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Liner Cementing
Table of Contents
Introduction................................................................................................................................................6-3 Topic Areas ............................................................................................................................................6-3 Learning Objectives ...............................................................................................................................6-3 Unit A: Types of Liners .............................................................................................................................6-3 Drilling Liners ........................................................................................................................................6-3 Production Liners ...................................................................................................................................6-4 Stub Liners .............................................................................................................................................6-4 Scab Liners.............................................................................................................................................6-4 Quiz A: Types of Liners.........................................................................................................................6-5 Unit B: Setting Liners ................................................................................................................................6-6 Preparing Liners .....................................................................................................................................6-6 Making Up Liners ..................................................................................................................................6-6 Running Liners.......................................................................................................................................6-7 Quiz B: Setting Liners............................................................................................................................6-7 Unit C: Cementing Liners ..........................................................................................................................6-8 Single Stage Method ..............................................................................................................................6-8 Delayed-Set Method...............................................................................................................................6-9 Quiz C: Cementing Liners......................................................................................................................6-9 Unit D: Liner Calculations.......................................................................................................................6-10 The Required Calculated Results .........................................................................................................6-10 Well Parameters ...................................................................................................................................6-10 Liner Cementing Job One.....................................................................................................................6-12 1 Cement Volume ...............................................................................................................................6-13 2 Sacks of Cement ..............................................................................................................................6-15 3 Mixing Water Required ...................................................................................................................6-15 4 Displacement Fluids Required .........................................................................................................6-15 5 Top of Cement with Drillpipe In and Drillpipe Out ........................................................................6-16 6 Pressure to Land the Plug ................................................................................................................6-17 Quiz D: Liner Calculations...................................................................................................................6-17 Answers to Unit Quizzes .........................................................................................................................6-18
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Introduction
In the past, it was common to have several strings of casing in a deep well. All these strings extended from the wellhead to different depths. However, another method is now used for varying well conditions. This time, and money, saving method involves the hanging of a casing string from the bottom of a cemented casing string. These hanging casing strings are called liners and they are used in almost every deep well completion. C. Cementing Liners D. Liner Calculations
Learning Objectives
Upon completion of this section, you should be familiar with The different types of liners How liners are set The different techniques of cementing liners How to perform liner cementing calculations
Topic Areas
The section units are A. Types of Liners B. Setting Liners
Drilling Liners
A drilling liner (sometimes called an intermediate liner) is a string of casing that is hung from another casing of a larger diameter, which has already been cemented downhole (Fig. 6.1). It is used above a producing zone to case off open holes so that deeper drilling may be performed. A drilling liner helps control water or gas production Figure 6.1 Drilling and Production Liners.
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Production Liners
A production liner is a string of casing that is hung from a drilling liner or casing in the producing formation (Fig. 6.1). This type of liner is then cemented and perforated like any other completion string. It provides isolation and support when casing has been set above the production zone.
ends and is used under the same conditions as a stub liner. Both stub and scab liners can be set with part of their weight on the liner below or they may be hung uphole on existing casing (Fig. 6.2).
Stub Liners
A stub liner (or tie back liner) is usually a short string of casing which provides an upward extension for a drilling liner. It is run when: casing above the drilling liner has been damaged in some way (by corrosion, etc.) a liner is leaking greater resistance is needed for other reasons (abnormal pressure, etc.). Figure 6.2 A. Scab Liner and B. Stub Liner.
Scab Liners
A scab liner is unusual in that it is often not cemented once it has been run downhole and is therefore retrievable. It has a packoff on both
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Preparing Liners
Before setting a liner, the entire length of hole to be lined must be drilled. It is very important to prepare the liner before lowering it into the wellbore; the mill finish must be removed so that cement can form a better bond with the liner. This usually is done by sandblasting or weathering the liner. The hole must be well-conditioned to set a liner because of the small annular space. To condition the mud system, circulate at least enough drilling fluid to displace the annular volume twice. Decisions must be made about how much overlap there should be between the casing and the liner. The amount of overlap varies between 50 and 500 feet. For example, if higher pressure zones are penetrated, there should be more overlap than in lower pressure zones.
Making Up Liners
The liner is made up like any casing string. While suspended in the rotary table, it is made up joint by joint. A float shoe is made up on the first joint and a float collar is attached on the second or third joint to provide a seat for the liner-wiper plug. Sometimes a landing collar is also made up one joint above the float collar (Fig. 6.3). In this case, the landing collar provides a seat for the plug. Centralizers are important in liner jobs because the clearance between the liner and casing is
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Running Liners
Running speeds should be slow to reduce the ram effect. The liner can cause added pressure on the formation, resulting in breakdown or lost circulation. Speeds of 2 to 3 minutes per stand (90 ft drill pipe) are usually allowed for cased holes. After a liner has been lowered into the well, the slips are activated so that the liner hangers are wedged against the casing. Liner hangers are set in one of two ways: Mechanical- slips are activated by rotating and reciprocating the drill pipe
Hydraulic- hydraulic pressure applied to the setting string activates the slips.
Hydraulic equipment is used less often. However, it is less likely to set accidentally and is preferred in crooked holes. Once the liner is set, the drill pipe should be temporarily raised a few feet. The weight indicator should be checked to be sure that the liner has actually been released. Spacer fluid is then pumped down-hole so that a good cement bond can be obtained. The seal formed by a good cement job is especially important at the shoe and at the top of the liner.
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Regardless of the method chosen, batch mixing is generally preferred because of the complexities in obtaining the best slurry composition for a particular job. In designing the composition of cement slurry, the following factors must be considered: Temperature of the well Pressure caused by small annular clearance (possibility of lost circulation) Formation fluids Pump or thickening time Strength or stability of the cement Figure 6.4 Single Stage Method. Bottom plugs are generally not run in liner cementing; therefore, as the two plugs descend, they wipe mud off the liner. This mud, trapped between the shoe and the collar, should not go into the annulus to contaminate the cement. The drill pipe and setting tool are then pulled out of the hole. It is risky to reverse out excess cement at this point because this process would exert extra pressure on the annulus. The extra pressure could break down the formation and cause lost circulation. This would leave the overlap area unprotected. Instead, the cement is drilled out after it has set, which should result in a good bond in the liner-casing overlap.
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Delayed-Set Method
The delayed-set method is used in certain geographical locations when a relatively short liner is called for in wells with low fluid levels. It is carried out by pumping delayed-set cement down the drill pipe. The drill pipe is then pulled out and the liner and attachments are lowered into the hole (Fig. 6.5). The closed float collar valve in the liner forces the cement up the annulus. This increases the chances for obtaining a more uniform cement sheath around the liner. However, since delayed-set cement is used, WOC time is greater-sometimes two days or more. After any of these procedures have been completed, the liner's seal is tested. The casing is then cleaned and, if necessary, the cement is drilled out so that the remainder of necessary completion operations can take place.
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Well Parameters
Following are the well parameters that you must have to perform the above calculations: A. Liner Size B. Liner Top C. Well Fluid D. Hole Size E. Liner Total Depth F. Shoe Track Length G. Required Cement (on top of liner) H. Excess Volume Required (percent) I. J. Size of Previous Casing Depth of Previous Casing
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K 4A I C G B H J D 4B 5 1D 1C
6 critical calculations that need to be made with every liner casing job
Cement VolumeThe volume of cement required to fill the required footage of the shoe rack, annulus, lap and cap.
1A 1B 1C 1D
Shoe Track Volume Open Hole Volume Liner Lap Volume Liner Cap Volume
2 3 4 5 6
Sacks of CementConverting the required volume of cement into sacks. Mixing water for required slurries. Displacement fluid required: 4A 4B Drill pipe volume to top of liner. Liner casing volume to top of shoe track.
Top of Cement with drill pipe in and top of cement with drill pipe out. Pressure to Land the PlugDifferential pressure required to pump the plug to the top of the shoe track
Well Parameters
A B C D E F G H I J K Liner Size Liner Top Well Fluid Hole Size Liner Total Depth Shoe Track Length Required Cement (on top of liner) Excess Volume Required (percent) Size of Previous Casing Depth of Previous Casing Drill pipe size, weight, thread
1B
F E
1A
The next part of this section presents an example liner job and shows the calculations.
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Description
Liner Size Liner Top Well Fluid Hole Size Liner Total Depth Shoe Track Length Required Cement (on top of liner) Excess Volume Required (percent) Size of Previous Casing Depth of Previous Casing Drill pipe size, weight, thread
Data
7 in, 29 lb/ft, N-80 11, 600 ft 12.4 lb/gal 8 in. 12,925 ft 81 ft 300 ft cap 10% 9 5/8 in, 47 lb/ft, N-80 11,930 ft 4.5 in, 16.6 lb/ft
Figure 6.6 Schematic of example well for exercise. On the following page is the worksheet used for determining slurry volumes.
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start from the shoe track and work your way up the annulus to solve for height of cement with the drill pipe at the liner hanger. Volume of Cement Delivered
225 sk 1.57 ft /sk 1A 1B Shoe Track Volume 3 81 ft 0.2085 ft /ft Open Hole Annular Volume
3
= =
353.25 ft 16.89 ft
3
Class G Cement 35% SSA-1 (silica flour) 0.5% CFR-3 (dispersant) 0.1% HR-5 (retarder) Water
Note: This volume was based on perfect hole + 10% excess (additional volume). We will calculate perfect hole, knowing that this will increase the top of cement and give us worst case for pressure to land the plug. TD Liner: Depth Previous Casing: 995 ft 0.1268 ft /ft
3
8.33 =
Total mixing water must be entered under absolute gallons before totaling. Find the weight of the mixed cement by using this formula: Total Pounds Total Absolute gallons = lb/gal Find the cement yield in cubic feet per sack by using this formula: Total Absolute gal 7.4805 gal/ft (constant) = ft /sk The mixing water per sack is the sum of the gallons in the far right column Cement Density Cement Yield Mixing Water Required 182.525 11.7423 11.7423 = 7.4805 = 15.5 1.57 6.61 lb/gal ft /sk gal/sk
3 3 3
1D
1C
1D
1C
From the well parameters and the data from this worksheet, we can now calculate the six requirements.
1B
1B
1 Cement Volume
Cement Volume is an extremely critical calculation in a liner situation (as with all jobs). In particular with liners, if you underestimate cement volume, you could leave the previous casing shoe unprotected. Therefore, it is your responsibility to know the volume of cement delivered and to ensure that the volume of cement is sufficient to execute the job. Working from the known volume of cement, 225 sk, you must solve for the height of cement above the liner. To accomplish this you must
1A
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Looking in Section 221, Table 221-D, we find that the volume factor is not printed for 9 5/8 in. casing. There is an easy way to calculate this factor. All you need to know is 1. Drillpipe O.D. 4.5 in 2. Casing I.D. we look up the I.D. in section 210, Table 214, page 23 and find the I.D. for 9 5/8 in., 47 lb/ft, casing is 8.681 in. The formula for calculating the volume factor is found in section 240, page 10. Linear feet per Cubic Feet = 183.35 D2 - nd2 where: D = Diameter of hole, inches (or I.D. casing) d = Outside Diameter of tubing, inches n = number of tubing strings (in our case, we are calculating the annulus between 9 5/8 in. casing and 4.5 in. drill pipe) Applying the Formula:
1D - Liner Cap Volume (Annular Volume Between Drill Pipe and Casing)
This is the volume above the liner hanger inside the intermediate casing commonly referred to as Liner Cap Cement. This volume will reach its maximum height when the plug lands. This will give you the maximum differential pressure (pressure to land plug). As you pull drill pipe, the height will decrease until the drill pipe is pulled above the slurry. Therefore, we will make two calculations: (a) Height of Cement with drillpipe in Liner Hanger (b) Height of Cement with drillpipe pulled above the Cement Column. Total Cement Volume: Shoe Track Volume: Annular Hole Volume: (perfect hole): Liner Lap Volume: Resulting Cap Volume: 353.25 ft3 - 16.89 ft
3
Height of Cement (with drillpipe in) We have calculated that 162.74 ft3 of cement will remain above the Liner Top. We should be able to multiply by the ft/ft3 volume factor of the 4.5 in drill pipe 9 5/8 in. intermediate casing.
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Height of Cement (with drillpipe out) This calculation is a lot simpler in that we are only concerned with the 9 5/8 in, 47 lb/ft capacity. Looking up the capacity value we calculate the following 162.74 ft3 2.433 ft/ft3 = 395.95 ft This means that after pulling drill pipe above the cement on top of the liner, the height of the cement column will be 395.95 ft above the liner top so yes, we have enough cement to complete this job.
4A
2 Sacks of Cement
In this job, we were given 225 sacks of cement. But, it is fairly easy to see that in future job calculations (to predict how much cement to order) you must calculate 4 different volumes of cement in a liner job (Figure 6.7), 1A - Shoe Track Volume 1B - Open Hole Annular Volume (Plus Excess Cement) 1C - Liner Lap Volume 1D - Liner Cap Volume
4B
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then latches into a larger plug in the liner hanger. If we slow our pump rate down and watch closely for a pressure increase, we will then have an accurate volume up to that point in the job. Then we can focus on displacing the liner casing capacity to the top of the shoe track.
TOC 10,310.23 ft
TOC 11,058.08 ft
4A - Drillpipe Volume
4 in. 16.6 lb/ft Top of Liner at 11,600 ft (Section 210, Table 212B, Page 9): 11,600 ft 0.01422 bbl/ft = 164.95 bbl
12,844 ft - 11,600 ft (top of liner) = 1244 ft of 7 in., 29 lb/ft liner (Section 210, Table 214, Page 21) 1244 ft 0.0371 bbl/ft = 46.15 bbl Therefore, we will pump: 164.95 bbl Drillpipe Capacity + 46.15 bbl Liner Capacity = 211.1 bbl total displacement
12,925 ft
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12,844 ft 12,925 ft
524 psi
2. With liners, if you underestimate _______________________, you could leave the previous casing shoe unprotected. 3. Liners are usually displaced with _______________________________ to prevent a large pressure differential at the liner hanger tool and at the surface. Now, look up the suggested answers in the Answer Key at the back of the section.
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6-13 6-16
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