Multi-stage Cementing

(Two-Stage Cementing)

Module 231M011
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 Revision History
Rev. Date Description Author
1.0 01/06/04 Technical validation F. Rashid - KTC

1.1 16/06/04 Spelling corrections C. Camman - SRPC

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 Objectives
By the end of this module, you will be able to explain:
– Reasons for a two-stage job (Multistage jobs)
– Hardware used for two-stage jobs
– Step by step job procedure for a two-stage job
– Special Job considerations
– Advantages and disadvantages of Multistage
cementing
– Alternative methods to two-stage jobs
– Calculations to perform a two-stage job
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 What is Multistage Cementing?
• A cement job performed in two or more stages is
called Multistage cementing
• Three standard multistage techniques are commonly
employed
– Regular two-stage cementing
– Continuous two-stage cementing
– Three-stage cementing
• The execution time of stage cementing increases the
rig time
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 Reasons for Multistage Cementing
• Reduce the hydrostatic column
– Weak formation or Low Fracture Gradient
– Narrow Frac and pore pressures window
– Most common reason for two-stage cementing
• Upper zone to be cemented with a special cement
system
– Salt or Gas zone
– Higher density, Higher compressive strength
– Cost Reduction
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 Reasons for Multistage Cementing
• Avoid long cementing intervals
– Logistics
– Temperature difference
• Leave some zones uncemented
– Cost Reduction
– Cuttings Re-Injection

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 Hardware for two-stage jobs
Closing plug

Stage collar
Opening bomb

First stage plug

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 Stage Collar – Running Position
• Casing is at bottom and
Stage collar is closed
• Start mud circulation

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 Stage Collar – 1st Stage Cementing
• Start 1st-stage cement job
• Release 1st-stage plug and
start displacement
• 1st-stage plug
– passes through stage collar
– lands at float collar
(displacement is completed)
• Opening bomb is dropped
and wait for 15 minutes
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 Stage Collar – 2nd Stage Cementing
• Opening Bomb lands on
stage collar
• Pressure up and open the
stage collar
• Now circulation starts
through ports at stage collar
• Start 2nd-stage cement job
• Release closing plug and
start displacement
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 Stage Collar – Closed Position
• Closing plug (2nd-stage plug)
is landed on the stage collar
• Pressure up and close the
stage collar
• Cement slurry will remain in
annulus and will not flow
back

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 Special Considerations
Stage Collar Does Not Open!
• Possible Solutions:
1. Wait: Bomb may not have arrived yet
2. Increase Pump Pressure
– Note: Max Pressure < Burst Pressure of casing
3. Run Drill Pipes in the hole and try to open mechanically
4. Perforate above collar and cement
– Note: Might perforate through 2 casing
– No mechanical closing
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 Special Considerations
To WOC or not to WOC!
• Possible Solutions:
1. WOC: YES! If height of the 2nd stage slurry may fracture
the “weak formation"
2. Otherwise – NO

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 Special Considerations
Where to place Stage Collar
• Problem Formation
4100’

– Weak formation
– Lost circulation zone weak formation
7100 -7250
FG: 0.6 psi/ft

• Solution: 8400 - 8450

weak formation FG:0.68 psi/ft
– Above the LC zone, it will
reduces the hydrostatic TD:10200’

above the problem zone

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 Special Considerations
Where to place Stage Collar
• Problem Formation
– Salt Zone
2400’

– Gas Zone
5500’
Problem zone
• Solution: 5850’

– Below the Problem zone to

reduce the slurry volume TD:10400’

• 200 ft below for salt

• 500 ft below for gas
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 Special Considerations
Collar Inside Previous Casing
• Many clients insist on this.
Why ?
– To avoid “jetting” effect on
the formation while circulating
or cementing
– To ensure that if the collar
fails to open, at least the open
hole section is cemented

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 Special Considerations
External Casing Packer
• Purpose
– To give an extra seal below
the stage collar
• How do they function?
– As the wiper plug (first stage)
seals, pressuring up shears
the pins and the displacement
fluid is pumped into the
packer, inflating it
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 Special Considerations
Others
• ALWAYS - Open the collar immediately and circulate
out excess cement
• Note: Control circulating pressures, avoid fracturing
any weak formations
• 1st-stage lead slurry should have sufficient thickening
time to allow circulating out the excess slurry without
any problems after the stage collar is opened
• Slow down to 2-3 bpm when the first stage plug
passes through stage collar
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 Some Other Points
• The stage collar is eventually drilled out leaving the
same "drift" as the rest of the casing
• A stage collar is considered to be a "weak" point in the
casing by many clients and so many avoid using them
• Use a good amount of pre-flushes, as there is no bottom
plug for either stage and there are many chances for
cement to get contaminated and have a wet shoe
• 3 Stage cementing is the same as 2 stage, but with an
extra Stage!
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 Alternatives
Reduce the hydrostatic column
• Use of lightweight slurries
– Foam Cement
– LiteCRETE*
• This leads to:
– Complex designs
– Logistical problems
– Expensive slurries

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* Mark of Schlumberger
 Example
• Well information:
– 13 3/8 in 68lb/ft, shoe at 2,789 ft
– 9-5/8 in 53.5 lb/ft intermediate casing from surface to 6,398 ft
– 9 5/8 in stage collar at 4,265.3 ft
– 12 ¼ in open hole
– Float collar at 6,348.8 ft
• Top of cement required 2,461 ft
• Calculate:
– Slurry Volume and Displacement
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 2-Stage Cementing Job - Example

13 3/8 in 68 lb/ft Casing

ft3/ft bbl/ft
Top of cement at 2,461 ft
4 Csg
13 3/8 in shoe at 2,789 ft
Csg-csg
3
9 5/8 in Stage collar at 4,265.3 ft
OH
12 ¼ in O.H.

9 5/8 in 53.50 lb/ft Casing

2 9 5/8 in Float collar at 6,348.8 ft
1
9 5/8 in Shoe at 6,398 ft

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 2 Stage Cement Job - Answers
• First Stage
– Slurry Volume:
V1=[(6,398 ft – 6,348.8 ft) x 0.0708 bbl/ft]= 3.48 bbl
V2=[(6,398 ft – 4,365.3 ft) x 0.0558 bbl/ft]= 113.47 bbl
– Displacement Volume:
VDESP1=6,348.8 ft x 0.0708 bbl/ft = 449.50 bbl
• Second Stage
– Slurry Volume:
V3=[(4,265.3 ft – 2,789 ft) x 0.0558 bbl/ft]= 82.35 bbl
V4=[(2,789 ft –2,461 ft) x 0.0597 bbl/ft)= 19.59 bbl
– Displacement Volume:
VDESP2=4,265.3 ft x 0.0708 bbl/ft= 302 bbls
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 PROBLEM 1: Problems PROBLEM 2:

Frac Gradient: 0.8 psi/ft Frac Gradient: 0.8 psi/ft

Mud: 12 ppg Mud: 11.2 ppg

4100’

2400’
7100 -7250
weak formation FG: 0.6 psi/ft
5500’
salt zone salt zone
5850’ 8400 - 8450
weak formation
FG:0.68 psi/ft

TD:10400’ TD:10200’

Answer the following:

1. Would you recommend a 2-stage? Why?
2. What depth would the Collar be?
3. What is the maximum density of slurry possible
25 Two-stage Cementing during the first stage? (assume cement to stage collar)
KTC/UTC 4. Where would the TOC be for the first stage?
 Conclusion
Multistage cementing is a solution, but it is not
always the best option
– Advantages
– Disadvantages
• Logistics, Cost
• Stage collar represents a weak point in the string
• Poor Mud removal, Contaminated slurries

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Case Study
North Africa

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* Mark of Schlumberger