Optimum ST Plugs
Optimum ST Plugs
Optimum ST Plugs
1- Abstract
2- Background
3- Main reasons for side track plug failures
4- Side track plugs history
5- Modern challenges in setting Side track plugs
6- The questions to ask before setting a side track plug
7- Cement evolution
8- Side tracks plugs with DPs and tubings
9- Side tracks plugs with special tools
10- Various procedures to set a cement plug
11- Procedures to initiate a side track
12- Field examples and writing reports
13- Other cement plug considerations
14- Tricks, tips and economics
15- Cased holes applications
16- Surface equipment and field specific problems
17- Conclusions
18- Epilog (Specific Schlumberger techniques)
Page 1 of 49
This information is CONFIDENTIAL and must not be copied in whole or any part and should be filed
accordingly by the addressee. It must not be shown to or discussed with anyone outside the
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Setting effective sidetrack plugs
C. Ingold, M. Popov
1- Abstract:
Setting cement plugs to abandon a well or cure losses is usually simple. Setting a side track
plug to kick off or to get away from a casing is more difficult. Modern drilling patterns often require
higher quality plugs especially in hard formations. No cement can match the compressive strength of
the hardest formations. New cementing blends allow compressive strengths unthinkable 15 years ago
but require more planning and preparation.
Nothing should be left to improvisation even though creativity may be needed with limited
local resources.
This document is a recap of most techniques associated with side track plugs and comes in
addition to two other papers (Soft science of Side track part 1 and 2).
We are indebted to people from different Schlumberger segments who have contributed. This
paper should help rig supervisors, cementers and directional drillers what to recommend and when.
Side track plugs can be improved both on surface (procedures, equipment, blends) and
downhole (placement tools and procedures)
.
2- Background:
When side tracks are unplanned unbudgeted events, clients just want to get back to drilling
quickly and tend to take short cuts. Spending 6 hours extra time or 50000 dollars for an extra product
is a fraction of the cost implications of a plug failure.
When looking at older manuals, one can realize the changes that have occurred. There is a
wider variety of hole sizes and more than three sizes of DP. Profiles are more challenging and plugs
may be set at high inclinations. Setting good side track plugs in oil base mud, in hot holes and hard
formations is difficult. Cement placement, running in and out safely or leaving chunks of cement in
the drill string (MWD jamming) require special attention. Clients expect to use one BHA and one bit
to drill an entire phase where applicable. Setting a cement plug may therefore be more complex.
Good procedures and execution do not mean success when excessive rig time is needed. A
side track requiring an extra trip to run an aggressive deflection technique is a partial failure.
When a cement plug is softer than the formation (99% of cases), the success of the operation
relies on the directional driller’s shoulder. The deal is to define how soft is “too soft”.
The best plugs can reach over 10000 PSI compressive strength versus 19000 PSI and above for
a “quartz based sandstone”. Sidetracking is very easy when the cement is harder than the formation.
Rock compressive strength is hard to evaluate. In practice, the drillability of the cement versus
the formation is what you go by.
In most cases, the directional driller rarely knows the plug quality when picking up the BHA.
In the past, when a plug was dressed with a slick BHA there were more options. Clients should
therefore spare no effort to allocate the right resources to do it right the first time.
Note: Any bit will drill cement. Cement can be drilled by any drilling mechanism (crushing, hitting, digging, scrapping
etc...). On the other hand a diamond bit may drill cement but will ball up on a plastic formation. Models to determine rock
compressive strength exist but would be hard to apply (in one case, a drill bit, an estimate of rock ductility of a particular
subterranean formation in conjunction with WOB, RPM, and ROPis used as input. US Patent 4914591).
Page 2 of 49
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Setting effective sidetrack plugs
C. Ingold, M. Popov
Cased holes:
Cement plug failures may be identical in the case of section milled windows. A motor can kick
off from a shorter section than modern rotary steerables. Consequently if a motor has to be used first it
means an extra trip. In the case of a whipstock, the quality of the cement bond is of prime importance
as “casing tracking” may happen. A high quality cement plug set as a remedial action will be very
important and will present its own challenges.
A cement plug set inside casing and on top of a plug should not be subjected to slippage. A
cement plug set to fix casing tracking below a whipstock should also be less susceptible to slippage.
On the other hand, a side track performed from or inside a casing is more limited in space. It is
usually a one shot option. The cost of a failure will be felt immediately resulting in downtime.
A high quality cement plug across a section milled window is more important when a rotary
steerable is used as a deflection tool.
Notes:
A superior cement plug may be a key selling point for clients wishing to drill an entire phase with
a single BHA.
Section milled window are longer when rotary steerables are used (about 40 ft for motors and 60
to 80 ft with rotary steerables).
Page 3 of 49
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accordingly by the addressee. It must not be shown to or discussed with anyone outside the
SCHLUMBERGER organization.
Setting effective sidetrack plugs
C. Ingold, M. Popov
BHA description with Steerable motors (90’s): (The “one trip culture”)
With steerable motors, clients would not dress off cement plugs and the DD was often tempted
to run the highest possible bend. In practice instead of running a 1.5 bend, a 1.83 bend would be run.
A 1.83 bend on a 6 ¾ motor can be rotated but the wear and tear on radial bearing is higher.
Note: In those cases where the side track did not succeed, the directional driller still had the possibility
to run a sharper bend which would bring back the number of trips to a minimum of three.
The ultimate goal is to drill the well or the phase with a single bit and BHA. In a nutshell,
it is ironic to see modern drilling tools may require better cement plugs quality than before.
Page 4 of 49
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Setting effective sidetrack plugs
C. Ingold, M. Popov
Comments:
- The use of salt water to minimize contamination is simply not applicable with several mud systems.
Note: Cement can affect polymer mud systems and can induce flocculation on some water base muds.
Cement is a mixture of calcium aluminates and silicates made by combining lime and clay while
heating. Slaked cement contains about 62.5% calcium hydroxide which normally raises mud PH.
- Running 3 ½ DP in an 8 ½ hole is acceptable but 5 7/8 DP is not a good idea even in a 12 ¼ hole.
In addition to that, running open ended DP is dangerous on a deviated well with sharp DLS. The DP
could end up being plugged before reaching bottom. Also open ended DP tends to initiate channels as
opposed to a DV tool. The length of the tail pipe should be longer than the plug.
- 5000 PSI compressive strength is not needed everywhere. Nowadays 6000 PSI compressive
strength (a good value 15 years ago) can be obtained without pumping 17.5 ppg cement.
Note: 17.5 ppg used to be the limit except when hematite was used with a jet hopper system.
- 10000 PSI plugs can be designed for difficult cases.
- While strength retrogression is a serious problem on hot holes, cement silica will not eliminate the
need for heavy slurrys. Currently, a cement system with 35 % silica can be engineered based on
CemCRETE principle to develop compressive strength as high as 10000 PSI. CemCRETE systems
will be described in this paper.
Today, 4500 PSI compressive strength can be obtained in 24 hours with a slurry density of 14.5 ppg.
Modern equipment including batch mixing allows very high density with higher compressive strength.
There are better types of spacers and washs. These are especially important in oil base mud, at high
angles and whenever the difference in weight between cement and mud is low. Schlumberger
WELLCLEAN II engineering solution offers a portfolio of specialized products, software and lab
testing procedures to optimize mud removal and minimize contamination of slurry.
Placement techniques have improved. The use of sponges or darts to avoid leaving cement
traces in the pipe (MWD jamming) is quite common.
Setting a high quality plug in oil base mud off bottom at high inclination is still a challenge.
This information is CONFIDENTIAL and must not be copied in whole or any part and should be filed
accordingly by the addressee. It must not be shown to or discussed with anyone outside the
SCHLUMBERGER organization.
Setting effective sidetrack plugs
C. Ingold, M. Popov
Note: Setting a plug above heavy mud is good to minimize slippage but channeling of cement through
the mud is possible. On the other hand, a heavy cement plug in light mud may not channel but may be
prone to slippage.
Page 6 of 49
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accordingly by the addressee. It must not be shown to or discussed with anyone outside the
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Setting effective sidetrack plugs
C. Ingold, M. Popov
6- Operational considerations:
10.Has the plug design been placed before in the same field?
Page 7 of 49
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accordingly by the addressee. It must not be shown to or discussed with anyone outside the
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Setting effective sidetrack plugs
C. Ingold, M. Popov
Example: A 500 ft column of cement in an 8 ½ hole represents about 35 bls. If the mud weight in the
hole is 9 ppg and the cement weights 17 ppg, the difference in hydrostatic alone is over 200 PSI.
While excess cement is circulated out, additional pressure will be applied. Reverse circulation may not
be applicable. But for some extreme cases (5 ½ DP in 8 ½ hole), pressure drop in the string is higher
than pressure drop in the annulus. Generally, the driller and the mud logger monitor pit level and trip
tank while tripping or drilling. They may not know the exact quantity of spacer and cement pumped.
After circulating the well, the trip tank will be filled and the pit level will be reset. By that time, losses
may have ceased. The difference in hydrostatic plus the ECD may cause losses and slippage.
EX: If as little as 8 bls of fluid (22% of 35 bls) are lost to the formation, it represents over 100 ft
translating in an apparent 100 ft of slippage. Knowing the first 200 ft of cement are often
contaminated (especially with oil base mud) it means over half of the plug is lost.
Other tools:
To improve cement placement, the use of tubing will allow less disturbance on the plug while
pulling out. On a deviated well, there is always the risk of plugging the pipe while running in. It is
therefore necessary to avoid open ended tubing or DP. Common tools run are illustrated below.
Page 8 of 49
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accordingly by the addressee. It must not be shown to or discussed with anyone outside the
SCHLUMBERGER organization.
Setting effective sidetrack plugs
C. Ingold, M. Popov
Other considerations:
A spot with a high DLS far from bottom may be preferred by the directional driller. This
option may be left as a contingency plan.
Page 9 of 49
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accordingly by the addressee. It must not be shown to or discussed with anyone outside the
SCHLUMBERGER organization.
Setting effective sidetrack plugs
C. Ingold, M. Popov
In a hard formation, a plug with high compressive strength is needed. If the well is vertical
with no DLS, side track plug needs to be even harder. 19.4 ppg plugs with compressive strength
exceeding 10000 PSI and high resistance to impact have been pumped. The optimized particle size
distribution system (OPSD) allows very high density. The impact resistance is enhanced by adding
metallic micro ribbon particles. The cement will be less prone to break up with chunks falling in and
getting the pipe stuck.
The ability to drill a formation (Drillability) is not the same as compressive strength but they
are related. A plug with 5000 PSI compressive strength (from lab tests) three times softer than the
formation may be drillable at an ROP 4 times higher. Isolation may be fine but it may be too soft.
The directional driller may not know the compressive strength of the formation or that of the
cement. He/she looks at the ROP (drillability) with a given set of parameters.
In reality, providing the cement plug is homogenous and long enough, an aggressive deflection
technique should allow the side track to succeed.
The absolute minimum any directional driller would require to side track on the average job is
a cement plug that can sustain tagging 20000 pounds WOB with pumps on. In case a motor is used,
tagging with weight alone may not give a good indication of plug worthiness except on top holes.
In the past, a plug drilled at 36 FPH (5 min for 3 ft) was considered good in medium hard formations:
- 5 minutes for 3 feet with a classic tricone with light WOB, 60 RPM on a slick BHA
This rule is still good on simple jobs. Side track plugs rarely get evaluated with slick BHAs
and tricone bits. Against a formation that drills at 2 FPH, a “36 FPH” cement plug is still very soft.
Clients tend to expect the directional driller to attempt anyway.
Note: Ideally, the directional driller needs to know whether an aggressive technique is needed
before running in. This is critical on a deep hole where trip time is significant.
On a vertical hole, gravity and hole geometry are of no help. The cement needs to be A1.
Page 10 of 49
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accordingly by the addressee. It must not be shown to or discussed with anyone outside the
SCHLUMBERGER organization.
Setting effective sidetrack plugs
C. Ingold, M. Popov
Obviously, anyone would much rather know immediately whether a second cement plug is
needed rather than go through the entire side track process. On a deep hole, over 48 hours could be
lost from the time the side track is declared a failure to the time the second side track is attempted.
It may be smarter to loose 5 hours or less to set a light plug to offer a solid base. A light
cement plug is set for isolation purposes thus offering a better base for a high density plug.
Example:
Slippage and losses are feared and cement plug is to be set off bottom in oil base mud
A light cement plug (say 14.5 ppg) should be set with the objective of covering 300 ft of hole
below the side track plug. After waiting for the setting time, hole should be circulated at the top of the
cement plug. The plug should not be tagged with the stinger or open ended DP without light
circulation as the tail pipe could get plugged or stuck.
Lighter cement should also be less prone to slippage. This procedure may allow to determine
whether slippage is happenening.
Other considerations:
With the help of the mud loggers, such a procedure would help determining hole diameter and
adjust accordingly the slurry volume of the second plug. There would be two chances to do so, upon
completing the cement plug and when circulating above the calculated top.
Everything is linked. Slippage will cause contamination as surely as insufficient mud removal.
The following will minimize both.
- Use of non reactive “wash” or “spacers”
- Use of a “Parabow” or equivalent. This should impede plug slippage.
Note: There is also the possibility to set a light cement plug, a chemical plug or a barite plug as
described in section 13.
Page 11 of 49
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accordingly by the addressee. It must not be shown to or discussed with anyone outside the
SCHLUMBERGER organization.
Setting effective sidetrack plugs
C. Ingold, M. Popov
Other considerations:
Pumping a long plug can induce losses or a fracture. A risk analysis may be needed.
A longer spacer would allow minimizing hydrostatic pressure increase.
Setting a cement plug in a large hole may actually help the side track process.
Note: The bit would hit the formation with a more favorable angle. The mud logger may be reporting
longer than usual the ritual phrase: “100 % cement” sample on the shakers.
There are cases of clients underreaming a section to place a more effective cement plug.
A mud weight as high as the cement will be harder to remove. The use of a wash may be the
key point in removing the mud and avoiding channels. Ideally the mud weight below the cement plug
should be heavier than the cement to prevent slippage. In that respect, a barite plug as described in
section 13 may be a valid option.
Other considerations:
A cement plug with a density barely higher than the mud would have little effect on the
hydrostatic. (A long cement plug should not be a problem and will also contribute to mud removal)
Page 12 of 49
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accordingly by the addressee. It must not be shown to or discussed with anyone outside the
SCHLUMBERGER organization.
Setting effective sidetrack plugs
C. Ingold, M. Popov
Question # 10: Has the plug design been placed before in the same field?
In the past, once a plug was considered adequate, it was the directional driller’s responsibility
to succeed. Clients had a tendency to be very optimistic when evaluating side track plugs.
Nowadays, the directional driller does not have a chance to test the plug and therefore cannot
decide on the best tool to run.
When setting a cement plug, one can never disregard previous experience especially when
drilling contractor and service companies do the exact same thing.
On a given field, using the same rig and the same mud, a new cement plug design may not
work as planned. Identifying the reasons for past plug failures or side tracking problems is what
counts.
Note: A mediocre plug may be good enough with an aggressive deflection technique. The high
DLS caused may be a serious limitation when side track is shallow. High side forces and key
seats may be a problem.
Page 13 of 49
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accordingly by the addressee. It must not be shown to or discussed with anyone outside the
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Setting effective sidetrack plugs
C. Ingold, M. Popov
7- Cement evolution:
Cement evolution is very well described in SPE/IADC paper 79908. Included is a resume of
this paper. More information and graphs are displayed in the epilog.
Traditional cement slurry systems for sidetracks have been focused on the development of high
compressive strength through reduced water content. Conventional high compressive strength cement
systems exhibit low resistance to impact and low resistance to fracture propagation through the set
cement.
Many studies (mostly placement and tools) have been conducted to improve success rates of
open hole kickoff plugs. For a long time, less effort was directed toward optimizing the cement
systems utilized.
In areas with extremely hard formations, problems still exist with proper placement and
conventional slurry designs.
Recent developments in oil well cement system have incorporated a unique micro-ribbon
technology with an optimized particle size distribution to increase the durability, load bearing capacity
and resistance to fracture propagation of set cement.
Page 14 of 49
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Setting effective sidetrack plugs
C. Ingold, M. Popov
In a nutshell:
The combination of optimized particle size distribution slurries with metallic micro-ribbon
technology has resulted in high compressive strengths and enhanced mechanical properties. Success
ratio in very hard formation has been increased as well as a significant reduction in the time (and the
cost) required to achieve side tracks for a major oil and gas operator in Abhu Dhabi.
Page 15 of 49
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accordingly by the addressee. It must not be shown to or discussed with anyone outside the
SCHLUMBERGER organization.
Setting effective sidetrack plugs
C. Ingold, M. Popov
A cement plug can be placed with DP (for example 3 ½ DP in 12 ¼ hole) but it is best to use a
string of tubing to guarantee minimum plug disturbance while pulling out.
Generally speaking, cement plugs are set in plug flow for several reasons:
- Inability to obtain turbulent flow between tubing and an open hole several times larger.
- Accuracy required during displacement requires extra care especially on small volumes.
- If turbulent flow was possible, it would create high ECD especially with a tapered drill string.
Note: If 5 ½ and 3 ½ DP were used in an 8 ½ hole (not recommended) the pumping rate may cause fracturing.
At high inclination there are several more problems to deal with. Pipe centralization will not
be optimal and it is best to have the smallest possible size. In the case of drilling mud, the effect of
yield value is negligible at inclinations above 55 degrees. The effect of turbulent flow and pipe
rotation predominates for hole cleaning.
If a cement plug has a density comparable to the mud, the importance of wash and spacers
ahead becomes crucial. Cementing software has to be utilized to design good mud removal by
selecting adequate rheologies of spacer and cement slurry. Schlumberger offers CemCADE,
WELLCLEAN II simulator, WELLCLEAN II Advisor and PlugAdvisor. All those softwares are
complementing each other.
Cement plugs are usually set in wells that have been thoroughly circulated. Setting a plug at
90 degrees of inclination is almost impossible.
The three main problems at high inclination are:
- Channels
- Free water
- Plug disturbing debris and wall cake while pulling out.
Free-water breakout from cement slurry to the high side has been suggested as a cause of
cement failure at high angle. Free water should not be a problem on ST plugs except for isolation
purposes. Reduced water cement slurries (16.5 ppg plus) should be less affected as well. New cement
slurries based on CemCRETE principle provide excellent slurry stability and no free water.
A cement plug should be set in a clean hole. Settling of solids from drilling mud to the low
side of the hole creates a continuous channel of uncemented material difficult to remove. Pipe
rotation is highly recommendable during plug placement. Pipe rotation will not allow cleaning
suddenly the hole as the cement is pumped but will allow a more uniform placement of the plug.
Note: High pipe rotation is used to assist in hole cleaning when drilling high angle holes but the
annular flow is higher than with a string of tubing (the idea is to prevent debris from settling).
Page 16 of 49
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accordingly by the addressee. It must not be shown to or discussed with anyone outside the
SCHLUMBERGER organization.
Setting effective sidetrack plugs
C. Ingold, M. Popov
Page 17 of 49
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accordingly by the addressee. It must not be shown to or discussed with anyone outside the
SCHLUMBERGER organization.
Setting effective sidetrack plugs
C. Ingold, M. Popov
Note: When OH size is known, the right size tool is run with aluminum pipe, it will work well.
Main advantages:
• Cement slurry is separated with top and bottom dart limiting contamination
• Aluminum rigid centralizers for tailpipe are available to optimize mud removal
• Tool is providing a competent base for cement slurry
• No risk to contaminate cement when POOH as tailpipe always stays in cement.
• TRT (tubing release tool) can be used without packer for long abandonment plugs leaving
tailpipe in cement
Page 18 of 49
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accordingly by the addressee. It must not be shown to or discussed with anyone outside the
SCHLUMBERGER organization.
Setting effective sidetrack plugs
C. Ingold, M. Popov
Note: Once the TamPlug is set, the cement plug can be placed above with no risks of slippage.
Page 19 of 49
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accordingly by the addressee. It must not be shown to or discussed with anyone outside the
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Setting effective sidetrack plugs
C. Ingold, M. Popov
Problem diagnosis:
The following list may help to diagnose the most common field problems
Page 20 of 49
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accordingly by the addressee. It must not be shown to or discussed with anyone outside the
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Setting effective sidetrack plugs
C. Ingold, M. Popov
Plug catcher:
Plug catchers may not be needed on shallow side tracks but are recommended on challenging
jobs. Before plug catchers were used, the general rule was to underdisplace in order to avoid making
a mess on drill floor while pulling out (back flow).
Note: Pulling wet is one thing, experiencing back flow is another.
While it is still important to calculate ECD and hydrostatic column, plug catchers tend to
eliminate displacement problems. Uncertainties in DP capacity, hole diameter or losses while
pumping cement are less of a concern.
The plug catcher is placed on top of the stinger or DV tool and the displacement is achieved in
three steps. There should be little or no uncertainty in pipe displacement. The cement is slightly
under displaced inside the string. The string is lifted close to the top of the cement plug in the
annulus. The rest of the cement is displaced until the dart reaches its seat. The string is then pulled
clearly above the cement plug. More pressure is applied which allows circulating any excess cement.
Plug catcher are great to prevent leaving chunks of cement inside the pipe and allow pumping
the entire cement plug in the hole. With conventional techniques, several barrels of cement are often
circulated to surface.
As far as cleaning DP, there is also the possibility to use large sponge balls to help wipe out the DP.
Note: Schlumberger pumping services has plug catchers normally used with CT or slim holes.
The coilTools plug catcher is used with coilTools cement plug. The plug catcher is available
in two versions with tubing connections (CS Hydrill):
- The sideported plug catcher (OD ranging from 1.688 to 2.563)
- The pump-through plug catcher (OD ranging from 2.125 to 3.50)
The sideported plug catcher directs all flow out the sideports of the catcher body.
The pump-through plug catcher allows the fluid to be directed through the tool, making it
compatible with other downhole tools run below it. Plug catchers are usable with parabow and even
open hole whipstocks. (Description in InTouch # 4729459)
Page 21 of 49
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Setting effective sidetrack plugs
C. Ingold, M. Popov
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Setting effective sidetrack plugs
C. Ingold, M. Popov
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accordingly by the addressee. It must not be shown to or discussed with anyone outside the
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Setting effective sidetrack plugs
C. Ingold, M. Popov
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Setting effective sidetrack plugs
C. Ingold, M. Popov
Page 25 of 49
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accordingly by the addressee. It must not be shown to or discussed with anyone outside the
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Setting effective sidetrack plugs
C. Ingold, M. Popov
Recommendations reviewed:
Despite the various tools available to improve kick off plug success rate, balancing plug
method is by far most common method. Recommendations for balancing pugs are a summary of best
practices developed over the years. However, latest studies have showed that following those best
practices may not guarantee success.
Two phenomena’s have been overlooked:
1. Volume of under-displacement and contamination during POOH
2. Contamination during placement inside work string and in annulus
Volume of under-displacement
Common practice is to under-displace by 1-2 BBL and allow fluids to balance themselves
when treating line is disconnected from the work string. This will work for a one size work string
from top to bottom. This rule can not be applied in case of drill pipe and smaller size tail pipe.
Treating line is disconnected and rig is ready to POOH. Cement is perfectly balanced – level A
inside work string and level B in the annulus are at the same depth (left picture). During POOH (right
picture) it is impossible to mountain balanced situation because of different capacity of DP and tail
pipe, i.e. volume of spacer behind does not change (colored green) but now it is inside smaller tubing.
The height is different and hydrostatic pressure at the level A is different. This case will lead to large
cement contamination when spacer behind goes into annular space occupied by cement slurry.
Long tail pipe is not solving described problem. In case long enough tail pipe is covering
cement slurry and spacer, drilling fluid will have same effect (picture below).
Note: Underdisplacing by a larger amount at the cost of leaving cement longer in the tail pipe will
allow minimizing the problem.
Page 26 of 49
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Setting effective sidetrack plugs
C. Ingold, M. Popov
Solution:
When pulling the pipe out of the hole in a vertical configuration, the total volume of fluids
inside the drill pipe is reduced by the amount at the top of the string (big diameter)
That same volume is transferred to the bottom of the string (small diameter) meaning that the
same amount of fluids needs to come out at the bottom of the pipe. Because of the smaller diameter,
the fluids levels are lowered much faster than the speed of the pull out of the pipe in the small
diameter portion of the pipe!
Conclusion: If a tapered string is used, the level of the interfaces inside the DP must be higher
than the ones outside the DP before pulling out for them to match at the end of the pull out.
Under-displacement is required for the interfaces to match when the pipe is out of the plug.
Page 27 of 49
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Setting effective sidetrack plugs
C. Ingold, M. Popov
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accordingly by the addressee. It must not be shown to or discussed with anyone outside the
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Setting effective sidetrack plugs
C. Ingold, M. Popov
Software provides assistance in optimizing rheological properties of cement slurry and spacer
to minimize mixing effect and improve mud removal. Simulations of deep deviated wells can show
the need of mechanical separation of cement slurry as separating fluids failed proving stable
interfaces.
Note: Based on simulation results, user can decide when it is mandatory to use mechanical
separation of the slurry to ensure successful cement plug placement.
Page 29 of 49
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Setting effective sidetrack plugs
C. Ingold, M. Popov
Sidetracking is normally performed with motors or with rotary steerables. Motors normally
allow greater flexibility and higher DLS. In case of challenging side tracks, they may be the best
option. Complex well profiles are harder and slower to drill with motors than with rotary steerables.
Note: Clients want BHAs that can drill a well in a single run. A side track achieved with a
motor may be considered unsatisfactory if a trip is needed to run a rotary steerable.
On the other hand rotary steerables usually have lower DLS capability and a longer “take off”
distance. This is the reason to spare no effort in designing the best possible plugs especially when
conditions are tough.
While “controlled drilling” (or time drilling) works quite well with motors, the same cannot be
said about “push the bit” type rotary steerables. Using “time drilling” cannot be totally discarded yet
some clients operating on deep offshore project would rather not hear the word.
When performing a side track on a fairly straight hole against a soft formation, there are no
reasons to spent excessive time performing “controlled drilling”.
Example: Side track plug is set from 3500’ to 2900’ MD in a formation that drills at 150 FPH. Side
track point is supposed to be at 3100’ MD. Cement is tagged at 2850’ and drills at 300 FPH by 3000’
MD. There is no reason to time drill regardless of the technique used. The best is probably to initiate
the side track 20 to 50 ft before (3050’) and to go for it. If by 3150’ MD, there is no evidence of a
side track then controlled drilling may be initiated.
When performing a side track against a very hard formation, time drilling with a rotary steerable
may not be done at first by the DD. In case of a long plug, he/she may decide to leave time drilling as
a last resort. There will be more parameters to take into account such as the hole inclination and the
well profile. Usually the DD will leave a way out taking advantage of sudden change in well direction
and go directly opposite.
Note: The client and the directional driller prefer to have the hardest possible side track plug in
order to speed up the process.
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Setting effective sidetrack plugs
C. Ingold, M. Popov
Comments: With a tricone bit, a side track can even be initiated a couple of feet inside the casing
for some special cases.
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Setting effective sidetrack plugs
C. Ingold, M. Popov
- An 8 ½ pilot hole required to be plugged back from 9969’ MD and side tracked. Two 650 ft
conventional plugs were placed to cover the bottom intervals. A 45 bls high impact resistant plugs
mixed at 19 ppg was placed above the top plug covering an interval from 8675’ to 8250’ MD. The
optimized particle size distribution (OPSD) cement developped 8500 PSI compressive strength and
contained metallic micro ribbon particles . After 19 hours, the plug was tagged at 8250’ MD with an 8
½ rock bit and a 2.1 deg bent housing motor. The cement plug was dressed to 8292’ and the side track
was initiated at a controlled ROP of 6 FPH. At 8315’ MD, the shaker indicated 100 % formation (4
hours had elapsed). Drilling was resumed as planned.
Note: There may have been some slippage and an overgauge hole as plug length was 425 ft.
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This is a field where on three occasions, the plugs were contaminated. These side tracks were
performed in 12 ¼ holes with 12.5 ppg oil base mud (Versaclean) around 33° inclination in
formations with ROPS of 120 FPH. Cement plugs were set with 580 ft of 3 ½ DP and 5 7/8 DP.
Rotary steerable PD X5 and PDC bits only were used. Time drilling was performed on 100 %
settings. In one case a mud motor with higher DLS capability would have allowed achieving the side
track but would have required a trip to run back the PowerDrive.
Note: The PowerDrive allows drilling quicker especially when the profile to follow is complex
- Plug# 1 was placed above a bridge plug set 5200’ MD. Plug was set from 4520’ MD to 5100’ MD
and a sponge was used to wipe the pipe. After 22 hours, dressing of the plug was initiated but was
found to be excessively soft until 4600’. At 4785’ MD decision was made to wait for 8 hours. After
30 hours in total, dressing off was resumed with a marginal reduction in ROP. Decision was made to
attempt side tracking. Eventually at 4950’ a setting 180 degrees opposite to the hole direction (2deg
DLS) allowed to get off by 5000’ ft (torque and weight indicated the side track had succeeded).
- Plug# 2 was a failure. It was placed above two cement plugs from 10100’ MD. Top plug was set at
4600’ to 5200’ MD. Hole was washed from 4300’ to 4850’ where traces were felt. It was possible to
wash through without rotation. Side track was attempted with a 100 % setting on the rotary steerable.
After 6 hours, the depth reached was 4952’ MD (102’ time drilled at 17 FPH). By that time, the
cement had been in place 44 hours. Time drilling continued for an additional 9 hours until 5168’ MD
at ROPs as low as 10 FPH. Cement could sustain at times 50000 lbs weight and would sometimes
just free fall. It seems the plug had set as several “pods” and had migrated down at least 60 ft.
- Plug# 3 was placed from 5252’ MD where the stinger tagged on what was left of the previous plug.
A 700 ft plug was placed. 18 hours after placing the plug, at the theoretical top, nothing was felt.
Decision was made to wait an additional 3 hours. Washing down was resumed and top of plug was
found at 4800’ MD (250’ lower). At 4822’ the plug could hold 20000 lbs and time drilling was
initiated at 19 FPH. By 4830’ MD signs were positive and by 4860’ side track had succeeded.
Note: placing a side track plug on top of an existing plug works better. The risk of slippage is
eliminated even though losses and hole enlargement can still play a role in cement contamination.
Comments: Testing cement returns at the top of the plug with light circulation after five hours
would have helped detecting slippage. Less time would have been lost as opposed to attempt
side tracking 24 hours later.
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Setting effective sidetrack plugs
C. Ingold, M. Popov
- Cement was placed at 2000 ft MD in a zone where the typical ROP is 120 FPH in a 12 ¼ vertical
well. Decision was made to attempt side tracking even though after 18 hours, the cement was soft (5
ft in 2 minutes or 150 FPH). The cement used was a 14.5 ppg slurry engineered to reach 3800 PSI
after 18 hours and 4500 PSI after 24. The BHA used was a classic Powerpak stabilized and set on 1.5
bend with a tricone bit. Considering the shallow depth and the cement height, the risk was limited. It
took 1.5 hour and 21 ft to have positive indications and to resume drilling normally.
- In 2004, on an 8 ½ vertical hole, the string got stuck at 9756’ MD yet circulation and rotation were
possible. Decision was made to set a side track cement plug and to cut the pipe at 9640’ MD with a
chemical cutter. 25 bls cement were spotted representing an estimated 250 ft (with 30 % wash out).
DuraSTONE cement was selected for its excellent mechanical properties and 18 ppg was achieved
with D166 coarse material and D163 fine. Lab tests showed over 6000 PSI compressive strength after
24 hours without the fibers. Metallic fibers (D187) were added and good rheology was obtained to
prevent the fibers from settling. The cement was thoroughly blended with proper QA/QC.
The cement was spotted from 9580’ MD with tail pipes made of 2 7/8 tubing
The cement was batch mixed and the job was performed as per the following procedure:
- 10 bls chemical wash followed by 2 bls of 18 ppg cement without fibers at 5 BPM
- 21 bls of Durastone 18 ppg with fibers (D187) at 5 BPM
- 2 bls of 18 ppg cement without fibers and 0.4 bl of water at 5 BPM
- Displacement with 144.83 bls of 10.7 ppg KCL mud
No pressure imbalance observed and string was pulled clear and two volumes were reverse circulated.
Comments: The job was a success but there is no mention of the setting used on the motor.
With a formation so hard and the mud weight so low, slippage could have occurred. Setting a
light cement plug could have been done. The plug volume could probably have been increase.
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- This is the story of a cement plug that failed. The failure report is poorly documented and hard to
interpret. It also draws questionable conclusions.
An 8 ½ hole was abandoned at 10500’ MD. 9 5/8 shoe was set at 8770’ MD and mud weight
was 10.6 ppg. A 15.8 ppg plug was placed and tested by tagging weight with a bit at 10168’ MD.
Below 9550’ MD, a 35 bls viscous pill was spotted to minimize slippage.
The side track plug (150% excess) was pumped as per the following sequence:
- 30 bls of 12 ppg spacer followed by 20 bls of water at 6 BPM
- 61 bls of 16.5 ppg cement at 6 BPM
- 2 bls of water followed by 155 bls of 10.2 ppg mud
Cement plug seemed balanced and the circulation at 9200’ showed water, spacer and 10 bls of
contaminated cement. About 40 hours were spent time drilling from 9313’ to 9472’ MD.
Comments: Although the formation was softer below the shoe, decision to side track at 9300’
where the well had 5 degrees of inclination seems logical if Motor was pointed opposite the dog
leg. The report states a motor set on 1.83 bend could have achieved the side track. Even if this
is true, running a 1.83 bend usually means a trip in the long run. The cement was inconsistent
and a successful side track would have taken longer.
It also seems strange to pump water after the spacer as balancing the plug would be impossible–
hydrostatic pressure is higher in the annulus due to presence of heavier spacer.
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Setting effective sidetrack plugs
C. Ingold, M. Popov
Writing reports:
Writing reports both on failures and success is often insufficient and one sided. It may be
difficult for a Schlumberger DD to obtain the cement data from the competition just like a cementer
from Schlumberger may have trouble asking the DD from another company the procedures used.
The objective is to find the best solutions. On many reports, items such as mud properties and
mud type are not well documented. Type of drill pipe and tail pipe is not mentioned much less the use
of stingers, sponges and other accessories. Cement compressive strength and types of additives used
are not well documented. Even if the products codes are unknown, the recipe can be established as
long as they are recorded.
As far as directional drilling, the time interval between setting the plug, dressing the plug and
attempting to side track needs to be described. The previous well profiles with surveys along with the
new plan needs to be known.
Finally, until the next casing is in the ground, there could be issues associated with a plug
breaking off and sticking the pipe. This may be hard to document but is nevertheless important.
In addition to the questions in chapter 6, these items are essential to confirm whether the
design is good or not.
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Setting effective sidetrack plugs
C. Ingold, M. Popov
Chemical means:
Some North Sea operators spot a pill below the cement plug. The pill consists of Bentonite
mixed with Sodium Silicate (D075). Barite may be added to obtain the required weight. Compatibility
with cement and mud should carefully be evaluated. One could add the emerging technology of
“swellable packers” that can react in oil or in water. Unfortunately a swellable packer would have to
be somehow attached or spaced out with tubing or DP until it has a chance to swell.
Note: A plug catcher could be included and used to set the cement plug after the bentonite pill.
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Setting effective sidetrack plugs
C. Ingold, M. Popov
Note: Once the barite has settled, the lighter fluid should be circulated out.
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Setting effective sidetrack plugs
C. Ingold, M. Popov
Table for a 100 ft 21 ppg barite plug. 150 ft of settled volume is the value recommended.
Hole Settled Settled Barite Phosphate Fresh Slurry
Size Volume Volume sx or SAPP Water Volume
In. Ft3 bbl/100' lbs bbl bbl bbl
13.5 100 17.7 265 14.2 20.2 38.1
12 78.35 14 208 11.1 15.9 30
11 66 11.8 175 9.4 13.3 25.2
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Setting effective sidetrack plugs
C. Ingold, M. Popov
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Setting effective sidetrack plugs
C. Ingold, M. Popov
Mud properties:
If possible, yield point and PV of the mud should be reduced before pumping the plug.
Pumping a nut-plug pill down the string can help remove traces of cement resting on the low side of
the drill pipe.
Note: It may be possible to set an isolation plug in view of improving plug placement later.
DP specific problems:
Many reputable companies use books with small errors on pipe displacement. Generally
speaking, many handbooks tent to state the dimensions of grade “G” DP.
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Setting effective sidetrack plugs
C. Ingold, M. Popov
String rotation:
Rotating the string as the cement goes in open hole should allow a more uniform placement.
Rotation while circulating or reversing out should prevent leaving small chunks of cement in the drill
string close to the internal upset of each joint. In both cases, 30 to 60 RPM is enough.
Rotation while circulating out cement is not needed with a sponge or a plug catcher.
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Setting effective sidetrack plugs
C. Ingold, M. Popov
Economics:
The best is to do it right the first time. Clients need to realize spending a little on a barite pill, a
plug catcher or setting a light cement plugs may be an investment.
Example: The well is 12000 ft deep and decision is made to initiate a side track at 10000 ft MD to
drill a deviated well. The fluid in the hole is oil base mud and the weight is 12 ppg. ROP at 10000 ft
is 100 FPH and when cement is good, side tracks can be achieved in 3 hours. Client does not want to
hear about barite plug, light cement plugs and much less about plug catchers and “Parabows”.
The rig alone costs 100 K$ per day.
Without going into “operation associated costs”, loss of production, interest rates and whatever
else, the cost of failure will be very high and would easily justify 6 hours extra time or any tool.
On the optimistic chart below the time lost starts whenever decision is almost made to pull out.
During the decision time, the company man will usually let the directional driller try one more time.
On could argue it would still be possible to pull out and run a radical BHA. A minimum of 4 trips
would take in the example described 22 hours plus the time spent time drilling.
6.00 1.00 5.00 1.00 5.00 2.00 11.00 7.00 3.00 41.00
Note: The chart above is for a rig costing with all associated cost 100 k per day.
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Setting effective sidetrack plugs
C. Ingold, M. Popov
The main driving forces behind using cement in lieu of a whipstock were “Through tubing
rotary drilling” (TTRD) in general and “Coiled tubing drilling” (CTD) in particular. The need to run a
BHA through a production string and to punch a hole inside a larger casing appeared as the main
challenge. Collapsible whisptsocks were developed and new cement systems were used.
When PDC bits and diamond bits were introduced, people knew the kind of damage a bent
motor would cause with a bit turning for too long inside casing. Some clients had very strict rules
about shallow tests with PDC or diamond bits when using a “bent sub motor” or a steerable motor.
Other clients would not even drill out a casing shoe with motor and PDC. Most people have seen large
metal sheets coming out on a shale shaker while drilling out cement inside casing with motors. Many
of these rules have been relaxed or adapted to local conditions. A mild bend or a limited amount of
cement to drill is not always a problem.
The introduction of high compressive strength cement with fibers has allowed performing what
seemed unrealistic with conventional cement plugs.
The microribbon technology promotes a smooth “gun barrel” hole maintaining hole integrity
and reducing the risk of “cement rocks” falling off the sheath and snagging the drilling assembly.
Note: In the following cases, this is certainly a technique that deserves special attention:
- Collapsible whipstock cannot be deployed.
- Window to be performed in a light casing of softer steel
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Setting effective sidetrack plugs
C. Ingold, M. Popov
Note: On an HPHT job where the batch mixing equipment was not available, two denscrete plugs were
mixed at 17.5 ppg on the fly with competitor equipment (InTouch 4276937).
Note: Slurry volume for cement plugs is not big so it is recommended to use batch mixer
to ensure homogeneous slurry density and accurate volume. DensCRETE technology always
requires batch mixer
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Setting effective sidetrack plugs
C. Ingold, M. Popov
17- Conclusion:
A cement plug set at 2000 ft in a water base mud does not need to be over engineered. When a
difficult side track is decided, any measure likely to help should be studied. Slippage, losses,
contamination and compatibility between the mud, the cement, spacers and wash should be evaluated.
The mud weight and viscosity may be reduced. Preparing clean tanks for spacers or wash are simple
measures to remove from the “critical path”.
Charts showing compressive strengths based on ROP and hole size would be nice to have.
The number of bit types and the fact they are selected for their performance in drilling formation
would make it difficult. The adherence to a set of parameters would also be a problem.
An average cement plug well spotted should allow sidetracking even if it means drilling a
smaller hole or using an aggressive technique. On the other hand, a high compressive strength plug
contaminated for whatever reason may not allow side tracking at all.
On a deviated hole, the plan may not call for a side track opposite of the dog leg or towards the
low side but it is an option. On the other hand, on a vertical hole with no dog leg and in hard rock,
there is no substitute for a good cement plug
It is possible to set a plug, wait until cement reaches 500psi compressive strength and go back
to the theoretical top with light circulation to evaluate slippage. This will determine whether setting a
second plug is needed.
Cement technology has improved tremendously yet client expectations have gone up. Rotary
steerables require better sidetrack plugs and do not respond as well as motors to time drilling.
Far from being a problem, this should be viewed as an opportunity to utilize superior products,
better procedures and the best tools.
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Setting effective sidetrack plugs
C. Ingold, M. Popov
CemCRETE uses particle size distribution to optimize solid and liquid content
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Setting effective sidetrack plugs
C. Ingold, M. Popov
CemCRETE is created by increasing the Packing Volume Fraction in the powder (PVF)
This information is CONFIDENTIAL and must not be copied in whole or any part and should be filed
accordingly by the addressee. It must not be shown to or discussed with anyone outside the
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Setting effective sidetrack plugs
C. Ingold, M. Popov
+ =
Hart’s 2001
Meritorious Award
for
Engineering Innovation
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Setting effective sidetrack plugs
C. Ingold, M. Popov
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Setting effective sidetrack plugs
C. Ingold, M. Popov
Warnings:
• Rheology
- A minimum yield stress value of 10 lbf/100ft2 (Herschel-Bulkley) is mandatory
Or
- The 3 rpm (10 sec. Gel) reading with spring F1 is at least 15
• Restrictions
- Never sample D187-laden slurry through small ball valves of recirculating mixer or blender
- Never pump through a restriction smaller in diameter than 18 mm or 0.7 in.
• Spacers
- Always pump a viscosified spacer ahead and behind a D187 -laden slurry if a freshwater
spacer is used
• Tools and Placement
- It is advised not to pump this system through a diverter
- Once inside displacement string avoid halting pumping
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