SPE-189921-MS

Methods and Processes to Help Improve the Operational Efficiency and

Reliability of Wireline-Run Cement Plugs

Q. Wu, P. Chamarthy, A. Lindsey, and J. G. Thompson, Halliburton

Copyright 2018, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE/ICoTA Coiled Tubing & Well Intervention Conference & Exhibition held in The Woodlands, TX, USA, 27-28
March 2018.

This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents
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Abstract
Cement plugs are a widely used well intervention method to achieve zonal isolation and well plug and
abandonment. The current practice of cementing using wireline was reviewed on a system level to identify
the primary challenges. Existing cement mix properties, such as compressive strength and wait-on-cement
(WOC) time, were characterized using standard API RP 10B-2 (2013) tests. The sensitivity of these mixes
to various wellbore temperature and pressure conditions was also studied. Based on the understanding of
the current practice, modifications of the compositions, packaging, and mixing procedures in the field were
proposed and tested accordingly. Based on the experimental results, the properties of the current cement
mixes showed high sensitivity to temperature variations as small as 10°F. To achieve a cement plug as
expected, accurate knowledge of the well temperature profile and precise selection of the best additives for
such small temperature intervals are necessary. If crossflow occurs, then setting a plug itself can change the
temperature profile. This makes cement plug operations even more challenging during actual field practice.
The cement mixes were modified and tailored to reduce their sensitivity to temperature without affecting
the dump time and strength development. This paper discusses the challenges associated with wireline-run
cementing operations and presents a simple and streamlined process developed to help reduce operational
time and minimize costs. The study also discusses cement mixes customized for dump bailer operations.

Introduction
During the productive life of an oil and gas well, plug cementing operations can be performed to restore or
increase production, such as alter the gas/oil ratio (GOR) or control water production (Nelson and Guillot
2006). Cement plugs isolate a certain well zone (e.g., depleted zone), providing options to perforate a new
well zone. They can also be used to temporarily or permanently abandon a well or a specific well zone.
Several tools and techniques exist to place cement plugs using wireline and coil tubing. This study focuses
on plug cementing using a dump bailer run by wireline (Fig. 1).
2 SPE-189921-MS

Figure 1—Dump-bailer tool and method to place a cement plug (Nelson and Guillot 2006).

In some well intervention applications, the cementing process can consume more than 40% of the total
operation time. In the current oil and gas market, there is an increasing demand to improve well intervention
operations through lower costs and shorter operation times [or nonproductive time (NPT)]. It is necessary
to decrease the time necessary for cementing in those operations. In addition, cement plug failures result
in more than 1,000 hours of lost time and USD 20 million in NPT (Hudson et al. 2015). These types of
cement plug failures include the following:

• Cement plug loss resulting from insufficient bond strength

• Weak or even unset cement plug that fails to provide a hydraulic seal or hold pressure

• Cement plug not set at the designed depth

There are multiple causes for these failures, such as cement slurry contamination, inadequate mixing and
displacement methods, and incorrect downhole temperature used for slurry design. Several studies discuss
improving plug cementing by advancing cement-plug procedures (Heathman 1996), providing a model to
minimize the risk of cement plug failure (Olutimehin and Odunuga 2012), and applying an innovative tool
and process to set cement plugs (Marriott et al. 2006). This paper focuses on temperature variation effects
on WOC time and bond strength, providing suggestions and comments to help improve plug cementing
on a system level.

Background
First, it is essential to understand the key challenges associated with plug cementing runs using a dump
bailer and wireline. Several factors control the quality of the cement plugs and the total amount of time
necessary for cementing.

WOC Time
WOC time is the amount of time necessary to suspend operations to allow the cement slurry to solidify,
harden, and develop compressive strength. WOC time can range from a few hours to several days, depending
on the slurry design, required compressive strength, and downhole conditions. Any interruption to the
cement slurry during WOC time can lead to cracks, voids, and pathways for gas and/or fluid, which can
SPE-189921-MS 3

compromise zonal isolation. Existing cement mixes usually have a recommended WOC time of 24 hours
to achieve sufficient strength for the cement plug.

Dump Time
The WOC time can be shortened by reducing the retarder quantity added to the slurry. This can also shorten
the dump time. The C1 cement slurry used here begins gelling and thickening 90 minutes after mixing,
which is the maximum limit of the dump time. After 90 minutes, the slurry becomes difficult to dump from
the bailer and could become hardened in the bailer. For example, typical wireline has a run-in-hole (RIH)
speed of 100 ft/min. A cement mix with a 90-minute dump time can be only set up to 9,000 ft in the well.
However, there is a strong need for a cement plug to be set in deeper wells. For some gas wells, the setting
depth is usually 14,000 ft.

Volume of Dump Bailer

The typical capacity of a 10-ft bailer varies from 0.64 gal (1 3/8-in. bailer) to 9.24 gal (5-in. bailer),
depending on the diameter. Multiple bailers can be stacked into a longer bailer string. Because of the
diameter of the pipe and the maximum height provided by the crane, the total length of the bailer string
is limited.

Bond Strength
The shear bond strength between the hardened cement and the casings is the most essential property to
seal a specific zone in a well and hold pressure. In the industry, to achieve a long-term hydraulic seal, the
minimum cement plug length can be calculated using the following equation:

(1)

where l is the minimum plug length (ft), ΔP is the differential pressure, ID is casing inner diameter, τ is the
shear bond strengths between the plug and casing at 24 hours, and Fdev is the deviation factor. The safety
factor of 2 is used considering the minimal slurry dilution and the morphology of a composite multidump
plug.
The actual bond strength is significantly affected by the cement slurry processing, dumping technique,
and well conditions. Other factors, such as temperature fluctuations (Carpenter et al. 1992) and chemical
shrinkage of cement during hydration (Parcevaux and Sault 1984), can also affect the bond performance. In
addition, the presence of the following materials in or near the setting depth can negatively affect the quality
of cementing operations and substantially reduce the integrity of cement plugs: crude oil, condensate, scale,
paraffin, heavy brine, and dry gas.
Based on experimental observations, the shear bond strength under ideal conditions can be estimated to
be approximately 10% of the compressive strength (Evans and Carter 1962) (Fig. 2). Thus, in this study,
the compressive strength of cement samples was measured and evaluated to estimate shear bond strength.
4 SPE-189921-MS

Figure 2—Shear strength ≈10% of compressive strength based on experimental observation (Evans and Carter 1962).

Cement Plug Length and Number of Runs

Cement plug length is determined by Eq. 1, taking into consideration the shear bond strength between the
casing and the hardened cement, the casing ID, well deviation, and amount of pressure needed to be held,
with the assumption that the cement slurry is properly dumped in static wellbore conditions and is minimally
contaminated. Using a cement mix with a stronger bond strength to the steel casings is a key solution to help
reduce the necessary cement plug length and thus decrease the number of runs. Thus, reducing the length
of the cement plug and number of bailer runs is an important goal.

Materials
Two types of cement slurry systems were used in this study. The first type (referred to as C1) is prepackaged
and preblended based on the service temperature. For every 10°F, a different retarder package is used to
adjust the dump time or gel and thickening time. This system provides a convenient and universal cement
mix for most applications. The slurry is highly acceptable for field use, as it is easier to order and maintain
inventory and less likelihood exists for error. However, a disadvantage is that this system relies on accurate
mixing by the field personnel at the operation site.
The second type (referred to as C2) is a cement slurry mix customized and tailored based on the
requirements of each application. In this study, the targeted temperature is 250°F. The C1 cement mix with
packages designed for a temperature range between 246 to 255°F was selected as an example to set a baseline
for this slurry system. The C2 cement mix was composed based on the operational requirements.

Experimental Method
Both C1 and C2 cement mixes are prepared in accordance to API standards (API RP 10A 2011; API RP 10B-2
2013) using a high-shear mixer. The powder blend was added into mix water at 4,000 rev/min within 15
seconds followed by mixing at 12,000 rev/min for 35 seconds. The slurries were transferred to the equipment
within 5 minutes of mixing.
Compressive strength tests were conducted following the recommended practice in API RP 10B-2 (2013)
using an ultrasonic cement analyzer (UCA) and a load frame. In a UCA, the transit time of an ultrasonic
signal transmitted through the cement sample is recorded continuously, which can be converted into the
compressive strength of the slurry based on the predetermined correlation. After 24 hours in the UCA,
the cylindrical cement samples were demolded carefully from the UCA and crushed by the load frame to
SPE-189921-MS 5

obtain their compressive strength. All UCA tests were conducted at 3,000 psi pressure. The C1 cement mix
was tested at temperatures of 240, 250, and 260°F. The C2 cement mix was tested at temperatures of 240,
250, 260, and 280°F. These tests provided information about the sensitivity of these two mixes in terms of
strength development in case temperatures varied from those designed.

Results and Discussion

Fig. 3 shows the compressive strength of the C1 cement mix is 2,350 psi at 12 hours and 3,150 psi at 24
hours. Both compressive strengths at 12 and 24 hours fall into the range of historical data for the C1 cement
mix. The WOC time is approximately 20 hours, which matches the recommended WOC time of 24 hours.
In general, this shows that if the mixing instructions are strictly followed, the performance of C1 cement
is as expected.

Figure 3—Compressive strength development profile obtained from the UCA for C1 cement mix.

Temperature Sensitivity of C1 Cement Mix

The performance baseline of the 250°F C1 cement mix was set using data from UCA testing conducted at
the designed temperature. Two scenarios were simulated and tested to study the temperature sensitivity of
this mix. For the first case, to simulate a situation where the downhole temperature is lower than expected,
the 250°F cement mix was tested at 240°F. Fig. 4 shows the cement hydration reaction and compressive
strength development were delayed. The setting time was prolonged and the compressive strength was lower
at 12 and 24 hours. For the second case, to simulate a situation where the downhole temperature is higher
than expected, the 250°F cement mix was tested at 260°F. The setting time reduced, as expected. However,
a reduction in compressive strength was also observed. Because this mix is preblended, prepackaged, and
the components of the materials are unknown, two hypotheses were proposed for this behavior:

• Hypothesis 1: strength retrogression caused by insufficient silica sources (sand, quartz) (Gibson
2011)
• Hypothesis 2: uncontrolled expansion resulting from the expanding agent in the cement mix
6 SPE-189921-MS

Figure 4—250°F C1 cement mix placed at 240, 250, and 260°F.

For Hypothesis 1, strength retrogression often occurs when Portland cement is exposed to a high-
temperature environment. Such behavior is characterized by the breakdown of the set cement matrix,
causing a loss of zonal isolation. Because it is the standard industry practice to add extra silica, the existing
cement mix, C1, is expected to have sufficient silica compound. For Hypothesis 2, the cement slurries
expansion was observed at different temperatures. At higher temperatures, more expansion was observed.
At 270°F, excessive expansion was observed (Fig. 5), resulting in failure of the UCA fiberglass sleeve.

Figure 5—Damage to the UCA fiberglass sleeve resulting from the expansion of C1 cement mix at 270°F.

Comparison Between C1 and C2 Cement Mixes

Fig. 6 shows that the C2 cement mix has 50% higher compressive strength at 24 hours compared to that for
C1 cement, with a minimal impact on setting time, even without slurry optimization. The C2 cement mix
has a faster strength development than the C1 cement mix, which shows significant potential for improving
plug cementing operations. The compressive strength increase can lead to increased shear bond strength at
the preferred well conditions, which means the necessary length of the cement column can be reduced.
SPE-189921-MS 7

Figure 6—Comparison between C1 and C2 cement mixes.

Temperature Sensitivity of C2 Cement Mix

The customized C2 cement mix did show some sensitivity to temperature variations. With higher
compressive strength, there are margins for compressive strength, setting time, and WOC time when
the downhole temperature varies from expected values. Optimization can also be conducted because all
components are known and available.

Figure 7—C2 cement mix placed at various temperatures.

Table 1 summarizes the properties and performance of both C1 and C2 cement mixes.
8 SPE-189921-MS

Table 1—Comparison of external and in-house test data.

Historical Data for

Test Data for C1 Cement Mix Test Data for C2 Cement Mix
C1 Cement Mix

Compressive strength at 12 hours 1,125 to 2,025 (45% of 24-

2,350 3,700
(psi) hour compressive strength)
Compressive strength at 24 hours
2,500 to 4,500 3,150 4,500
(psi)
Shear bond strength at 24 hours (psi) 380 315 450
Minimum plug length (ft) for
10,000-psi pressure differential and 10* 10* 6**
6.5-in. ID
Setting time (hours) N/A 3.5 4
WOC time for 3,000 psi (hours) 12 24 9.5

* A minimum plug length of 10 ft is recommended for all plug-back operations.

** The minimum plug length is estimated under good downhole conditions.

Service Optimization
The improved performance of C2 cement slurry can be used to optimize the service and provide better
value. In many cases, the plug length and WOC time are regulated by the local government or company
policies. However, this does provide the operator with added flexibility to tailor the service according its
specific needs (Fig. 8).

Figure 8—Optimization of service by improving performance of cement slurry.

For example, if WOC time remains the same at 24 hours, to achieve a compressive strength of 3,000 psi,
the length of the cement column can be reduced by half, which means fewer bailer runs. If the length of the
cement column is unchanged, the WOC time can be reduced from 20 to 9.5 hours to achieve a compressive
strength of 3,000 psi. Both the WOC time and cement column length can be optimized to help improve
plug cementing. As a result, the operator can realize a 15 to 25% savings in the overall time needed to
perform the operation.

Conclusion
To help reduce the operation time of well intervention services, it is important to optimize cementing
processes. Existing prepackaged cement mixes show sensitivity to temperature variations as small as 10°F.
SPE-189921-MS 9

Although customized cement mixes still show sensitivity to temperature, their improvement in compressive
strength provides a margin to either reduce the WOC time or decrease the cement column length and
therefore the number of bailer runs, depending on operator preference.
Three aspects are the focus for improvement:

Operations
Standardized training can be provided to the field crew. Premixed dry powder blends and water can be
shipped to help reduce the likelihood of adding incorrect additives or all additive packages. A checklist can
be provided to help ensure the correct mix is selected and that handling instructions are strictly followed.

Materials
Cement mix optimization can be further conducted to reduce temperature sensitivity, provide more
resistance to contamination, etc. Cement mixes can be customized for wireline-run cement plugs based on
varying downhole conditions.

Tools
In-situ and accurate downhole temperature measurements can be performed using temperature gauges in
the last run before cementing to obtain accurate readings.

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