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NO20160085A1 - Cement set activators for set-delayed cement compositions and associated methods - Google Patents

Cement set activators for set-delayed cement compositions and associated methods Download PDF

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NO20160085A1
NO20160085A1 NO20160085A NO20160085A NO20160085A1 NO 20160085 A1 NO20160085 A1 NO 20160085A1 NO 20160085 A NO20160085 A NO 20160085A NO 20160085 A NO20160085 A NO 20160085A NO 20160085 A1 NO20160085 A1 NO 20160085A1
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cement composition
liquid additive
delayed cement
polyphosphate
delayed
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NO20160085A
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NO347526B1 (en
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Lance Everett Brothers
Peter James Boul
Thomas J Pisklak
Pauline Akinyi Otieno
Kyriacos Agapiou
Ronnie Glen Morgan
Baya Adams
Samuel J Lewis
Cody Glenn Harris
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Halliburton Energy Services Inc
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Priority claimed from US14/090,494 external-priority patent/US9371712B2/en
Application filed by Halliburton Energy Services Inc filed Critical Halliburton Energy Services Inc
Publication of NO20160085A1 publication Critical patent/NO20160085A1/en
Publication of NO347526B1 publication Critical patent/NO347526B1/en

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    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09KMATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K8/00Compositions for drilling of boreholes or wells; Compositions for treating boreholes or wells, e.g. for completion or for remedial operations
    • C09K8/42Compositions for cementing, e.g. for cementing casings into boreholes; Compositions for plugging, e.g. for killing wells
    • EFIXED CONSTRUCTIONS
    • E21EARTH OR ROCK DRILLING; MINING
    • E21BEARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B33/00Sealing or packing boreholes or wells
    • E21B33/10Sealing or packing boreholes or wells in the borehole
    • E21B33/13Methods or devices for cementing, for plugging holes, crevices or the like
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B22/00Use of inorganic materials as active ingredients for mortars, concrete or artificial stone, e.g. accelerators or shrinkage compensating agents
    • C04B22/08Acids or salts thereof
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    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B24/00Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
    • C04B24/24Macromolecular compounds
    • C04B24/26Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C04B28/10Lime cements or magnesium oxide cements
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/18Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing mixtures of the silica-lime type
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B40/00Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B40/00Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
    • C04B40/0028Aspects relating to the mixing step of the mortar preparation
    • C04B40/0039Premixtures of ingredients
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09KMATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K8/00Compositions for drilling of boreholes or wells; Compositions for treating boreholes or wells, e.g. for completion or for remedial operations
    • C09K8/42Compositions for cementing, e.g. for cementing casings into boreholes; Compositions for plugging, e.g. for killing wells
    • C09K8/46Compositions for cementing, e.g. for cementing casings into boreholes; Compositions for plugging, e.g. for killing wells containing inorganic binders, e.g. Portland cement
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09KMATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K8/00Compositions for drilling of boreholes or wells; Compositions for treating boreholes or wells, e.g. for completion or for remedial operations
    • C09K8/42Compositions for cementing, e.g. for cementing casings into boreholes; Compositions for plugging, e.g. for killing wells
    • C09K8/46Compositions for cementing, e.g. for cementing casings into boreholes; Compositions for plugging, e.g. for killing wells containing inorganic binders, e.g. Portland cement
    • C09K8/467Compositions for cementing, e.g. for cementing casings into boreholes; Compositions for plugging, e.g. for killing wells containing inorganic binders, e.g. Portland cement containing additives for specific purposes
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2103/00Function or property of ingredients for mortars, concrete or artificial stone
    • C04B2103/10Accelerators; Activators
    • C04B2103/12Set accelerators
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2103/00Function or property of ingredients for mortars, concrete or artificial stone
    • C04B2103/20Retarders
    • C04B2103/22Set retarders
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2103/00Function or property of ingredients for mortars, concrete or artificial stone
    • C04B2103/30Water reducers, plasticisers, air-entrainers, flow improvers
    • C04B2103/32Superplasticisers

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  • Geochemistry & Mineralogy (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)
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  • Consolidation Of Soil By Introduction Of Solidifying Substances Into Soil (AREA)

Description

CEMENT SET ACTTVATORS FOR SET-DELAYED CEMENT
COMPOSITIONS AND ASSOCIATED METHODS
BACKGROUND
[0001] Embodiments relate to subterranean cementirig operations and, in certain embodimenis, to set-delayed cement compositions and methods of using set-delayed cement compositions in subterranean formations.
[0002] Cement compositions may be used in a varieiy of subterranean operations. For example, in subterranean well constrwction, a pipe string (e.g., casing, liners, expandable tubulars, etc.) may be run into a wellbore and cenlertted in place. The process of cementing the pipe string in place ts commonly referred to as "primary cementing." lii a typical primary cementing method, a cement composition may be purøped into an annulus between the walls of the wellbore and the exterior surface of the pipe string disposed therein. The cement composition may set irt the annalar space, thereby forming an annular sheath of hardened, substantialiy impermeable cement (i.e., a cement sheath) that may support and position the pipe string in the wellbore and may bond the exterior surface of the pipe string to the subterranean formation. Among other things, the cement sheath surrounding the pipe string functions to prevent the migration of fluids in the annulus,-as well as protectmg the pipe string from corrosion. Cement compositions also may be used in remedia! cementing methods, for example, to sea) cracks or hoies in pipe strings or cement sheaths, to seal highly permeable formation zones or fractures, to place a cement plug, and the like.
[0003] A broad variety of cement compositions have been used in subterranean cementing operations. in some instances, set-delayed cement compositions have been used. Set-delayed cement compositions arecharacterized byremaining in a pumpable fluid state for at least about one day (e.g., at least about 7 days, about 2 weeks, about 2 years or more) at room temperature (é.g,, about 80c F) m quiéscerit storage. When desired for use, the sei-delayed cement compositions should be capable of being activated whereby reasonable compressive strengths are developed. For example, a cement set accelerator may be added to a set-delayed cement composition whereby the composition sets into a hardened mass. Among other things, the set-delayed cement composition may be suitable for use in wellbore applications, for example, where it is desired to prepare the cement composition in advance. This may allow, for example, the cement composition to be stored prior to its use. In addition, this may allow, for example, the cement composition to be prepared at a conveiitent location and then transported to the job si te. Accordingly, capital expeodi tures may be reduced due to a reduction in the need for on-site bulk storage and mixing equipment. This may be particularly useful for offshore cementing operations where space onboard the vessels may be limited.
[0004] While set-delayed cement com<p>ositions have been developed heretofore, chafienges exist with their suecessful use in subterranean cementing operations. For example, set-delayed cement compositions prepared with Portland cement may have undesired gelation issues which can limit their use and etTeetivenéss in cementing operations, Other set-delayed compositions that have been deveioperi, for example, those compristng hydrated Utne and quartz, may be effecttve in some operations but may have limited use at lowér temperaturés as they may not develop sufficierit compressive strength when used in subterranean formations håving lower bottom bole static temperatures>
BRIEF PESCRIFTION OF THE DRAWINGS
[0001] These drawings illustrate certain aspects of some of the embodiments of the present method, and should not be used to limit or defme the method.
[0002] FIG. i illustrates a system for the preparation and delivery of a set-delayed cement composition to a wellbore i n accordance with certain embodiments.
[0003] FIG. 2A illustrates surface equipment that may be used in the piacement of a set-delayed cement composition in a wellbore in accordance with certain embodiments,
[0004] FIG. 2B itluslrates the piacement of a set-delayed cement composition into a Wellbore annulus in aeeordaneé with certain embodiments.
[0005] FIG. 3 is a graph of the dispersant amount vs. the thickening time of set-delayed cement compositions activated with a liquid additive comprising a monovalent salt and polyphosphate acti vator combination.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0006] Embodiments rekte to subterranean cementing operations and, in certain embodiments, to set-delayed cement compositions and mefhods of using set-delayed cement compositions in subterranean formations. In particular embodiments, improved cement set activators used for the activation of set-delayed cement compositions may be provided. Embodiments of the cement sét activators may be used to activate a set-delayed cement composition while also achicvmg desirable thickening times and compressive strength development.
[0007] Embodiments of the set-delayed cement compositions may generally comprise water, pumice, hydrated lime, and a set retarder. Optionally, the set-delayed cement compositions may further comprise a dispersant. Embodiments of the set-delayed cement compositions may be tbamed. Advantageously, embodiments of the set-delayed cement compositions røay be capable of remaining in a pumpable fluid state for an extended period of time. For example, the set-delayed cement compositions may remain in a pumpable fluid state for at least about I day, about 2 weeks, about 2 years, or longer. Advantageously, the set-delayed cement compositions may develop reasonable compressive strengths aller activation at relatively Iow temperatures. While the set-delayed cement compositions may be suitabie for a number of subterranean cementing operations, they may be particularly suitabie for use in subterranean formations håving relatively iow bottom hoie static temperatures, e.g., temperatures less tban about 200*F or ranging from about 100°F to about 200"F. ln alternative embodiments. the set-delayed cement compositions may be used in subterranean formations håving bottom hole static temperatures up to 450<*>F or higher.
[0008] The water used in embodiments of the set-delayed cement compositions may be trom any source provided that it does not eontatn an excess of compounds ihat may undesirably afiéct other components in the set-delayed cement compositions. For example, a set-delayed cement composition may comprise fresh water or salt water. Salt water generally may include one or more dissolved salts therein and may be saturated or unsaturated as desired for a particular application. Seawater or brines may be suitabie for use in embodiments. Further, the water may be present in an amount sufficient to form a pumpable shirry. In certain embodiments, the water may be present in the set-delayed cement composition in an amount in the range of from about 33% to about 200% by weight of the pumice. ln certain embodiments, the water may be present in the set-delayed cement compositions in an amount in the range of from about 35% to about 70% by weight of the pumice; One of ordinary skill in the ari with the benefit of this disclosure will récognize the appropriate amount of water for a chosen application.
[0000] Embodiments of the set-delayed cement compositions may comprise pumice. Generally, pumice ts a volcanic rock that can exhibit cementitious properties in that it may set and harden in the presence of hydrated lime and water. The pumice may also be ground. Generally, the pumice may have any particie size disiributkm as desired for a parlicular application, in certain embodiments, the pumice may have a mean particie .sjze in a range of from about 1 micron to about 200 microns. The mean particie size corresponds to d50 values as measured by particie size analysers such as those manufactured by Malvern Instruments, Worcestershire, United Kingdom, ln speciflc embodiments, the pumice may have a mean particie size in a range of from about i micron to about 200 microns, from about 5 microns to about 100 microns, or from about 10 microns to about 50 microns. in one particular embodiment, the pumice may have a mean particie size of less f han about 15 microns. An example of a suitabie pumice is available from Hess Pumice Products, Inc., Malad, Idaho, as DS-325 lightweight aggregate, håving a particie size of less than about 15 microns. It should be appreciated that particie sizes too small may have mixability problems while particie sizes too large may not be effecttvely suspended in the compositions. One of ordinary skil! in the art, with the benefit of this disclosure, should be able to select a particie size for the pumice suitabie for a chosen application.
[0010] Embodiments of the set-delayed cement compositions may comprise hydrated lime. As used herein, the term ''hydrated i i røe-* will be understood to mean calcium hydroxide. ln some embodiments, the hydrated lime may be provided as quicklime (calcium oxide) which hydrates when mixed with water to form the hydrated lime. The hydrated lime may be included in embodiments of the set-delayed cement compositions, for example, to form a hydraulic composition with the pumice. For example»the hydrated lime may be included in a pumice-to-hydrated-lime weight ratio of about 10:1 to about 1:1 or 3:1 to about 5:1. Where present, the hydrated lime may be included in the set-delayed cement compositions in an amount in the range of from about 10% to about i 00% by weight of the pumice, for example. In some embodiments, the hydrated lime may be present in an amount ranging between any of and/or including any of about 10%, about 20%, about 40%, about 60%, about 80%, or about 100% by weight of the pumice. ln some embodiments, the cementitious components present in the set-delayed cement .composition may consist essentially of the pumice and the hydrated lime. For example, the cementitious components may primar?ly comprise the pumice and the hydrated lime without any additiona! components (e.g., Portland cement, fly ash*slag cement) that hydraulieaily set in the presence of water. One of ordinary skill in the art, with the benefit of this-disclosure, will recognizé the appropriate amount of"the hydrated lime to include for a chosen. application.
[0011] Embodiments of the set-delayed cement compositions may comprise a set retarder, A broad variety of set retarders may be suitabie for use in the set-delayed cement compositions. For example, the set retarder may comprise phosphonic acids, such as ethylenediamine tetra(methylene phosphonic acid), diethylenetriamine penta(methylene phosphonic acid), etc,; lignosujfbnaies, such as sodium lignosulfonate, caicium lignosuitbnate, etc; salts such as stannous sulfate, lead aectate, monobasic caicium phosphate, organic acids, such as citric acid, tartaric acid, etc; cellulose derivatives such as hydroxyl ethyl cellulose (HEC) and carboxymethyl hydroxyethyl cellulose (CMHEC); synthetic co- or ter-polymers comprising sulfbnate and carboxylic acid groups such as suiixmate-ftarctkmaltøed acrylamtde-acrylic acid eo-polymers; borate compounds such as alkali borates, sodium metaborate, sodium tetraborate, potassiura pentaborate; derivatives thereof, or mixtures thereof. Examples of suitabie set retarders include. among others, phosphonic acid derivatives. One example of a suitabie set retarder is Micro Matrix* cement retarder, available from Halliburton Energy Services, Inc. Generally, the set retarder may be present in the set-delayed cement compositions in an amount sufficient to delay the setting for a desired time. in some embodiments, the set retarder may be present in the set-delayed cement compositions in an amount in the range of trom about 0.01% to about 10% by weight
■of the pumice. ln specific embodiments, the set retarder may be present in an amount ranging between any of and/or including any of about 0.01%, about 0.1%, about 1%, about 2%, about 4%, about 6%, about 8%, or about 10% by weight of the pumice. One of ordinary skill in the art, with the benefit of this disclosure, will récogmze the appropriate amount of the set retarder to inc i ude for a chosen appl icati on.
[00.12] As prevtousty mentioned, embodiments of the set-delayed cement compositions may optionaliy comprise a dispersant Examples of suitabie dispersants include, without limitation, suifbnated-fbrnialdehyde-based dispersants (e.g., sulfonated acetone formaldehyde condensaie), examples of which may include Daxad<*>19 dispersant available from Geo Specialty Chemicals, Ambler, Pennsylvania. Other suitabie dispersants may be polycarboxylated ether dispersants such as liquimenf* 558 i F and Liquimeni<*>514L dispersants available from BASF Corporation Houston, Texas; or EthacryJ'<*>G dispersant available from Coatex, Genay, France. An additional example of a suitabie commerciaiiy available dispersant is CFR>M-3 dispersant, available from Hailiburlon Energy Services, Inc, Houston, Texas. The Liquiment<*>514L dispersant may comprise 36% by weight of the polycarboxylated ether in water. While a variety of dispersants may be used in accordance
with embodiments, polycarboxylated ether dispersants may be particulariy suitabie for use in some embodiments. Without being limited by theory, it is believed that polycarboxylated ether dispersants may synergistically interact with other components of the set-delayed cement composition. For example, it is believed that the polycarboxylated ether dispersants may réaet with certain set retarders (e.g., phosphonic acid derivatives) resuiting in formation of a gel that suspends the pumice and hydrated lime in the composition for an extended period of time.
[0013] In some embodiments, the dispersant may be included in the set-delayed Cement compositions ihan amount in the range of from about 0.01% to about 5% by weight of the pumice. In specific embodiments, the dispersant may be present in an amount ranging between any of and/or inciuding any of about 0.01%, about 0.1%, about 0.5%, about 1%, about 2%, about 3%, about 4%, or about 5% by weight of the pumice. One of ordinary skill in the art, with the benefit of this disclosure, will recognize the appropriate amount of the dispersant to include for a chosen application.
[0014] Other additives suitabie for use in subterranean cementing operations also may be included in embodiments of the set-delayed cement compositions. Examples of such additives include, but are not limited to: weighting agents, lightweight additives, gas-geneniting additives, mechanical-property-enhancing additives, lost-circulation materials, fiitration-eontrol additives, fluid-loss-control additives, defoaming agents, Foam.bg agents, thixotropic additives, and combinations thereof. in embodiments, one or more of these additives may be added to the set-delayed cement compositions after storing but prior to the piacement of a sét-deiayed cement composition into a subterranean formation. Å person håving ordinary skill in the art, with the benefit of this disclosure, should readily be able to determine the type and amount of additive useful for a particular application and desired result.
[0015] Those of ordinary skill in the ari will appreciate that embodiments of the set-delayed cement compositions generally should have a density suitabie for a particular application. By way of example, the set-delayed cement compositions may have a density in the range of from about 4 pounds per gallon ("lb/gar) to about 20 lb/gal. In certain embodiments, the set-delayed cement compositions may have a density in the range of from about 8 lb/gal to about 17 lb/gal Embodiments of the set-delayed cement compositions may be foamed or unfoamed or may comprise other means to reduce their densities, such as hoilow microspheres, low-density elastic beads, or other density-reducing additives known in the art. ln embodiments, the density may be reduced after storing the composition, but prior to piacement in a subterranean formation. Those of ordinary ski il in the art, wi th the benefit of this disclosure, will recognize the appropriate density for a particular application.
[0016] As previously memioned, the set-delayed cement compositions may have a delayed set in that they remain in a pumpable fluid state for at least one day (e.g., at least about 1 day, about 2 weeks, about 2 years or more) at room temperature (e.g., about 80° F) in quiescent storage. For example, the set-delayed cement compositions may remain in a pumpable fluid state for a period of time from about 1 day to about 7 days or more. ln some embodiments, tise set-delayed cement compositions may remain in a pumpable fluid state for at least about 1 day, about 7 days, about 10 days, about 20 days, about 30 days, about 40 days, about 50 days, about 60 days, or longer. A fluid is eonsidered to be in a pumpable fluid state where the fluid has a consistency of less than 70 Bearden untts of consistency ("Bc"), as measured on a préssurized consistometer in accordance with the proeedure for determining cement thickening times set forth in API RF Practice 10B-2, Reeommended Prctclkefor festing Well Cemente, First Edition, Jury 2005.
[0017] YV hen desired for use, embodiments of the set-delayed cement compositions may be activated (e.g., by combination with an activator) to set into a hardened mass. The term "eement set activator" or "activator", as used herein, refers to an additive that activates a set-delayed or heavily retarded cement composition and may aiso accelerate the setting of the set-delayed, heavily retarded, or other cement composition. By way of example, embodiments of the set-delayed cement compositions may be activated to form a hardened mass in a time period in the range of from about 1 hour to about 12 hours. For example, embodiments of the set-delayed cement compositions may set to form a hardened mass in a time period ranging betwéen any of and/or ihcluding any of about 1 day, about 2 days, about 4 days, about 6 days, about 8 days, about 10 days, or about 12 days.
[0018] ln some embodiments, the set-delayed cement compositions may set to have a desirable compressive strength after activation. Compréssive strength is generally the capacity of a material or structure to withstand axially directed pushing fbrces. The compressive strength may be measured at a specified time after the set-delayed cement composition has been activated and the resultant composition is maintained under specified temperature and pressure eonditions. Compressive strength can be measured by eifhér destructive or non-desfractive methods. The destroctive method physically tests the strength of treatment fluid samples at various points in time by crushing the samples in a compression-testing mach ine. The compressive strength is calculated fram the fatlure load divided by the cross-sectional area resisting the load and is reported in uuits of pound-force per square inch (psi). Non~destructive methods may employ a UCA™ ultrasonic cement analyzer, available from Fann instrument Company, Houston, TX. Compressive strength values may be determined in accordance with API RP 108-2. Reeommended Practice for 7' estiftg WeU Cements, First Edition, July 2005,
[0019] By way of example, the set-delayed cement compositions may develop a 24-hour compressive strength in the range of from about 50 psi to about 5000 psi, alternatively, from about 100 psi to about 4500 psi, or alternatively from about 500 psi to about 4000 psi. in some embodiments, the set-delayed cement compositions may develop a compressive strength in 24 hours of at least about 50 psi, at least about 100 psi, at least about 500 psi, or more. in some embodiments, the compressive strength values may be determined using destructive or non-destruetive methods at a temperature ranging from 100°F to 200°F.
[0020] ln some embodiments, the set-delayed cement compositions may have desirable thickening times after activation. Thickening time typically refers to the time a fluid, such as a set-delayed cement composition, remains in a fluid staté capable of being pumped. A number of different laboratory techniques may be used to measure thickening time. A pressurtzed consistometer, operated in accordance with the proeedure set forth in the afbrementioned API RP Practice 10B-2, may be used to measure whether a fluid is in a pumpable fluid state. The thickening time may be the time for the treatment fluid to reach 70 Se and may he reported as the time to reach ?0 Bc. in some embodiments, the cement compositions may have a thickening time of greater than about 1 hour, alternatively, greater than about 2 hours, alternatively greater than about 5 hours ai 3,000 psi and temperatures in a range of from about 50°F to about 400CF, alternatively, in a range of from about 80CF to about 250<<>>F, and alternatively at a temperature of about 140°F.
[0021] Embodiments may include the addition of a cement set activator to the set-delayed cement compositions. Examples of suitabie cement set activators include, but are not limited to: æeolites, amines such as triethanolamine, diefhanolamine; silicates such as sodium siticate; zinc formåte; calcium acetate; Groups IA and HA hydroxides such as sodium hydroxide, magnesium hydroxide, and calcium hydroxide; monovalent salts such as sodium chloride: divalent salts such as calcium chloride; nanosilica {i.e., silica håving a particie size of less than or equal to about 100 nanometers); polyphosphates; and combinations thereof. in some embodiments, a combination of the poiyphosphate and a monovalent salt may be used for activation. The monovalent salt may be any salt that dissociates to form a monovalent cation, such as sodium and potassium salts. Specific examples of suitabie monovalent salts include potassium sulfate, and sodium sulfate, A variety of different polyphosphates may be used in combination with the monovalent salt for activation of the set-delayed cement compositions, including polymeric metaphosphate salts, phosphate salts, and combinations thereof. Specific examples of polymeric metaphosphate salts that may be used include sodium hexametaphosphate, sodium trimeta<p>hospbate, sodium tetrametaphosphate, sodium pentametaphosphate, sodium heptametaphosphate, sodium octametaphosphate, and combinations thereof. A specific example of a suitabie cement set activator comprises a combination of sodium sulfate and sodium hexametaphosphate. In particular embodiments, the activator may be provided and added to the set-delayed cement composition as a liquid additive, for example, a liquid additive comprising a monovalent salt, a polyphosphate, and optionally a dispersant.
[0022] Some embodiments may include a cement set activator comprising nanosilica. As used herein, the term ''nanosiliea'' refers lo silica håving a particie size of less than or equal to about 100 nanometers ("nm"). The size of the nanosilica may be measured using any suitabie technique. It should be undefstood that the measured size of the nanosilica may vary based on measurement technique, sample preparation, and sample conditions such as temperature, eoncentration, etc. One technique for measuring the particie size of the nanosilica is Transmission Eiectron Microscopy (TEM). An example of a commercially available product based on laser diffraction is the ZETASIZER Nano ZS particie size analyzer supplied by Mai vern Instruments, Worcerstershire, UK. ln some embodiments, the nanosilica may comprise colloidal nanosilica. The nanosilica may be stabil i/ed using any suitabie technique. ln some embodiments, the nanosilica may be stabilized with a metal oxide, such as lithium oxide, sodium oxide, potassium oxide, and/or a combination thereof. Additionaily the nanosilica may be stabilized with an amine and/or a metal oxide as mentioned above. Embodiments of the nanosiiicas have an additional advantage in that they have been known to fill in pore space in cements which can result in superior mechanicai properties in the cement after it has set.
[0023] Some embodiments may include a cement set activator comprising a combination of å monovalent salt and a polyphosphate. The monovalent satt and the polyphosphate may be combined prior to addition to the set-delayed cement composition or may be separately added to the set-delayed cement composition. The monovalent salt may he any salt that dissociates to form a monovalent cation, such as sodium and potassium salts, Specific examples of suitabie monovalent salts include potassium sul fate and sodium sulfate. A variety of different polyphosphates may be used in combination with the monovalent salt for activation of the set-delayed cement compositions, including polymeric metaphosphate salts, phosphate salts, and combinations thereof, for example. Specific examples of polymeric metaphosphate salts that may be used include sodium hexametaphosphate, sodium trimetaphosphate, sodium tetrametaphosphate, sodium pentametaphosphate, sodium heptametaphosphate, sodium octametaphosphate, and combinations thereof. A specific exampie of a suitabie cement set activator comprixes a combination of sodium sulfate and sodkim hexametaphosphate. lnterestingly, sodium hexametaphosphate is also known in the art to be a strong retarder of Portland cements. Because of the unique chemistry of polyphosphates, polyphosphates may be used as a cement set activator for embodiments of the set-delayed cement compositions disciosed herein. The ratio of the monovalent salt to the polyphosphate may range, for example, from about 5:1 to about 1:25 or from about 1:1 to about 1:10. Embodiments of the cement set activator may comprise the monovalent salt and the polyphosphate salt. in a ratio {monovalent salt to polyphosphate) ranging between any of and/or including any of about 5:1, 2:1, about 1:1, about 1:2, about 1:5. about 1:10, about 1:20, or about 1:25.
[0024] ln some embodiments, the combination of the monovalent salt and the polyphosphate may be mixed with a dispersant and water to form a liquid additive for activation of a set-delayed cement composition. Examples of suitabie dispersants include, without limitation, the previously described dispersants, such as sulfohated-formaldehyde-based dispersants and polycarboxylated ether dispersants. One example of a suitabie sultbnated-fonnaldehyde-based dispersant is a sulfonated acetone ibrmaldehyde condensate, available frbm Halliburion Energy Services, Inc., as CFR-3™ dispersant. One example of a suitabie polycarboxylated ether dispersant is Liquimenf* 5I4L or 5581F dispersants, available from BASF Corporation, Houston, Texas.
[0025] The liquid additive may funetion as a cement set activator. As discussed above, a cement set activator may also accelerate the setting of the set-delayed or heavily retarded cement. The use of a liquid additive to aecélerafé a set-delayed or heavily retarded cement is dependent, upon the compositional makeup of the liquid additive as well as the compositional makeup of the set-delayed or heavily retarded cement. With the benefit of this disclosure, one of ordinary skill in the art should be åble to fbrmutate a liquid additive to activate and/or accelerate a set-delayed or heavily retarded cement composition.
[0026] The formulation of the liquid additive is a delicate balance that correlates with the specific compositional makeup of the set-delayed cement composition. The amount of the monovalent salt and the polyphosphate must be carefully balanced in reiation to the dispersant. Å liquid additive with an irregular mixture of components may lead to a set-delayed cement composition with less than optimal rheology. In some embodiments, the liquid additive may be added to the set-delayed cement composition in an amount of from about 1% to about 20% by weight of the set-delayed cement composition and, alternatively, from about 1 % to about 10% by weight of the set-delayed cement composition.
[0027] The monovalent salt may be present hi the liquid additive in an amount of about 0.1% to about 30% by weight of the Hquid additive, in specific embodiments, the polyphosphate may be present in an amount ranging between any of and/or including any of about 0.1 %, about 1.0%, about 10%, or about 30% by weight of the liquid additive. With the benefit of this disclosure, one of ordinary skil! ihthe art should be abie to formulate a li<q>uid additive with a sufficient amount of polyphosphate for a specific application.
[0028] The polyphosphate may be present in the liquid additive in an amount of about 0.1% to about 30% by weight of the liquid additive. In specific embodiments, the polyphosphate may be present in an amount ranging between any of and/or including any of about 0.1%, about 1.0%, about 10%, or about 30% by weight of the liquid additive. With the benefit of this disclosure, one of ordinary skill in the art should be able to formulate a liquid additive with a sufTieient amount of polyphosphate for a specific application.
[0029] The dispersant may be present in the liquid additive in an amount of about 0.1% to about 90% by weight of the liquid additive, ln specific embodiments, the dispersant may be present in an amount ranging between any of an&%r including any of about 0.1%, about!%, about 50%, or about 90% by weight of the liquid additive. With the benefit of this disclosure, one of ordinary skill in the art should be abie to formulate a liquid additive with a sufficient amount of dispersant lor a specific application.
[0030] The water may be present in the liquid additi ve in an amount of about 50% to about 90% by weight of the liquid additive, ln specific embodiments, the water may be present in an amount ranging between any of and/or including any of about 50%, about 60%, about 75%, or about 90% by weight of the liquid additive. With the benefit of this disclosure, one of ordinary skill in the art should be able to formulate a liquid additive with a sufficient amount of water for a specific appiication. [0031 ] ln accordance with embodiments, the component ratio of the liquid additive may be relative to the makeup of the set-delayed cement composition. Whereby the amounts of the monovalent salt, polyphosphate, and the dispersant are therefbre a funetion of the amounts of the lime, pumice, and sum total of the water (i.e. the water in the set-delayed cement composition and any water in the liquid additive) used in the activated cement composition.
[0032] Without being limited by theory, the matn limitations in the fonnulation of the liquid additive are the solubility limits of the monovalent salt and the polyphosphate; and the amount of dispersant necessary lo provide the cement wi th an acceptable rheology. The solubility limit is innate to the chosen monovalent salt and polyphosphate and therefbre not alterable; however, the amount of dispersant is i tnked to the amounts of the monovalent salt and polyphosphate. The amounts of the monovalent salt/polyphos<p>hate and the dispersant are in a pseudo direct relationship, whereby in a balanced formulation increasing the amount of one requires an increase in the amount of the other to maintain a balanced composition. For example, if the monovalent salt and the polyphosphate amounts are increased, the dispersant must also be increased or the cement composition will be too thick to pump. On the contrary, if the dispersant amount is increased, the cement composition will be too thin and the solid particulates may settle out of solution unless the amounts of the monovalent salt and the polyphosphate are also increased.
[0033] ln some embodiments, the liquid additive should provide for a thickening time at wellbore eonditions of greater than about 1 hour, alternatively, greater than about 2 hours, alternatively greater than about 5 hours. ln some embodiments, the liquid additive may provide a thickening time at wellbore eonditions of about four to about six hours. Ås déseribed above, thickening time typicaliy refers tp the time a fluid, such as a cement composition, remains in a fluid state capable of being pumped. The liquid additive affects the rheology of the cement composition. Therefbre, a liquid additive may affect the pump time of a cement. If cement rheology is not optimal the activated cement composition may be too thick or too thin, and therefbre would be unsuitable for the desired pump time.
[0034] ln some embodiments, the liquid additive may provide a set-delayed or heavily retarded cement with desirable 24-hour mechanical properties. Desirable mechanicai properties include 24 hour compressive strength that is greater than 250 psi, a uniform density (i.e. no settling), and the absence of any free fluid.
[0035] Without being limited by tbeory, a description of a mechanism for acti vation of a lime and pumice set-delayed cement composition using a set-delayed cemeni aciivator comprising a combination of sodium sulfate and sodium hexametaphosphate is provided. it is believed that the sodium sulfate produces sodium hydroxide upon reaction with the lime. This reaction ca uses a resulting rise in the pH of the slurry and consequently an increase in the rate of dissolution of silicon dioxide. Cement hydration rate has a direct relationshlp with the proportion of free silicates and/or ahiminosilicates. Sodium hexametaphosphate chelates and incre&ses the dissolution rate of calciu■ ■ m ■ ■ hvy.droxide. The combination of sodium sulfate and sodium hexametaphosphate creates a synergy in various compositions of set-delayed cement compositions that provides berter results than the singular use of either cement set activator.
[0036] The cement set activator may be added to embodiments of the set-delayed cement composition in an amount sufficient to induce the set-delayed cement composition to set into a hardened mass. ln certain embodiments, the cement set activator may be added to the set-delayed cement composition in an amount in the range of about 0.1% to about 20% by weight of the pumice. In speeilic embodiments, the cement set activator may be present in an amount ranging between any of and/or including any of about 0.1%, about 1%, about 5%, about 10%, about 15%, or about 20% by weight of the pumice. One of ordinary skill in the art, with the benefit of this disclosure, will recogttize the appropriate amount of cement set activator to include for a chosen application.
[0037] As will be appreciated by those of ordinary skill in the art, embodiments of the set-delayed cement compositions may bc used in a variety of subterranean operations, including primary and remedia! cementing. In some embodiments, a set-delayed cement composition may be provided that comprises water, pumice, hydrated lime, a set retarder, and optionally a dispersant. The set-delayed cement composition may be introduced into a subterranean formation and allowed to set therein. As used herein, introducing the set-delayed cement composition into a subterranean formation includes introduction into atiy portion of the subterranean formation, including, without limitation, into a wellbore drilled into the subterranean formation, into a near wellbore region surrounding the wellbore, or into both. Embodiments may further include activation of the set-delayed cement composition. The activation of the set-delayed cement composition may comprise, for example, the addition of a cement set activator to the set-delayed cement composition.
[0038] In some embodiments, a set-deiayed cement composition may be provided that cbmprises water, pumice, hydrated lime, a sei retarder, and optionally a dispersant. The set-delayed cement composition may be stored, for example, in a vessel or other suitabie container. The set-delayed cement composition may be permitted to remain in storage for a desired time period. For example, the set-delayéd cement composition may remain in storage for a time period of about i day or longer. For example, the set-delayed cement composition may remain in storage for a time period of about 1 day, about 2 days, about 5 days, about 7 days, about 10 days, about 20 days, about 30 days, about 40 days, about 50 days, about 60 days, or longer, fn some embodiments, the set-delayed cement composition may remain in storage for a time period in a range of trom about 1 day to about 7 days or longer. Thereafter, the set-deiayed cement composition may be activated, tor example, by addition of a cement set activator, introduced into a subterranean formation, and allowed td set therein.
[0039] In primary cementing embodiments, for example, embodiments of the set-delayed cement composition may be introduced into an annular space between a conduit located in a wellbore and the walls of a wellbore (and/or a larger conduit in the wellbore), wherein the wellbore penetrates the subterranean formation. The set-deiayed cement composition may be allowed to set in the annular space to form an annuiar sheath of hardened cement. The set-deiayed cement composition may form a barrier that preven ts the migration of fluids in the wellbore. The set-delayed cement composition may also, for example, support the conduit in the wellbore.
[0040] ln remedia! cementing embodiments, a set-delayed cement composition may be used, for example, in squeeze-cementing operations or in the piacement of cement plugs. By way of example, the set-delayed composition may be placed m a wellbore to pl ug an opening (e.g., a void or crack) in the formation, in a gravel paek, in the conduit, in the Cement sheath, and/or between the cement sheath and the conduit (e.g., a microannulus).
[0041] An embodiment comprises a method of cementing comprising: providing a set-delayed cement composition comprising water, pumice, hydrated lime, and a set retarder; activating the set-delayed cement composition with a liquid additive to produce ah activated cement composition, wherein the liquid additive comprises a monovalent salt, a polyphosphate, a dispersant, and water; and ailowing the activated cement composition to set,
[0042] An embodiment comprises an activated cement composition comprising: water; pumice; hydrated lime; a set retarder; a monovalent sali; aud a polyphosphate.
[0043] An embodiment comprises a cementing system comprising: a set-delayed cement composition comprising: water, pumice, hydrated lime, and a set retarder; and a liquid additive for activation of the set-delayed cement composition comprising: water, a monovalent salt, a polyphosphate, and a dispersant.
[0044] Referring now to FIG. I, the preparation of a set-delayed cement composition in accordance with example embodiments will now be deseribed. FIG. 1 illustrates a system 2 for the preparation of a set-delayed cement composition and subsequent delivery of the composition to a wellbore in accordance with certain embodiments. As shown, the set-delayed cement composition may be mixed in mixing equipment 4, such as a jet mixer, re-circulating mixer, or a batch mixer, for example, and then pumped via pumping equipment 6 to the wellbore. ln some embodiments, the mixing equipment 4 and the pumping equipment 6 may be disposed on one or more cement trucks as will be apparent to those of ordinary skill in the art. In some embodiments, a jet mixer may be used, for example, to continuously mix the lime/settable material with the water as it is being pumped to the wellbore. In set-delayed embodiments, a re-circuiating mixer and''or a batch mixer may be used to mix the set-deiayed cement composition, and the activator may be added to the mixer as a powder prior to pumping the cement composition downhole. Additionally, batch mixer type units for the slurry may be plumbed in line with a separate tank contaimng a cement set activator. The cement set activator may then be fed in-iine with the slurry as it is pumped out of the mixing unit.
[0045] An example technique for placing a set-delayed cement composition into a subterranean formation will now be deseribed with reference to FlGS. 2A and 28. FIG. 2A illustrates surface equipment 10 that may be used in piacement of a set-delayed cement composition in accordance with certain embodiments. It should be noted that while FIG. 2A generally depicts a land-based operation, those skilled in the art will readily recognjze that the principles deseribed herein are equally applicable to subsea operations that employ floating or sea-based platibrms and rigs, without; departing from the scope of the disclosure. As illustrated by FIG. 2 A, the surface equipment 10 may include a cementing unit 12. which may include one or more cement trucks. The cementing unit 12 may include mixing equipment 4 and pumping equipment 6 (e.g., EIG , I) as will be apparent to those of ordinary skill in the art. The cementing unit 12 may pump a set-delayed cement composition 14 through a feed pipe 16 and to a cementing head 18 which conveys the set-delayed cement composition Hdownhole.
[0046] Turning now to FIG. 2B, the set-delayed cement composition 14 may be placed into a subterranean formation 20 in accordance with example embodiments. As illustrated, a wellbore 22 may be drtlled into the subterranean formation 20. While wellbore 22 is shown extending generally verticaliy into the subterranean formation 20, the principles deseribed herein are also applicable to wellbores that extend at an angle through the subterranean formation 20, such as horisontal and slanted wellbores. As illustrated, the wellbore 22 comprises walis 24. ln the illustrated embodiment, a surface casing 26 has been inserted into the wellbore 22. The surface casing 26 may be cemented to the wails 24 of the wellbore 22 by cement sheath 28. In the illustrated embodiment, one or more additional conduits (e.g., intermediate casing, production casing, liners, etc), showtv here as casing 30 may also be disposed in the wellbore 22. As illustrated, theré is a wellbore annulus 32 formed between the casing 30 and the wails 24 of the wellbore 22 and/or the surface casing 26. One or more centralizers 34 may be attached to the casing 30, for example, to centraltee the casing 30 in the wellbore 22 prior to and during the cementing operatien.
[0047] With continued reference to FIG. 2B, the set-delayed cement composition 14 may be pumped down the interior of the casing 30. The set-delayed cement composition 14 may be allowed to flo w down the interior of the casing 30 through the casing shoe 42 at the bottom of the casing 30 and up around the casing 30 into the wellbore annulus 32. The set-delayed cement composition 14 may be allowed to set in the wellbore annulus 32, for example, to form a cement sheath thai supports and positions the casing 30 in the wellbore 22, While not illustrated, other techniques may also be utilized for introduction of the set-delayed eement composition 14, By way of example, reverse circulation techniques may be used that include intrøducing the set-delayed cement composition 14 into the subterranean formation 20 by way of the wellbore annulus 32 instead of through the casing 30.
[0048] As it is introduced, the set-delayed cement composition 14 may displace other fluids 3.6, such as drilling fluids and/or spacer fluids that may be present in the interior of the casing 30 and/or the wellbore annulus 32. At least a portion of the displaced fluids 36 may exit the wellbore annulus 32 via a flow line 38 and be depositcd, for example, in one or more retention pits 40 (e.g., a mud pit), as shown on FIG, 2A. Referring again to FIG. 2B, a bottom plug 44 may be introduced into the wellbore 22 ahead of the set-deiayed cement composition 14, for example, to separate the set-delayed cement composition 14 from the fluids 36 that may be inside the casing 30 prior to cementing. After the bottom plug 44 reaches the landing coilar 46, a diaphragm or other suitabie device should rupture to allow the set-delayed cement composition 14 through the bottom plug 44. In FIG. 2B, the bottom plug 44 ts shown on the landing coilar 46. In the illustrated embodiment, a iop plug 48 may be introduced into the wellbore 22 behind the set-delayed cement composition 14. The top plug 48 may separate the set-delayed cement composition 14 from a displacement fluid 50 and also push the set-delayed cement composition 14 through the bottom plug 44.
[0049] The exemplary set-delayed cement compositions disclosed herein may directly or indiréctly affect one of more components or pieces of equipment associated with the preparation, deiivery, reeapture, recycling, reuse, and/or disposai of the disclosed set-delayed cement compositions. For example, the disclosed set-delayed cement compositions may directly or indiréctly affect one or more røixers, related mixing equipment, mud pits, storage facilities or units, composition separators, heat exchangers, sensors, gauges, pumps, eompressors, and the like used generate, store, monitor, regulate, and''or reeondition the éxemplary set-delayed cement compositions. The disclosed set-delayed cement compositions may also directly or indiréctly affect any transport or deiivery equipment used to convey the set-delayed cement compositions to a well site pr downhole such as, for example, any transport vessels, conduits, pipelines, trucks, tubulars, ånd/or pipes used to compositi onal ly move the set-delayed cement compositions from one location to another, any pumps, eompressors, or motors (e.g., topside or downhole) used to drive the set-deiayed cement compositions into motion, any valves or related joints used to regulate the pressure or flow rate of the set-delayed cement compositions, and any sensors (i.e,, pressure and temperature), gauges, and/or combinations thereof, and the like. The disclosed set-delayed cement compositions may also directly or indiréctly affect the vartous downhole equipment and tools that may eome ihto contact with, the set-delayed cement compositions such as, but not limited to, wellbore casing, wellbore liner, completion string, insert sirings, drill string, coiled tubing, slickiine, wireline, drill pipe, drill eollårs, mud motors, downhole motors and/or pumps, cement pumps, surfaee-mounted motors and/or pumps, centraljzers, turbolizers, scratchers, floats (e.g., shoes, collars, val ves, etc), logging tools and related telemetry equipment, actuators (e.g., eiectromechanical devices, hydromeehanical devices, etc), sliding sleeves, production sieeves, plugs, screens, filters, flow control devices (e.g., inflow control devices, autonomous Inflow control devices, outflow control devices, etc), couplings (e.g., electro-hydraulic wet connect, dry connect, inductive coupler, etc), control lines (e.g., eleefrical, fiber optie, hydraulic, etc), surveillance lines, drill bits and reamers, sensors or distributed sensors, downhole heat exchangers, va! ves and corresponding actuation devices, too! seals, packers, cement plugs, bridge plugs, and other wellbore isolation devices, or components, and the like.
[0050] To facilitate a hetter understanding of the present embodiments, the following examples of certain aspeets of some embodiments are given, m no way should the foliowing examples be read to limit, or define, the entire scope of the embodiments.
EXAMPLES
Example 1
[0051 ] The following example describes an example liquid additive composition for use with an example set-delayed cement composition. for this example, the liquid additive was added to the set detayed eémeni composition in the amount of 8% of the total mass of the combined hydrated lime and pumice. After activation, the activated set-delayed cement composition had a thickening time of 5.5 hours at I00?F. The thickening time was røeasuring using a pressnrixed consistometer ai 100°F in accordance with the proeedure for determining cement thickening times set forfh in API RP Practice 10B-2, Mcommendéd Practice for 7' esting Weli Cements. First Edition, July 2005. As discussed above, varying the concentration of the dispersant without adjusiing the monovalent salt and polyphosphate to compensate may produce an activated slurry with less than optimal rheology and may alter the thickening time.
[0052] The example set-delayed cement composition comprised water; DS-325 lightweight aggregate pumice, available from Hess Pumice Products, Inc., Malad, Idaho; hydrated lime; Liquiment 558 IF* dispersant, available from BASF Corporation, Houston, Texas; and Micro Matrix<*>cement retarder (MMCR), available from Halliburton Energy Services, Ine,, Duncan, Oklahoma. The compositional makeup is presented in Table I below. The amounts listed in Table 1 are shovvn as a percentage by weight: of the pumice.
[0053] The example liquid additive comprised water, a monovalent (sodium sulfate), a polyphosphate (sodium hexametaphosphate), and Liquiment 5581 F8* dispersant. The compositional makeup is presented in Table 2 below. The amounts listed are shown as a percentage of the total composition of the liquid additive.
Example 2
[0054] ln this example, a series of six liquid additive samples were prepared for use with an example set-delayed cement composition. The composition for the set-delayed cement composition is presented in Table 3 below. In fable 3, "%bwP" stands for "percentage by weight of pumice" and "gal/sk" stands for "gallons per sack 46 Ib. sack of pumice,** The liquid additive comprised water, a monovalent salt (sodium sulfate), a polyphosphate (sodium hexametaphosphate), and Liquiment 5581 F* dispersant The water, monovalent salt, and polyphosphate amounts were held constant as shown in Table 4 below. The dispersant concenteatiohwas varied each of the six samples as shown in Table 5 below. The liquid additive from Table 4 was added to the set-delayed cement composition from Table 3 such that the liquid additive comprised 10% of the combined weight of the set-delayed cement composition and the liquid additive.
[0055] The dispersant amounts varied from a range of 0.00% to 4.3%. The rheology of the slurries also varied based on the amount of dispersant present since the monovalent salt and polyphosphate amounts were held constant. To reiterate, the dispersant amount is a percentage of the total activated composition. After preparation, the rheologicai properties of the samples were determined using a Model 35A Fann Viscometer and a No. 2 spring with a Fann Yield Stress Adapter, in accordance with the proeedure set forth in API RP Practice 108-2, Recmtmentkd Practice for Testing W& tf Cnmetits. The data is presented in Table 5 below. The rheologicai data shown in Table 5 are apparent viscosity values measured at a hear rate of 100(1 /sec).
[0056] Example 2 illustrates that varying the dispersant amount, without eompensating by adjusting the monovalent salt and the polyphosphate amounts, may ereate slurries with less; than optimal rheologies.
[0057] Slurry Sample t from fable 5 was unworkable and was not pourabie. Archimedes tests were perfbrmed for the remaining 5 slurries. In order to do the Archimedes tests, eaeh of the samples was poured into 2" x 4" cylinders and lett to set at 140!>F lor 24 hours. The set samples were then cut into three equally spaeed parts along the lenglh of the cylinders. Using the Archimedes prineiple of density and displacement, the densities of the samples were determined and reeorded tii units of lb/gal. f he results are presented in Table 6 below.
[0058] Samples 2-5 had no significant settling issues. Sample 6 did display settling, In general, the more dispersant that is added, the less viscous the cement slurry will be. Sample 5 pdssessed the best slurry characteristies and woujd be the optimal ehoiee compared to the other 5 samples on this measure alone. The other slurries could potent ial ly be optimal when such factors as cosi and early mechanical strength development are tåken intoaceount.
Example 3
[0059] The slurry composition presented in Table 3 above was used as an example set-deiayed cement composition. The example liquid additive formuiation, however, ts di Heren t from the one presented in Table 4. fable 7 lists a new liquid additive formuiation specific to this example.
[0060] Table 8 depicts the different values for the dispersant deseribed in Table 7» Four different dispersant amounts were used. The dispersant coneentratipn is a percentage of the total weight of the activated slurry. The dispersant amount ranged from 0.0% to 4.3%. After preparation, the rheologicai properties of the samples were determined using a Mode i 35A Fann Viscometer and a No. 2 spring with a Fann Yield Stress Adapter, in accordance with the proeedure set forth in API R P Practice i 0B-2, Recommmded Practice for Testing Wéil Cemenis, The data is presented in Table 8 below. The rheologicai data shown in Table 8 are apparent viscosity values measured at a shear rate of 100 (i/sée).
[0061] Archimedes tests were performed for the 4 slurry samples, lii order to do the Archimedes tests, each of the samples was cut into three equally spaced parts. Using the Archimedes principle of density and displaceméht, the densities of the samples were deiermined and recorded in units of lb/gal. The results are presented in Table 9 below.
[0062] Signifieant settling occurred in Samples 9 and 10, representing 0.68% and 4.3% dispersant respectively. ln comparison with Example 2, this indicates that redticing the amount of liquid additive added to the sample may also cause the optimum liquid additive dispereanl concentration to change. Here the optimum concentration was 0.45% dispersant, whereas in the previous example the optimum concentration was 2.4%.
Example 4
[0063] In this example, the slurry deseribed in Table 3 was used for the base composition. The liquid additive formuiation is deseribed in Table 10 below. The monovalent salt was sodium sulfate. "The polyphosphate was sodium hexametaphosphate. The dispersant was Coatex 1702, available from Coatex Inc., Chester, South Carolina. As illustrated in Table 11, the dispersant concentration varied from 0.45% to 833%.
[0064] In order to determine the effect of varying the dispersant concentration on the compressive strength of set samples, the compressive strength of each sampie was measured after live days. The destruetive compressive strength was measured by allowing the samples to cure in a 2" by 4" piastic cy i inder that was piaced in a wa ter bath at 190c F to form set cylinders. Immediately after removal from the water bath, destruetive compressive strengths were determined using a méchanical press in accordance with API RP 10B-2, Recommended Practice for Testing Well Cemente. The results of this test are set forth below in Table 12, in units of psi. The reported compressive strengths are an average for two cylinders; of each sample.
[0065] Varying the dispersant concentration had a direct impact on the compressive strength of the samples. This effect was stronger than the settling effect of adding dispersant. It therefbre stands to reasbn that the dispersant can have an antagonistic effect oh the sodium hexametaphosphate activation of the extended li fe slurry when retarded with the phosphonate, nitrilotrismethylenetriphosphonic acid.
[0066] Archimedes tests were performed for Samples 1 -5. Each of the samples was poured into 2" x 4" cylinders and left to set at 140°F for ftve days. The set samples were then cut into threé equaily spaeed parts along the length of the cy i inders. Using the Archimedes principle of density and displacement, the densities of the samples were determined and recorded. The results are presented in 'fables 13-17 below, where PPG is the symbol lor units of lb/gal.
[0067] Samples 4 and 5 displayed «light settling behavior.
Example 5
[0068] ln this example, ten sample liquid additives were prepared for use with a set-delayed cement composition. The compositional makeup of the set-delayed cement composition is presented in Table 18 below. The liquid additive comprised water, a monovalent salt in the form of sodium sulfate, a polyphosphate in the form of sodium hexametaphosphate. and Liquiment 5581 F* dispersant. It should be noted that the percentages of the monovalent salt and the polyphosphate were held constant throughout the experiment while the dispersant concentration was varied. The composition of the liquid additive is illustrated below in Table 19. All of the listed amounts are shown as a percentage of the total composition of the liquid additive. The liquid additive from Table 19 was added to the set-delayed cement composition deseribed in Table 18 such that the monovalent salt and polyphosphate were present in the combined amount of 1.25 % bwP or 1.00% bwP.
[0069] The dispersant amount varied from a range of 0.10% to 1.39%. The thickening time of the slurries varied based on the amount of dispersant, since the monovalent salt and poiyphosphate were held constant.
[0070] The compressive strength and thickening times of each sample were measured. The destruetive compressive strength was measured by allowing the samples to cure in a 2" by 4" plastie eylinder that was placed in a water bath at 190°F to form set cylinders. lmmediately after removal from the water bath, destruetive compressive strengths were determined using a mechanieal press in accordance with API RP 10B-2, Recommended Practice for Testing Weli Cemenm. The results of this test are set forth in Table 20 below. The reported compressive strengths are an average for three cylinders of each sample.
[0071] Varying the dispersant concentration of the liquid additive allowed the thickening time of the set-deiayed cement composition to be control ied. This added benefit was realized through the observation that the thickening time of the cement samples increased with increasing dispersant amount. Por the liquid additive samples containing 1.25% bwP monovalent salt-polyphosphaté, the relationship is almost linear as shown in FIG. 3.
[0072] lt should be understood that the compositions and methods are deseribed in terms of "comprising," "containing," or "including" various components or steps, the compositions and methods can also "consist essentially of<*>or "consist of<*>the various components and steps. Moreovér, the indefinite articles "a" or "an," as used in the elaims, are defined herein to mean one or more than one of the element that it introduces.
[0073] For the sake of brevity, only certain ranges are explicitly disclosed herein. However, ranges from any lower limit may be combined with any upper limit to recite a range not explicitly recited, as well as, ranges from any lower limit may be combined with any other iower limit to recite a range not explicitly recited, in the same way, ranges trom any upper limit may be combined with any other upper limit to recite a range not explicitly recited. Additionally, whenever a numerical range with a lower limit and an upper limit is disclosed, any numher and any included range falling within the range are specificaliy disclosed. In particular, every range of values (of the form, "from about a to about b," or, equivalently, "from approximately a to b," or, equivalently, "from approximately a-b") disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values even if not explicitly recited. Thus, every point or individual vaiue may serve as i ts own lower or upper limit combined with any other point or individual value or any other lower or upper limit, to recite a range not explicitly recited.
[0074] Therefbre, the present embodiments are well adapted to attain the ends and advantages raentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the present embodiments may be modified and practiced in different but equivalent manners apparent to those skil ied in the art håving the benefit of the teachings herein. Alihough individual embodiments are discussed, all combinations of each embodiment are eontemplated and eovered by the disclosure. Furthermore, no limitations are intended to the details of construetion or design herein shown, other than as deseribed in the elaims below. Also, the terms in the elaims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. it is therefore evident that the particular illustrative embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit, of the present disclosure. If there is any conflict in the usages of a word or term in this specification and one or more patent(s) or other documents that may be incorporated herein by reference, the deilnitions that are consistent with this specification should be adopted.

Claims (20)

1. A method of cementing comprising: providing a .set-delayed cement composition comprising water, pumice, hydrated lime, and a set retarder; activating the set-delayed cement composition with a liquid additive to produce ah activated cement composition, wherein the liquid additive comprises a monovalent salt, a polyphosphate, a dispersant, and Water; and allowing the activated cement composition to set.
2. A method according to claim 1 wherein the liquid additive is added to the set-delayed cement composition in an amount of about 1% to about 20% by weight. of the set-delayed cement composition.
3. A method according to claim 1 or 2 wherein the monovalent salt Is present in the liquid additive in an amount of about 0.1 % to about 30% by weight of the liquid additive, wherein the polyphosphate is present in the liquid additive in an amount of about 0.1% to about 30% by weight of the liquid additive, wherein the dispersant is present in the liquid additive in an amount of about 0.1% to about 90% by weight6f the liquid additive, and wherein the water is present in the liquid additive in an amount of about 50% to about 90% by weight of the liquid additive.
4. A method according to any of elaims 1 to 3 wherein the polyphosphate comprises sodium hexametaphosphate.
5. A method according to any of elaims 1 to 4 wherein the monovalent salt comprises sodium sulfate.
6. A method according to any of elaims 1 to 5 wherein the dispersant comprises a polycarboxylated ether.
7. A method according to any of elaims 1 to 6 wherein the ratio of the monovalent salt to the polyphosphate is from about 5:1 to about 1:25.
8. A method according to any of elaims I to 3 or 7 wherein the polyphosphate comprises sodium hexametaphosphate, the monovalent salt comprises sodium sulfate, and the dispersant comprises a polycarboxylated ether.
9. A method according to any of elaims 1 to 8 wherein the set-deiayed cement composition remains in a pumpable fluid state for a time period of about 4 hours to about 6 hours after activation.
10. A method according to any of elaims 1 to 9 furthér comprising storing the set-deiayed cement composition for a period of about 1 day or longer.
I L A method according to any of elaims 1 to 10 further comprising introducing the activated cement composition into a subterranean formation.
12. A method according to any of elaims 1 to 11 further comprising pumping the activated cement composition through a conduit, through a casing shpe, and into a wellbore annulus.
13. An activated cement composition comprising water; pumice; hydrated lime; a set retarder, a monovalent salt; and a polyphosphate.
14. An activated cement composition according to claim 13 comprising one or more of the features defined in any one of elaims 4 to 8.
15. A cementing system compri si ng: a set-delayed cement composition comprising: water, pumice, hydrated lime, and a set retarder; and a liquid additive for activation of the set-delayed cement composition comprising: water, a monovalent salt, a polyphosphate, and a dispersant.
16. A cementing system according to claim 15 wherein the ratio of the monovalent salt to the polyphosphate is from about 5: i to about 1:25.
17. A cementing system according to claim 15 or 16 wherein the polyphosphate comprises sodium hexametaphosphate.
18. A cementing system according to any of elaims 15 to 17 wherein the monovalent salt comprises sodium sulfate, and wherein the dispersant comprises a polycarboxylated ether.
19, A cementing system according to claim 15 or 16 wherein the polyphosphate comprises sodiuni hexametaphosphate;, the monovalent sålt comprisés sodium sulfate, and the dispersant comprises a polycarboxylated ether.
20. A cementin<g>system according to any of elaims 15 to 19 further comprising: mixing equipment for mixing the set-delayed cement composition and the liquid additive to prøduce an activated set-delayed cement composition; and pumping equipment for delivering the activated set-delayed cement composition into a wellbore.
NO20160085A 2013-09-09 2014-09-08 Cement set activators for set-delayed cement compositions and associated methods NO347526B1 (en)

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