in weight and viscosity (Figure)

• Thermal Activated Resin can be adjusted to determined formation

temperatures between 20 – 150 C.


Slide 8


• Kristen Knudsen

• Thermal activated solids free resin that can deeply penetrate

formations.

• Provide a full seal off micro cracks and channels.

• Best solution for well integrity challenges.

• “Drill & Treat” with this product, results in huge cost savings.

• Extraordinary bonding to steel.

• Compatible with most fluids and extremely tolerable to

contamination ( Up to 45% ).


Slide 9


• Kristen Knudsen

• Phases of thermal activated resin

reaction:

• Gel time: Elapsed time between

resin reaching application’s

temperature and starting of

exothermal reaction.

• Setting time: Total elapsed time

between sample reaching

application’s temperature and

exothermic peak returned to the

baseline.


Slide 10


• Kristen Knudsen

Thermal Activated Resin additive materials:

• Curing Initiator

• Accelerators

• Inhibitors

• Viscosifier

• Weight Fillers

• Thermal Activated Resin Cleaner

• Thermal Activated Resin Solvent


Slide 11


• Kristen Knudsen

Thermal Activated Resin vs. Traditional Cement

Properties Thermal Activated Resin Traditional Cement

Water permeability, mD < 0.5 1,600

Compressive strength, Mpa 77 58

Flexural Strength, Mpa 43 10

Failure flexural strain, % 1.9 0.32

E-Modulus, Mpa 2,240 3,700

Tensile Strength, Mpa 60 1

Density, S.G. 0.75 – 2.5 1.5 +

Right angle setting Yes No


Slide 12


• Kristen Knudsen

Thermal activated resin has wide range of applications such as:

• Lost Circulation Material.

• Casings leak repairs.

• Plugs for P&A.

• Squeeze jobs to seal off leaks.

• Zonal Isolation / Water and Gas Shut off.

• Casing cementing and top filling jobs (CCA)

• Control line plug off.

• Inflatable Packer material for permanent packers.

• Sand consolidation.

• Sand plugging

• Multilateral strengthening.

CASE HISTORY

Slide 13


• Kristen Knudsen

The Karan Field is located

offshore of the Arabian Gulf in

Saudi Arabian territorial waters.

First non-associated gas field

being developed in the

Kingdom of Saudi Arabia.

Parameters Value or Range

Formation name Sudair Formation

Depth of LCM application (ft) 10,100 – 10,714

Hole size (inch) 12 ½

Losses rate (BPH) 300

Mud weight inside the well (pcf) 152

Dynamic Temperature @ depth (F) 194

Parameters of the Loss of

Circulation Problem

CASE HISTORY

Slide 14


• Kristen Knudsen

Pre testing results for a fast thermal activated resin setting time

Recipe for the

thermal activated

resin slurry

Temperature

(F)

Curing

Initiator

(%)

Start

Time

Time when

reached Temp

Gel

Time

Gel Time

(min)

Overall

Setting Time

(min)

194 4 12:21 12:31 12:42 11 13

194 5 12:21 12:31 12:39 8 9

194 7 12:21 12:31 12:36 5 6

Additives Volume / Weight

Thermal activated resin 4,500 ltrs

Weight Filler 14,500 Kg

Viscosifier 60 Kg

Curing Initiator 166 ltrs

Drill and Treat Case History

Slide 15


• Kristen Knudsen

CONCLUSIONS

Slide 16


• Kristen Knudsen

• Thermal activated resin as a Lost Control Material provides the

best solution for well integrity and loss of circulation in the oil and

gas industry.

• Temperature profile is crucial for an accurate thermal activate

resin design.

• Formation was isolated, stopped losses and got 100% return in

offshore well located in Karan Field.

• Top of cured thermal activated resin pill was tag with drill pipe

with 10,000 psi.

• Resumed drilling operations with 100 ft/hr without any problems.

after tagging top of thermal activated resin pill.

Thanks you for your kind attention!

Questions?

Slide 17

iptc 18151-ms first application of thermal activated resin ... lcm_presentation 10-12 december...

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