US 5,340,397 AGrant
Set Retarded Ultra Fine Cement Compositions and Methods
Issue Date:1994-08-23
•15 Claims
Abstract
Set retarded ultra fine cement compositions which remain pumpable for a predictable period of time at temperatures up to about 240.degree. F. are provided. The compositions are basically comprised of an ultra fine hydraulic cement, sufficient water to form a pumpable slurry and a set retarder comprised of a methylenephosphonic acid derivative.
Metadata
Assignee
- Halliburton Company
Inventor
- Lance E. Brothers
Application Information
Application Number:US 1138766
Filing Date:1993-08-30
Priority Date:1992-05-27
Art Unit:118
Classifications
IPC:
C04B 2412C04B 2416
Field of Search:
106166523524405714;724;727;819;823;725285;293;294130650266
Patent Drawings
This patent does not have any drawings.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to cement compositions utilized in the completion and repair of wells, and more particularly, to set retarded ultra fine cement compositions and methods of their use.
2. Description of the Prior Art
In cementing operations such as those carried out in completing and repairing oil, gas and water wells, a hydraulic cement composition is prepared by mixing a hydraulic cement with water and other additives, the composition is placed into a subterranean zone to be cemented and allowed to set into a hard substantially impermeable mass therein.
In the operation of wells used in the recovery of fluids from or the introduction of fluids into subterranean formations problems relating to the unwanted passage of fluids and/or fine solids into or from undesirable locations in the formation or well bore sometimes occur. This unwanted passage of fluids and/or fine solids can severely disrupt or terminate the desired operation of a well.
The problems involving the unwanted passage of fluids referred to above, ordinarily involve the movement of fluids, such as oil, gas or water through very small undesirable openings. These problems are not unique and the solutions have traditionally involved apparatus, methods and compositions adapted to cover, seal or to otherwise plug the openings to thereby terminate the unwanted passage of fluid through the openings. The openings referred to above include: holes or cracks in well casing; spaces such as holes, cracks, voids or channels in the cement sheath deposited in the annular space between the formation face and well casing; very small spaces--called microannuli--between the cement sheath referred to above, and the exterior surface of the well casing or formation; and permeable spaces in gravel packs and formations.
It is clear that holes or cracks in well casing and/or cement sheath can permit the unwanted and therefore uncontrolled passage of fluids therethrough. Sometimes, of course, holes are deliberately made in casing and sheath by a known process called perforating in order to permit the controlled recovery of fluid from a formation or to permit the controlled introduction of fluid into a formation. The sealing or plugging of such holes or cracks, whether or not made deliberately, has been conducted by attempts to place or otherwise force a substance into the hole or crack and permitting it to remain therein to thereby plug the opening. Naturally, the substance will not plug the opening if it will not enter the opening. If the substance does not fit then, at best, a bridge, patch, or skin may be formed over the opening to produce, perhaps, a temporary termination of the unwanted fluid flow.
Substances used in methods to terminate the unwanted passage of fluids through holes or cracks in casing and/or sheath have been compositions comprised of hydraulic cement, wherein the methods employ hydraulic pressure to force a water slurry of the cement into the cracks and holes wherein the cement is permitted to harden. These methods are variously referred to in the art as squeeze cementing, squeezing or as squeeze jobs. The success of squeezing hydraulic cement into such holes and cracks is among other factors a function of the size of the hole relative to the particle size of the cement as well as the properties of the slurry. As mentioned earlier, if the particle size of the cement is greater than the crack width, the cement will not enter and at best a patch instead of a plug is the result. A problem therefore is to substantially reduce cement particle size without reducing the hardening and strength characteristics of hydraulic cement.
During the construction of a well it is known to place a volume of a water slurry of a hydraulic cement into the annular space between the walls of the well bore and the exterior of the casing wherein the cement is permitted to solidify to thereby form an annular sheath of hardened cement. The objective of the sheath, the construction of which is referred to as primary cementing, includes physical support and positioning of the casing in the borehole and prevention of unwanted fluid (liquid and gas) migration between various formations penetrated by the well bore. If, for some reason, the hardened sheath contains spaces such as voids, cracks or channels due to problems involved in the placement of the slurry it is clear that the sheath may not be capable of providing the desired objectives. Accordingly, by employing known techniques to locate the voids, channels or cracks, a perforation penetrating the spaces can be made in the casing and sheath and cement then squeezed into the spaces via the perforation so as to place the sheath in a more desirable condition for protecting and supporting the casing and providing fluid flow control. As mentioned earlier, the success of the squeeze job is at least a function of the size of the space or spaces to be filled relative to the particle size of the cement.
Another problem incidental to the formation of the cement sheath revolves about the occasional failure of the sheath to tightly bond to the exterior wall of the casing or the interior of the borehole. This failure can produce a very thin annular space called a microannulus between the exterior wall of the casing and the sheath or the sheath and the borehole. For the reasons already discussed, it is important to place a substance, such as a hydraulic cement, in the microannulus to enable the sheath to fully provide the intended benefits. Again, as stated above, the success of squeezing cement into a microannulus space is dependent upon the relative size of the space and the particle size of the cement.
The solid portions of some producing formations are not sufficiently stable and therefore tend to break down into small pieces under the influence of the pressure difference between the formation and the well bore. When fluid, such as oil or water, flows under the influence of the pressure difference from the formation to the well bore the small pieces referred to above can be carried with the fluid into the well bore. Over a period of time, these pieces can build up and eventually damage the well and associated equipment and terminate production. The art has solved this problem by placing in the well bore a production aid which is referred to in the art as a gravel pack. A gravel pack is usually comprised of a mass of sand within the interior of a well. The sand bed completely surrounds a length of tubular goods containing very narrow slots or small holes; such goods are sometimes referred to as slotted liners or sand screens. The slots or holes permit the flow of fluid therethrough but are too narrow to permit the passage of the sand. The slotted liner or sand screen can be connected through a packer situated up-hole of the gravel pack to production tubing extended from the wellhead. The gravel pack ordinarily consists of siliceous material having sand grains in the range of from about 10 to about 100 mesh.
The gravel pack, which can be situated in the casing in the perforated interval, traps the small pieces of formation material, for convenience herein referred to as formation fines or sand, which flows from the formation with the fluid through the perforations and into the gravel pack. Accordingly, neither formation sand nor gravel pack sand penetrates the slotted tubing and only fluid is permitted to pass into the tubular goods.
The above expedient performs nicely until undesired fluid begins to penetrate the gravel pack from the formation. At that point the flow of undesired fluid, such as water, must be terminated preferably in a way which will not necessitate removal of the gravel pack.
The problems referred to above uniformly deal with the unwanted passage of materials into or from very small undesirable openings in a well, including the cement sheath constructed during a primary cementing procedure. Still another problem involved in the construction and repair of wells involves the primary cementing procedure itself.
Primary cementing, as described above, is conducted during the construction of a well and involves the placement of a volume of a slurry of a hydraulic cement and water into the annular space between the walls of the well bore and the exterior of primary casing such as conductor pipe, surface casing, and intermediate and production strings. The slurry is permitted to solidify in the annulus to form a sheath of hardened cement, the purpose of which is to provide physical support and positioning of the casing in the well bore and to isolate various formations penetrated by the well bore one from another.
A problem encountered during primary cementing is centered upon the weight (that is the density) of the slurry itself. In certain circumstances the hydrostatic pressure developed by a column of slurry overcomes the resistance offered by a formation in which case the formation fractures or otherwise breaks down with the result that a portion of the slurry enters the formation and the desired sheath is not formed. The formation breakdown thus occurs prior in time to development of sufficient rigidity or hardening of the cement to enable it to be self-supporting.
One solution has been to reduce the density of the slurry so that the pressure developed by the required slurry height will not exceed the ability of the formation to resist breakdown. This expedient can result in sheaths having physical deficiencies such as reduced strength or increased permeability or both. Another solution has been to reduce the weight of the slurry while maintaining density by reducing the quantity of slurry pumped in a single lift or stage to thus reduce the height of slurry. This expedient requires several separate stages in order to produce the required sheath length. Time must pass between stages in order to permit previous stages to develop strength sufficient to support the weight of succeeding stages. The time expended waiting on cement to set is lost time in the process of constructing the well.
Still another problem involved in the operation of wells revolves about the unwanted movement of water via cracks and fractures in the subterranean formation, whether naturally occurring or deliberately produced, from the formation into the well bore. Terminating this water movement may require remedial efforts other than those referred to previously which feature plugging perforations, holes, cracks and the like in casing, cement sheath and gravel packs, all of which occur within the confines of the well bore itself.
Recently, a better solution to all of the problems mentioned above has been developed and utilized successfully. The solution involves the use of ultra fine hydraulic cement compositions and is described in detail, for example, in U.S. Pat. No. 5,086,850 issued on Feb. 11, 1992. The ultra fine cement compositions and methods described in U.S. Pat. No. 5,086,850 have been utilized successfully in primary cementing, squeeze cementing and the other forms of well cementing mentioned. However, a problem which has persisted in the use of ultra fine cement compositions occurs when the compositions are subjected to high temperatures, i.e., temperatures in the general range of from about 140.degree. F. to about 250.degree. F. In carrying out cementing operations of the type described above in deep hot wells, the ultra fine cement composition is heated to temperatures in the above mentioned range which, heretofore, has often caused premature gelling of the cement composition and the very severe problems attendant thereto. While prior art set retarders have been included in the ultra fine cement compositions, e.g., lignosulfonates, predictable retardation of the compositions at temperatures above about 140.degree. F. has not been obtained.
Thus, there remains a need for a set retarded ultra fine cement composition which remains pumpable for a predictable period of time and for methods of using such composition in remedial cementing and primary cementing operations.
SUMMARY OF THE INVENTION
By the present invention, set retarded ultra fine cement compositions which remain pumpable for a predictable period of time and methods of using such compositions are provided which meet the need recited above and overcome the shortcomings of the prior art. The set retarded compositions of this invention are comprised of an ultra fine hydraulic cement having a particle size no greater than about 30 microns and a Blaine Fineness no less than about 6000 square centimeters per gram, sufficient water to form a pumpable slurry and a set retarder. The set retarder is comprised of a methylenephosphonic acid derivative present in the slurry in an amount in the range of from about 0.09% to about 2.0% by weight of dry cement therein. The methylenephosphonic acid derivative is selected from the group consisting of:
compounds having the general formula: ##STR1## wherein: R.sub.1, R.sub.2 and R.sub.3 are independently hydrogen, --CH.sub.2 PO.sub.3 (X).sub.2 or --CH.sub.2 CH.sub.2 --O--PO.sub.3 (X).sub.2 with the limitation that one of R.sub.1, R.sub.2 and R.sub.3 is always --CH.sub.2 PO.sub.3 (X).sub.2 or --CH.sub.2 CH.sub.2 --O--PO.sub.3 (X).sub.2 ;
X is hydrogen, an alkali metal cation, ammonium, a protonated amine or an alkaline earth metal cation in which case there is only one X per methylenephosphonate group; and
at least one X is hydrogen which is associated with the nitrogen atom by way of an intramolecular hydrogen bond between the nitrogen atom and an oxygen atom attached to a phosphorus atom;
compounds having the general formula: ##STR2## wherein: n is an integer from 1 to 4;
R.sub.1 is hydrogen or --CH.sub.2 PO.sub.3 (X).sub.2 ;
R.sub.2 is hydrogen, --CH.sub.2 PO.sub.3 (X).sub.2 or --CH.sub.2 CH.sub.2 N (R.sub.3).sub.2 wherein R.sub.3 is hydrogen or --CH.sub.2 PO.sub.3 (X).sub.2 ;
X is hydrogen, an alkali metal cation, ammonium, a protonated amine or an alkaline earth metal cation in which case there is only one X per methylene phosphonate group; and
at least one of R.sub.1, R.sub.2 or R.sub.3 is --CH.sub.2 PO.sub.3 (X).sub.2 and one X is hydrogen which is associated with a nitrogen atom by way of an intramolecular hydrogen bond between the nitrogen atom and an oxygen atom attached to a phosphorus atom;
compounds having the general formula: ##STR3## wherein: n is an integer from 2 to 6;
R is hydrogen, --CH.sub.2 PO.sub.3 (X).sub.2 or --CH.sub.2 CH.sub.2 N(R.sub.1).sub.2 wherein R.sub.1 is hydrogen or --CH.sub.2 PO.sub.3 (X).sub.2 ;
X is hydrogen, an alkali metal cation, ammonium, a protonated amine or an alkaline earth metal cation in which case there is only one X per methylene phosphonate group; and
at least one R is --CH.sub.2 PO.sub.3 (X).sub.2 and one X is hydrogen which is associated with a nitrogen atom by way of an intramolecular hydrogen bond between the nitrogen atom and an oxygen atom attached to a phosphorus atom; and
compounds having the general formula: ##STR4## wherein: R.sub.1 is hydrogen or --CH.sub.3 ;
is --PO.sub.3 (X).sub.2 or --CH.sub.2 PO.sub.3 (X).sub.2 ;
X is hydrogen, an alkali metal cation, ammonium, a protonated amine or an alkaline earth metal cation in which case there is only one X per methylene phosphonate group; and
when nitrogen is present, at least one X is hydrogen which is associated with the nitrogen atom by way of an intramolecular hydrogen bond between the nitrogen atom and an oxygen atom attached to a phosphorus atom.
It is, therefore, a general object of the present invention to provide set retarded ultra fine cement compositions and methods.
Other objects, features and advantages of the present invention will be readily apparent to those skilled in the art upon a reading of the description of preferred embodiments which follows.
DESCRIPTION OF PREFERRED EMBODIMENTS
The set retarded ultra fine cement compositions of this invention remain pumpable for a predictable period of time at temperatures above about 140.degree. F. whereby the cement compositions can be pumped into a zone to be treated without fear of premature gelation occurring. As will be understood by those skilled in the art, when a cement composition prematurely develops gel strength prior to being placed, the composition becomes unpumpable and can set in undesirable locations such as in the well bore, in conduits disposed in the well bore or in surface pipe and equipment.
The compositions of this invention are basically comprised of ultra fine hydraulic cement, sufficient water to form a pumpable slurry and a set retarder which causes the composition to remain pumpable for a predetermined period of time before gelation and setting of the composition occurs.
The ultra fine hydraulic cement is comprised of particles of cementitious material having diameters no larger than about 30 microns, preferably no larger than about 17 microns, and still more preferably no larger than about 11 microns. The distribution of various sized particles within the cementitious material, i.e., the particle size distribution, features 90 percent of them having a diameter not greater than about 25 microns, preferably about 10 microns and still more preferably about 7 microns, 50 percent having a diameter not greater than about 10 microns, preferably about 6 microns and still more preferably about 4 microns and 20 percent of the particles having a diameter not greater than about 5 microns, preferably about 3 microns and still more preferably about 2 microns.
The particle size of hydraulic cement can also be indirectly expressed in terms of the surface area per unit weight of a given sample of material. This value, sometimes referred to as Blaine Fineness or as specific surface area, can be expressed in units of square centimeters per gram (cm.sup.2 /gram), and is an indication of the ability of a cementitious material to chemically interact with other materials. Reactivity is believed to increase with increase in Blaine Fineness. The Blaine Fineness of the hydraulic cement used in the cementing methods of this invention is no less than about 6000 cm.sup.2 /gram. The value is preferably greater than about 7000, more preferably about 10,000, and still more preferably greater than about 13,000 cm.sup.2 /gram.
Cementitious materials of particle size and fineness as set out above are disclosed in various prior U.S. patents including U.S. Pat. No. 4,761,183 to Clark, which is drawn to slag, as defined herein, and mixtures thereof with Portland cement, and U.S. Pat. No. 4,160,674 to Sawyer, which is drawn to Portland cement. The cementitious materials preferred for use in this invention are Portland cement and combinations thereof with slag wherein the quantity of Portland cement included in any mixture of Portland cement and slag used can be as low as 10 percent but is preferably no less than about 40 percent, more preferably about 60 percent, still more preferably about 80 percent and most preferably 100% Portland cement by weight of mixture.
Some of the problems solved by the use of a cementitious material of very small particle size are attributable to the ability of the material to pass through very narrow openings and penetrate into low permeability gravel packs and formations. To solve other problems described above, the material when slurried in water must exhibit a sufficiently low slurry density to enable use in situations requiring a light-weight cement which nevertheless develops satisfactory high compressive strength. In this regard the large surface area of the cement, i.e., the Blaine Fineness, renders it more reactive than cements of lower Blaine Fineness; accordingly, quantities of water greater than quantities usually employed in well cementing operations can be employed to thereby enable the formulation of slurries of low density and low viscosity without unsatisfactory loss in strength.
Thus, slurries useful herein can be formulated utilizing ratios of the weight of water per unit weight of cementitious material in the range of from about 0.5 to about 5.0, preferably from about 1.0 to about 1.75 and still more preferably from about 1.00 to about 1.5 pounds water per pound of cementitious material. Water to cement ratios in excess of about 1.75 and up to about 5.0 can be formulated for highly specialized applications requiring slurries of very low density and very low viscosity. It is noted, however, that slurries having such high water ratios tend to exhibit free water separation and excessive solids settling. Additives can be utilized to control free water separation and solids settling.
The slurry densities of the fine cements of this invention are lower than cements having usual particle sizes because of the high water ratios required to wet all of the surface area of the fine cement. The compressive strengths, however, of the set lower density slurries are satisfactory for both primary cementing and remedial cementing purposes especially in view of the greater reactivity of the fine cements. Also, and particularly in the case of slurries formulated at high water ratios, where penetration into very small holes, cracks and openings is the goal, water may indeed be eventually forced out of the fine penetrating particles to thereby deposit in the target crack, opening or porosity a dense, high-strength and highly water impermeable mass of set cement.
Considering the range of water-to-cement ratios disclosed above, the densities of slurries which can be formulated utilizing the fine cement of this invention are in the range from about 9.4 to about 14.9, preferably from about 11.0 to about 12.5 and still more preferably in the range of from about 11.5 to 12.5 pounds per gallon of slurry.
One particular advantage, in addition to the low slurry densities available herein, is that the high water ratios produce low heats of hydration. Thus, the fine particle size hydraulic cement of this invention is quite useful when conducting cementing operations, and particularly primary cementing operations, adjacent to structures which may undergo undesired physical breakdown in the presence of produced heat. Examples of such structures include permafrost and gas hydrate zones.
Still another particular advantage accruing from using the ultra fine particle size Portland cement of this invention is the observed unexpected expansion of the cement during setting. This expansion property can help prevent the formation of microannuli when the cement is used in primary cementing operations and can help the formation of very tightly fitting plugs when the cement is used in squeeze cementing.
It is believed that this desirable expansive feature of the fine particle size Portland cement is due to the chemical content thereof and particularly to the high concentration of crystalline tricalcium aluminate (C.sub.3 A) and sulfates present therein. See, for example, Table VII. It is thought that a Portland cement having a maximum particle size of about 11 microns, a Blaine Fineness of preferably greater than about 10,000 cm.sup.2 /gram, a C.sub.3 A crystalline content of preferably about 3.0 percent or more and a sulfate content of preferably about 1.0 percent or more will exhibit expansive characteristics desirable in an oil field cement.
Slurries of water and the fine particle size cement of this invention, as previously mentioned, are very useful to penetrate, fill and harden in fine holes, cracks and spaces such as might be expected to be found in well casing, cement sheaths, gravel packs and subterranean formations in the vicinity of a well bore. By way of example, it is believed that such slurries are useful to penetrate subterranean formations having effective permeabilities as low as about 3000 to about 5000 millidarcies. Accordingly, a condition known as water coning, in which water from a subterranean formation enters the well bore in a rising or coning fashion, can be terminated by squeezing a slurry of fine particle size cement of this invention into formations producing such water, wherein the formations to be penetrated can have effective permeabilities as low as 3000 to 5000 millidarcies.
In addition, a water slurry of the fine particle size cement of this invention can be utilized to terminate the unwanted flow of water through a zone in a gravel pack. In this regard such a slurry can be formulated to permeate and set in a gravel pack consisting of a packed sand bed wherein the sand in the pack has a particle size as low as 100 mesh (about 150 micron). Such a procedure can be utilized to plug channels in gravel packs created by flowing steam as well as by flowing water.
Still further, a water slurry of the fine particle size cement of this invention can be formulated to penetrate, plug and set in fine cracks in well pipe and in channels and microannulus spaces in and around the cement sheath wherein such fine cracks can be as narrow as about 0.05 millimeters (0.002 inches).
With regard to the above uses, but without being bound by the following slurry design aid, it is considered for commercial design purposes that a particle of given size in a suitable slurry as described herein can penetrate, fill and set in a crack, hole or void having a size of approximately 5 times greater than the size of the particle. Thus the 0.05 millimeter (50 micron) crack referred to above can be penetrated by a slurry of particles having a size of about 10 microns which is within the scope of the cement of this invention.
It was mentioned previously that the rate of hardening of the fine cement of this invention is related to the Blaine Fineness wherein the hardening rate increases as Blaine Fineness increases. In addition, the hardening rate is also related to the specific cementitious material being used and the temperature of the environment wherein the hardening reaction is proceeding. Thus fine particle size Portland cement, as hereinafter defined, hardens more rapidly in low temperature environments in the range of from about 30.degree. F. to about 100.degree. F. than does fine particle size slag cement, hereinafter defined. Also Portland cement hardens more rapidly at elevated temperatures than does slag cement.
As also mentioned above, when an ultra fine hydraulic cement slurry is used in well applications wherein the slurry is heated to temperatures in the range of from about 140.degree. F. to 245.degree. F. and higher, the cement slurry has been subject to flash gelation whereby the time that the slurry remains pumpable has been unpredictable. Even when an ultra fine cement slurry includes heretofore utilized set retarders such as lignosulfonates and other known retarders, premature gelation and setting has occurred. This problem is solved in accordance with the present invention by including in the ultra fine cement composition a set retarder comprised of a methylenephosphonic acid derivative selected from the group consisting of:
(1) compounds having the general formula: ##STR5## wherein: R.sub.1, R.sub.2 and R.sub.3 are independently hydrogen, --CH.sub.2 PO.sub.3 (X).sub.2 or --CH.sub.2 CH.sub.2 --O--PO.sub.3 (X).sub.2 with the limitation that one of R.sub.1, R.sub.2 and R.sub.3 is always --CH.sub.2 PO.sub.3 (X).sub.2 or --CH.sub.2 CH.sub.2 --O--PO.sub.3 (X).sub.2 ;
X is hydrogen, an alkali metal cation, ammonium, a protonated amine or an alkaline earth metal cation in which case there is only one X per methylenephosphonate group; and
at least one X is hydrogen which is associated with the nitrogen atom by way of an intramolecular hydrogen bond between the nitrogen atom and an oxygen atom attached to a phosphorus atom;
(2) compounds having the general formula: ##STR6## wherein: n is an integer from 1 to 4;
R.sub.1 is hydrogen or --CH.sub.2 PO.sub.3 (X).sub.2 ;
R.sub.2 is hydrogen, --CH.sub.2 PO.sub.3 (X).sub.2 or --CH.sub.2 CH.sub.2 N(R.sub.3).sub.2 wherein R.sub.3 is hydrogen or --CH.sub.2 PO.sub.3 (X).sub.2 ;
X is hydrogen, an alkali metal cation, ammonium, a protonated amine or an alkaline earth metal cation in which case there is only one X per methylene phosphonate group; and
at least one of R.sub.1, R.sub.2 or R.sub.3 is --CH.sub.2 PO.sub.3 (X).sub.2 and one X is hydrogen which is associated with a nitrogen atom by way of an intramolecular hydrogen bond between the nitrogen atom and an oxygen atom attached to a phosphorus atom;
(3) compounds having the general formula: ##STR7## wherein: n is an integer from 2 to 6;
R is hydrogen, --CH.sub.2 PO.sub.3 (X).sub.2 or --CH.sub.2 CH.sub.2 N(R.sub.1).sub.2 wherein R.sub.1 is hydrogen or --CH.sub.2 PO.sub.3 (X).sub.2 ;
X is hydrogen, an alkali metal cation, ammonium, a protonated amine or an alkaline earth metal cation in which case there is only one X per methylene phosphonate group; and
at least one R is --CH.sub.2 PO.sub.3 (X).sub.2 and one X is hydrogen which is associated with a nitrogen atom by way of an intramolecular hydrogen bond between the nitrogen atom and an oxygen atom attached to a phosphorus atom; and
(4) compounds having the general formula: ##STR8## wherein: R.sub.1 is hydrogen or --CH.sub.3 ;
R.sub.2 is --PO.sub.3 (X).sub.2 or --CH.sub.2 PO.sub.3 (X).sub.2 ;
X is hydrogen, an alkali metal cation, ammonium, a protonated amine or an alkaline earth metal cation in which case there is only one X per methylene phosphonate group; and
when nitrogen is present, at least one X is hydrogen which is associated with the nitrogen atom by way of an intramolecular hydrogen bond between the nitrogen atom and an oxygen atom attached to a phosphorus atom.
Depending upon the particular amount of the methylenephosphonic acid derivative retarder included in the ultra fine cement slurry, the slurry remains pumpable for a predetermined period of time. Generally, the methylenephosphonic acid derivative set retarder is included in the slurry in an amount ranging from about 0.09% to about 2.0% by weight of dry cement in the slurry. As has been the practice in the art, prior to the preparation and pumping of an ultra fine cement slurry including a set retarder of this invention, the particular amount of retarder to be included in the slurry for a desired pumping time can be pre-determined by testing.
Particularly suitable methylenephosphonic acid derivative set retarders falling within the definition set forth in category (1) above are aminotri(methylenephosphonic acid), the sodium salt of aminotri(methylenephosphonic acid) and triethanol amine substituted with three moles of methylenephosphonic acid. Of the foregoing retarders, aminotri(methylenephosphonic acid) is preferred. Particularly suitable retarders falling within category (2) above include ethylenediamine substituted with 1 to 4 moles of methylenephosphonic acid, the sodium salt of the foregoing compound, diethylenetriamine substituted with 1 to 5 moles of methylenephosphonic acid and triethylenetetramine substituted with 1 to 6 moles of methylenephosphonic acid. Of these, diethylenetriaminepenta(methylenephosphonic acid) is preferred. Preferred category (3) retarders are ethylenediaminetetra(methylenephosphonic acid) and hexamethylenediaminetetra(methylenephosphonic acid). A preferred category (4) retarder is 1-hydroxyethylidene-1,1-diphosphonic acid (HEDP). The most preferred set retarder for use in accordance with this invention is aminotri(methylenephosphonic acid).
The above described preferred set retarders are preferably included in an ultra fine cement slurry in an amount in the range of from about 0.05% to about 2.5%, most preferably an amount in the range of from about 0.09% to about 2.0% by weight of dry cement.
In addition to a set retarder as described above, the ultra fine cement compositions of the present invention preferably include a dispersing agent to facilitate the dispersion of individual ultra fine cement particles in water and to help prevent the formation of large agglomerated particles or lumping.
While a variety of dispersing agents can be used, a particularly suitable dispersing agent is a polymer prepared by the caustic-catalyzed condensation of formaldehyde with acetone or a substance derived from acetone wherein the polymer contains sodium sulfonate groups. Such a dispersing agent is commercially available from the Halliburton Company of Duncan, Okla., under the trade designation CFR-3.TM., and is described in detail in U.S. Pat. No. 4,557,763 issued on Dec. 10, 1985 to George et al. The dispersing agent is generally added to the water utilized to form the ultra fine cement slurry whereby it is present in the slurry in an amount in the range of from about 0.5% to about 2.0% by weight of dry cement therein.
Another cement composition additive which is preferably included in the ultra fine cement compositions of this invention is a fluid loss control additive. A variety of such additives are available and can be used. A particularly preferred such additive is comprised of a copolymer of N,N-dimethylacrylamide and 2-acrylamido, 2-methyl propane sulfonic acid. The copolymer is commercially available from the Halliburton Company under the trade designation HALAD.TM.-344 and is also described in U.S. Pat. No. 4,557,763. The copolymer is combined with an ultra fine cement composition in an amount in the range of from about 0.5% to about 2.0% by weight of dry cement therein.
Another preferred fluid loss control agent which can be used is a graft polymer comprised of a lignin, lignite, derivatized cellulose or synthetic backbone having a grafted pendant group comprising one of homopolymers, copolymers and terpolymers of 2-acrylamido, 2-methyl propane sulfonic acid, acrylonitrile, N,N-dimethylacrylamide, acrylic acid and N,N-dialkylaminoethylmethacrylate. Such a graft polymer fluid loss control agent is available from the Halliburton Company of Duncan, Okla., under the trade designation HALAD.RTM.-413, and is described in U.S. Pat. No. 4,703,801 issued Nov. 3, 1987 to Fry et al. When used, the graft polymer is combined with an ultra fine cement composition in an amount in the range of from about 0.5% to about 2.0% by weight of dry cement.
Other commonly used additives in well cement compositions may also be utilized in the compositions of this invention including additives for reducing the density of the compositions such as nitrogen, perlite, fly ash, silica fume, microspheres and the like. Also, in order to help prevent the loss of compressive strength of said cement over time, a condition referred to as compressive strength retrogression, silica flour can be included in the compositions. Generally, if silica flour is utilized it is added to the compositions of this invention in amounts in the range of from about 0.15 to about 1.0 pounds of silica flour per pound of hydraulic cement used.
The tables which follow provide information and data concerning the chemical, physical and performance properties of four hydraulic cements. Three of the cements are Portland cements and the fourth is a slag cement. One of the cements, identified as API Class A, due to particle size only, is not within the scope of this invention. The remaining three cements are within the scope of this invention.
Tables I and II provide physical data including specific surface, specific gravity, blending and particle size analysis.
Tables III and IV provide performance data including compressive strength developed by stated slurries and penetration by stated slurries.
Tables V, VI, VII and VIII provide chemical content as determined by various different analysis techniques.
Table IX provides a chemical analysis of Portland type III cement as disclosed in U.S. Pat. No. 4,160,674 to Sawyer.
Referring now to Tables I, II, III, IV, V, VI, VII and VIII set out above, there is presented, in convenient tabular form, a comparison of various properties of four different cementitious materials each of which exhibit hydraulic activity. "Hydraulic activity" and "reactivity" as used herein mean the chemical nature of a material to set and harden, upon being mixed with water, without contact with the atmosphere (e.g., the ability to harden under water) due to the interaction of the constituents of the material rather than by evaporation of the water. The term "hydraulic cement" as used herein means all inorganic cementitious materials of known type which comprise compounds of calcium aluminum, silicon, oxygen and/or sulfur which exhibit "hydraulic activity" that is which set solid and harden in the presence of water. Cements of this type include common Portland cements, fast setting or extra fast setting, sulfate resistant cements, modified cements, alumina cements, high alumina cements, calcium aluminate cements, and cements which contain secondary components such as fly ash, pozzalona and the like. See for example Roca et al., U.S. Pat. No. 4,681,634. There are in existence inorganic cementitious materials other than those exemplified in Tables I-VIII which exhibit hydraulic activity, but this invention is preferably limited to the types included in Tables I-VIII.
Accordingly, Portland cement, one of the materials listed in the Tables is made by sintering (thermally treating) a ground mixture of raw materials one of which is usually composed mainly of calcium carbonate (as limestone) and another of which is usually composed mainly of aluminum silicates (as clay or shale) to obtain a mixture of lime, aluminum oxide, silicon dioxide and ferric oxide. During the sintering process chemical reactions occur which produce nodules, called clinkers, which are primarily composed of mixed calcium silicates (C.sub.2 S) and C.sub.3 S), calcium aluminates (C.sub.3 A) and calcium aluminoferrites (C.sub.4 AF) all of which compounds contribute to the hydraulic activity of Portland cement. See for example Braunauer, U.S. Pat. No. 3,689,294; Buchet, et al., U.S. Pat. No. 4,054,460; and Gartner, U.S Pat. No. 4,619,702. An example of a chemical analysis of Portland cement clinker is provided by Skvara, U.S. Pat. No. 4,551,176 as follows:
Portland cements are classified by the American Society of Testing Materials (ASTM) into five major types identified by Roman Numerals I, II, III, IV and V and by the American Petroleum Institute into at least 9 categories identified by the letters A, B, C, D, E, F, G, H and J. The classifications are based on chemical composition and physical properties.
Sawyer in U.S. Pat. No. 4,160,674 specifically discloses a Type III Portland cement exhibiting high early compressive strength wherein: substantially all particles in the cement are of a size of about 20 microns and smaller; the Blaine Fineness is about 8990 cm.sup.2 /gram; and the specific gravity is 3.00. Sawyer provides an analysis of the Type III material, which is referred to as the "fine product". The analysis is set out in Table IX below.
Galer, et al., in U.S. Pat. No. 4,350,533 provides abbreviations for chemical formulas of cement compounds in accordance with general practice in the cement industry as follows:
C represents calcium oxide (CaO)
A represents aluminum oxide (Al.sub.2 O.sub.3)
F represents ferric oxide (Fe.sub.2 O.sub.3)
M represents magnesium oxide (MgO)
S represents silicon dioxide (SiO.sub.2)
K represents potassium oxide (K.sub.2 O)
N represents sodium oxide (Na.sub.2 O)
H represents water (H.sub.2 O)
S represents sulfur trioxide (SO.sub.3)
C represents carbon dioxide (CO.sub.2)
Accordingly, based upon the above abbreviations the chemical composition of the Type III Portland cement disclosed by Sawyer (Table IX above) is:
Tables I-VIII also include a hydraulic cement material identified as "SLAG/Portland" which is a combination of Portland cement and slag.
"Slag" as used herein, means a granulated, blastfurnace, by-product formed in the production of cast iron and is broadly comprised of the oxidized impurities found in iron ore.
During the operation of a blast furnace to remove iron from iron ore a molten waste product is formed. By preventing this molten product from crystallizing, and thereby losing its energy of crystallization, a super-cooled liquid or non-crystalline glassy material can be formed thus retaining the energy of crystallization. This non-crystalline, glassy material, which has also been described as a vitreous substance free from crystalline substances as determined by X-ray diffraction analysis, is said to be capable of exhibiting hydraulic activity upon being reduced in size by grinding from a particle size of 1 to 5 millimeters to a fine particle size in the range of from about 1 to about 100 microns. Many commentators, including Clarke in U.S. Pat. No. 4,761,183 and Forss in U.S. Pat. No. 4,306,912, state that the glass content of the material, in order to exhibit latent hydraulic activity, must be high and preferably above about 95 percent.
Crystallization of the molten blast-furnace waste product can be prevented and the super cooled liquid or glass can be formed by rapidly chilling the molten waste. This rapid chilling can be effected by spraying the molten waste with streams of water which operation causes rapid solidification and formation of a water slurry of small, glassy, sand-like particles. The slurry is then thermally dried to remove substantially all moisture to thereby produce a dry blend of coarse particles. This dry blend of particles, having a particle size in the range of 1 to 5 millimeters, is then ground to reduce particle size to values in the range of from 1 to about 100 microns and preferably less than about 325 mesh (45 microns) to produce the granulated, blast-furnace byproduct herein defined as "Slag". See, for example, Miyoshi et al., U.S. Pat. No. 4,443,260; Allemand et al., U.S. Patent No. 3,809,665; Buchet et al., U.S. Pat. No. 4,054,460; Gee et al., U.S. Pat. No. 4,242,142; Clarke, U.S. Pat. No. 4,761,183; and Forss, U.S. Pat. No. 4,306,912.
Clarke U.S. Pat. No. '183 and Miyoshi et al., in U.S. Pat. No. 4,306,910 disclose the following analysis, said by them to be representative of the usual ranges of chemical content of slag.
Clarke further states that the density of slag is considered to be 2.92 grams per cubic centimeter.
Another analysis of slag is provided by Yamaguchi et al., in U.S. Pat. No. 3,904,568 as follows:
Miyoshi et al., U.S. Pat. No. '910 states that the hydraulic activity of slag is low if the particle size of the slag is in the range of 1 to 5 millimeters and accordingly, suggest that the particle size of slag should be reduced by grinding to a value of at least about 5 microns or less; and still further state that the slag, by itself, even after grinding has no or very low hydraulic activity and thus requires activation or stimulation such as by the addition thereto of slaked lime (CaOH.sub.2 O). Other additives to stimulate or activate the hydraulic activity of Slag include sodium hydroxide, sodium sulfate sodium carbonate, sodium silicate, potassium sulfate and Portland cement. See for example Clarke, U.S. Pat. No. 4,761,183 and Clarke, U.S. Pat. No. 4,897,119.
According to Forss in U.S. Pat. No. 4,306,912 grinding slag to a high specific surface, e.g., in the range of from about 4000 to about 8000 cm.sup.2 /gram, can increase the hydraulic activity and hardening rate of the material. Forss also states that it is known that grinding cement clinker beyond a certain limit is not beneficial because additional fineness hardly improves the properties of hardening and strength. On the other hand Birchall et al., in U.S. Pat. No. 4,353,747 state that the strength of Portland cement can be improved by reducing the weight average mean particle size of Portland cement to a value of less than 20 microns.
The various methods for conducting cementing operations normally associated with wells in subterranean hydrocarbon producing formations are generally known. These basic techniques with changes, as required, can be employed to place the fine particle size cement of this invention in position to solve the various problems addressed herein.
The techniques which can be used herein are set out below in outline format.
Procedure I, "Method for Placing Cement in a Microannulus",
Procedure II, "Method for Placing Cement in Voids, Cracks and Channels in the Cement Sheath",
Procedure III, "Method for Plugging Cracks and Perforations in Casing",
Procedure IV, "Alternate Method for Repair of Cracks in Casing" and
Procedure V, "Method for Terminating Water Flow Through a Gravel Pack and the Matrix of a Subterranean Formation" can be employed to perform remedial cementing operations within a wellbore.
Procedure VI, "Method for Terminating the Flow of Water from a Zone in a Subterranean Formation" can be employed to perform remedial cementing operations outside of a well bore in the formation.
Procedure VII, "Method for Using Ultra Fine Cement in Primary Cementing Operations," can be employed to perform primary cementing.
Procedure I
Method for Placing Cement in a Microannulus
1. Determine the location, size and upper and lowermost linear limits of the microannulus relative to the axis of the well bore. This determination may be accomplished by use of a conventional cement bond log procedure.
2. BLOCK SQUEEZE TECHNIQUE
(a) Perforate the well casing so as to intersect the microannulus at its lowest point relative to the wellhead.
(b) Isolate the perforation by placing a bridge plug in the casing below the perforation and a packer in the casing above the perforation to thereby define a space within the casing between the bridge plug and packer which is in communication with the microannulus via the perforation; establish communication with the wellhead via tubing from the wellhead to the packer.
c. Introduce an acid solution into the microannulus via tubing from the wellhead to the packer, the defined space and the perforation. The purpose of the acid, which can be a 15% hydrochloric acid solution, is to prepare the perforation and microannulus for cementing.
d. Introduce water into the microannulus via the tubing and perforation to establish an injection rate.
e. Introduce a water slurry of the cement composition of the invention into the microannulus. The slurry must be of sufficient volume to form a plug in the entire lower portion of the microannulus to prevent passage of fluid therethrough. Introduction of the slurry must be effected at a pressure less than the pressure required to fracture the formation.
f. Remove excess slurry from tubular goods and casing.
g. Shut well in, preferably under pressure, to permit the cement to harden.
h. Remove the tubing, the packer and the bridge plug from the well and perforate the well casing so as to intersect the microannulus at its uppermost point relative to the wellhead.
i. Repeat steps "b" through "g" with respect to the perforation made in step "h".
The block squeeze method described in steps 2a-2i thus produces water blocks at the extreme linear limits of a microannulus but does not completely fill the microannulus with cement.
The use of acid, as described in Step 2c, may be eliminated in the performance of the procedure when the cement of this invention is employed. 3. ROLLOVER TECHNIQUE
(a) Perforate the well casing in two locations, so as to intersect the microannulus at its uppermost point and its lowermost point relative to the wellhead.
(b) Isolate the zones below the perforated interval by placing a bridge plug in the casing below the perforation in the lowermost point of the microannulus.
(c) Place a drillable packer in the casing between the uppermost perforation and the lowermost perforation to thus establish a space within the casing between the bridge plug and drillable packer.
(d) Establish communication between the wellhead and the defined space via tubular goods from the wellhead to the packer.
(e) Establish communication between the perforations by introducing an acid solution into the microannulus via the tubing, the defined space and the lowermost perforation and permitting the solution to exit the microannulus via the uppermost perforation.
(f) Fill the microannulus with a water slurry of the cement composition of this invention by introducing the slurry into the microannulus via the tubing, the defined space, and the lowermost perforation and maintaining such introduction until the slurry exits the microannulus via the uppermost perforation.
(g) Remove excess slurry from the defined space by backwashing.
(h) Shut well in, preferably under pressure, to permit the cement to harden.
(i) Drill set cement above drillable packer and drill through packer and remove bridge plug.
The rollover squeeze method described in steps 3a-3i results in a microannulus completely filled with the cement composition of this invention.
The use of acid, as described in Step 3e, may be eliminated in the performance of the procedure when the cement of this invention is employed.
Procedure II
Method for Placing Cement in Voids, Cracks and Channels in the Cement Sheath
Utilize the procedure described in Procedure I for placing the cement composition of this invention in microannuli, however, as an additional step, a chemical flush preceding introduction of the cement slurry maybe employed. The purpose of the flush, which is not essential to the procedure, is to condition the hardened cement in the sheath for bonding. An example of a suitable such reactive chemical pre-flush is sodium silicate.
Procedure III
Method for Plugging Cracks and Perforations in Casing
1. Locate the casing hole by conventional means.
2. Isolate the hole by placing a bridge plug in the casing below the hole and a packer in the casing above the hole to thereby define a space within the casing between the bridge plug and packer; establish communication with the wellhead via tubing from the wellhead to the packer.
3. Introduce an acid solution into the hole via tubing from the wellhead to the packer and the defined space. The acid, which can be a 15% hydrochloric acid solution, will prepare the hole for cementing.
4. Introduce water into the hole via the tubing to establish an injection rate.
5. Introduce a water slurry of the cement composition of the invention into the hole via tubing from the wellhead to the packer and the defined space. The slurry must be of sufficient volume to form a plug in the hole to prevent passage of fluid therethrough. Introduction of the slurry must be effected at a pressure less than the pressure required to fracture the formation.
6. Remove excess slurry from the defined space by backwashing.
7. Shut well in preferably under pressure to permit the cement to harden.
The use of acid as described in Step 3 may be eliminated in the performance of the procedure when the cement of this invention is employed.
Procedure IV
Alternate Method For Repair of Cracks in Casing
1. Locate crack in casing by conventional means.
2. Place a bridge plug in the casing below the crack to thereby isolate the crack from portions of the casing below the crack.
3. Introduce tubing into the casing from the wellhead 15 to a location in the approximate vicinity of the crack.
4. Remove any debris from the portion of the casing above the bridge plug by introducing therein water via the tubing and circulating the same out the casing.
5. Introduce a water slurry of the cement composition of this invention via the tubing into the casing above the bridge plug in an amount sufficient to cover the crack.
6. Increase the pressure in the casing above the slurry to force the slurry to slowly penetrate into the crack and continue to increase casing pressure to assure such penetration.
7. Shut well in under pressure and do not release the pressure for a period of time, preferably about 24 hours, to permit the cement to harden in the crack.
8. Remove set cement from casing by drilling.
9. Pressure casing with water to determine whether repaired crack prevents loss of water.
Procedure V
Method For Terminating Water Flow Through a Gravel Pack and the Matrix of a Subterranean Formation
1. Place a volume of a slurry of hydraulic cement in water within the slotted liner. The volume of slurry placed should be in an amount at least sufficient to saturate the portion of the gravel pack through which the unwanted water is flowing. The slurry may be spotted by permitting it to flow from the wellhead via tubing extended therefrom to the liner or by lowering it to the liner in a section of pipe having a valve in the bottom portion thereof and thereafter opening the valve and literally dumping the slurry in the liner. The section of pipe and valve is referred to as a dump bailer.
2. Apply pressure against the slurry in an amount sufficient to force the slurry from the liner and into and through the gravel pack and at least partially into the portion of the formation from which undesirable water is being produced. The pressure applied to the slurry should not be of sufficient intensity to make a fracture in the formation.
3. Maintain applied pressure for a time sufficient to permit the cement to harden before the well is returned to production.
Procedure VI
Method for Terminating the Flow of Water From a Zone in a Subterranean Formation
1. Locate the zone within the subterranean formation from which water is being produced. This task may be performed by using known methods of identifying casing perforations through which water is flowing. The water may be flowing from a fracture or from a high permeability portion in the zone.
2. Isolate the identified perforations by placing a bridge plug in the casing, a bridge plug below the perforations, and a packer in the casing above the perforations to thereby define a space within the casing between the bridge plug and packer which is in communication with the zone via the perforations; establish communication with the wellhead via tubing from the wellhead to the packer.
3. Introduce a spacer fluid such as diesel oil into the zone via the tubing and perforations.
4. Introduce a slurry of the cement composition of the invention in a hydrocarbon liquid into the zone. The cement must be of sufficient volume to form a plug in the zone to prevent passage of fluid therethrough. Introduction of the cement is preferably effected at a pressure less than the pressure required to fracture the zone.
5. Introduce an overflush fluid such as diesel oil into the zone via the tubing and perforations to help in the introduction of the hydrocarbon-cement slurry into the zone.
6. Shut well in for 24 hours, preferably under pressure, to permit the cement to hydrate with formation water in zone and harden. Remove the tubing, the packer and the bridge plug from the well.
Procedure VII
Method for Using Ultra Fine Cement in Primary Cementing Operations
The method of cementing primary oil field casings using ultra fine cement slurries include conductor pipe, surface casing, intermediate casing, production casing, drilling liner, production liner, scab liner and tieback casing.
1. Pump the slurry or any preceding or following fluid down the casing (tubing or drill pipe) and back up the annular space between the casing and the drilled hole.
2. (optional) Precede all fluids with a "bottom" wiper plug to clean drilling fluid from the casing.
3. (optional) Pump a preflush chemical wash or "spacer" to serve as a drilling fluid removal agent and as a compatible spacer between the drilling fluid and the cement slurry.
4. Pump the cement slurry.
5. (optional) Follow the cement slurry with a conventional cement slurry.
6. Follow the cement slurry with a "top" wiper plug.
7. Pump a commonly used displacement fluid (water, drilling fluid, e.g.) to force the cement slurry down the casing and up into the annulus. Pump enough fluid to displace the required amount of casing volume. The "top" plug should land on a baffle or "float collar" closing off the flow of fluid to the annulus.
8. Pressure up to ensure that the top plug has landed.
9. Release pressure on casing to test if the "float" is holding to keep the cement in the annulus.
10. Terminate any operation in the well bore for a time sufficient to permit the cement to set (WOC).
As will be understood by those skilled in the art, a variety of other uses in the drilling, completion and production of wells not specifically mentioned herein can be made of the set retarded ultra fine cement compositions of this invention.
A particularly preferred set retarded ultra fine cement composition which remains pumpable for a predictable period of time at temperatures up to about 245.degree. F. and higher is comprised of the following components:
(a) an ultra fine hydraulic cement having a particle size no greater than about 30 microns, a Blaine Fineness no less than about 6000 square centimeters per gram, 90 percent of the particles having a diameter no greater than about 25 microns, 50 percent of the particles having a diameter no greater than about 10 microns and 20 percent of the particles having a diameter no greater than about 6 microns;
(b) sufficient water to form a pumpable slurry (normally an amount in the range of from about 0.5 to about 5.0 pounds of water per pound of dry cement used);
(c) a set retarder comprised of aminotri(methylenephosphonic acid) present in the slurry in an amount in the range of from about 0.09% to about 2.0% by weight of dry cement therein;
(d) a dispersing agent comprised of a polymer prepared by the caustic-catalyzed condensation of formaldehyde with acetone or a substance derived from acetone wherein the polymer contains sodium sulfonate groups present in the slurry in an amount in the range of from about 0.5% to about 2.0% by weight of dry cement therein; and
(e) a fluid loss control agent comprised of a copolymer of N,N-dimethylacrylamide and 2-acrylamido, 2-methyl propane sulfonic acid present in the slurry in an amount in the range of from about 0.5% to about 2.0% by weight of dry cement therein.
The methods of this invention for cementing a subterranean zone penetrated by a well bore at a temperature in the range of from about 140.degree. F. to about 245.degree. F. comprise the steps of pumping a set retarded ultra fine cement composition of this invention into the subterranean zone, and then allowing the cement composition to set into a hard substantially impermeable mass in the zone. Depending upon the specific purpose of the cementing operation, one of the various procedures described above and the additional steps thereof may be used.
In order to further illustrate the compositions and methods of this invention, the following examples are given.
EXAMPLE 1
A number of set retarded ultra fine cement compositions of the present invention were prepared and tested for thickening times and 24 hour compressive strengths in accordance with API standard procedures. That is, the thickening time and compressive strength tests were conducted in accordance with the API Specification for Materials and Testing for Well Cement, API Spec. 10, published by the American Petroleum Institute, Washington, D.C. Compressive strength tests were performed in accordance with Section 7 of the above specification and the thickening time tests were conducted in accordance with Section 8 of the specification. A first group of test slurries were prepared containing ultra fine Portland cement and water in an amount of 6 gallons of water per 50 pounds of cement having a density of 12.5 pounds per gallon. The slurries contained various quantities of set retarder, a dispersant and a fluid loss control agent and were tested for thickening time at 140.degree. F. BHCT. Two of the test slurries were tested for 24 hour compressive strengths at temperatures of 160.degree. F. and 180.degree. F. The results of these tests are set forth in Table X below.
A group of additional test slurries were prepared containing Ultra Fine Portland cement and water in an amount of 9.22 gallons of water per 50 pounds of cement and having a density of 11.3 pounds per gallon. These test slurries also contained various quantities of set retarder, dispersant and fluid loss control agent, and were tested for thickening times at 140.degree. F. BHCT and 24 hour compressive strengths at temperatures of 160.degree. F. and 180.degree. F. The results of these tests are set forth in Table XI.
From Tables X and XI it can be seen that at 140.degree. F. BHCT, the thickening time response versus retarder concentration is predictable.
It has therefore been known that the presence of certain fluid loss control agents, e.g., a copolymer of N,N-dimethylacrylamide and 2-acrylamido, 2-methyl propane sulfonic acid, extends the thickening times of set retarded cement slurries at high temperatures. As shown in Tables X and XI, at 140.degree. F. the presence of the fluid loss control agent does not have a pronounced effect on thickening times. However, as shown in Table XII below, at 187.degree. F. the presence of the fluid loss control agent in retarded cement slurries causes the thickening times to more than double.
EXAMPLE 2
Additional set retarded ultra fine cement compositions of this invention were prepared having densities of 12.5 pounds per gallon and 11.3 pounds per gallon and containing various quantities of set retarder. The slurries were tested for thickening times at 187.degree. F. BHCT, and some of the compositions were tested for 24 hour compressive strengths at temperatures of 200.degree. F. and 220.degree. F. The results of these tests are set forth in Tables XIII and XIV.
From Tables XIII and XIV, it can again be seen that the thickening times of the set retarded ultra fine cement compositions of this invention are predictable based on the concentrations of retarder and fluid loss control agent in the compositions.
EXAMPLE 3
Additional set retarded cement compositions of the present invention were prepared having densities of 12.5 pounds per gallon and containing silica flour, dispersing agent, various quantities of set retarder and various quantities of fluid loss control agents. The cement slurries were tested for thickening times at 245.degree. F. BHCT. The results of these tests are given in Table XV.
From Table XV it can be seen that the fluid loss control agents substantially extend the thickening times provided by the set retarder, but the times are still predictable.
In addition to thickening time at 245.degree. F. a number of the test slurries were tested for fluid loss control and 24 hour compressive strengths at 250.degree. F. The results of these tests are set forth in Table XVI below.
Table XVII below sets forth the compressive strengths of set retarded ultra fine cement compositions of this invention having various densities, containing various amounts of set retarder and containing various amounts of fluid loss control agents.
From Tables XVI and XVII, it can be seen that the set retarded compositions of the present invention have good fluid loss control and remain pumpable for predictable periods of time at high temperatures.
Thus, the present invention is well adapted to carry out the objects and attain the ends and advantages mentioned as well as those which are inherent therein. While numerous changes to the invention may be made by those skilled in the art, such changes are encompassed within the spirit of this invention as defined by the appended claims.
Claims
What is claimed is:
1. A set retarded ultra fine cement composition which remains pumpable for a predictable period of time within a range of from about 1 to about 16 hours up to about 245.degree. F. comprising: an ultra fine hydraulic cement having a particle size no greater than about 30 microns and a Blaine Fineness no less than about 6000 square centimeters per gram; sufficient water to form a pumpable slurry; and a set retarder consisting essentially of a methylenephosphonic acid derivative present in said slurry in an amount in the range of from about 0.05% to about 2.5% by weight of dry cement therein; said methylenephosphonic acid derivative being selected from the group consisting of: compounds having the general formula: ##STR9## wherein: R.sub.1, R.sub.2 and R.sub.3 are independently hydrogen, --CH.sub.2 PO.sub.3 (X).sub.2 or --CH.sub.2 CH.sub.2 --O--PO.sub.3 (X).sub.2 with the limitation that one of R.sub.1, R.sub.2 and R.sub.3 is always --CH.sub.2 PO.sub.3 (X).sub.2 or --CH.sub.2 CH.sub.2 --O--PO.sub.3 (X).sub.2 ; X is hydrogen, an alkali metal cation, ammonium, a protonated amine or an alkaline earth metal cation in which case there is only one X per methylenephosphonate group; and at least one X is hydrogen which is associated with the nitrogen atom by way of an intramolecular hydrogen bond between the nitrogen atom and an oxygen atom attached to a phosphorous atom; compounds having the general formula: ##STR10## wherein: n is an integer from 1 to 4; R.sub.1 is hydrogen or --CH.sub.2 PO.sub.3 (X).sub.2 ; R.sub.2 is hydrogen, --CH.sub.2 PO.sub.3 (X).sub.2 or --CH.sub.2 CH.sub.2 --N (R.sub.3).sub.2 wherein R.sub.3 is hydrogen or --CH.sub.2 PO.sub.3 (X).sub.2 ; X is hydrogen, an alkali metal cation, ammonium, a protonated amine or an alkaline earth metal cation in which case there is only one X per methylene phosphonate group; and at least one of R.sub.1, R.sub.2 or R.sub.3 is --CH.sub.2 PO.sub.3 (X).sub.2 and one X is hydrogen which is associated with a nitrogen atom by way of an intramolecular hydrogen bond between the nitrogen atom and an oxygen atom attached to a phosphorous atom; compounds having the general formula: ##STR11## wherein: n is an integer from 2 to 6; R is hydrogen or --CH.sub.2 PO.sub.3 (X).sub.2 or --CH.sub.2 CH.sub.2 N(R.sub.1).sub.2 wherein R.sub.1 is hydrogen or --CH.sub.2 PO.sub.3 (X).sub.2 ; X is hydrogen, an alkali metal cation, ammonium, a protonated amine or an alkaline earth metal cation in which case there is only one X per methylene phosphonate group; and at least one of R is --CH.sub.2 PO.sub.3 (X).sub.2 and one X is hydrogen which is associated with a nitrogen atom by way of an intramolecular hydrogen bond between the nitrogen atom and an oxygen atom attached to a phosphorous atom; and compounds having the general formula: ##STR12## wherein: R.sub.1 is hydrogen or --CH.sub.3 ; R.sub.2 is --PO.sub.3 (X).sub.2 or --CH.sub.2 PO.sub.3 (X).sub.2 ; X is hydrogen, an alkali metal cation, ammonium, a protonated amine or an alkaline earth metal cation in which case there is only one X per methylene phosphonate group; and when nitrogen is present, at least one X is hydrogen which is associated with the nitrogen atom by way of an intramolecular hydrogen bond between the nitrogen atom and an oxygen atom attached to a phosphorous atom.
2. The composition of claim 1 wherein said set retarder is selected from the group consisting of aminotri(methylenephosphonic acid), diethylenetriaminepenta(methylenephosphonic acid), ethylenediaminetetra(methylenephosphonic acid), hexamethylenediaminetetra(methylenephosphonic acid) and 1-hydroxyethylidene-1,1-diphosphonic acid.
3. The composition of claim 1 wherein said water is present in said slurry in an amount in the range of from about 0.5 to about 5.0 pounds of water per pound of dry cement therein.
4. The composition of claim 1 which further comprises a dispersing agent.
5. The composition of claim 4 wherein said dispersing agent is selected from the group consisting of a polymer prepared by the caustic-catalyzed condensation of formaldehyde with acetone and a substance derived from acetone wherein said polymer contains sodium sulfonate groups, and is present in said slurry in an amount in the range of from about 0.5% to about 2.0% by weight of dry cement therein.
6. The composition of claim 1 which further comprises a fluid loss control agent.
7. The composition of claim 6 wherein said fluid loss control agent selected from the group consisting of a copolymer of N,N-dimethylacrylamide and 2-acrylamido, 2-methyl propane sulfonic acid and a graft polymer comprised of a lignin, lignite, derivatized cellulose or synthetic backbone having a grafted pendant group comprising one of 2-acrylamido-2-methyl propane sulfonic acid, acrylonitrile, N,N-dimethylacrylamide, acrylic acid and N,N-dialkylaminoethylmethacrylate.
8. The composition of claim 1 wherein said hydraulic cement is a blend of slag and Portland cement.
9. The composition of claim 8 wherein the particle size of said hydraulic cement blend is no greater than about 17 microns, the Blaine Fineness is no less than about 7,000 square centimeters per gram, 90% of said particles have a diameter not greater than about 10 microns, 50% of said particles have a diameter not greater than about 6 microns and 20% of said particles have a diameter not greater than about 3 microns.
10. The composition of claim 9 wherein said ratio of water to cement is in the range of from about 1.0 to about 1.75 pounds of water per pound of cement.
11. The composition of claim 1 wherein said cement is Portland cement.
12. The composition of claim 11 wherein the maximum particle size of said Portland cement is about 11 microns, the Blaine Fineness is about 10,000 square centimeters per gram, 90% of said particles have a diameter not greater than about 7 microns, 50% of said particles have a diameter not greater than about 4 microns and 20% of said particles have a diameter not greater than about 2 microns.
13. The composition of claim 12 wherein the C.sub.3 A crystalline content of said Portland cement is at least about 3.0% by weight of said cement and the sulfate content of said Portland cement is at least about 1.0% by weight of said cement.
14. A set retarded ultra fine cement composition which remains pumpable for a predictable period of time within a range of from about 1 to about 16 hours at temperatures up to about 245.degree. F. comprising: an ultra fine hydraulic cement having a particle size no greater than about 30 microns, a Blaine Fineness no less than about 6000 square centimeters per gram, 90% of said particles have a diameter no greater than about 25 microns, 50% of said particles having a diameter no greater than about 10 microns and 20% of said particles having a diameter no greater than about 6 microns; sufficient water to from a pumpable slurry; a set retarder consisting of aminotri(methylenephosphic acid) present in said slurry in an amount in the range of from about 0.9% to about 2.0% by weight of dry cement therein; a dispersing agent comprised of a polymer prepared by the caustic-catalyzed condensation of formaldehyde with acetone or a substance derived from acetone wherein said polymer contains sodium sulfonate groups present in an amount in the range of from about 0.5% to about 2.0% by weight of dry cement therein; and a fluid loss control agent comprised of a polymer of N,N-dimethylacrylamide and 2-acrylamido, 2-methyl propane sulfonic acid present in an amount in the range of from about 0.5% to about 2.0% by weight of dry cement therein.
15. The composition of claim 14 wherein said water is present in said slurry in an amount in the range of from about 1.0 to about 1.6 pounds of water per pound of dry cement therein.