Application of light-weight cementing slurries during well construction at Tatneft PJSC assets

UDK: 622.245.422
DOI: 10.24887/0028-2448-2021-7-14-17
Key words: oil-well cement, light-weight cement, lightweight agent, casing cementing
Authors: A.R. Iskhakov (TatNIPIneft, RF, Bugulma), I.M. Zaripov (TatNIPIneft, RF, Bugulma), S.I. Amerkhanova (TatNIPIneft, RF, Bugulma), A.M. Zaripov (TatNIPIneft, RF, Bugulma), A.A. Ismagilov (TatNIPIneft, RF, Bugulma), A.Sh. Shayakhmetov (TatNIPIneft, RF, Bugulma)

Well construction in carbonate rock intervals is accompanied by presence of cavernous fractured zones with low reservoir pressure and is complicated by drill mud and cement slurry losses. Loss of circulation is a typical problem for the most of the Tatarstan fields, so, best practices have been established during the decades. Two-stage cementing technique and light-weight cement slurries are used to provide top of cement up to the wellhead. Light-weight cementing slurry is prepared by adding agents of much lower density compared to cement or those agents that increase water-cement ratio. The major drawbacks of light-weight slurries are low set cement strength and technical difficulties of cement mixing.

The paper summarizes light-weight slurries development for production casing cementing at Tatneft assets. Light-weight cement slurries can be prepared based on standard cement using several techniques. These include increasing the volume of liquid phase in a slurry by adding, for example, water retaining agents; mixing of standard cement with lower-density fluids, such as oil and oil products; adding of solid agents with lower density than that of cement; cement slurry aerating. Tatneft was the first to use clays and gel powders as lightweight agents. The Company still uses light-weight cement slurries based on oil-well Portland cement and bentonite powder which are mixed in the dry state by multiple repacking at cement Contractors storage depot. The key contributor to density reduction is high water cement ratio, which adversely affects the set cement strength. Previously, different agents were used as light porous fillers for cement slurries, including perlite, expanded clay, foamed vermiculite, pumice, lignin. However, because of low triaxial compressive strength of porous fillers, they had limited application area. For this reason, other types of materials have come into common use, such as aluminosilicate, glass, ceramic and foam-glass microbeads.

References

1. Kateev I.S., Issledovanie i sovershenstvovanie sposobov povysheniya kachestva krepleniya skvazhin na pozdney stadii razrabotki neftyanykh mestorozhdeniy (Research and improvement of methods for improving the quality of well casing at the late stage of oil field development): thesis of candidate of technical science, Ufa, 1978.

2. Iskhakov A.R., Zaripov I.M., Ismagilov A.A., Razrabotka tekhnologii tsementirovaniya obsadnykh kolonn s ispol'zovaniem alyumosilikatnykh polykh mikrosfer (Development of casing cementing technology using hollow aluminosilicate microspheres), Proceedings of youth scientific and practical conference dedicated to the production of three billion tons of oil by Tatneft OAO, Al'met'evsk, 2007, Part 1, pp. 5455.

3. Ryabokon' S.A., Novokhatskiy D.F., Sovremennoe sostoyanie v oblasti tamponazhnykh tsementov i rastvorov (Current state in the oil-well cements and mortars), Collected papers Sovremennaya tekhnologiya i tekhnicheskie sredstva dlya krepleniya i remontno-izolyatsionnykh rabot neftyanykh i gazovykh skvazhin (Modern technology and technical means for casing and repair and insulation works of oil and gas wells), Proceedings of NPO Burenie OAO, 2000, V. 5, pp. 7588.

4. Gazizov M.G., Zaripov A.M., Zaripov I.M. et al., Optimizatsiya retseptury tamponazhnogo rastvora s ispol'zovaniem poristykh steklyannykh polnotelykh granul pri tsementirovanii ekspluatatsionnykh kolonn v OAO Tatneft' (Optimization of the grouting slurry formulation using porous glass full-bodied granules when cementing production strings at Tatneft), Collected papers Reagenty i materialy, tekhnologicheskie sostavy i burovye zhidkosti dlya stroitel'stva, ekspluatatsii i kapital'nogo remonta neftyanykh, gazovykh i gazokondensatnykh skvazhin (Reagents and materials, technological compositions and drilling fluids for construction, operation and overhaul of oil, gas and gas condensate wells), Proceedings of XVI International scientific-practical conference, Suzdal, 58 July 2012, Vladimir: Publ. of VlSU, 2012, pp. 130135.

5. Kateev R.I., Amerkhanova S.I., Zaripov I.M. et al., Tamponazhnyy rastvor so steklyannymi granulami (Grouting mortar with glass granules), Proceedings of TatNIPIneft' / Tatneft', 2013, V. 81, pp. 275281.

6. Vakula A.Ya., Belonogov S.V., Kateev R.I. et al., Pilot using of alleviated cement slurry in "Tatneft" JSC (In Russ.), Burenie i neft', 2013, no. 4, pp. 2628.

7. Kateev R.I., Zaripov A.M., Shayakhmetov A.Sh., Rezul'taty opytno-promyslovykh ispytaniy oblegchennykh tamponazhnykh rastvorov v PAO Tatneft' pri tsementirovanii v odnu stupen' (Results of field trials of lightweight grouting slurries at Tatneft PJSC during one-stage cementing), Collected papers Reagenty i materialy dlya stroitel'stva, ekspluatatsii i remonta neftyanykh, gazovykh skvazhin: proizvodstvo, svoystva i opyt primeneniya. Ekologicheskie aspekty neftegazovogo kompleksa (Reagents and materials for the construction, operation and repair of oil and gas wells: production, properties and application experience. Environmental aspects of the oil and gas complex), Proceedings of XXII International scientific-practical conference, 5-8 June 2018, Vladimir: Arkaim Publ., 2018, pp. 8285.

8. Patent RU 2 588 026 C1, Lightweight plugging composition, Inventors: Kateev R.I., Amerkhanova S.I., Shayakhmetov A.Sh., Gabbasov T.M., Latypova D.V., Gazizov M.G.

9. Zaripov I.M., Iskhakov A.R., Kateev R.I., Zaripov A.M., Tatnefts experience in well completion using fiberglass-reinforced plastic casing strings (In Russ.), Neftyanoe khozyaystvo = Oil Industry, 2018, no. 7, pp. 1819, DOI: 10.24887/0028-2448-2018-7-18-19.

10. Patent RU 2 720 025 C1, Casing string cementing method in well, Inventors: Zaripov I.M., Iskhakov A.R., Shayakhmetov A.Sh.

11. Kateev R.I., Zaripov A.M., Bikbulatov R.R., Kozlov A.V., Lightweight cement slurry with the addition of a foam glass ceramic (In Russ.), Burenie i neft', 2018, no. 3, pp. 2831.

12. Zaripov I.M., Iskhakov A.R., Kateev R.I. et al., Issledovanie kombinirovannogo napolnitelya dlya uluchsheniya tamponiruyushchikh svoystv tsementnogo rastvora (Study of the combined filler to improve the plugging properties of the cement slurry), Proceedings of TatNIPIneft' / Tatneft', 2019, V. 87, pp. 240245.

13. Shigabutdinov A.S., Gimatdinov V.N., Shakirov I.R. et al., Pilot industrial work on the introduction of foam cementing technology (In Russ.), Burenie i neft', 2020, no. 4, pp. 2832.

Well construction in carbonate rock intervals is accompanied by presence of cavernous fractured zones with low reservoir pressure and is complicated by drill mud and cement slurry losses. Loss of circulation is a typical problem for the most of the Tatarstan fields, so, best practices have been established during the decades. Two-stage cementing technique and light-weight cement slurries are used to provide top of cement up to the wellhead. Light-weight cementing slurry is prepared by adding agents of much lower density compared to cement or those agents that increase water-cement ratio. The major drawbacks of light-weight slurries are low set cement strength and technical difficulties of cement mixing.

The paper summarizes light-weight slurries development for production casing cementing at Tatneft assets. Light-weight cement slurries can be prepared based on standard cement using several techniques. These include increasing the volume of liquid phase in a slurry by adding, for example, water retaining agents; mixing of standard cement with lower-density fluids, such as oil and oil products; adding of solid agents with lower density than that of cement; cement slurry aerating. Tatneft was the first to use clays and gel powders as lightweight agents. The Company still uses light-weight cement slurries based on oil-well Portland cement and bentonite powder which are mixed in the dry state by multiple repacking at cement Contractors storage depot. The key contributor to density reduction is high water cement ratio, which adversely affects the set cement strength. Previously, different agents were used as light porous fillers for cement slurries, including perlite, expanded clay, foamed vermiculite, pumice, lignin. However, because of low triaxial compressive strength of porous fillers, they had limited application area. For this reason, other types of materials have come into common use, such as aluminosilicate, glass, ceramic and foam-glass microbeads.

References

1. Kateev I.S., Issledovanie i sovershenstvovanie sposobov povysheniya kachestva krepleniya skvazhin na pozdney stadii razrabotki neftyanykh mestorozhdeniy (Research and improvement of methods for improving the quality of well casing at the late stage of oil field development): thesis of candidate of technical science, Ufa, 1978.

2. Iskhakov A.R., Zaripov I.M., Ismagilov A.A., Razrabotka tekhnologii tsementirovaniya obsadnykh kolonn s ispol'zovaniem alyumosilikatnykh polykh mikrosfer (Development of casing cementing technology using hollow aluminosilicate microspheres), Proceedings of youth scientific and practical conference dedicated to the production of three billion tons of oil by Tatneft OAO, Al'met'evsk, 2007, Part 1, pp. 5455.

3. Ryabokon' S.A., Novokhatskiy D.F., Sovremennoe sostoyanie v oblasti tamponazhnykh tsementov i rastvorov (Current state in the oil-well cements and mortars), Collected papers Sovremennaya tekhnologiya i tekhnicheskie sredstva dlya krepleniya i remontno-izolyatsionnykh rabot neftyanykh i gazovykh skvazhin (Modern technology and technical means for casing and repair and insulation works of oil and gas wells), Proceedings of NPO Burenie OAO, 2000, V. 5, pp. 7588.

4. Gazizov M.G., Zaripov A.M., Zaripov I.M. et al., Optimizatsiya retseptury tamponazhnogo rastvora s ispol'zovaniem poristykh steklyannykh polnotelykh granul pri tsementirovanii ekspluatatsionnykh kolonn v OAO Tatneft' (Optimization of the grouting slurry formulation using porous glass full-bodied granules when cementing production strings at Tatneft), Collected papers Reagenty i materialy, tekhnologicheskie sostavy i burovye zhidkosti dlya stroitel'stva, ekspluatatsii i kapital'nogo remonta neftyanykh, gazovykh i gazokondensatnykh skvazhin (Reagents and materials, technological compositions and drilling fluids for construction, operation and overhaul of oil, gas and gas condensate wells), Proceedings of XVI International scientific-practical conference, Suzdal, 58 July 2012, Vladimir: Publ. of VlSU, 2012, pp. 130135.

5. Kateev R.I., Amerkhanova S.I., Zaripov I.M. et al., Tamponazhnyy rastvor so steklyannymi granulami (Grouting mortar with glass granules), Proceedings of TatNIPIneft' / Tatneft', 2013, V. 81, pp. 275281.

6. Vakula A.Ya., Belonogov S.V., Kateev R.I. et al., Pilot using of alleviated cement slurry in "Tatneft" JSC (In Russ.), Burenie i neft', 2013, no. 4, pp. 2628.

7. Kateev R.I., Zaripov A.M., Shayakhmetov A.Sh., Rezul'taty opytno-promyslovykh ispytaniy oblegchennykh tamponazhnykh rastvorov v PAO Tatneft' pri tsementirovanii v odnu stupen' (Results of field trials of lightweight grouting slurries at Tatneft PJSC during one-stage cementing), Collected papers Reagenty i materialy dlya stroitel'stva, ekspluatatsii i remonta neftyanykh, gazovykh skvazhin: proizvodstvo, svoystva i opyt primeneniya. Ekologicheskie aspekty neftegazovogo kompleksa (Reagents and materials for the construction, operation and repair of oil and gas wells: production, properties and application experience. Environmental aspects of the oil and gas complex), Proceedings of XXII International scientific-practical conference, 5-8 June 2018, Vladimir: Arkaim Publ., 2018, pp. 8285.

8. Patent RU 2 588 026 C1, Lightweight plugging composition, Inventors: Kateev R.I., Amerkhanova S.I., Shayakhmetov A.Sh., Gabbasov T.M., Latypova D.V., Gazizov M.G.

9. Zaripov I.M., Iskhakov A.R., Kateev R.I., Zaripov A.M., Tatnefts experience in well completion using fiberglass-reinforced plastic casing strings (In Russ.), Neftyanoe khozyaystvo = Oil Industry, 2018, no. 7, pp. 1819, DOI: 10.24887/0028-2448-2018-7-18-19.

10. Patent RU 2 720 025 C1, Casing string cementing method in well, Inventors: Zaripov I.M., Iskhakov A.R., Shayakhmetov A.Sh.

11. Kateev R.I., Zaripov A.M., Bikbulatov R.R., Kozlov A.V., Lightweight cement slurry with the addition of a foam glass ceramic (In Russ.), Burenie i neft', 2018, no. 3, pp. 2831.

12. Zaripov I.M., Iskhakov A.R., Kateev R.I. et al., Issledovanie kombinirovannogo napolnitelya dlya uluchsheniya tamponiruyushchikh svoystv tsementnogo rastvora (Study of the combined filler to improve the plugging properties of the cement slurry), Proceedings of TatNIPIneft' / Tatneft', 2019, V. 87, pp. 240245.

13. Shigabutdinov A.S., Gimatdinov V.N., Shakirov I.R. et al., Pilot industrial work on the introduction of foam cementing technology (In Russ.), Burenie i neft', 2020, no. 4, pp. 2832.


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