Mud Erodibility Technology Impact on Cementing Operations

Large Scale Experiments Have Shown

Gelation plus dehydration of the mud across permeability is one of the main causes of mud displacement (removal) problems

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Large Scale Experiments Have Shown (cont.)

Extended shutdowns: very detrimental to the hole cleaning (circulatable hole) process Age: of the Partially Dehydrated-Gelled (PDG) mud: very detrimental Removal of the PDG: Requires energy

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Vertical Hole - Large Scale Experiments

PDG

Formation

Cement

Casing

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Inclined Hole - Large Scale Experiments

PDG and settled solids

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Next Step
Study mechanism of mud cake deposition and erosion with the goal of developing better means for improved removal

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Objectives
Build an experimental setup to study the mechanism of mud deposition and removal Develop a mathematical model Recommend procedures for field operations

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Model about 20+ ft long

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Experimental Procedure
Day 1:
Water calibration in turbulent flow Mud calibration: 2, 4 BPM - No filtrate collected Mud circulation: 1 BPM, 1hr Filtrate collected Mud circulation: 3 and 5 BPM Filtrate collected Shutdown, 18 hrs, 100 psi differential

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Experimental Procedure (cont.)

Days 2 and 3:
Mud circulation at 1 BPM to near steady-state Same as above at 2, 3 and 5 BPM Shutdown with 100 psi differential

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Experimental Procedure (cont.)

Day 4:
Same as day 2 Spacer fluid pumped Cement slurry pumped Model cured for 48 hrs

Later:
Model cut in sections Observations made Pictures taken
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Tests Results - Example

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PDG Thickness vs. Time

PDG Thickness (in) Rate (bpm) Day 2 Day3 ~1 0.4 0.44 ~2 0.37 0.40 ~3 0.338 0.373 ~5 0.335 0.375 Day5 0.415 0.41 0.402

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Important Conclusions
Rate (wall shear stress) is needed to remove the PDG Extremely high rates can be detrimental to the PDG removal process The older the PDG, the harder it is to remove it

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Proposed Mechanism
Opposing Forces:
Differential pressure against permeability causes the deposition of filter cake and PDG Erosion by flowing fluid tends to remove the PDG

PDG drilling fluid and filter cake are eroded as long as pressure drop (wall stress) in the annulus exceeds a certain value Shear stress at the wall: hydrodynamic force responsible for the erosion Adhesion forces: resistance to erosion
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Proposed Mechanism (cont.)

Erosion takes Place for as long as the shear stress at the wall (point of contact between the flowing fluid and the static PDG or filter cake) exceeds the yield stress of the PDG or filter cake.

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Compare magnitude of the values

Can the stress of the PDG be inferred from normally reported mud properties?
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Conversion Factor
Wall Shear Stress and Friction Pressure relationship: = De x P/4L Wall Stress (lb/100 ft2) = 300 x De (in) x P (psi)/(4 x L (ft)) P (psi) = Wall Stress (lb/100 ft2) x L (ft)/ (300 x De (in))
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Lab Work
Since stress levels of the PDG need to be measured in the lab to be able to design jobs to effectively erode the PDG. Then: Develop and test erodibility cell Test erodibility of muds Design rates and spacer properties to erode PDG and filter cake
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Large Scale Test Cell

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PDGs of Different Muds

Over all, PDGs of oil base, MOBM and SOBM have been found to be thinner and easier to remove that those generated by water base muds. Levels: ~ 25 lb/100ft2 Worst PDGs are those generated by poor quality water base muds: poor fluid loss control, progressive gels, etc. Levels: as high as 100 + lb/100ft2

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Using a Simulator and lab Measurements to Better Design Cement Jobs

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