Casing strings and methods of using such strings in subterranean cementing operations

• US 7,284,608 B2
• Filed: 10/26/2004
• Issued: 10/23/2007
• Est. Priority Date: 10/26/2004
• Status: Active Grant

• Current Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Original Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Inventors: Badalamenti, Anthony M., Reddy, B. Raghava, Rogers, Henry E., Blanchard, Karl W., Turton, Simon, Faul, Ronald R., Griffith, James E., Crowder, Michael G.
• Primary Examiner(s): SUCHFIELD, GEORGE A
• Application Number:
  US10/973,331
• Publication Number:
  US 20060086502A1
• Time in Patent Office: 1,092 Days
• Field of Search: 166/207, 166/242.1, 166/285, 166291-294, 166/300, 166/376, 166/902, 106/819, 106/823, 106/DIG.1, 507/207, 507/231, 507/244, 507/265, 507/269, 507/273, 507/277, 507/928
• US Class Current: 166/291
• CPC Class Codes: C04B 14/104 Bentonite, e.g. montmorillonite
• CPC Class Codes: C04B 14/108 Shale, slate colliery shale C04B18/125
• CPC Class Codes: C04B 14/20 Mica; Vermiculite mechanical splitting B28D
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 18/141 Slags
• CPC Class Codes: C04B 18/146 Silica fume
• CPC Class Codes: C04B 20/002 Hollow or porous granular materials
• CPC Class Codes: C04B 2103/22 Set retarders
• CPC Class Codes: C04B 2103/40 Surface-active agents, dispersants
• CPC Class Codes: C04B 2103/408 Dispersants
• CPC Class Codes: C04B 2103/44 Thickening, gelling or viscosity increasing agents
• CPC Class Codes: C04B 2103/50 Defoamers, air detrainers
• CPC Class Codes: C04B 2103/67 Biocides
• CPC Class Codes: C04B 24/003 Phosphorus-containing compounds
• CPC Class Codes: C04B 24/006 Boron-containing compounds
• CPC Class Codes: C04B 24/08 Fats; Fatty oils; Ester type waxes; Higher fatty acids, i.e. having at least seven carbon atoms in an unbroken chain bound to a carboxyl group; Oxidised oils or fats
• CPC Class Codes: C04B 24/085 Higher fatty acids
• CPC Class Codes: C04B 24/163 obtained by reactions only involving carbon-to-carbon unsaturated bonds
• CPC Class Codes: C04B 24/18 Lignin sulfonic acid or derivatives thereof, e.g. sulfite lye
• CPC Class Codes: C04B 24/383 Cellulose or derivatives thereof
• CPC Class Codes: C04B 28/02 : containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 40/0658 : Retarder inhibited mortars activated by the addition of accelerators or retarder-neutralising agents
• CPC Class Codes: C09K 8/467 : containing additives for specific purposes
• CPC Class Codes: E21B 33/14 : for cementing casings into boreholes
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete
• CPC Class Codes: Y10S 106/01 : Fly ash
• CPC Class Codes: Y10S 166/902 : for inhibiting corrosion or coating
• CPC Class Codes: Y10S 507/928 : Spacing slug or preflush fluid

Abstract

Improved casing strings, and methods of using improved casing strings in subterranean operations, are provided. An example of a method is a method of cementing a pipe string in a subterranean formation. Another example of a method is a method of cementing a pipe string in a well bore. An example of an apparatus is an improved pipe string comprising at least one pipe section; and a delivery system of an activator; wherein the delivery system of an activator is disposed adjacent an outer surface of the at least one pipe section.

Claims

1. A method of cementing a pipe string in a subterranean formation, comprising:

providing a well bore having a first fluid disposed therein;

placing a second fluid into the well bore so as to displace at least a portion of the first fluid therefrom, the second fluid comprising a hydraulic settable component;

placing in the well bore a pipe string having at least one activator disposed adjacent an outer surface thereof;

permitting the second fluid and the activator to contact each other;

permitting the second fluid to set in the well bore; and

placing a cement composition into the well bore to displace at least a portion of the second fluid therefrom, wherein placing a cement composition into the well bore to displace at least a portion of the second fluid therefrom is performed before permitting the second fluid to set in the well bore.

2. The method of claim 1 wherein the first fluid is a drilling fluid.

3. The method of claim 1 further comprising permitting the cement composition to set in the well bore, wherein permitting the cement composition to set in the well bore is performed before permitting the second fluid to set in the well bore.

4. The method of claim 1 wherein the second fluid further comprises an invert emulsion comprising oil, water, and an emulsifying agent and wherein the invert emulsion is present in the second fluid in an amount in the range of from about 20% to about 60% by weight of the second fluid.

5. The method of claim 4 wherein the water is present in the invert emulsion in an amount in the range of from about 30% to about 60% by volume of the invert emulsion.

6. The method of claim 4 wherein the emulsifying agent comprises a blend of oxidized tall oil fatty acids.

7. The method of claim 4 wherein the emulsifying agent comprises a tall oil diethanolamide.

8. The method of claim 1 wherein the hydraulic settable component is a hydraulic cement selected from the group consisting of a Portland cement, pozzolanic cement, gypsum cement, high alumina cement, silica cement, and a high alkalinity cement.

9. The method of claim 8 wherein the hydraulic cement comprises a component selected from shale and blast furnace slag.

10. The method of claim 1 wherein the second fluid further comprises a set retarder selected from the group consisting of a lignosulfonate, an organic acid, phosphonic acid, a phosphonic acid derivative, a salt, a carboxymethylated hydroxyethylated cellulose, a synthetic co- or ter-polymer comprising sulfonate and carboxylic acid groups, and a borate compound.

11. The method of claim 10 wherein the borate compound is sodium tetraborate or potassium pentaborate.

12. The method of claim 10 wherein the set retarder is present in the second fluid in an amount in the range of from about 0.1% to about 10% by weight of the hydraulic cement.

13. The method of claim 1 wherein the second fluid further comprises a component selected from the group consisting of a surfactant, a dispersant, mica, fibers, a bactericide, a formation conditioning agent, a fixed-density weighting agent, fumed silica, bentonite, fly ash, a fluid loss control additive, an expanding additive, a defoamer, a viscosifier, hollow microspheres, and a mixture thereof.

14. The method of claim 1 wherein the activator is an amine compound.

15. The method of claim 14 wherein the amine compound is triethanol amine, diethanol amine, tripropanol amine, tri-isopropanol amine, or a mixture thereof.

16. The method of claim 1 wherein the activator is a salt of a material selected from the group consisting of:

calcium, sodium, magnesium, and aluminum.

17. The method of claim 1 wherein the activator is calcium chloride, sodium chloride, sodium aluminate, sodium silicate, magnesium chloride, or a mixture thereof.

18. The method of claim 1 wherein providing a pipe string comprising an activator on an outer surface of the pipe string further comprises spraying the activator onto the outer surface of the pipe string, and permitting the activator to dry.

19. The method of claim 18 further comprising encapsulating the activator in an activator-encapsulant.

20. The method of claim 1 wherein providing a pipe string comprising an activator on an outer surface of the pipe string further comprises affixing the activator to a first side of a substrate having two sides, and affixing the second side of the substrate to the outer surface of the pipe string.

21. The method of claim 20 further comprising encapsulating the activator in an activator-encapsulant.

22. The method of claim 21 wherein the activator-encapsulant is selected from the group consisting of:

a polyester;

a 3-hydroxybutyrate/3-hydroxyvalerate copolymer;

a polymer comprising lactic acid;

a polymer comprising glycolic acid;

a polycaprolactone;

a polyethylene succinate;

a polybutylene succinate;

a poly(ethylene vinylacetate);

a poly(vinylacetate);

a polymer comprising dioxanone;

a cellulose ester;

an ethylene-carbon-monoxide polymer;

polyglycine;

polycaprolactam;

poly(gamma-glutamic acid);

a polyurethane;

a polyamide; and

a polymer comprising bisphenol-A.

23. The method of claim 21 wherein the activator-encapsulant comprises a latex composition comprising a crosslinker.

24. The method of claim 21 wherein the activator-encapsulant comprises a polymer comprising an oxidizable monomer.

25. The method of claim 24 wherein the oxidizable monomer is butadiene.

26. The method of claim 24 wherein the activator-encapsulant is a styrene-butadiene copolymer, or a butadiene acrylonitrile copolymer.

27. The method of claim 24 further comprising dissolving or degrading the activator-encapsulant by contacting the activator-encapsulant with an oxidizer.

28. The method of claim 27 wherein dissolving or degrading the activator-encapsulant by contacting the activator-encapsulant with an oxidizer is performed before permitting the second fluid and the activator to contact each other.

29. The method of claim 27 wherein the oxidizer is sodium persulfate, potassium persulfate, sodium perborate, sodium peroxide, sodium hypochlorite, or sodium chlorite.

30. The method of claim 1 further comprising encapsulating the activator in an activator-encapsulant, wherein the pipe string comprises an expandable tubular, and wherein permitting the second fluid and the activator to contact each other so as to cause the second fluid to set in the well bore comprises expanding the pipe string, whereby the activator-encapsulant is broken to expose the activator.

31. The method of claim 1 wherein the activator is an initiator.

32. The method of claim 1 wherein the activator is an initiator that comprises lime.

33. The method of claim 1 wherein the pipe string further comprises a second activator, wherein the second activator is a cement-composition-activator.

34. The method of claim 33 further comprising placing a cement composition into the well bore to displace at least a portion of the second fluid therefrom, wherein placing a cement composition into the well bore to displace at least a portion of the second fluid therefrom is performed before permitting the second fluid to set in the well bore, permitting the cement composition and the cement-composition-activator to contact each other;

and permitting the cement composition to set in the well bore, wherein permitting the cement composition to set in the well bore is performed before permitting the second fluid to set in the well bore.

35. The method claim 1 wherein the second fluid further comprises a gel strength inhibiting agent, a set retarder, and a water source.

36. The method of claim 1 wherein the hydraulic settable component is ASTM Class C fly ash or ASTM Class F fly ash.

37. A method of cementing a pipe string in a subterranean formation, comprising:

providing a well bore having a first fluid disposed therein;

placing a second fluid into the well bore so as to displace at least a portion of the first fluid therefrom, the second fluid comprising a hydraulic settable component;

placing in the well bore a pipe string having at least one activator encapsulated in an activator-encapsulant and disposed adjacent an outer surface thereof;

permitting the second fluid and the activator to contact each other; and

permitting the second fluid to set in the well bore;

wherein providing a pipe string comprising an activator on an outer surface of the pipe string further comprises affixing the activator to a first side of a substrate having two sides, and affixing the second side of the substrate to the outer surface of the pipe string; and

wherein the activator-encapsulant comprises a thermoplastic material.

38. The method of claim 37 wherein the thermoplastic material comprises a base-hydrolyzable functional group.

39. The method of claim 38 wherein the base-hydrolyzable functional group is an ester, an amide, or an anhydride.

40. A method of cementing a pipe string in a subterranean formation, comprising:

providing a well bore having a first fluid disposed therein;

placing a second fluid into the well bore so as to displace at least a portion of the first fluid therefrom, wherein the second fluid is a fluid comprising a hydraulic cement, a set retarder, and an invert emulsion comprising oil, water, and an emulsifying agent or a fluid comprising hydraulic settable component, a gel strength inhibiting agent, a set retarder, and a water source;

providing a pipe string having at least one activator disposed adjacent an outer surface thereof;

placing the pipe string in the well bore;

permitting the second fluid and the activator to contact each other;

permitting the second fluid to set in the well bore; and

placing a cement composition into the well bore to displace at least a portion of the second fluid therefrom, wherein placing a cement composition into the well bore to displace at least a portion of the second fluid therefrom is performed before permitting the second fluid to set in the well bore.

41. The method of claim 40 further comprising permitting the cement composition to set in the well bore, wherein permitting the cement composition to set in the well bore is performed before permitting the second fluid to set in the well bore.

42. The method of claim 40 wherein the hydraulic settable component is ASTM Class C fly ash or ASTM Class F fly ash.

43. The method of claim 40 wherein providing a pipe string comprising an activator on an outer surface of the pipe string further comprises spraying the activator onto the outer surface of the pipe string, and permitting the activator to dry.

44. The method of claim 43 further comprising encapsulating the activator in an activator-encapsulant.

45. The method of claim 40 wherein providing a pipe string comprising an activator on an outer surface of the pipe string further comprises affixing the activator to a first side of a substrate having two sides, and affixing the second side of the substrate to the outer surface of the pipe string.

46. The method of claim 45 further comprising encapsulating the activator in an activator-encapsulant.

47. The method of claim 46 further comprising dissolving or degrading the activator-encapsulant by contacting the activator-encapsulant with an oxidizer.

48. The method of claim 47 wherein dissolving or degrading the activator-encapsulant by contacting the activator-encapsulant with an oxidizer is performed before permitting the second fluid and the activator to contact each other.

49. The method of claim 47 wherein the oxidizer is sodium persulfate, potassium persulfate, sodium perborate, sodium peroxide, sodium hypochlorite, or sodium chlorite.

50. The method of claim 40, further comprising encapsulating the activator in a suitable activator-encapsulant, wherein the pipe string comprises an expandable tubular, and wherein permitting the second fluid and the activator to contact each other so as to cause the second fluid to set in the well bore comprises expanding the pipe string, whereby the activator-encapsulant is broken to expose the activator.

51. The method of claim 40 wherein the pipe string further comprises a second activator, wherein the second activator is a cement-composition-activator.

52. The method of claim 51 further comprising placing a cement composition into the well bore to displace at least a portion of the second fluid therefrom, wherein placing a cement composition into the well bore to displace at least a portion of the second fluid therefrom is performed before permitting the second fluid to set in the well bore, permitting the cement composition and the cement-composition-activator to contact each other;

and permitting the cement composition to set in the well bore, wherein permitting the cement composition to set in the well bore is performed before permitting the second fluid to set in the well bore.

53. A method of cementing a pipe string in a well bore, comprising:

placing a well fluid comprising a hydraulic settable component into the well bore;

placing in the well bore a pipe string having a cement-composition-activator and a well-fluid-activator disposed on an outer surface thereof;

placing a cement composition in the well bore;

permitting the cement composition and the cement-composition-activator to contact each other;

permitting the well fluid and the well-fluid-activator to contact each other;

permitting the cement composition to set in the well bore; and

permitting the well fluid to set in the well bore.

54. The method of claim 53 wherein the well fluid further comprises a gel strength inhibiting agent, a set retarder, and a water source.

55. The method of claim 53 wherein the hydraulic settable component is ASTM Class C fly ash or ASTM Class F fly ash.

56. The method of claim 53 wherein the hydraulic settable component is hydraulic cement and wherein the well fluid further comprises a set retarder, and an invert emulsion comprising oil, water, and an emulsifying surfactant.

57. The method of claim 56 wherein the invert emulsion is present in the well fluid in an amount in the range of from about 20% to about 60% by weight of the well fluid.

58. The method of claim 56 wherein the water is present in the well fluid in an amount in the range of from about 30% to about 60% by volume of the invert emulsion.

59. The method of claim 56 wherein the hydraulic cement is selected from the group consisting of a Portland cement, pozzolanic cement, gypsum cement, high alumina cement, silica cements and a high alkalinity cement.

60. The method of claim 56 wherein the hydraulic cement comprises a component selected from the group consisting of shale and blast furnace slag.

61. The method of claim 56 wherein the set retarder is selected from the group consisting of a lignosulfonate, an organic acid, phosphonic acid, a phosphonic acid derivative, a salt, a carboxymethylated hydroxyethylated cellulose, a synthetic co- or ter-polymer comprising sulfonate and carboxylic acid groups, and a borate compound.

62. The method of claim 56 wherein the set retarder is sodium tetraborate or potassium pentaborate.

63. The method of claim 56 wherein the set retarder is present in the well fluid in an amount in the range of from about 0.1% to about 10% by weight of the hydraulic cement.

64. The method of claim 56 wherein the emulsifying surfactant comprises a blend of oxidized tall oil fatty acids.

65. The method of claim 56 wherein the emulsifying surfactant comprises a tall oil diethanolamide.

66. The method of claim 56 wherein the well fluid further comprises a component selected from the group consisting of a surfactant, a dispersant, mica, fibers, a bactericide, a formation conditioning agent, a fixed-density weighting agent, fumed silica, bentonite, fly ash, a fluid loss control additive, an expanding additive, a defoamer, a viscosifier, hollow microspheres, and a mixture thereof.

67. The method of claim 53 wherein the well-fluid-activator is an amine compound.

68. The method of claim 67 wherein the amine compound is triethanol amine, diethanol amine, tripropanol amine, tri-isopropanol amine, or a mixture thereof.

69. The method of claim 53 wherein the well-fluid-activator is a salt of a material selected from the group consisting of:

calcium, sodium, magnesium, and aluminum.

70. The method of claim 53 wherein the well-fluid-activator is calcium chloride, sodium chloride, sodium aluminate, sodium silicate, magnesium chloride, or a mixture thereof.

71. The method of claim 53 wherein providing a pipe string comprising a well-fluid-activator and a cement-composition-activator on an outer surface of the pipe string further comprises spraying at least one of the well-fluid-activator and the cement-composition-activator onto the outer surface of the pipe string, and permitting the at least one of the well-fluid-activator and the cement-composition-activator to dry.

72. The method of claim 53 wherein providing a pipe string comprising a well-fluid-activator and a cement-composition-activator on an outer surface of the pipe string further comprises affixing at least one of the well-fluid-activator and the cement-composition-activator to a first side of a substrate having two sides, and affixing the second side of the substrate to the outer surface of the pipe string.

73. The method of claim 53, further comprising encapsulating the cement-composition-activator and the well-fluid-activator in an activator-encapsulant, wherein the pipe string comprises an expandable tubular, and wherein permitting the cement composition and the cement-composition-activator to contact each other and permitting the well fluid and the well-fluid-activator to contact each other comprises expanding the pipe string, whereby the activator-encapsulant is broken to expose the cement-composition-activator and the well-fluid-activator.

74. The method of claim 53 wherein the well-fluid-activator is an initiator.

75. The method of claim 53 wherein the well-fluid-activator is an initiator that comprises lime.