Casing Centralizers: Are We Using Too Many or Too Few?
4 likes1,983 views
This document discusses the importance of casing centralizers in cementing operations and poses the question of whether too many or too few are being used. It outlines various types of centralizers, their properties, and emphasizes the need for proper selection and placement to achieve optimal standoff, which directly impacts cementing job quality. The paper promotes the use of the software 'centradesign' for optimizing centralizer placement to enhance performance and reduce costs.
Casing Centralizers: Are We Using Too Many or Too Few?
- 1. Casing Centralizers: Are We Using Too Many or Too Few? Pegasus Vertex, Inc. Drilling Software | Sophisticated Yet Simple White Paper
- 2. CONTENTS I. Challenges ..................................................................................... II. Background Types of Centralizers: Bow-Spring ........................................................................................ Rigid ................................................................................................... Semi-Rigid ......................................................................................... Mold-On ............................................................................................. IV. Casing Deflection ....................................................................... V. Buoyance ..................................................................................... 3 4 5 5 5 7 9 III. Standoff ....................................................................................... 6 VI. Modeling Theory ................................................................................................ Calculation Modes ............................................................................. Case Study ........................................................................................ Specify Spacing ................................................................................. Specify Standoff ................................................................................. Optimum Placement .......................................................................... 10 11 12 13 15 16 VII. Conclusion ................................................................................. VIII. References ................................................................................ 18 19
- 3. Pegasus Vertex, Inc. Casing Centralizers: Are We Using Too Many or Too Few? 3 I. Challenges Casing centralizer is a mechanical device secured around the casing at various locations to keep the casing from contacting the wellbore walls. As a result of casing centralization, a continuous annular clearance around the casing allows cement to completely seal the casing to the borehole wall. Casing centralization is one of the key elements to ensure the quality of a cementing job by pre- venting mud channeling and poor zonal isolation. Centralizers can also assist in the running of the casing and the prevention of differential sticking. Its usage is extensive! It is estimated that 10 million centralizers are manufactured and used every year globally. Centralizer manufacturers likely want to increase the demand for centralizers. However, operators on the other hand, may wonder: “Should we use that many?” While centralizers are used extensively, well problems continue to arise due to poor cementing jobs. Centralizer properties and placements directly or indirectly affect the quality of the cementing job. The challenge that both operators and service companies face is to choose the right type of cen- tralizers and place the right amount at the optimum positions on the casing to achieve a good standoff profile.
- 4. Pegasus Vertex, Inc. Casing Centralizers: Are We Using Too Many or Too Few? 4 II. Background Types of Centralizers There are 4 types of centralizers (Fig. 1): bow-spring, rigid, semi-rigid, and mold-on; each with its own pros and cons. Bow Rigid Semi Mold-on Fig. 1. Types of centralizers 1. Bow-Spring Since the bow springs are slightly larger than the wellbore, they can provide complete centralization in vertical or slightly deviated wells. Due to the flexibility of bows, they can pass through narrow hole sections and expand in the targeted locations. The shape and stiffness of the bows determine the restoring force, which is defined as the resis- tance force when a bow is compressed by 1/3 of its uncompressed height. The effectiveness of this type of centralizer is heavily dependent on the restoring force. When the casing is heavy and/or the wellbore is highly deviated, they may not support the casing very well. For example, on a riser tieback casing string, a helically buckled casing could create a side force of 50,000 to 100,000 lbf (222 to 445 kN), well beyond the capabilities of the spring-bow centralizer. A solid centralizer would be able to meet the requirements.
- 5. Pegasus Vertex, Inc. Casing Centralizers: Are We Using Too Many or Too Few? 5 2. Rigid Rigid centralizers are built out of solid steel bar or cast iron, with a fixed blade height and are sized to fit a specific casing or hole size. This type is rugged and works well even in deviated wellbores, regardless of the side force. They provide a guaranteed standoff and function as bearings during the pipe rotation, but since the centralizers are smaller than the wellbore, they will not provide a good centralization as the bow-spring type centralizers in vertical wells. 3. Semi-Rigid Semi-rigid centralizers are made of double crested bows, which provide desirable features found in both the spring bow and the rigid centralizers. The spring characteristic of the bows allows the semi-rigid centralizers to compress in order to get through tight spots and severe doglegs. The double-crested bow provides restoring forces that exceed those standards set forth in the API specifications and therefore exhibits certain features normally associated with rigid centralizers. 4. Mold-On The mold-on centralizer blades, made of carbon fiber ceramic materials, can be applied directly to the casing surface. The blade length, angle and spacing can be designed to fit specific well appli- cations, especially for the close tolerance annulus. The non-metallic composite can also reduce the friction in extended reach laterals to prevent casing buckling.
- 6. Pegasus Vertex, Inc. Casing Centralizers: Are We Using Too Many or Too Few? 6 III. Standoff The term standoff (SO) describes the extent to which the pipe is centered (Fig. 2). If a casing is perfectly centered, the standoff is 100%. A standoff of 0% means that the pipe touches the well- bore. Regardless of the centralizer type, the goal is to provide a positive standoff, preferably above 67%, throughout the casing string. The casing deflection between centralizers obeys the laws of physics. An engineering analysis can help both operators and service companies arrive at the optimized number and placement of centralizers for a particular well. The casing standoff depends on the following conditions: • Well path and hole size • Casing OD and weight • Centralizer properties • Position and densities of mud and cement slurries (buoyance) Fig. 2. Definition of standoff
- 7. Pegasus Vertex, Inc. Casing Centralizers: Are We Using Too Many or Too Few? 7 IV. Casing Deflection Between centralizers, the casing string can sag or deflect the side force. To study the casing deflection, one should study the force balance for a pipe segment. (Fig. 3) There are 2 types of forces on the casing: • Gravitational force on the pipe body, pulling the casing downward • Axial tension force at the end, pushing the casing upward Depending on the weight and tension, the net side force is either upward or downward. Fig. 3. Force balance
- 8. Pegasus Vertex, Inc. Casing Centralizers: Are We Using Too Many or Too Few? 8 To obtain the side force, we start the analysis from the bottom and perform the calculations for each element. Step by step, we move upward to obtain the side force profile, as shown below in Fig. 4. In the profile, the red lines indicate that the side force is acting upward and that the casing touches the upper side of the well. The blue lines indicate that the side force is acting downward and that the casing touches the lower side of the well. In a typical wellbore (build-and-drop), the standoff profile of the casing without a centralizer looks like the one shown in the Fig. 5. Fig. 4. Side force calculation and profile Side Force Fig. 5. Standoff profile without centralizers
- 9. Pegasus Vertex, Inc. Casing Centralizers: Are We Using Too Many or Too Few? 9 V. Buoyance Any fluids present in the wellbore create an up-lifting force (buoyancy) on the casing, making the casing light. During a cementing job, when the heavy cement slurry is inside the casing, and the drilling mud is in the annulus, the casing is at its “heaviest”. As the cement slurry turns at the corner and light displacement fluids occupy the casing interior, the casing is at its “lightest”. Luckily, when designing the centralizer placement, one needs only consider this “lightest” casing condition. Fig. 6 illustrates the buoyancy conditions at various stages of the cementing job. To better design the centralizer placement, one needs to know the top of cement (TOC), the cement slurry densities, the mud weight, etc. The density differential of the cement slurry and the mud improves the standoff profile. Fig. 6. Casing deflection between centralizers 1. Prior cementing job 2. Cement inside casing 3. Cement in annulus
- 10. Pegasus Vertex, Inc. Casing Centralizers: Are We Using Too Many or Too Few? 10 IV. Modeling Theory The puzzle of the centralizer selection and the centralizer placement can be best solved by using com- puter models. Over the past 20 years, a variety of models have been developed—some utilizing sim- ple Microsoft Excel® spreadsheets, others as part of cementing software. These efforts help engineers to understand the importance of casing centralizers and placement. Since 2000, PVI has been working with both operators and centralizer manufacturers and developed CentraDesign, the advanced engineering software geared towards the centralizer placement analysis. There are 2 methods to model the casing deflection between centralizers: the hinged-ends model (Lee, Smith and Tighe) and the fixed-ends model (Juvkam-wold and Jiang Wu). The hinged-ends model assumes that a casing string transmits no bending moment across centraliz- ers. This assumption results in the excessively high casing deflection. This was replaced by the more advanced fixed-ends model, which should be used to calculate the deflection between the centralizers. In this more sophisticated model, the casing deflection between the centralizers in a 3D wellbore no longer occurs solely in the vertical plane nor in the dogleg plane; instead occurs as a spatial deflection composed of 2 plane deflections: one in the dogleg plan and the other in the plane perpendicular to the dogleg plane. The resulting deflection is the vector summation of these 2 deflections, caused by the axial tension and the casing weight. CentraDesign uses this latest model to predict the casing deflection in a 3D well, which calculates the contribution from the azimuth angle’s changes too. For bow spring centralizers, the compression of the bows themselves caused by the side force on the centralizer also must be considered in the standoff calculation.
- 11. Pegasus Vertex, Inc. Casing Centralizers: Are We Using Too Many or Too Few? 11 Calculation Modes 3 methods are used to design the placement of centralizers. 20, 40, 80 ft Specify Spacing Specify Standoff Optimum Spacing Users specify the spacing. Software checks the standoff. Users specify the standoff at the mid-span, between the cen- tralizers. Software calculates the spacing. ? 40 ft 70% ? 70% Users specify the standoff and the spacing increments. Soft- ware calculates the spacing. In the first approach, the spacing is specified utilizing the users’ experience; the software then checks for the satisfactory standoff at the centralizers and at the middle of the span. This mode offers the simple-to-install centralizer placement because of its constant spacing. This method, however, may compromise the quality of the standoff or the quantity of the centralizers, because the side force changes as the wellbore deviates. For users without significant experience, or who prefer that the software calculates the spacing, the second approach (specify standoff) can be used. Simply specify the required standoff at the middle span, and the program uses a numerical method to obtain the centralizer placement, so that the standoff at the middle point between the centralizers is as specified. The “specify standoff” mode ensures the minimum standoff of the casing between the centralizers, while yielding a difficult-to-fol- low placement program. To benefit from the best elements of these approaches, we have developed an optimum placement solution, the third method in the diagram. In this approach, users can specify the standoff with an incremental spacing requirement. This ensures the standoff requirements, yet results in a not-diffi- cult-to-follow placement program. For high impact operations such as deep water and use of inline bow spring centralizers, these methods can be used once a casing schematic is available to opti- mize the exact placement of each centralizer.
- 12. Pegasus Vertex, Inc. Casing Centralizers: Are We Using Too Many or Too Few? 12 Case Study With the help of computer modeling, the centralizer placement optimization becomes easy to perform for all types of wells. Ideally, this kind of optimization should be done before each casing job. Here is an example of optimization. (Fig. 7) The example shown in Fig. 7 has a kick-off point of 2,000 ft. The previous casing (ID = 8.535”) was set at the same depth. Our goal is to centralize the 12,345 ft of a 4 1/2” casing, deviated from 0° to 90°. The centralizer considered in the picture is the bow spring type with a restoring force of 800 lbf. Fig. 7. Example well
- 13. Pegasus Vertex, Inc. Casing Centralizers: Are We Using Too Many or Too Few? 13 Specify Spacing 40 feet are used for the centralizer spacing (1 centralizer per joint). Fig. 8 shows the resulting stand- off profile. The blue line is the standoff at the centralizer, while the red line is the standoff at the mid- dle point between the centralizers, which is always lower than that at the centralizers. Because bow spring centralizers are used here, the standoff at the middle point between centralizers is the summa- tion of the casing sagging between the centralizers and the bow spring compression at the centraliz- ers. For this approach, the required number of centralizers is 309. From 2,000 ft to 7,000 ft (inclination from 0° to 30°), the standoff at mid-span is between 100% and 70%, which meets the industry standard of 67%. From 7,000 ft to 12,345 ft (inclination from 30° to 90°), the standoff drops from 60%, which is risky, because a poor standoff profile at this section may cause potential cementing problems. Fig. 8. Standoff profile (specified spacing = 40 ft)
- 14. Pegasus Vertex, Inc. Casing Centralizers: Are We Using Too Many or Too Few? 14 Now try 2 centralizers per joint (spacing of 20 ft). Fig. 9 shows the resulting standoff profile. The number of centralizers needed is 617. The standoff at the mid-span is very good, at more than 90%. This new placement may be too conservative and can leave engineers wondering: “Are we using too many centralizers?” Fig. 9. Standoff profile (specified spacing = 20 ft)
- 15. Pegasus Vertex, Inc. Casing Centralizers: Are We Using Too Many or Too Few? 15 Specify Standoff Alternatively, the required standoff can be specified by the user, while the software instructs the user on how to space the centralizers. With the required 70% standoff throughout a 4 1/2” casing, CentraDesign displays the following spac- ing necessary to achieve the specified standoff. The total number of centralizers used here is 230, a significant reduction from previous approaches. Logically, as the well builds up from 0° to 90° the inclination angle, the spacing decreases: the casing needs more support in the deviated or horizontal sections, but putting centralizers strictly following the placement required by Fig. 10 is somewhat impractical. Fig. 10. Calculated spacing required to achieve 70% standoff
- 16. Pegasus Vertex, Inc. Casing Centralizers: Are We Using Too Many or Too Few? 16 Optimum Placement To get the best elements from both approaches, we have designed the optimum placement solution, which is specifying the standoff (70%) with the incremental spacing requirements (20 ft). The resulting standoff profile and spacing required are displaced in Fig. 11 and Fig. 12, respectively. This method meets the standoff requirements and gives an easy-to-follow spacing. The result of the total number of centralizer is 360. Fig. 11. Optimum placement - Standoff profile Fig. 12. Optimum placement - Spacing
- 17. Pegasus Vertex, Inc. Casing Centralizers: Are We Using Too Many or Too Few? 17 The results of the three placement modes previously illustrated are summarized in Table 1. The optimum placement gives a satisfactory standoff, an ease of field installation, and good economics. Table 1. Centralizer placement comparison
- 18. Pegasus Vertex, Inc. Casing Centralizers: Are We Using Too Many or Too Few? 18 VII. Conclusion Our industry is blessed with many talented and experienced engineers. We also have centralizer ven- dors producing the very best and top quality products. It is critical that we maximize the engineering potential while selecting the proper types of centralizers, and placements. A software like CentraDesign should be an integral part of the total approach of the centralizer placement optimization. When optimizing the centralizer placement, consider the following: • Each well is different. Our past experience may not apply to the next well. • Operators aim to obtain a satisfactory standoff with less centralizers. • Centralizer vendors similarly aim to obtain a satisfactory standoff to sell more units. • CentraDesign optimizes the centralizer placement and usage, and reduces risks and costs. For more information on CentraDesign, please contact PVI at: Pegasus Vertex, Inc. 6100 Corporate Dr., Suite 448, Houston, TX 77036 Tel: (713) 981-5558 / Fax: (713) 981-5556 sales@pvisoftware.com Fig. 13. Total approach of casing centralization Vendor People CentraDesign
- 19. Pegasus Vertex, Inc. Casing Centralizers: Are We Using Too Many or Too Few? 19 VIII. References 1. Gefei Liu, Lawrence Weber, “Centralizer Selection and Placement Optimization” (SPE 150345), SPE Deep-water Drilling Conference and Exhibition, Galveston, Texas, June 2012. 2. Erik B. Nelson and Dominique Guillot, Well Cementing, 2nd Edition, published by Schlumberger, 2006. 3. API Specification 10D, 2002: “Casing Centralizers”, Sixth Edition 4. Juvkam-Word, H.C. and Wu, Jiang 1992: “Casing Deflection and Centralizer Spacing Calcula- tions,” SPE Drilling Engineering, P. 268 – 274, December. 5. Lee, H. K., Smith, R. C., and Tighe, R. E., 1986: “Optimal Spacing for Casing Centralizers”, SPE Drilling Engineering, P. 122 – 130, April. 6. Wu, Jiang, Chen, P., and Juvkam – Word H. C., 1991: “Casing Centralization in Horizontal Wells”, Popular Horizontal, P. 14 – 21, April/June. 7. C.A. Johancsik, et al, Torque and Drag in Directional Wells – Prediction and Measurement, SPE Reprint Series, No. 30, Directional Drilling, 1990, P. 130.