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LCP to be produced for the actual operation was increased by ppg. The slurry was agitated for 30 minutes prior to the initial
a magnitude of four. The mixing process began when the data gathering being completed. Samples were then taken
vessel was ready to accept the LCP. The total batch would from the tanks and sent for laboratory analysis. The vessel
amount to 600 bbl of 15-ppg slurry. Two 120-bbl blenders, was released and headed to sea.
equipped with an eductor system, would accommodate the The plan was to travel at a high rate of speed to a point 50
introduction of the dry cement into the base fluid. The liquid miles offshore and secure the vessel to a platform or buoy.
suspension gel was transferred into one of the two blenders This would simulate the initial voyage of the LCP to the rig
and the additional liquid components were added. These and the resultant standby. After spending 12 hours on the
include the plasticizer, retarder, and free fluid control agent. buoy, the vessel would then traverse open water alternating
The additional components were homogenized for 20 minutes; between 12-hour periods of open water travel and standby.
and the rheology of the base fluid was measured and Since the only time the DP-II would be engaged would be at
compared to lab values. When homogenization was complete the rig during the job, it was decided not to include time on the
and the viscosity was at the designed values, the dry cement DP-II as a part of the test. The reason for this omission is that
blend was then added to the base fluid via a bulk line the only time the DP-II would actually be engaged would be
connected to a standard eductor system that re-circulated the when the LCP was being pumped into the wellbore. No
base fluid. The time to density was then recorded. Once the significant information could be obtained by using the DP-II
LCP was at the required density, the slurry was homogenized during the field trial.
for a minimum of 30 minutes. The homogenization period for Data was gathered every six hours both before and after
the LCP is critical. Experience with the LCP indicates that the slurry was agitated. Data gathered included:
improper homogenization can cause slurry longevity issues.
For this reason the base slurry is held to a viscosity standard of 1. Stability of the LCP using a probe
no more than a +/- 5% of the laboratory Fann 35 600 & 300 2. Density of LCP
values and no more than +/- 20% for the 6 & 3 values. If 3. Rheology at ambient temperature
these values are not within range additional homogenization is 4. Temperatures were recorded at these locations with a
required. Only one of six batches that were prepared for the laser type thermometer:
field trial required additional homogenization. Gulf of Mexico
As each batch was completed, and QA / QC checks were Top of Slurry
completed the LCP was transferred to its respective tank on Deck (Ambient)
the vessel. This task was accomplished with a high volume Below Deck Compartment
diaphragm pump. Void Adjacent to Liquid Mud Tanks
Liquid Storage Tank Modification There was considerable amount of speculation that the heat
A special riser with a hatch was built then attached to the lost from the surrounding environment would be excessive
manhole of that tank. The function of the riser was to allow and would cause longevity issues for the LCP. No data could
access to the tank in the event of rough seas where water be found to substantiate or alleviate these concerns. One
frequently covers the entire work deck. The riser elevated the reason for this lack of data is that liquid mud does not gel to
opening of the hatch three feet. The hatch on the riser was the point of becoming a solid when heated, as would a cement
built with quick connect style dogs to facilitate easy access. slurry. Therefore latent heat is of minimal concern to the
The only other modification deemed necessary was the drilling fluids industry. Fig 1 illustrates the effects of the
addition of a 2-inch chemical injection line. This line was external temperatures and their impact on the LCP. This field
installed in the advent that it became necessary to treat the trial was conducted late in the year and the data seems to
LCP during the field trial. The line was attached very near to suggest that heat was lost from the LCP and not the opposite.
the intake side of the lowest fan mixer in the tank and The GOM temperature was nearly 20F cooler than the initial
extended to inside the riser, just below the hatch. Because of temperature of the LCP. The temperature curve of the LCP
the position of the lower end of the injection line, it would be closely resembles the ambient temperature curve as well as the
possible to distribute treatment chemicals quickly and evenly GOM temperature curve.
throughout the tank by introducing them directly into the LCP Since the heat generated by the engines and the mixers in
as it passes through the fan mixer. the tanks appear to have little effect on slurry temperature, we
could predict that in the summer months the LCP temperature
Sea Trial would not rise much over the temperature of the GOM, or the
The sea trial was scheduled to last a total of 10 days. The first ambient temperature, whichever is greater. The rise in
seven days would be spent with the LCP at the 15-ppg density. temperature seen after agitation was due to the fact that the
At the end of 7 days, the slurry would be brought to the dock slurry was cooler near the surface than it was in the center of
and split evenly. The original tank would retain 300 bbls; and the tank and the warmer slurry was brought to the surface
300 bbls would be transferred to another tank, where the during agitation. Temperature was monitored at various
density would be decreased to 12.5 ppg. The original tank points in the agitation process to determine if the heat gain
would be weighted up to 16.5 ppg with a weighting agent. was from agitation. The gain in temperature did not come
The LCP occupied one tank once it was transferred into the from the agitation process, but a layering effect produced by
vessel. The total capacity of the tank chosen for the test was the slurry cooling at the top.
750 bbl. The total volume of LCP on board was 600 bbl of 15
4 IADC/SPE 98894
Another data set gathered was the slurry viscosity. As was stored at the bulk blending facility in the permanent bulk
with temperature, viscosity was also monitored every six tanks and was blown to the tank until the appropriate density
hours both before and after agitation. Viscosity data was was achieved. Density data for the 15-ppg slurry can be seen
gathered and plotted on both a log and linear scale. Based on in fig. 2.
these data, it was determined that the fluid exhibited properties
matching the modified power law model for fluid behavior. Sea Trial : Final 3 Days
Points plotted on the log/log plot produce a straight line, The two slurries were then subjected to 3 more days of sea
which indicates a match for power law fluid behavior. trials. Data was gathered following the same format set up for
Figs. 3-4 illustrate values for n & K that were calculated the 15-ppg base slurry. The 12.5 ppg slurry showed almost no
using the viscosity module of a current cementing wellbore solid settling and absolutely no density reduction. Calculated
simulator. Days 1-7 are plotted. The viscometer readings n and K values yielded results opposite the 15-ppg slurry.
used were those taken at midnight. Temperature data for The n value decreased which indicates the fluid moving away
points plotted can be seen in fig.1. (Note the increase in K from Newtonian flow behavior. The K value increased
after day 2.) K is the consistency index, an increase in K slightly indicating a possible increase in solids concentration.
could indicate gellation of the LCP. On day two an additional Although slight the slurry was actually gaining viscosity.
quantity of anti-settling agent was added to the LCP by means These same changes were seen in the n and K values for the
of the chemical addition line. The amount per/bbl was equal 16.5 ppg slurry. The 15.0 ppg slurry was weighted up to 16.5
to the amount that was originally blended into the LCP at the ppg on Dec 13 and pumped off the vessel on Dec 16, a 100-
blending facility. bbl sample was retained at the bulk blending facility for an
Being a polymer with a very high water requirement as additional eight days for evaluation. The slurry remained
well as high viscosity, it was important to determine if this pumpable with no settling or gelation.
additional amount of anti-settling agent could be added to the
tanks or would have to be incorporated into the original blend. Discussion
After the addition of the anti-settling agent, the K value A large-scale test was devised that which demonstrated that
increased which would indicate that the fluid was being LCP technology could be utilized by taking advantage of an
incorporated into the LCP and returning settled solids to the infrastructure being used primarily for the transport of liquid
mixture. The n value, which is the flow behavior index, drilling mud. It was the goal of this test was to ascertain if
indicates the slurry is becoming less Newtonian immediately LCP could withstand the rigors of maritime travel, as well as
after the addition of the anti-settling agent. Viscosity data the associated logistics, without losing the value for which it
indicates a gradual thinning of the 15 ppg LCP over the 7-day was intended. The test vessel required very little in the way of
period. The post-agitation density of the LCP remained a modifications because of the similarity of drilling mud and
constant 15 ppg until day 5 with a gradual decrease to 14.9 cement in its liquid state. Pending a successful test it would
ppg on day 7. then be possible for the appropriate vessel to transport,
maintain, and deliver the equivalent of tens-of-thousands of
Sea Trial : Day 8 sacks of cement to a rig in one run.
The vessel returned from offshore on day eight to the bulk The major areas of concern were addressed and the
blending facility, where the slurry was split into two tanks. evaluation was structured in such a way as to find any
This was accomplished by using the vessels progressive weaknesses in the system prior to implementing the
cavity pump. The slurry was pumped via the discharge system technology in a full scale operation, which would first be the
that is used to deliver liquid mud to the rig. The slurry is execution of the aforementioned 20-inch job. Since an LCP
pulled from the bottom of the liquid mud tank through a 12- had never been intentionally placed in the liquid mud tanks of
inch suction line, discharged through the pump, and then on to an offshore vessel, there was no prior history to rely upon. The
the discharge manifold on the deck of the vessel. A 3-inch end result of this full scale field trial was the decision to
hose was connected to the manifold and run into the top of the employ the LCP in a large volume 20-inch casing cementing
tank that the new slurry would occupy. This tank was also operation.
fitted with a riser to prevent seawater contamination. It must
be noted, that during the transfer, the maximum rate of the Conclusions
vessels progressive cavity pump was tested. It was 1. The test demonstrated liquid cement premix could be
determined that at 80% capacity the pump could transfer fluid, readily adapted to large, complex cement jobs with
on deck, 240 gpm faster than what was required for the actual the use of existing, properly equipped offshore
job vessels.
Upon completion of splitting the volume of LCP, liquid
2. The test demonstrated the stability of the base premix
suspension gel was added to the first tank in the amount of 18
as well as diluted slurry and weighted slurry for
gpb in order to reduce the density from 15 ppg to 12.5 ppg.
extended periods of time and the effects of the low
With this task complete, a weighting agent was then
frequency vibration and heave produced by the vessel
introduced to the remaining tank. This was accomplished by
were minimal.
utilizing the same circulating system previously mentioned
and circulating the 15-ppg LCP back into the tank. The 3. Temperature effects from the vessels equipment
weighting agent would be introduced through a standard below deck were not as pronounced as first
eductor system mounted on the riser. The weighting agent presumed.
IADC/SPE 98894 5
4. The test demonstrated that although the agitation in 2. Merritt, J.W.: "Premixed Cement Slurry Solves Problems
the vessels tanks is more than adequate for the LCP, Associated With Conventional Oilwell Cementing," paper
highly viscous fluids with a high water requirement SPE 93897, presented at the 2005 Production and
could not be injected directly into the tank and Operations Symposium, Oklahoma City, OK, 17-19
incorporated into the mixture efficiently. April, 2005
References
90
85
80
75
70
65
60
55
0 1 2 3 4 5 6 7 8
Mid. Temp. before agitation
Mid. Temp after agitation
GOM Temperature
Noon Deck Temp
Empty Tank on Bottom
Noon below deck Temp
15.15
15.1
15.05
15
Density
14.95
14.9
14.85
14.8
14.75
0 1 2 3 4 5 6 7 8
Mid. Density
Days before agitation
Mid. Density after agitation
0.5800
0.5750
0.5700
0.5650
0.5600
0.5550
0.5500
0.5450
0.5400
0.5350
0 1 2 3 4 5 6 7 8
0.1200
0.1100
0.1000
0.0900
0.0800
0.0700
0.0600
0 1 2 3 4 5 6 7 8