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How can you effectively manage casing and cementing costs?

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Casing and cementing are essential operations for the integrity, safety, and performance of oil and gas wells. However, they also represent significant costs that can vary depending on the well design, location, and market conditions. Therefore, it is important to plan and execute these operations efficiently and effectively, while minimizing risks and maximizing value. In this article, we will discuss some strategies and best practices to help you manage casing and cementing costs in drilling engineering.

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Plan with precision:

Advance planning helps in keeping costs down and getting a better well. By ordering materials like rolled steel products months ahead, you avoid last-minute expenses and ensure you have the right grades on hand.### *Embrace new technologies:Leveraging innovations such as expandable casing and self-healing cement can significantly reduce material and labor costs. These advancements improve operational performance, ensuring long-term reliability and durability.

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1 Understand the objectives and requirements

The first step to manage casing and cementing costs is to clearly define the objectives and requirements of the well. These include the wellbore geometry, the reservoir characteristics, the production targets, the environmental and regulatory constraints, and the operational challenges. By understanding these factors, you can select the optimal casing and cementing program that meets the technical, economic, and safety criteria for the well.

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George Vassilellis

Upstream Energy Advisor
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Advance planning helps in keeping costs down and getting a better well. Not all wells are the same and in each design the right grade and weight is needed, but it most cases it may not be available at the time of completion. On demand manufacturing of rolled steel products and tubulars requires at least 4 months advance ordering, but it can make a big difference. On the other hand, drilling pad campaigns of more than 3 wells at a time make it possible to optimize procurement and transport without sacrificing well design. Casing placement is the most sensitive operation and even a minor glitch may cause cementing and completion operation to escalate in cost and complexity. Good drilling is paramount.

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Jesse Nyokabi

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Perhaps the most critical component of the drilling process to the integrity and longevity of a Geothermal well is the cementation of the casings. The design of the cementing programme shall utilize materials and procedures which are most likely to ensure that the total length of both the cased annulus and the open hole annulus is completely filled with sound cement which will withstand long-term exposure to geothermal fluids and temperature.

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2 Optimize the casing and cementing design

The second step is to optimize the casing and cementing design using engineering tools and methods. These include software applications, analytical models, laboratory tests, field data, and industry standards. By using these tools and methods, you can optimize the casing size, weight, grade, connection, and centralization, as well as the cement type, volume, density, additives, and placement. You can also evaluate the mechanical and hydraulic performance, the cement bond quality, the isolation effectiveness, and the potential failure modes of the casing and cementing system.

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Soliman Elkhouli

Training Consultant (Drilling, Completion & workover Operations)
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It is well life dependable. In case of short life well consider light casing design and partial cementing while vice versa in case of long life and sour fluid producing wells but do not compromise the well integrity to reduce the cost under any circumstances

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Vusal Hagverdiyev

Senior Drilling Engineer at BP
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Normally, mud density is reduced with a casing on bottom prior to cement job in order to reduce ECD during the job itself. Nowadays, we started to manage this ECD reduction via pumping low density mud pills ahead of the slurry without mud density reduction, which helps to gain huge rig time / cost. Care must be taken while pumping low density pills in terms of flow during and/or post cementing job.

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Lee Krystinik

Principal at Equus Energy Partners, LLC
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Geological factors are an important component. We recently encountered a very soft and permeable formation that would not have tolerated the weight of a full string of heavy cement. For a number of reasons, a DV tool wasn't an option and we successfully pumped a lighter mix for the upper hole.

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Jesse Nyokabi

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Optimizing the casing and cementing design using engineering tools and methods is a critical stage too during drilling operations. These include software applications, analytical models, laboratory tests, field data, and industry standards. By using these tools and methods, you can optimize the casing size, weight, grade, connection, and centralization, as well as the cement type, volume, density, additives, and placement.

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3 Implement quality assurance and control

The third step is to implement quality assurance and control measures throughout the casing and cementing operations. These include pre-job planning, equipment inspection, material verification, personnel training, operational procedures, contingency plans, and post-job evaluation. By implementing these measures, you can ensure that the casing and cementing operations are executed according to the design specifications, that the equipment and materials are fit for purpose, that the personnel are competent and qualified, and that any deviations or problems are identified and resolved.

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Jesse Nyokabi

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Implementations of quality assurance and control measures throughout the casing and cementing operations. These include pre-job planning, equipment inspection, material verification, personnel training, operational procedures, contingency plans, and post-job evaluation.

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4 Leverage new technologies and innovations

The fourth step is to leverage new technologies and innovations that can enhance the efficiency and effectiveness of the casing and cementing operations. These include advanced materials, such as high-strength steel, corrosion-resistant alloys, or lightweight composites; novel techniques, such as expandable casing, multistage cementing, or self-healing cement; and smart devices, such as wireless sensors, real-time monitoring, or intelligent completion. By leveraging these technologies and innovations, you can reduce the material and labor costs, improve the operational performance, and increase the reliability and durability of the casing and cementing system.

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Vusal Hagverdiyev

Senior Drilling Engineer at BP
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2-stage cementing with a port collar was a consideration for one of our recent wells with fullbore casing job. It helps to mitigate potential issues during the 1st stage (losses) in terms of preventing potential SCP behind the casing. Pros and cons of this option needs to be analysed against liner + tieback design well-by-well basis

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5 Collaborate with stakeholders and partners

The fifth step is to collaborate with stakeholders and partners that are involved in or affected by the casing and cementing operations. These include the well owner, the operator, the service provider, the regulator, the community, and the environment. By collaborating with these stakeholders and partners, you can align the expectations and interests, share the information and resources, coordinate the activities and schedules, and resolve the issues and conflicts. You can also benefit from the expertise, experience, and feedback of each stakeholder and partner.

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6 Monitor and evaluate the results and performance

The sixth and final step is to monitor and evaluate the results and performance of the casing and cementing operations. This includes collecting and analyzing the data and information, such as the operational parameters, the cement logs, the pressure tests, the production tests, and the well integrity indicators. By monitoring and evaluating these results and performance, you can verify the quality and compliance of the casing and cementing operations, identify the strengths and weaknesses, and implement the improvements and corrections. You can also measure the value and return of the casing and cementing operations, and compare them with the costs and risks.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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How can you effectively manage casing and cementing costs?

1

2

3

4

5

6

7

1 Understand the objectives and requirements

2 Optimize the casing and cementing design

3 Implement quality assurance and control

4 Leverage new technologies and innovations

5 Collaborate with stakeholders and partners

6 Monitor and evaluate the results and performance

7 Here’s what else to consider

Drilling Engineering

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How can you effectively manage casing and cementing costs?

1

2

3

4

5

6

7

1 Understand the objectives and requirements

2 Optimize the casing and cementing design

3 Implement quality assurance and control

4 Leverage new technologies and innovations

5 Collaborate with stakeholders and partners

6 Monitor and evaluate the results and performance

7 Here’s what else to consider

Drilling Engineering

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