400bbl Batchmixer oil well cementing

1. Magnum Cementing Services
February 29, 2016
Benefits of Large Volume Cement Batch Mixing
in Horizontal Well Casing Design

2. Overview
Cement Mixing Methods
• Continuous Mixing: High Energy Recirculating Mixing and Pumping
• Batch Mixing: Mixing cement + additives in a large tank before pumping
downhole
Cementing Operational Best Practices
• Annular Velocity & Mud Displacement
• Density Control
Case Study: SAGD Pair (Injector and Producer)
• Drilling Best Practices/Fit for Purpose Cementing Equipment
• Cement Bond Log Comparison
CADE • Benefits of Large Volume Cement Batch Mixing in Horizontal Well Casing Design • Brian Lim / Kelly Soucy
(SPE-174492-MS Eliminating the ‘Silver Bullet’ from SAGD Casing Cementing)

3. Mixing and Pumping Cement
Storage Bulk Plant Wellsite
Liquid Additives
Liquid
Mixing
Water
Bulk Transfer
Slurry
Mixing
Dry
Blending
Dry Cement
Dry Additives Slurry
Pumping
Slurry
Pumping
CADE • Benefits of Large Volume Cement Batch Mixing in Horizontal Well Casing Design • Brian Lim / Kelly Soucy

4. Cement Mixing Methods
Continuous Mixing
High Energy Recirculating Cement
Mixer
• Prevalent industry mixer type
• Mass flow/density measurement
• Reduced density variance
compared to conventional/
ground mixing
Limitations
• Slurry: Low residence/hydration
time
• Bulk cement transfer rates
• Operator/programming errors
CADE • Benefits of Large Volume Cement Batch Mixing in Horizontal Well Casing Design • Brian Lim / Kelly Soucy

5. Cement Mixing Methods
Batch Mixing
Cement Batch Mixing
• High levels of mixing energy
• Extended Residence Time
• Full cement and additive hydration
• Significantly reduce cement density fluctuation
Limitations
• Batch mixers have traditionally been designed to mix slurry volumes of 16m3 or less.
• Liners, Remedial Squeezes, Cement through Coiled Tubing
CADE • Benefits of Large Volume Cement Batch Mixing in Horizontal Well Casing Design • Brian Lim / Kelly Soucy

6. MagBatchTM
MagBatch Mix Advantages
• Improved annular velocities required for large annulus cementing
• 63m3 Capacity
• Continuous Batch Mixing Capability
• Precision density control & additive distribution
• High mixing energy: Extended surface residence & hydration time
• Separation of mixing from injection operations
• Slurry assessment/acceptance prior to injection
CADE • Benefits of Large Volume Cement Batch Mixing in Horizontal Well Casing Design • Brian Lim / Kelly Soucy

7. Annular Velocity
Source: Hart, W. A., & Smith, T. R. (1990, November 1).
Improved Cementing Practices Reduce Cementing Failures. Petroleum Society of Canada. doi:10.2118/90‐06‐01S
Open Hole
250.8mm
68 m/min
120 m/min
79 m/min
45 m/min
CADE • Benefits of Large Volume Cement Batch Mixing in Horizontal Well Casing Design • Brian Lim / Kelly Soucy
Open Hole
222.3mm
Open Hole
222.3mm
Open Hole
250.8mm
Casing 177.8mm
Casing 177.8mm

8. Annular Velocity ≥ 80m/min
Source: Hart, W. A., & Smith, T. R. (1990, November 1).
Improved Cementing Practices Reduce Cementing Failures. Petroleum Society of Canada. doi:10.2118/90‐06‐01S
Casing
p
Cement in
Annular
Space
Drilling
Mud
Displacement Efficiency Cemented Area
Annular Area
CADE • Benefits of Large Volume Cement Batch Mixing in Horizontal Well Casing Design • Brian Lim / Kelly Soucy

9. Annular Velocity > 80m/min
CADE • Benefits of Large Volume Cement Batch Mixing in Horizontal Well Casing Design • Brian Lim / Kelly Soucy
(SPE-174492-MS Eliminating the ‘Silver Bullet’ from SAGD Casing Cementing)

10. Density Consistency at Common Rates
Continuous Mixing
CADE • Benefits of Large Volume Cement Batch Mixing in Horizontal Well Casing Design • Brian Lim / Kelly Soucy

11. Density Consistency at High Rates
MagBatch
CADE • Benefits of Large Volume Cement Batch Mixing in Horizontal Well Casing Design • Brian Lim / Kelly Soucy

12. Effect of Slurry Density on Cement Properties
Slurry Density
Density
(kg/m³)
Mix
Water
(m³/t)
Yield
(m³/t)
Thick
Time
(hr:min)
Fluid
Loss
(cc/30min)
Free
Fluid
(%)
Compressive
Strength
(MPa/hrs)
@ 15°C
1860 0.44 0.77 4:20 26 0.1 4.0/24
1885 0.43 0.76 4:07 22 0.0 4.8/24
1910 0.40 0.73 2:35 20 0.0 5.4/24
CADE • Benefits of Large Volume Cement Batch Mixing in Horizontal Well Casing Design • Brian Lim / Kelly Soucy

13. Best Practice
The fluid being displaced must be
lighter/thinner than the fluid displacing it.
Function of many properties:
• Hole Geometry
• Density
• Rheological Profile
Pressure Drop Hierarchy
CADE • Benefits of Large Volume Cement Batch Mixing in Horizontal Well Casing Design • Brian Lim / Kelly Soucy

14. Challenges
• Large diameter boreholes/casing
• Intermediate Casing cemented in
• Shallow, cool formations
• Temperature cycles to 2750 C
• Pressure cycles to 7 000 kPa
SAGD Well Construction
CADE • Benefits of Large Volume Cement Batch Mixing in Horizontal Well Casing Design • Brian Lim / Kelly Soucy

15. Well Profile Example
Well Pair Placement Ranges
• TVD: ~ 375 – 535 m
• HZ Length: ~ 800 m
SAGD Well Placement & Profile
339.7mm Surface in 444.5mm Hole
244.5mm Intermediate Csg with
Premium Connection in mm
311.2mm Hole
177.8mm Slotted Liner in 222.3mm Hole
CADE • Benefits of Large Volume Cement Batch Mixing in Horizontal Well Casing Design • Brian Lim / Kelly Soucy

16. Magnum Spacer: MagActive Sweep OB
Reacts on contact with brines/cement to:
• Seal off weeping porosity
• Reduce cement fallback
• Improve cement shear bond strength
Water Wetting Package
• Strip/emulsify residual bitumen
• Improve pipe/formation bonding
• Increase solubility in cold/hard waters
Intermediate Casing Flushes & Spacers
CADE • Benefits of Large Volume Cement Batch Mixing in Horizontal Well Casing Design • Brian Lim / Kelly Soucy

17. Oilwell Thermally Stable Blend
• Provide/maintain casing annular hydraulic isolation
• Support casing mechanically during drilling and production cycles
• Improve long term external corrosion protection
• 2750 C & 7 000 kPa
Intermediate Casing Cement
BHCT
(°C)
BHST
(°C)
Density
(kg/m³)
Mix
Water
(m³/t)
Yield
(m³/t)
Thick
Time
(hr:min)
Fluid
Loss
(cc/30min)
Free
Fluid
(%)
Compressive
Strength
(MPa/hrs)
@ 15°C
25 15 1885 0.43 0.76 4:07 22 0.0 4.8/24
CADE • Benefits of Large Volume Cement Batch Mixing in Horizontal Well Casing Design • Brian Lim / Kelly Soucy

18. MagBatchTM ‐ Intermediate Casing Cementing
CADE • Benefits of Large Volume Cement Batch Mixing in Horizontal Well Casing Design • Brian Lim / Kelly Soucy

19. Cement Mixing Methods
Min Max Min Max Min Max Min Max
1 63 1100 2400 0.1 1.6 0.2 4.2
Batch Capacity
(m³)
Mixing Capability
(kg/m³)
Batch Mixing Rate
(m³/min)
Downhole
Pumping Rate
(m³/min)
CADE • Benefits of Large Volume Cement Batch Mixing in Horizontal Well Casing Design • Brian Lim / Kelly Soucy

20. Cement Injection & Displacement
Higher Annular Velocity (AV) Injection/Displacement
• Improved drill fluid/cuttings removal (80m/min Optimal)
• Paired quintuplex pumping units
• Optimized for high rate/ lower pressure pumping
• Triaxle body job design
• Stand‐alone mixing/pumping ‐ versatility
Min Max Min Max Min Max
1100 2400 0.1 1.6 0.1 2.1
Mixing Capability
(kg/m³)
Mixing Rate
(m³/min)
Pump Rate
(m³/min)
CADE • Benefits of Large Volume Cement Batch Mixing in Horizontal Well Casing Design • Brian Lim / Kelly Soucy

21. • Bottom wiper plug ahead of water preflush
• Coriolis mass flowmeters density measurement
• Batch mixer operated to 95% capacity
• Total pumping times ~ 60 minutes
CADE • Benefits of Large Volume Cement Batch Mixing in Horizontal Well Casing Design • Brian Lim / Kelly Soucy
Intermediate Casing Cement Job
MAG Active OB
Preflush and
Scavenger
Thermal
Cement
Displacement Total
Volume
(m³)
15 ‐ 20 50 ‐ 60 25 ‐ 30 90 ‐ 110
Density
(kg/m³)
1000 – 1200 1885 1000 ‐
Rate
(m³/min)
2.6 2.6 2.6 ‐
FCCL Intermediate Casing Cement Pumping Schedule

22. 0
2
4
6
8
10
12
14
16
18
20
3:17:17 3:24:29 3:31:41 3:38:53 3:46:05 3:53:17 4:00:29 4:07:41 4:14:53
Pressure MPa Density kg/m3 * 100 Rate m3/min
Intermediate Casing Job Chart
CADE • Benefits of Large Volume Cement Batch Mixing in Horizontal Well Casing Design • Brian Lim / Kelly Soucy

23. Intermediate Casing Bond Log Comparison
CADE • Benefits of Large Volume Cement Batch Mixing in Horizontal Well Casing Design • Brian Lim / Kelly Soucy (SPE-174492-MS)
Drilling Details:
 Well Pair (Injector and Producer)
 Same Formation (~5m apart)
 Same Rig, Directional Profiles, Drilling Fluids
 Same Hole and Casing Sizes
 Batch Drilled (2 weeks apart)
Injector (MagBatchTM System)
 63 m3 Batchmixer
 2 Quintuplex Pumping Units
 2.6 m3/min injection/displacement
Producer (Conventional)
 2 Twin Trailer Cementing Units
 Automatic Density (microprocessor)
Control Mixers
 2.2 m3/min injection/displacement
MagBatchTM
MagBatchTM
Conventional
Conventional
Top Casing Section

24. Intermediate Casing Bond Log Comparison
CADE • Benefits of Large Volume Cement Batch Mixing in Horizontal Well Casing Design • Brian Lim / Kelly Soucy (SPE-174492-MS)
MagBatchTM
MagBatchTM
Conventional
Conventional
MagBatchTM
MagBatchTM
Conventional
Conventional
Bottom Csg Section
Middle Csg Section

25. Integrated Design Approach:
• Critical Design Criteria
• Operational Best Practices
• Fit for Purpose Equipment
Benefits of Batch Mixing
• Increasing Annular Velocity (~80m/min)
• Density control is key to matching design
• Quantifiable improvement
• Mitigate risks when mixing cement exceeding
rates of 1.5m³/min
CADE • Benefits of Large Volume Cement Batch Mixing in Horizontal Well Casing Design • Brian Lim / Kelly Soucy
(SPE-174492-MS Eliminating the ‘Silver Bullet’ from SAGD Casing Cementing)
Conclusion

26. Questions?
CADE • Benefits of Large Volume Cement Batch Mixing in Horizontal Well Casing Design • Brian Lim / Kelly Soucy
(SPE-174492-MS Eliminating the ‘Silver Bullet’ from SAGD Casing Cementing)
• 300+ Wells Cemented through various operators
• Achieved Placement Rates: 2.6m3/min to 4.0 m3/min
• Achieved Intermediate Placement Volumes: 40 m3 to 61 m3
• 300+ Wells Cemented through various operators
• Achieved Placement Rates: 2.6m3/min to 4.0 m3/min
• Achieved Intermediate Placement Volumes: 40 m3 to 61 m3