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Long Term Integrity of Cement Systems

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Long Term Integrity of Cement Systems

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    1. Long Term Integrity of Cement Systems Oct 4, 2002

    2. Agenda Participants/Financials Project Focus/Management Project Tasks Summary Action Items

    3. Participants Commitments MMS, Petrobas, Unocal, BP, ExxonMobil Saudi Aramco, ONGC, Conoco, AGIP DOE, Anadarko, PDVSA Potentials ChevronTexaco, Stat Oil What about Service Companies ?

    4. Financials Commitments - $50k each $600k 12 Companies Potential additional $100 to 150k Project Timing – 18 months

    5. Management of Project Fred Sabins – Project Manager Bryan Simmons – Operations Manager Lab support CSI Westport Rock Mechanics Mathematical Analysis – University of Houston Rock Properties Instruments - Chandler

    6. Project Communications Steering Committee – Voting Members Meeting notes/ voting privileges Short Monthly reports - Email Technical Quarterly Progress Report/Meeting Feb 2003

    7. Project Objective Determine the cement system properties that effects the ability of cements to seal fluids Primarily in Deep Water General application Develop a correlation of the cement properties to performance Determine laboratory methods to determine key properties

    8. Tasks Task 1 – Problem Analysis Task 2 – Property Determination Task 3 – Mathematical Analysis Task 4 – Testing Baseline Task 5 – Refine Procedures Task 6 – Composition Matrix Task 7 – Conduct Tests Task 8 – Analyze Results Task 9 – Decision Matrix

    9. Testing Program Deep Water/All Conditions in Gulf of Mexico Cement Slurries Class A Foamed Cement Bead Cement Class H Latex Cement Other modifications of above

    10. Conventional Tests Conditions – 45 F BHST, 65 F BHCT Tests Thickening Time - 4 to 6 hours Free Water < 1% Compressive Strength (24hr and 14 days) Fluid Loss, SGS when appropriate

    11. Thickening Time & Free Water

    12. Mechanical Integrity Issues Flow of Fluids Around the Cement Bonding, Microannulus, Deformation Through the matrix of the Cement Cracking, Permeability changes Stress Pressure, Temperature, Pipe Buckling, Formation Compaction Cycling Conditions

    13. Mechanical Properties Rock mechanics/Acoustic Measurements Tensile Strength/Youngs Modulus (T) Young’s Modulus/Poisson’s Ratio

    14. Tensile Strength Brazilian Test Method Tensile Strength Young’s Modules Maximum Yield

    16. Young’s Modules Compressional Tests Confining Loads – Defined by 0psi break Base line 14 day cure Acoustic Data Poisson’s Ratio

    17. Comparison of Compressive Strength

    18. Type 1 CYM

    19. 12 ppg Foam CYM

    20. 12 ppg Bead CYM

    21. Latex CYM

    22. Hydrostatic Cycles

    23. Acoustic Measurements Chandler’s New Mechanical Properties Device

    24. Chandler Device

    26. Performance Tests Shear Bond Measurements (Cycling conditions) Soft formations Hard Formations Annular Seal/Hassler Sleeve (Cycling Conditions) Soft Formations Hard Formations

    27. Temperature Cycling Procedures Samples are then cured at 45°F for 14 days. Samples are then temperature cycled from 45°F to 180°F to 45°F as described below: Samples are placed in a 96°F water bath for 1 hour. Samples are placed in a 180°F water bath for 4 hours. Samples are placed in a 96°F water bath for 1 hour. Samples are placed back in a 45°F water bath. The samples are cycled once per day during the cycling period.

    28. Shear Bonds

    29. Annular Seal Test Configurations The pipe-in-pipe configuration consists of a sandblasted internal pipe with an outer diameter (OD) of 1 1/16 in. and a sandblasted external pipe with an internal diameter (ID) of 3 in. and lengths of 6 in. A contoured base and top are used to center the internal pipe within the external pipe. The base extends into the annulus 1 in. and cement fills the annulus to a length of 4 in. The top 1 in. of annulus contains water. For the pipe-in-soft shear bonds, plastisol is used to allow the cement to cure in a less-rigid, lower-restraint environment. Plastisol is a mixture of a resin and a plasticizer that creates a soft, flexible substance. This particular plastisol blend (PolyOne’s Denflex PX-10510-A) creates a substance with a hardness of 40 duro. The pipe-in-pipe configuration consists of a sandblasted internal pipe with an outer diameter (OD) of 1 1/16 in. and a sandblasted external pipe with an internal diameter (ID) of 3 in. and lengths of 6 in. A contoured base and top are used to center the internal pipe within the external pipe. The base extends into the annulus 1 in. and cement fills the annulus to a length of 4 in. The top 1 in. of annulus contains water. For the pipe-in-soft shear bonds, plastisol is used to allow the cement to cure in a less-rigid, lower-restraint environment. Plastisol is a mixture of a resin and a plasticizer that creates a soft, flexible substance. This particular plastisol blend (PolyOne’s Denflex PX-10510-A) creates a substance with a hardness of 40 duro.

    30. Annular Seal Tests

    31. Annular Seal Test Model

    32. Pipe in Pipe Testing No fluid external to the cement 6” flanged models 6” flanged model with pressure (200 psi) 5’ flanged model vacuum system 5’ flanged model with pressure (200 psi) Conclusion – tight seal to gas

    33. Mathematical Model Presented by: University of Houston

    34. Future Work

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