Cement and Casing Failure Due to Extreme Temperatures and Corrosion

Challenge

Heavy oil operators want low cost wells that will last for the 7-10 years it will take to realize ultimate recovery. Past experience in thermal projects has shown that steam, in addition to heating the heavy oil, can cause very high temperatures and corrosive conditions that may impose considerable thermal stress and chemical attack on casing and cement sheaths. Cement and casing failures and sand production problems lead to reduced well performance and the loss of many production and injection wells each year.

Another challenge posed by heavy oil reservoirs, which need to be relatively shallow, is that they are usually drilled in shallow formations which are prone to lost circulation.

Solution

Halliburton, the industry leader in cement technology, offers a variety of insulated and corrosion resistant cement systems that are tailored to endure high steam temperatures and low pH and still provide effective zonal isolation for longer than conventional cements. These better engineered thermal cementing programs can help improve casing and cement design, resulting in longer-lasting wells. Indeed, the life of the well is extended 5 to 10 years by the reduction in cement and casing failures. It is also critical that the chosen cement sealant for a heavy oil well is designed efficiently for both placement and optimized hydraulic modeling, and also for the life of the well.

Halliburton's Key Products and Services

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Summary Summary Turbo Tech® II Multi-Activation Bypass Valve
The CleanWell® Turbo Tech® II multi-activated bypass valve is designed to allow up-hole boosting above liner tops during displacement or cleanout interventions. The Turbo Tech valve promotes best practices for displacement, allowing optimal circulating rates, pipe rotation and pipe reciprocation while circulating and boosting.
Summary Summary Cementing - Lost Circulation Materials
Lost circulation is the complete or partial loss of fluid to formation(s) as a result of hydrostatic and annular pressure from natural or induced causes. Losses can add extensively to the overall well cost.
Summary Summary LifeSeal™ Cements
Foamed cement solution designed for situations where conditions require a cement with greater elasticity, resiliency and the ability to react and respond to cement sheath failure by expanding to seal off unwanted flow should hydrocarbon flow through microannuli or cracks in the cement sheath at any point during the life of the well.
Summary Summary OptiCem™ Software
Calculates real-time equivalent circulating densities (ECDs) based on actual job volumes, rates and fluid densities for more realistic simulator and rheology models.
Summary Summary WellLife® Service
Models the integrity of the cement sheath and the risk of its failure as it is subjected to different well operations.
Summary Summary ZoneSeal® Isolation Process
A fully engineered zonal isolation process with automated controls to deliver the benefits of light-weight (foam) cement during placement and for the life of the well.
Summary Summary ZoneSealant™ 2000 Agent
A single-component cement foamer/stabilizer that can be used in fresh water, seawater, and salt slurries for use in standard applications requiring foamed cements.
Summary Summary Dual Injection ZoneSeal® Process Job—Western U.S.
In this Western U.S. well, the ZoneSeal® dual injection method was chosen because of significant CO2 gas breakthrough in the wellbore annulus (~3,000 ppm), plus the fact that pumping down the annulus was projected to be a way to contain/kill CO2 gas.
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