Type P ES and ES II™ Cementers Installation and Operating ... · The ES II stage cementer builds...

SAP No. 100075745-OC

Type P ES and ES II™ CementersInstallation and Operating Instructions

Contents

PrefaceIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-1Features and Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-2

New Capabilities of Halliburton Stage Cementers Run as a Preplanned Contingency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-2New Features For the ES II™ Stage Cementer . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-3

Operating Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-3

Chapter 1—InstallationInstallation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

Chapter 2—Operation with Free Fall™ Plug SetsFirst-Stage Bottom Plug Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1First-Stage Shutoff Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1Opening the Type P ES Cementer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2Closing the Type P ES Cementer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3Closing a Stage Cementer from an Unopened Position . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

Chapter 3—Operation with Displacement Type Plug SetsIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1First-Stage Bottom Plug Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1First-Stage Bypass Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1Displacement Type Opening Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2Closing the Type P ES Cementer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2Optional Casing Pressure Test—Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Chapter 4—Drilling OutIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Chapter 5—Potential Operating Problems with Stage CementersIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1Solutions for All Stage Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

Operating Plugs Fail to Seat and Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2Cementer too Close to the Shut-Off Baffle/First-Stage Shut-Off Plug . . . . . . . . . . .5-3Excessive Pipe Weight Suspended Below the Cementer. . . . . . . . . . . . . . . . . . . . . .5-3The Hole Angle or Doglegs at the Location of the Cementer Cause Excessive Side Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

Lost Circulation Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4Potential Operating Problems with Multistage Cementing Tools . . . . . . . . . . . . . . . . . .5-5

September 2014 Table of Contents i

SAP No. 100075745-OC Installation and Operating Instructions for Type P ES and ES II™ Cementers

Three-Stage Cementing with Two Stage Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5Stage Cementing with Optional First-Stage Top and Bottom Plugs . . . . . . . . . . . . .5-5Use of Incompatible Fluids During Multistage Cementing Displacements . . . . . . .5-5Second-Stage Displacement Closing Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6Importance of Casing Centralization when using ES Cementer Multistage Cement Tools . . . . . . . . . . . . . . . . . . . . . . . . .5-6

Chapter 6—TablesIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

Chapter 7—Pre and Post-job ChecklistsIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1Prejob Checklist for Type P ES and ES II™ Stage Cementers . . . . . . . . . . . . . . . . . . . .7-2Post-Job Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3

September 2014 Table of Contents ii

Preface

Preface

Introduction

This manual provides instructions for installing and operating Type P ES and ES II™ cementers (plug-opened version). Type P ES and ES II cementers are designed for use in almost any well, regardless of depth, pressure, or temperature. Type P ES and ES II cementers open mechanically when casing pressure is applied after the opening plug lands in the opening seat of the tool. The tools closes in the same manner when casing pressure is applied after the closing plug lands.

The ES stage cementer has been redesigned as the ES II stage cementer and is being phased out as ES II stage cementers become available in all sizes. Existing inventory of ES stage cementers can still be used and are considered fit for use when stored in their original packaging for no more than five years. The ES II stage cementer builds on fifteen years of performing stage cementing in support of Halliburton cementing operations worldwide.

The ES II stage cementer is operated with the same plugs that have been used with ES stage cementers. For this reason, this manual has been revised to include references to both ES and ES II stage cementers. Within the detailed instructions contained within this manual, ES and ES II nomenclature are used synonymously.

The long-term operating temperature limit for standard ES stage cementers is 275°F. The ESX stage cementer incorporates a seal package with an operating temperature limit of 350°F.

September 2014 Preface P-1

Installation and Operating Instructions for Type P ES and ES II™ Cementers 100075745-OC

Features and Applications

Type P ES and ES II cementers feature the following advantages:

• PDC drillability

• Smooth bore drillout

• Short, single piece mandrel

• Adjustable operating pressure

• Operates with standard free fall or displacement type plug sets

• Compatible with second-stage bottom plug sets

• Up to three separate stages with use of three stage-operating plug sets

New Capabilities of Halliburton Stage Cementers Run as a Preplanned Contingency

Many times, during a primary cement job on surface pipe, cement returns to the surface are not of sufficient quality/quantity to isolate freshwater zones or to meet regulatory/customer requirements. When this occurs, one common solution is to run a small “macaroni” string down the backside to fill or “top off” to help achieve surface isolation. This procedure is simple, but costly and time-consuming.

Another common solution for achieving competent cement at the surface is to run a stage cementer near the surface. If a stage cementer is run and the first-stage cement does not reach the surface, a second-stage job is performed using conventional two-stage cementing procedures. However, if the first-stage slurry comes to the surface, functioning the stage cementer could displace the slurry from the first stage that is already in place. Therefore, many operators leave the cementer unfunctioned.

However, if displacement occurs when a Halliburton ES or ES II stage cementer is installed in the string, the cementer must be functioned. The ES cementer is designed with an external sleeve as the pressure-holding member of the tool. Until the external sleeve is shifted to the closed position, the circulating ports in the mandrel remain exposed after drillout. Shifting to the closed position helps ensure casing integrity after drillout.

For a situation where first-stage cement comes to the surface and no second stage is required, Halliburton now offers a closing ring that can be placed on a standard Free Fall™ opening plug, which allows the stage cementer to be shifted from the unopen position to the fully closed position without displacing slurry already behind the tool. This closing ring allows the stage cementer to run as a contingency option only. The second stage is pumped, if necessary, but the stage tool can be fully closed if the second stage is not needed. In some casing sizes, a special contingency closing plug is available that replaces the standard Free Fall opening plug equipped with the closing ring.

CAUTION The Free Fall opening plug with closing ring must be deployed and the ES cementer shifted to the closed position while cement in the annulus at the tool is still fluid. External sleeve tools cannot be shifted to the closed position after cement has attained sufficient gel strength to render the sleeve immovable.

More details on the closing ring can be seen in Section 5.4 of the Casing Sales Manual.

P-2 Preface September 2014

100075745-OC Installation and Operating Instructions for Type P ES and ES II™ Cementers

New Features For the ES II™ Stage Cementer

• Dual lock rings for the external sleeve.

• Improved external sleeve locking mechanism provides multiple locking positions that engage consecutively as sleeve closes.

• O-ring seals protected from passing over grooves and debris.

• Angled external closing sleeve to help clear annular debris from blocking the sleeve travel.

• Repositioning of external sleeve lock rings to enhance seal reliability.

Operating Pressures

The Type P ES cementer comes with six opening shear pins and either six or eight closing shear pins (depending on the size of the tool) installed. Generally, removing any of the shear pins is unnecessary. With all closing pins installed, the cementer can be operated using a second-stage bottom plug set, if desired. If a lower closing pressure is required, one or two closing shear pins can be removed. The opening pressure and closing pressure with different numbers of shear pins are listed in Table 6.2 (Page 6-3) and Table 6.3 (Page 6-4).

September 2014 P-3

Chapter

1
Installation
Installation Instructions

Install centralizers above and below the Type P ES cementer within 5 ft of the pin and box connections. Remove any grease or pipe dope from the casing joints in which the cementer is to be made up. Make up the Type P ES cementer in the casing string as follows (Figure 1.1 through Figure 1.9).

1. Remove the box-end thread protector from the Type P ES cementer.

2. Clean casing threads to remove grease and pipe dope and apply Halliburton Weld A™ thread locking compound to the pin thread of the casing joint to be stabbed into the top of the cementer.

3. Swing the casing joint out over the rig floor. Alternatively, a circulating swage can be used to lift the cementer over the casing for threading as shown in the figures next.

4. Start the Type P ES cementer onto the pin thread. Make up the cementer onto the casing joint so that the cementer will not fall off the end of the casing when it is picked up off the rig floor.

5. Remove the pin-end thread protector from the Type P ES cementer.

6. Apply Halliburton Weld A thread locking compound to the pin thread.

7. Stab the pin thread of the cementer into the box thread of the casing joint in the rig slips.

8. Place make-up tongs on the joint above the cementer and back-up tongs on the joint below the cementer.

CAUTION Do not place tongs on the Type P ES cementer. Using tongs on this cementer can damage the tool.

9. Make up the Type P ES cementer to the same torque used to make up the casing.

10. Check for exposed threads (API casings). If exposed threads are found, go to the maximum torque allowed on the casing.

11. Lower the cementer into the hole.

12. Remove the mill make-up collar on top of the casing joint used to pick up the cementer.

September 2014 Installation 1-1


13. Clean casing threads to remove any grease or pipe dope. Apply Halliburton Weld A thread locking compound to the exposed pin thread.

14. Make up the casing collar.

15. Clean and apply Halliburton Weld A thread locking compound to the pin thread of the next casing joint.

16. Stab and make up the casing joint to normal torque.

17. Repeat Steps 12 through 16 for the next three joints.

1-2 Installation September 2014


CAUTION Welding is not normally required on Type P ES cementers and is not recommended without special instructions from the Casing Equipment Technology Department, Houston, TX. Do not weld on tools rated for sour gas service under any circum-stances.

Figure 1.1—ES II cementer on rig floor.



Figure 1.2—Swage and hoist ring.

1-4 Installation September 2014


NOTE The swage does not need to be installed power tight. Chain tong tight is sufficient for installation.

Figure 1.3—Swage installed into ES II cementer.



Figure 1.4—Pin thread protector removed and thread lock applied.

1-6 September 2014


Figure 1.5—Proper Halliburton Weld A thread locking compound application.

September 2014 1-7


Figure 1.6—Starting the casing pin thread onto the casing box thread.

1-8 September 2014


Figure 1.7—Do not place tongs on the cementer. The tongs can damage the cementer.

September 2014 1-9


Figure 1.8—Make-up tongs on the joint above cementer; backup tongs on the joint below cementer.

1-10 September 2014


Figure 1.9—Maximum spacing away from the cementer is 5 ft.

September 2014 1-11

Chapter

2
Operation with Free Fall™ Plug Sets
CAUTION If hole deviation at or above the Type P ES cementer exceeds 30° off vertical, Free Fall™ opening plugs should not be used. Use either a displacement type plug set or a Type H ES cementer (hydraulically opened). If covering the Type P ES cementer with first-stage cement, use caution when operating with Free Fall opening plugs. The lead cement from the first stage must have adequate pump time and static gel strength time to allow sufficient time for the Free Fall opening plug to reach the cementer, to open the tool, and to circulate the excess first-stage cement out of the hole. If this result is questionable, use either a displacement type plug set or a Type H ES cementer.

First-Stage Bottom Plug Set

Using a first-stage bottom plug set with the first-stage cement is optional and the plug set must be ordered as a separate item. When using a first-stage bottom plug set, place the bypass baffle on top of the upper float collar or float shoe. When using a first-stage bottom plug, observe the same reduction in displacement rate for passing the plug through the stage tools as outlined when using a shutoff plug.

First-Stage Shutoff Plug

The first-stage shutoff plug serves as the top cementing plug for the first stage of cement. The plug is released immediately behind the first-stage cement and is displaced to a pressure shutoff against the first-stage shutoff baffle or cement baffle adapter. Approximately 150 to 200 linear ft before the plug arrives at the stage tool, slow the displacement rate of the first-stage cement such that its velocity is less than 3 ft/sec (not to exceed 5 bbl/min). The following equation can be used to calculate the surface pump rate. Maintain this reduced displacement rate for 150 to 200 linear ft below the stage tool.

September 2014 Operation with Free Fall™ Plug Sets 2-1


This reduced rate can help prevent premature opening of the stage tool that could occur as the shutoff or bypass plug passes through the cementer.

1. If using a first-stage shutoff plug only, place the shutoff baffle into either (a) the top of the uppermost float valve, or (b) a casing collar one or more joints above the uppermost float.

NOTE If the casing is threaded with premium (non API) threads, the use of a premium shut-off baffle must be obtained and installed directly above the upper most float collar. Also, a baffle adapter can be used in place of the shutoff baffle. Order a Free Fall plug set specifically for the casing thread, size, grade, and weight that corresponds to the premium threaded casing in question.

2. If a first-stage bottom plug set is being used, the first-stage shutoff baffle must be installed one or more joints above the bypass baffle.

CAUTION Apply no more than 1,000 psi to any shutoff baffle installed in a casing coupling. If additional pressure is required, the shutoff baffle must be installed directly in the top of the upper float or a baffle adapter must be used.

Opening the Type P ES Cementer

NOTE Before performing pumping operations, review the compressibility calculations detailed in Step 4 on Page 2-5.

1. After pumping the first-stage shutoff plug to a pressure shutoff against the shutoff baffle, release casing pressure to determine if the float valves are holding.

CAUTION When releasing trapped casing pressure to check float valves or to determine if a stage cementing device is closed, do not forget to account for fluid compression or air entrainment in the trapped column of fluid. If flowback seems to persist, close in bleed valve and note the casing pressure. Open the bleed valve and flow back a few additional barrels. Close the bleed valve and note pressure. If close-in pressure is declining, the float valve is holding or the stage tool is closed. If the close-in pressure remains constant after bleeding to a pressure below the final circulating pressure, the device being tested is probably not holding or closed. If pressure-testing the casing after landing the first-stage shutoff plug, do so before releasing pressure to check the float valves. See caution note under First-Stage Shut-off Plug (Page 2-1). Do not exceed the strength limitations of the floating equipment or baffle adapter. See additional caution notes under Optional Casing Pressure Test—Precautions (Page 3-2).

Pump rate (bbl/min) = (3 ft/sec) × (Pipe ID2)

17.157

2-2 Operation with Free Fall™ Plug Sets September 2014


2. Remove the cap from the plug container and drop the Fee Fall opening plug into the casing. Screw the plug release plunger back in, load the closing plug, and reinstall the plug container cap.

3. Estimate the time needed for the Free Fall opening plug to reach the cementer because there is no surface indication when this occurs. The rate of fall normally ranges between 200 and 400 ft/min. Well conditions that affect the rate of fall are fluid viscosity, density, and hole devia-tion. When hole deviation at or above the cementer exceeds 30° from vertical, a displacement type plug set or a hydraulically opened cementer, such as the Type H ES cementer, should be used.

4. After the Free Fall opening plug lands on its seat in the cementer, apply pump pressure to open the cementing ports. The required opening pressure is stenciled on the cementer and its carton or crate, or may be found in Table 6.2 (Page 6-3). When the cementer opens, a rapid decrease in casing pressure should occur and circulation back to the surface should be re-established.

5. If the Type P ES cementer does not open, one of the following steps might be necessary:

• Allow more time for the Free Fall opening plug to reach its seat, or

• Flush debris from the opening seat of the cementer. Debris could be preventing the Free Fall opening plug from sealing. After each pressure buildup, rapidly release pressure to surge debris off the seat so the opening plug can seal. Monitor the volume required to achieve the opening pressure compared to the volume pumped to increase the pressure when the shutoff plug landed to determine whether the entire casing string is being pressured or only above the stage tool.

Closing the Type P ES Cementer

Follow these instructions to close the Type P ES cementer.

1. Release the closing plug immediately behind the second-stage cement, and displace with the required volume of displacement fluid.

2. When the closing plug is displaced to within 10 barrels of the cementer, adjust the pump rate to between 3 and 5 bbl/min to land the plug.

3. Once the closing plug impacts the closing seat in the cementer, increase casing pressure to close the cementer based upon the following formula.

See Table 6.3 (Page 6-4) for closing pressures.

Final displacement pressure

+ Closing pressure to close tool

+ 250 psi

= Pressure to close Type P ES cementer



Example:

4. Hold the closing pressure for two minutes, and then release casing pressure.

5. Observe flowback. If flowback persists after bleeding casing pressure to less than the final circulating pressure, indicating tool is still open, repressure casing with 250 psi additional pressure and hold two additional minutes.

Closing a Stage Cementer from an Unopened Position

For applications where the first stage cement achieves sufficient TOC height to eliminate the need for performing the second stage cement job, the ES stage cementer must be cycled from the unopened position to the closed position while the slurry is liquid in the annulus. The procedures below should be followed when closing a stage cementer from an unopened position.

1. Before performing the first stage cement job, the operator and cementing company should establish clear criteria for eliminating the second stage cement job. This criteria should be used to determine if the contingency closing plug will be used while the cement remains static in the annulus. The wait time between ending the first stage and shifting the tool closed, including free fall time, must be within the static gel strength time of the slurry used.

2. Before performing the first stage cement job, calculate the free fall time for the plug to fall from the surface to the stage tool assuming a falling rate of 200 ft/min.

3. Before performing the first stage cement job, calculate the surface pressure to be applied to close the stage tool using the contingency closing plug using the following formula for the tool being used:

Final displacement pressure 800 psi

Expected closing pressure (7-in., 20- to 26-lb tool) + 1,210 psi

Additional Pressure + 250 psi

Pressure to close = 2,260 psi

Opening pressure

+ Closing pressure

+ 500 psi

= Surface pressure to be applied

2-4 Operation with Free Fall™ Plug Sets September 2014


4. After landing the first stage shut-off plug, note the final pressure applied to land the plug. Increase the pressure by 500 psi and measure the fluid volume, Vrec, required to achieve this pressure increase. This information will be used to calculate the compressibility of the entire system using the following formula:

Example:

This value can be used to estimate the flowback required to check the floats. For example, the final landing pressure for the first stage is 1,500 psi and 2 bbl is required to pressure to 2,000 psi. The volume required to bleed back to zero can be estimated by:

5. Remove the cap from the plug container with a plunger fully extended.

6. Rest the contingency closing plug on the extended plunger and remove the lift line.

7. Retract the plunger and allow the plug to fall. Verify the plug has left the head from above. Once the contingency plug has left the head, reinstall the cap onto the plug container.

8. Wait for the Free Fall contingency plug to reach the stage tool.

9. In a single pressure cycle or ramp up, apply the contingency closing pressure calculated in Step 3 and hold for three minutes.

10. Record the fluid volume returned to achieve zero pressure at the surface. Using the volume recorded, calculate the partial system compressibility using the formula shown in Step 3. The calculated partial system compressibility should be less than the entire system compressibility. The smaller value should reflect the smaller total volume of fluid pressured from the surface to the stage tool compared to the volume from the surface to the shut-off plug. If the calculated partial compressibility factor is substantially equal to what was calculated when the shut-off plug landed, it indicates the entire casing volume is being pressurized, the stage tool is most likely not closed and Step 7 should be repeated with an additional 500 psi.

Entire system compressibility in psi/bbl = 500 psi/Vrec

500 psi ÷ 2 bbl

Total = 250 psi/bbl

2,000 psi ÷ 250 psi/bbl

Estimated flowback volume expected = 8 bbl


Chapter

4
Drilling Out
Introduction

Type P ES and ES II™ cementers can be drilled out any time after the second-stage cement has had sufficient time to set. Either conventional roller cone rock bits or PDC bits can be used.

Drillout procedures are detailed within SAP No. 100076323, Drilling Recommendations for Halliburton Cementing Plugs, Float Equipment and Related Cementing Casing Equipment with Fixed Cutter Bits, that is packaged with all Halliburton stage cementers. Further, Halliburton cementing casing equipment can be drilled with roller cone bits or mills using published drilling procedures from the bit manufacturer. Bit pumpoff attributed to debris packoff should always be considered during drillout.

September 2014 Drilling Out 4-1

Chapter

5
Potential Operating Problems with Stage Cementers
Introduction

This chapter discusses conditions that could lead to operating problems with stage-cementing tools and provides potential solutions to help avoid problem job occurrences. Potential problems can be placed into the following three categories: those that affect all stage tools, those that affect hydraulically opened tools, and those related to lost-circulation material (LCM).

NOTE This chapter does not replace the operating procedures packaged with the tool or published in the Casing Sales Manual or other related documents.

The following job conditions could threaten a successful job for all stage-cementing tools:

• Operating plugs fail to seat and seal.

• The cementer is too close to the shut-off baffle/first stage shut-off plug.

• Excessive pipe weight is suspended below the cementer.

• The hole angle or doglegs at the location of the cementer cause excessive side loading.

In addition, problems can occur if LCM is pumped through a stage cementer.

The following sections describe possible solutions for the three types of problems.

September 2014 Potential Operating Problems with Stage Cementers 5-1


Solutions for All Stage Tools

The following sections describe possible solutions for potential problems with all stage tools.

Operating Plugs Fail to Seat and Seal

If an operating plug, specifically a Free Fall™ opening plug, fails to seal, the most likely cause is debris buildup on the plug seat. Debris buildup (such as LCM or cuttings) can allow the entire casing string to be pressurized to the first-stage shut-off plug and baffle. To try to solve this problem, pressure the casing to 400 to 500 psi above the opening pressure and release the pressure as rapidly as possible. The surge of pressurized fluids beneath the plug can wash debris from the seat. Pressure again to open the tool and repeat if necessary.

In general, closing plugs rarely fail to seal. However, if the tool fails to close, as evidenced by backflow, performing the preceding steps might solve the problem.

NOTE When checking for backflow after closing a stage-cementing device, remember to account for the fluid compressibility of the fluid column in the casing above the closing plug.

Fluid compressibility can be checked by performing the following steps:

1. Backflowing a given volume and close in the pressure-release valve.

2. Observe the pressure.

3. Backflow another volume, close in, and recheck the pressure. If the pressure is declining, assume that the tool is closed and trapped air in the fluid above the closing plug is coming back.

4. Continue to bleed pressure to confirm that the tool is closed.

The expected amount of backflow should be indicated by (1) the amount of fluid required to pressure from plug landing to final closing pressure and (2) the anticipated fluid compression to land the plug, based on the required amount of fluid to pressure from plug bump to final closing. For example, if the closing pressure is 925 psi above final circulating pressure, the volume of fluid to reach closing pressure after bumping the closing plug is 6 bbl, and the plug landing pressure is 900 psi, expect to get approximately 12 bbl back.

NOTE Aerated displacement fluids can cause the volume of displacement fluid required to land a plug to be greater than the calculated volume. The more aeration in the fluid, the higher the error will be. Also be aware that pumping an aerated fluid creates com-pressed gases. As the resulting compressed gases rise to the surface, the gas bubbles expand many times their compressed size down hole and can produce hard fluid backflows as the expanding bubbles approach the surface.

5-2 Potential Operating Problems with Stage Cementers September 2014


Cementer too Close to the Shut-Off Baffle/First-Stage Shut-Off Plug

Generally, do not run a stage-cementing tool any closer than 250 ft above the shut-off baffle. If the distance is less, the fluid compression that the operating seats in the tool require to move far enough down might not be adequate. Smaller casing sizes are more problematic because the volume of fluid that can be compressed for a given length of space is smaller. “Hydraulically jacking” the tool into the desired operating position can solve this problem. To do this, release the casing pressure and reapply the desired operating pressure as required. Releasing the pressure trapped between the operating plug and the shut-off plug allows the operator to jack the sleeve down in increments until the desired operating sleeve position is reached.

External Sleeve (ES) and ESIPC™ cementers do not exhibit this type of problem as often as the MS and MSIPC cementers. The ES cementer line requires less sleeve travel, so the ES cementer versions can be run much closer to the first-stage shut-off baffle.

Excessive Pipe Weight Suspended Below the Cementer

Tensile loading applied to a tensile member (the mandrel of an ES/ESIPC cementer or the outer case of a MS/MSIPC cementer) causes the tensile member to elongate with a corresponding decrease in diameter. Because the internal operating seats of the stage tool are not subjected to any tensile load, their diameters do not change. When the tensile load is sufficient to eliminate the mating part clearance between the tensile member and the internal operating seats, the tool can become difficult to operate. This difficulty can occur even when the tensile load is well within the stage tool's rated tensile strength.

As a general rule, the length of suspended pipe beneath the stage tool should be limited to 5,000 ft or less for standard-grade (L-80) tools and higher. For tools rated for K-55 grade service, the length of suspended pipe should be limited to 3,000 ft or less. If longer lengths of pipe must be suspended beneath the stage tool, review contingency plans with the customer before beginning the job. If difficulty develops in operating the tool, make plans to temporarily relieve a portion of the tensile load hanging beneath the tool. The most direct approach is to calculate the amount the pipe stretches as a result of its own weight. To calculate the length of pipe hanging below the stage tool, see Table 204 in the “Dimensions Halliburton Cementing Tables,” Red Book. Slacking off the calculated amount of stretch, after the first-stage cement has attained sufficient gel strength to support the pipe, should place the stage tool at neutral weight. After the second-stage cement has been placed and the tool closed, pick up the full hook load to place the casing string in tension.

If the casing string extends to surface, this operation should be relatively simple, assuming that the casing is not handed at the rig floor. If the casing top is at the rig floor and an abnormally long length of pipe is suspended below the cementer, add an additional landing joint before starting the job. The additional joint is a safety precaution and helps prevent operational problems.

In a similar liner application, the problem becomes more complex. If it is suspected that excessive pipe weight is hanging below the stage tool, request that the liner hanger not be set until all cementing operations are complete.

Thermal effects also aggravate the problems related to tensile loading. The internal drillable seats have a higher coefficient of thermal expansion than the steel tensile members. For a given temperature change, the drillable seats expand at a slightly higher rate than do the steel tensile members. While the bottomhole temperature required to thermally lock the operating sleeves is far greater than the operating temperature of the tool, thermal heating of the tool slightly decreases the mating part clearance between the operating seats and the steel mandrel.



The Hole Angle or Doglegs at the Location of the Cementer Cause Excessive Side Loading

Stage-cementing tools should not be affected by side-loading effects because stage tools are more rigid than casing (the tools do not bend as easily). Always use adequate centralization immediately above and below the stage tool to keep the tool centered in the hole. If a stage-cementing tool is inadvertently located in an extremely tight dogleg, and operational problems occur with no other evident causes, attempt to change the loading imposed on the tool, either by slacking off or applying additional tension to relax the side loading on the tool.

Lost Circulation Material

LCM applies to all stage-cementing devices.

LCM should not be pumped through a stage cementer. The purpose of LCM is to form a bridge on porous media. LCM could bridge the cementing ports in a stage tool. Strong bridging agents, such as Gilsonite™, can be problematic. Weak bridging agents, such as Flocele™ cement additive, are not considered to be as large of a risk.

If LCM cements are pumped through a stage tool, maintain the proper slurry weight at all times. If the cement weight drops in a portion of the slurry, the material could fall out of suspension and slug the cementer with an abnormally high concentration of LCM. If a spacer fluid is pumped ahead of a cement containing LCM, the spacer must have sufficient viscosity to keep LCM in suspension at the cement/spacer interface.



Potential Operating Problems with Multistage Cementing Tools

Three-Stage Cementing with Two Stage Tools

• When cementing the casing in three stages, place two stage tools in the casing string.

• To reduce the IDs of the opening-sleeve seat and the releasing-sleeve closing seat of the lower-stage cementer, install the inserts provided in the plug set.

IMPORTANT Although both stage tools are identical, use the stage tool with the inserts as the lower tool.

• If using a Type H tool and a Type P tool together, make sure the Type H tool is the lower tool.

• Do not use two Type H tools when performing a three-stage cement job.

Stage Cementing with Optional First-Stage Top and Bottom Plugs

• Place the bottom-plug bypass adapter on top of the float collar.

• Place the first-stage shut-off plug insert baffle in the next casing connection up from the float collar.

• This will add to the length of the first-stage shoe joint track.

• The maximum amount of pressure that can be placed on an insert baffle located in a casing-collar connection is 1,000 psi.

• An insert baffle can be placed in a casing joint only if the ES cementer is a Type P tool.

• A baffle adapter collar is required to be used if a bottom plug is run on a Type H tool.

• Opening the Type H tool with hydraulic pressure will overpressure the maximum pressure rat-ing of an insert baffle suspended in a casing joint.

Use of Incompatible Fluids During Multistage Cementing Displacements

It has been a common practice to displace the first stage on a two-stage cement job with water up to the multistage cementing tool to allow for easier well completion and to eliminate the need to turn the whole well over to water during completion operations. Switching fluids during displacement allows mud to be at the multistage cementing tool so that when displacement stops and the tool is opened, mud can be circulated before the second stage.

When performing this operation, it is recommended to take the following precautions:

• Make sure the two-fluids interface is below the multistage cementing tool and not at or anywhere above the multistage cementing tool.

• Water-based muds with a water interface above the multistage cementing tool can produce barite and weighting material settling or fall out, which can then land and build up on the internal sleeves of the stage tool.

• Water- and oil-based muds can cause a viscous pill or emulsion to form above the stage tool and cause a Free Fall plug to fall and land, or possible pressure transmittal to the opening sleeve.



• If lost circulation occurs during the primary cementing operations and there is not enough mud returned to the pits to displace with, and mud and water need to be used for displacement, make note of where the two-fluid interface is in the casing string when displacement is over.

Second-Stage Displacement Closing Plug

Make sure that there is no internal-casing landing-equipment restriction for the second-stage displacement closing plug to pass through.

NOTE This plug has a built-in ring on the nose that is intended to land on the closing seat of the stage tool. The nose is not as flexible as a standard Five Wiper cementing plug or HWE® cementing pump down plug. Check the ODs of the nose for these plugs for wiper ODs.

Importance of Casing Centralization when using ES Cementer Multistage Cement Tools

Because of the Halliburton ES cementer design and the downward shifting movement of the external sleeve when locking the stage tool closed, it is important that the stage tool be centralized.

• Make sure there are centralizers placed on the casing string near the installation point of the stage tool. Spacing should be no greater than 5 ft away from the stage tool.

• Do not place centralizers directly on the stage tool or in a position on the casing string that would interfere with the travel of the external sleeve of the multistage cementing tool.

• Place one centralizer on the casing joint below the stage tool.

• Place one centralizer on the casing joint above the stage tool.

• Make sure the centralizers and limit clamps, if used, do not interfere with the direct installation of the stage tool and use of casing tongs.


Chapter

7
Pre and Post-job Checklists
Introduction

This chapter contains both pre and post-job checklists for operation of Type P ES and ES II stage cementers.

September 2014 Pre and Post-job Checklists 7-1


Prejob Checklist for Type P ES and ES II™ Stage Cementers

Type P ES/ES II Cementer Part No. ______________________________________________

Plug Set Part No. and Type _____________________________________________________

Hole Size__________________ Type P ES/ES II Cementer Max. OD ___________________

Hole Deviation at Shoe_____________________; at Cementer ________________________

Casing Size________________ Weight________________ Thread _____________________

Type P ES/ES II Cementer and Plug Set Info: First-Stage Shutoff Baffle ID__________ First-Stage Shutoff Plug Nose OD______________

ES Cementer Opening Seat ID______________ Opening Plug Max. OD_________________

ES Cementer Closing Seat ID_______________ Closing Plug Nose OD _________________

Plug Container Info: Plug Container Type _____________________________________________________

Plug release indicator working? Yes__________No___________

Plug Release Plunger: Number or turns out?____________; Turns in?______________

Handle lock working? Yes________No__________

Manifold Info: Lo Torc® valves working? Yes_______No_________

Valves closed to test lines? Yes_______No_________

Floating Equipment Info: Floating Equipment Vendor Name _______________________________________________

First-Stage Shutoff Baffle_______or Baffle Adapter_______(Check one)

If first-stage shutoff baffle is used, does floating equipment have a smooth, flat face for the first stage baffle to set on? Yes_______No________

Well Data: Hole TD___________________________Shoe depth________________________________

First-Stage Shutoff Baffle Depth_________________________________________________

Theoretical Top of First-Stage Cement ____________________________________________

Casing Displacement to First-Stage Shutoff Baffle __________________________________

Casing Displacement to Type P ES/ES II Cementer__________________________________

7-2 Pre and Post-job Checklists September 2014


Post-Job ReportTo help us provide quality products, please complete and return the following to:

[email protected]

Customer _______________________________________________________________

Location__________________________________________ Date of Job____________

Rig Name _______________________________________________________________

Type P ES/ES II Cementer Part No.________________ Plug Set Part No.____________

Mud Type______________________________ Mud Weight ______________________

Hole Depth____________________________ Hole Size _________________________

Hole Deviation: at Shoe__________________; at ES Cementer____________________

Last Previous Casing Size_____________ Weight_____________ Depth_____________

Cementing Information: First Stage: Second Stage:

Type: Lead____________ Tail___________Type: Lead____________ Tail _________

Weight: Lead___________ Tail__________Weight: Lead__________ Tail _________

Volume: Lead__________ Tail___________Volume: Lead___________ Tail _______

Displacement Information: First Stage: Second Stage:

Fluid Type__________ Weight__________ Fluid Type__________ Weight__________

Displacement Volume__________________ Displacement Volume _________________

Plug Landing Pressure_________________ Plug Landing Pressure _________________

Type P ES/ES II Cementer Opening Pressure______________; Closing Pressure ______

Were any problems encountered during the job?_________________________________

____________________________________________________________________

Completed By: ___________________________________________________________

Location:_________________________________________ Date__________________

September 2014 Pre and Post-job Checklists 7-3

Place Cementer Label HereJob Calculations

_________________________________

_________________________________

_________________________________

_________________________________

_________________________________

_________________________________

_________________________________

_________________________________

_________________________________

_________________________________

_________________________________

_________________________________

_________________________________

_________________________________

_________________________________

_________________________________

_________________________________

_________________________________

_________________________________

_________________________________

_________________________________

_________________________________

_________________________________

_________________________________

_________________________________

_________________________________

_________________________________

Caution: To prevent damage to the shutoff baffle if baffle adapter is not used, place the shutoff baffle on top of the float collar. Do not place in casing coupling with Type P Cementer.

Data recorded by:

_________________________________Name & Date

DN

0043

72

Date post:	17-Apr-2020
Category:	Documents
Upload:	others
View:	72 times
Download:	1 times

Type P ES and ES II™ Cementers Installation and Operating ... · The ES II stage cementer builds...

Documents