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The importance of real-time cementing monitoring was discounted by the oil & gas industry for years, until the Deepwater Horizon accident in 2010. The subsequent updates to US federal regulation 30 CFR Part 250 (released in 2016) caused a re-evaluation of the importance of real-time cementing services because of the role real-time well monitoring plays in the safety of critical well operations including cementing. Currently, cement job monitoring is limited to the acquisition of pressure, rate, and density measurements. Based on those measurements, a basic evaluation is performed during the job. A new software tool has been developed to improve the ability to make real-time interpretation to diagnose critical job parameters while the cement job is in progress. Acquisition of real-time data for cementing has evolved by using simulation models, which have helped to predict unstable wellbore conditions. These simulations enable both the well operator and service provider to take immediate decisions to eliminate or at least reduce an inadequate zonal isolation, which will affect the future of the well in the completion and productivity phases. The objective of this paper is to explain and demonstrate how the integration of cementing real-time data acquisition and cement design can be used as a successful technology to monitor and control critical job parameters like pressure behavior, flow rates, and equivalent circulating density (ECD) at different depths. The combined data can be broadcast to anywhere the operator is located to remotely follow the job execution and to perform hydraulic simulations and pressure match interpretation. At the same time, this process helps to ensure flawless service delivery and quality assurance during the cement job, providing critical information while delivering greater certainty and reduced risk of costly errors. A new real-time software tool was designed using an innovative platform that brings together cross-domain workflows based on a data management layer extended across different disciplines: petrophysics, geology, drilling, reservoir and production engineering, and geophysics. The platform offers a tightly integrated environment and it is the foundation for integrating future development of well-centric applications. |
