Chapter 10

Cementing-OptiCem Analysis
Overview
Cementing can be used to optimize cementing operations and minimize
the possibility of costly cementing errors.
In this section of the course, you will become familiar with all aspects
of using the Cementing-OptiCem module, including:
Available analysis modes
Defining operating parameters
Defining cement fluids
Calculating centralizer placement
Defining the cement job
Defining analysis parameters
Analyzing results

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Workflow
Activate Cementing by clicking the

button.

Open the Case using the Well Explorer.

Define the wellbore. (Case > Hole Section Editor)
Define the workstring. Use the same dialog to define all
workstrings (drillstrings, casings, liners, etc.) (Case > String)
Enter wellpath data. (Case > Wellpath > Editor)
Define the fluids used. You can define as many fluids as you want.
(Case > Fluid Editor)
Define the pore pressure gradients. (Case > Pore Pressure)
Define the fracture gradients. (Case > Fracture Gradient)
Define the geothermal gradient. (Case > Geothermal Gradient)
Define the cement circulating system. (Case > Cement
Circulating System)
Specify centralizer information. (Parameter > Centralizer
Placement)
Specify cement job data including volumes, fluids used, back
pressure and whether or not this is a foam job. (Parameter > Job
Data)
If this is a foam job, specify the foam job data. (Parameter > Foam
Data)
Specify wellbore temperatures, depths of interest and whether or
not returns are taken at the sea floor. (Parameter > Additional
Data)
Specify additional pressure that may be required to seat the plug
and the eccentricity (standoff) to be used in the calculations.
(Parameter > Analysis Data)
Analyze the results.

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Introducing Cementing Analysis

What is Cementing?
The Cementing module can be used to predict what occurs in the well
during cementing operations. Cementing can be used to evaluate the
effects of various conditions on the simulated cementing operation. You
can use Cementing to calculate:

Safe pump rates

Surface pressure
Downhole pressures
Nitrogen concentration
Foam volume
Downhole rheology
Temperature thinning of fluids

Starting Cementing Analysis

There are two ways to start the Cementing Module.

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Select Cementing from the Modules menu.

Click the Cementing button.

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Choose Cementing-OptiCem Analysis from Modules menu, or by

clicking the Cementing-OptiCem Module button.

Select desired Cementing-OptiCem Analysis mode

from submenu, or from Mode drop-down list.

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Defining the Case Data

Refer to Entering Case Data on page 162 for instructions on entering
data into the Case menu options. Case data specific to cementing will be
covered in this chapter.

Specify the Volume Excess %

The Case > Hole Section Editor is used to define the wellbore as the
current workstring sees it. You can also use the Case > Hole Section
Editor dialog to specify the extra percentage of annular cement volume
required for an enlarged wellbore. This volume will be based on the
Effective Hole Diameter field. For open hole sections, the Effective
Hole Diameter is used to represent the actual size of the hole. If you
specify the Effective Hole Diameter, the Volume Excess % is calculated
based on Effective Hole Diameter. Similarly, if you specify the Volume
Excess %, the Effective Hole Diameter will be calculated.
For example, if you are drilling an 8.5 inch hole that is 10% overgauge,
enter 8.5 for Hole Diameter and 10 for Volume Excess %. The extra
volume will be calculated. Do not use the Volume Excess % field to
raise the cement top. Use Parameter > Job Data to raise the cement
top.
Note: Specifying Volume Excess...

Be careful that you dont enlarge the wellbore in the Hole Diameter field and then
again using the Volume Excess % field.

Enter the Volume Excess % and the Effective Hole

Diameter is calculated.

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Defining the Cement Job

Defining the Cement Job Fluids
Defining Spacers

Use Case > Fluid Editor to define cement spacers by specifying the
basic characteristics of the fluid.
You dont need to activate the
spacer. Spacer use is specified
using Parameter > Job Data.

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To define a spacer, select Spacer

from the Type drop-down list.

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Defining Cement Slurries

Use Case > Fluid Editor to define cement slurries by specifying the
basic characteristics of the fluid.
You dont need to activate the
cement. Cement use is specified
using Parameter > Job Data.

To define a cement, check the

Cement box.

Specify the Standoff or Calculate the Centralizer Placement

Use the Parameter > Centralizer Placement dialog to calculate the
spacing between multiple centralizers and/or the variable standoff
between the casing and wellbore. Alternately, you can enter a manual
standoff value that applies to the entire well. Before using this dialog,
you should use the Centralizer catalog to specify all centralizers if you
plan on using centralizers not already in the catalog. Access the
Centralizer catalog using the Well Explorer. Refer to Working With
Catalogs on page 110 for more information.
Centralizer placement calculations are typically performed before
wellbore simulation. These calculations can also be performed

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independently using the Centralizer Placement mode. Refer to the

online help for more details concerning this dialog.
The Wellbore Fluid defaults from
the active fluid indicated on the
Case > Fluid Editor.

You can specify a

measured depth and
standoff above the top of
the centralized interval.

Enter the maximum and

minimum distance that can be
used when calculating centralizer
spacing.

Defining the Cement Job

Use the Parameter > Job Data dialog to define crucial job information
such as tracer fluid types, rate, volume, and placement for each fluid in
the cementing job. Refer to the online help for more information about
this dialog.

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Note: Mud

Erodibility

Mud Erodibility as used in cementing and WELLPLANs Cementing-OptiCem

refers to the ability of the wellbore fluid to be eroded away by a different fluid
passing by it in the annulus of the well. The Mud Erodibility option is available
only to Halliburton users. If you need this calculation performed, please contact
your local Halliburton Zonal Isolation Group.

Defining Temperatures, Depths of Interest and Offshore Returns

Information
The Parameter > Additional Data dialog is used to enter data for the
Wellbore Simulator mode in the Cementing module (OptiCem). This
dialog allows you to enter and manage offshore, zone depth, and
temperature information.

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Do not check this box because

we are not taking returns at
the sea floor.

Reservoir Zone and Fracture

Zone are the same in this
case.

Temperature can be defined in several ways.

If the Bottom Hole Circulating Temperature is
known, you can specify it.
You can calculate the API BHCT based on mud
outlet temperature and BHST.
You can specify a profile based on depth.
You can import a temperature profile from
WellCat.

Define the temperature

profile to be used or import
a temperature profile.

Specifying Additional Analysis Parameters

The Parameter > Analysis Data dialog provides supplemental control
of several values before performing the Wellbore Simulator
calculations.
If Eccentricity is turned off, then the wellbore simulator
performs its calculations assuming 100% standoff. If you want
the eccentricity calculations at a particular standoff, select the
Entered Standoff option on the Centralizer Placement Dialog.
Otherwise, it will run with an actual standoff profile.

To ensure proper plug

seating, additional pressure
may be applied to the
casing immediately after
the plug is landed.

Erodibility is only available to Halliburton personnel. If

you need this option, contact your local Zonal Isolation
Group.
Check Calculate Automatically for automatic
calculation of step size. Usually you will want to check
this box.

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Analyzing Results
Results for the Cementing analysis are presented in plots, tables and a
report. All results are available using the View menu.

What is the Circulating Pressure Throughout the Cement Job?

Use the View > Plot > Circ Pres and Den - Frac Zone plot to
determine the circulating pressure fluid volume pumped at the fracture
zone specified on Parameter > Additional Data.
The circulating pressure during the displacement
stage exceeds the fracture pressure.
These lines indicate when the
various stages occur.

Fracture
pressure

The formation breakdown pressure at this depth is indicated by one of

the curves on this plot. If the Automatic Rate Adjustment option was
selected (on Parameter > Job Data), then a second curve indicates the
safety factor. If the circulating pressure exceeds the fracture zone
pressure, the fluid can fracture the formation and result in lost
circulation from the wellbore.
If the circulating pressure exceeds the fracture zone pressure, reduce the
pump rates or turn on the Automatic Rate Adjustment option. If
reducing the pump rates does not completely solve the problem,
decrease the density of one or more fluids (with foamed fluids, or by

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increasing the nitrogen concentration), or decrease the volume of the

heaviest stages.
If you prefer, you can view this information as ECD versus volume
pumped.
Click the right mouse button anywhere on the plot to
open the plot selection box. Highlight the plot you
want displayed and click the left mouse button.

Observe the circulating

density as a function of
volume pumped.

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Is There Free Fall?

The View > Plot > Comparison of Rates In and Out plot displays the
total annular return rate and corresponding pump rate versus the fluid
pumped into the well. This data may be correlated with information in
the Volume and Rates Calculations table in the Cementing Report.
(View > Report)
Differences between the two rate curves indicates free fall without
nitrogen injection. If free fall occurs and the well goes on vacuum, the
rate out will initially exceed, and then fall below, the planned pumped
rate.

Notice that cement

free fall does occur
because rate out
initially exceeds the
rate in, but then
falls below the
pump rate in.

Notice the rate out initially

exceeds the rate in.

After initial high, rate out then

falls below rate in.

What is the Surface Pressure?

Use the View > Plot > Calculated Wellhead/Surface Pressure plot to
view the pressure changes as varying density fluids are pumped at
varying rates through the well. If the Surface Iron option was selected
(on the Case > Cement Circulating System dialog) this graph is titled
Calculated Surface Pressure. This data may be correlated with
information in the Volume and Rates Calculations table on the
cementing report.
The calculated wellhead pressure is lower than pump pressure because
of the hydrostatic head and friction in the lines between the pump and
cementing head.

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A horizontal graph line along the x-axis indicates free fall. Often, as the
majority of the cement moves from the casing to the annulus, the slope
of this curve beings to increase. Usually, it continues to increase as the
heavier cementing fluids are forced up the annular gap.

Free Fall indicated when pressure is constant.

Automatically Adjusting the Flowrate

Because the circulating pressure exceeds the fracture pressure using the
rates specified on the Parameter > Job Data dialog, you can allow the

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software to automatically adjust the pump rates. Click the Automatic

Rate Adjustment box on the Parameter > Job Data dialog.
Click Automatic Rate Adjustment to have the rate
adjusted to avoid exceeding the fracture pressure.
If you allow automatic rate adjustment, you must specify a
Safety Factor.

These rates will be adjusted.

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Using automatic rate

adjustment, the
maximum circulating
pressure is less than
the fracture pressure.
Notice the safe
pressure (based on
safety factor) is
indicated on the plot.

What Are the Adjusted Rates?

The View > Plot > Comparison of Rates In and Out plot displays the
total annular return rate and corresponding pump rate versus the fluid
pumped into the well. This data may be correlated with information in

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the Volume and Rates Calculations table in the Cementing Report.

(View > Report)
You can view the adjusted rates
using this plot. Rates have been
decreased to reduce the circulating
pressure as a result of checking the
Automatic Rate Adjustment box on
the Parameter > Job Data dialog.
Refer to the Job Data dialog to view
the rates specified prior to the rate
adjustment.

Using Foamed Cement

Using foamed cement is another means to reduce the circulating

pressures.
The Parameter > Foam Data dialog is available only if you check the
Use Foam Schedule box on the Parameter > Job Data dialog while
using the Wellbore Simulator analysis mode. This dialog lets you

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describe calculation methods and stages when simulating foam in a

cement job.
Select Constant or Staged Gas Flow to keep the
nitrogen constant for a segment.The foam
density will follow the pressure gradient, and
thus decreases from the bottom to the top of the
segment. The longer the segment, the greater
the density variance.

Type concentrations for

Surfactant, Stabilizer.

Select this option if the

nitrogen ratio will be adjusted
to offset pressure changes
and thus hold density more
constant. Use this option
only with automated nitrogen
pumping equipment.

Click the stage you

want to define using
the bottom portion of
this dialog.

This information is read-only.

It is defaulted from the Job
Data dialog.
The Gas Rate Stage
Number is used to tell
how many different gas
rates are to be used
under the Stage Gas
option and where each
of the rates are used.

In order to foam a segment,

you must check the Foam
box.

Enter Foam Density and Quality (the volume

percentage of gas in the foam) is calculated.
or

Enter Quality (the volume percentage of gas

in the foam) and Foam Density is calculated.

Using the Foam Schedule

Use View > Foam Schedule dialog to calculate and view the Foam
Pumping Schedule. This dialog lists liquid volume and gas rates of the
fluids left in the annulus at the end of the simulation. The calculated
hydrostatic pressure for the frac zone and reservoir zones are displayed
at the bottom of the table. The frac zone and reservoir zones are
specified using the Parameter > Additional Data dialog.

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Notice that some of these fluids may not be foamed. Some fluids may
not appear in this report if they were pumped completely out of the
annulus.
If an error occurs during the calculation process, an error dialog appears
displaying a description of the error. When you finish reading it, click
OK. The Error dialog and the Calculate dialog close so you can begin
working on solving the source of the error.

These are design depths (as specified on the Job Data dialog) and may not be the actual
depths. Review the View > Final Density and Hydrostatic plot for accurate cement
locations.
Click Calculate to ensure
you are looking at accurate
results.

Adjusted Liquid Volume and Adjusted Gas Rate

sliders adjust the cement tops or placement.

These are the calculated hydrostatic pressure

gradients for the depths of interest specified on
the Additional Data dialog.

Final Gas Rate and Adjusted

Final Gas Rate do not apply
when you are using constant or
stage gas flow.

To check results of the foam schedule calculation:

1) Check the Fluid Animations Schematic to see whether the
desired top of cement was achieved, check the Final Positions of
Stages table in the reports, or downhole density plot.
2) Check the circulation Pressure and Density-Fracture Zone graph
and the Circulation Pressure and Density-Reservoir Zone graphs
to see if the density is acceptable.
3) Adjust, rerun, and recheck the job as follows:

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Checking Results
If TOC is....

and ECD is....

then do this:

Low

Light

1. Increase density or decrease

quality.
2. Rerun the Foam Schedule.
3. Use the slider bar (top of
Foam Data dialog) to increase
the Adjusted Liquid Volume.
4. Click the Calculate button.
5. Check the Fluid Animation
Schematic and the Circ Pres
and Den plots.

Low

Acceptable

1. Use the slider bar (top of

Foam Data dialog) to increase
the Adjusted Liquid Volume.
2. Repeat steps 4 and 5 above.

Low

Heavy

1. Use the slider bar (top of

Foam Data dialog) to increase
the Adjusted Gas Rate.
2. Repeat steps 4 and 5 above.

Low

Light

1. Increase the density or

decrease quality.
2. Rerun the Foam Schedule.
3. Repeat steps 4 and 5 above.

Acceptable

Acceptable

Do nothing.

Acceptable

Heavy

1. Decrease density or increase

quality.
2. Rerun the Foam Schedule.
3. Repeat steps 4 and 5 above.

Acceptable

Heavy

1. Decrease density or increase

quality.
2. Rerun the Foam Simulator.
3. Repeat steps 4 and 5 above.

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Checking Results (Continued)

High**

Light

1. Manually decrease N2 in the

Adjusted Start Gas Rate
column.
2. If calculation method is
constant density, also
manually decrease N2 in the
Adj. Final Gas Rate column.
3. Repeat steps 4 and 5 above.

High**

Acceptable

1. Manually decrease liquid

volume in the Adj. Liq. Vol.
column.*
2. Repeat steps 4 and 5 above.

High**

Heavy

1. Decrease density or increase

quality.
2. Rerun the Foam Simulator.
3. Repeat steps 4 and 5 above.

* To estimate the percentage by which to change the volume, use the

percentage by which the simulated foamed length differs from the
desired length. (If the foamed length 1,500 feet and the desired length is
2,000 feet, increase by 33%.)
** This scenario is unlikely because the Fluid Placement calculations
should prevent excessive top of cement.
Repeat these steps until you are satisfied with the results. Round the
slurry and gas rate quantities before running the Wellbore Simulator.

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