supercement for annular seal and long-term integrity in deep, hot wells de-fc26-02nt41836
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Supercement for Annular Seal Supercement for Annular Seal and Long-term Integrity in and Long-term Integrity in Deep, Hot Wells Deep, Hot Wells
DE-FC26-02NT41836
Problem:Long Term Zone Problem:Long Term Zone Isolation in HTHP WellsIsolation in HTHP Wells
High Temperature and Pressure
Deviation angles - Placement is difficult
High Density systems – 17 to 20 ppg well fluids
High Pressure Gas – Gas migration
Narrow Annuli – High Friction
Liners versus longstrings
Tie Backs and Expandable Liners
CO2 and H2S common
Problem: Well Intervention is Problem: Well Intervention is Big CostBig Cost Survey – 15% of all primary jobs require remedial
cementing Estimate of 35% of HTHP primary jobs require remedial
cementing Cost estimate:
– On shore - $100k per squeeze (average 2 per)– Off shore - $500k per squeeze (average 2 per)
Bigger cost for Operators – Long Term loss of production– Interzonal flow– Water influx
Project ObjectivesProject Objectives Develop database of jobs for evaluation Determine the cement system properties that affects
the ability of cementing materials to provide long term zone isolation under deep hot conditions
Use recently developed laboratory methods to determine key properties
Evaluate various materials to generate the key properties
Develop Supercement systems!!!! Application for all wells including “deep hot”
Project Work Team Project Work Team CSI Technologies LLC
Material Manufacturers
Steering Committee
Operators
HTHP Well DatabaseHTHP Well Database
Develop database for HTHP Cementing– Determine critical well info and parameters– Successful cementing/completion– Unsuccessful cementing/completion– Confidentially is important (all contributing
members have access)– Track industry practices and results– Status – rollout week of 10-31-05
Update with outside data if possible
Deep Trek Technical Interest Deep Trek Technical Interest Web-SiteWeb-Site
CSI/DOE develop web-site – Clearing house for discussion, questions,
concerning Deep Trek wells– Focus mainly US but can include others– Look for trends, new information, repeating
issues, new technologies used etc.
Mechanical Integrity IssuesMechanical Integrity Issues Flow of Fluids
– Around the Cement Bonding, Microannulus, Deformation
– Through the matrix of the Cement Cracking, Permeability changes
– Stress Pressure, Temperature Stress Cycling Conditions Mechanical shock
Mechanical Integrity Issues - Mechanical Integrity Issues - SolutionsSolutions Improve material properties relative to Portland
Cements:– Higher Tensile Strength– Higher Ductility*– Lower Anelastic Strain– Higher Young’s Modulus
Correlate material properties with performance
Anelastic StrainAnelastic StrainDefinition: Permanent Deformation resulting from
Low-Intensity Stress Cycling
– Measured at 25% and 50% ultimate strength– Tensile and Compressive may be very different– All Portland cements exhibit behavior – Measured by comparing “ideal” (completely elastic)
behavior with actual– Low-level stress can modify ultimate strength
Potential HTHP SolutionsPotential HTHP Solutions
Multi-material solutions– Optimized sealing– Optimized strength
Placement methods Enhanced Portland performance Non-Portland materials Hybrid Portland materials
Phase I TasksPhase I Tasks
Literature Search on Portland and Non-Portland Binders
Evaluate materials at low temperatures Evaluate materials at high temperatures Evaluate materials with non-traditional
testing
Literature Search StrategyLiterature Search Strategy
Emphasis on non-Portland binder research Emphasis on ceramic acid-base reactions Effects of unconventional additives on
Portland cement properties Refractory cements Emphasis on non-oilfield binder
applications
Literature Search ResultsLiterature Search Results
Chemically-reactive fibers– Ceramic– Kevlar
Inorganic expansive additives– Molybdenum– High concentrations of MgO
Ceramicrete (ANL) Calcium Aluminum Silicate High-temperature resins
Material Evaluation StrategyMaterial Evaluation Strategy Conduct screening laboratory tests to determine
material properties
Advanced material property and performance testing on best materials from screening tests
Evaluate materials at low and high temps
Correlate material properties and performance
Material Evaluation StrategyMaterial Evaluation Strategy Conventional testing
– Compressive Strength– Tensile Strength
Kinetics and Placement– Thickening time– Consistency
Material Evaluation StrategyMaterial Evaluation Strategy Non-traditional testing
– Young’s Modulus– Anelastic Strain / Fatigue– Annular Seal performance under cyclic loading– Expansion– Shearbond
Material Evaluation ResultsMaterial Evaluation Results Candidate Phase II Materials
– 9 formulations in 3 product categories: Non-Portland
– High-temperature resin
– Calcium Aluminum Silicate
Portland with Unconventional Additives– MgO
– Molybdenum
Reactive Fibers– Modifier for other slurry systems
Material Evaluation ResultsMaterial Evaluation Results “Best” properties do not always mean best
performance
No single property is a reliable predictor of performance
Performance based on Annular Seal model
Preliminary numerical model relates energy application and resistance prior to loss of seal to cement properties
When available, evaluate Single-Wall Carbon Nanotubes as performance-enhancing additive
Material Evaluation ResultsMaterial Evaluation ResultsSystemSystem FormForm
ulaulaRecipeRecipe WatWat
ererDensDensityity
BaselinBaselinee
9999 H + 35% Silica FlourH + 35% Silica Flour 5.165.16 16.616.6
Mod Mod BaselineBaseline
7777 H+25% SBMC+15% MFA+2% H+25% SBMC+15% MFA+2% Daxad 9Daxad 9
2.502.50 19.719.7
MgOMgO 128128 Baseline 77 + 20% MgO HBaseline 77 + 20% MgO H 3.603.60 19.019.0
MolyMoly 132132 Baseline 99 + 0.5% MolyBaseline 99 + 0.5% Moly 5.195.19 16.616.6
MolyMoly 133133 Baseline 77 + 0.5% MolyBaseline 77 + 0.5% Moly 2.502.50 19.719.7
ResinResin 188188 Resin + Hardener + Reactive Resin + Hardener + Reactive DiluentDiluent
N/AN/A 9.09.0
SilicateSilicate 180180 NaSiONaSiO33 + CaOH + AlOOH + CaOH + AlOOH 24%24%
FiberFiber 130130 Baseline 99 + 1.0% Ceramic Baseline 99 + 1.0% Ceramic FibersFibers
5.215.21 16.616.6
FiberFiber 131131 Baseline 99 + 1.4% Ceramic Baseline 99 + 1.4% Ceramic FibersFibers
5.245.24 16.616.6
FiberFiber 136136 Baseline 77 + 0.5% Ceramic Baseline 77 + 0.5% Ceramic FibersFibers
2.502.50 19.619.6
Material Evaluation ResultsMaterial Evaluation Results
SystemSystem FormFormulaula
ComCompp
TensilTensilee
AS * AS * 1010-6-6
SBSB Ann Ann SealSeal
BaselineBaseline 9999 4,7904,790 705705 5.875.87 260260 44,850
Mod Mod BaselineBaseline
7777 5,6505,650 725725 3.493.49 470470 29.900
MgO MgO 128128 3,193,1900
281*281* * 1851850+0+
Pend HT
MolyMoly 132132 4,2804,280 1,0831,083 1.551.55 308308 1,325,360
MolyMoly 133133 6,686,6800
1,3661,366 0.850.85 570570 349,900
ResinResin 188188 5,555,5500
3,6903,690 18.23*18.23* 1851850+0+
In Proc
Silicate Silicate 180180 1,2401,240 970970 6.416.41 In Proc
FiberFiber 130130 3,7103,710 1,0161,016 4.044.04 300300 0
FiberFiber 131131 3,023,0200
1,1491,149 3.103.10 190190 8,250
Fiber Fiber 136136 4,5104,510 1,3121,312 1.591.59 1,0201,020 1,749,500
High-Temperature Epoxy ResinHigh-Temperature Epoxy Resin Solves problems with Furan Resins
– Shrinkage– Water intolerance– Weighting / Lightening destroys properties– Difficult to control kinetics
High-Temperature Epoxy Resins– Discovered as part of a different project– Traditional usage – HT winding insulation for electric motors– Evaluation revealed controllable kinetics at high temps– Material subjected to DeepTrek testing
High-Temperature Epoxy ResinHigh-Temperature Epoxy Resin Properties
– Very high tensile and compressive strength– High shearbond– Rubber-like
Absorbs large amount of energy without failure Difficult to test using conventional cement test protocols High anelastic strain over short time / Low anelastic strain
over long time (deforms, then rebounds)
High-Temperature Epoxy ResinHigh-Temperature Epoxy Resin Issues
– Liquid / liquid system– Health issues with handling– Highly exothermic – must cure under pressure– Can use conventional batch mixers– Dedicated automatic-controlled continuous mixer
feasible– Requires different test protocols and equipment to
adequately quantify properties and performance
Modifications to ResinModifications to Resin
Combine with Cement– Solids help with fluid loss – Penetration of big voids with cement– Filtrate of the fluid sets and consolidates
formations– Sealing and zone isloation not only in wellbore
but in the formation itself
Phase II TasksPhase II Tasks
Manufacture Supercement to specification Batch testing to confirm performance on
large scale Large-scale mixing, shearing, and drillout,
testing Field test, research test well
Phase II Result to DatePhase II Result to Date
Phase II Tasks nearly complete for Epoxy Resin – Field-scale mixing, shear, and drillout testing– Large-scale manufacturing– Field tests in low temperature (200 deg F) well
Phase II Remaining Work– Deep, Hot test well application– Test well applications of other candidate systems
Phase II Results to DatePhase II Results to Date
Continuing materials property and performance testing to refine formulations– Epoxy Resin– Calcium Aluminum Silicate– MgO and Moly (performance)– Hybrid Epoxy Resin / Portland Cement
Interesting properties Fills matrix voids with strength and ductility-contributing
material
Testing IssuesTesting Issues Cannot measure tensile strength via Splitting
Method for highly expansive cements
Cannot measure tensile Young’s Modulus with indirect Splitting method
“Ultimate” Annular Seal test must be conducted at elevated temperatures
Expansion of highly-expansive cements cannot be measured with current tests
Testing Issues - SolutionTesting Issues - Solution Design new test equipment, develop testing
protocols, and perform validation tests– “Direct” tensile strength test– Expansion under elevated temperature and
pressure conditions– High temperature Annular Seal
Phase II Extension Proposal to Develop apparatus, protocols, and validation
Direct Tensile Strength MethodDirect Tensile Strength Method No industry-
authorized method
Different methods give different results
Proposed method yields tensile YM
High Temperature ExpansionHigh Temperature Expansion Utilize split
sleeve Expansion
imposes forces on transducers
Continuous measurement of expansive forces
High Temperature Annular SealHigh Temperature Annular Seal Test resistance for
gas flow continuously at temperature and pressure
Different methods give different results
Proposed method yields tensile YM
Phase III – 2007-2008Phase III – 2007-2008
Evaluate Supercement in Field Applications Cost / benefit analysis Commericalization / Technology Transfer
Deep Star ProjectDeep Star Project
Determine current technology and gaps in cementing and zone isolation at HTHP wells primarily in deep water
Considering leveraging Deep Trek for addressing key gap in cementing
CO2 and H2S resistance at elevated T and P Estimated funding at $1million (non DOE
funds)
SummarySummary Successful Phase I – multiple candidate
systems of interest Successful Phase II to date with Epoxy
Resin Additional test apparatus and protocols
required to evaluate candidate systems under HTHP conditions