Set-Delayed Cement Compositions for Lost Circulation Control

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Solution Overview

Problem

Lost circulation of drilling fluids and other treatment fluids into subterranean formations poses significant challenges due to the inability of existing technologies to effectively control fluid migration and maintain structural integrity in wellbore operations, leading to increased costs, environmental burdens, and operational inefficiencies.

Innovation Solution

The development of set-delayed cement compositions comprising pumice, hydrated lime, and a set retarder, which remain pumpable for extended periods before rapidly developing static gel strength to seal lost circulation zones and provide compressive support, allowing for effective control of fluid migration and structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of time

If conventional cement compositions are used, then fluid loss is controlled, but the cement sets too quickly allowing insufficient time for pumping and placement

Engineering Contradiction:

Improvepumping timeVSAvoidfluid loss control

Core Design Contradiction:

Loss of timeVSReliability

Solution Approach 1:

The cement composition is prepared with all components (cement, pumice, water, and retarder) mixed together in advance before pumping. The retarder is pre-incorporated into the mix to delay setting during pumping and placement operations, eliminating the need for separate retarder addition steps and ensuring the cement remains pumpable throughout the operation.

Inventive Principle:

Principle #10Preliminary action

2Loss of time

If set-delayed cement compositions are used, then pumping time is extended, but compressive strength development is delayed

Engineering Contradiction:

Improvepumping timeVSAvoidcompressive strength

Core Design Contradiction:

Loss of timeVSStrength

Solution Approach 1:

The composition uses specific parameters: pumice particle size of 0.003 to 0.06 inches, water-to-cement ratio of 0.4 to 0.6, and retarder concentration of 0.1 to 5 pounds per barrel of slurry. These parameter ranges optimize the balance between extended pumpability and timely strength development for lost circulation control.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If more pumice is added to the cement composition, then fluid loss control improves, but the composition becomes too thick to pump

Engineering Contradiction:

Improvefluid loss controlVSAvoidpumpability

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The water-to-cement ratio is optimized to 0.4 to 0.6, and retarder is added at 0.1 to 5 pounds per barrel of slurry. These parameter adjustments compensate for the thickening effect of pumice, maintaining pumpability while achieving effective fluid loss control through the pumice particles.

Inventive Principle:

Principle #35Parameter changes

4Reliability

If rapid setting is achieved, then fluid loss control is improved, but pumping and placement time is reduced

Engineering Contradiction:

Improvefluid loss controlVSAvoidpumping time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The retarder is pre-incorporated into the cement composition before pumping. This preliminary action ensures that the cement remains fluid and pumpable throughout the pumping and placement operations, then sets rapidly once placed to achieve effective fluid loss control in the lost circulation zone.

Inventive Principle:

Principle #10Preliminary action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The set-delayed cement compositions effectively plug off lost circulation zones, reduce fluid loss, and provide sufficient compressive strength to support well structures, enabling continued drilling operations while minimizing environmental impact and operational costs.

Implementation Method 1

set-delayed cement compositions are characterized by remaining in a pumpable fluid state for an extended period of time

Methodology Applied

Scientific EffectHydration inhibition:

Implementation Method 2

comprising pumice, hydrated lime, and a set retarder

Methodology Applied

Scientific EffectBuoyancy: Archimedes' Principle (Buoyancy)

Implementation Method 3

When desired for use, the set-delayed cement compositions should be capable of being activated whereby reasonable compressive strengths are developed

Methodology Applied

Scientific EffectCement setting:

Implementation Method 4

The loss of treatment fluids into the formation is undesirable... The set-delayed cement compositions effectively plug off lost circulation zones

Methodology Applied

Scientific EffectPlugging:

Data Source

PatentUS9856169B2Lost circulation compositions comprising pumice and associated methods

Publication Date: 2018.01.02 HALLIBURTON ENERGY SERVICES INC

AI summary

Disclosed are lost circulation treatment fluids and methods of sealing lost circulation zones. Embodiments include a lost circulation treatment fluid comprising pumice, hydrated lime, a set retarder, and water.