SPE 160853

Precise Approach to Isolate Fractured Water Bearing Lower Zone in

Complex Saudi Arabian Gas Well by Placing Ceramic Proppant and Cement
in Restricted Depth Utilizing HPCT to Withstand High Bottom-hole Pressure
during Fracturing Treatment in the Upper Zone: A Case History
Ataur R. Malik, Jorge E. Duarte, Hamad F. Kulaib, Mohammed A. Atwi, SPE, Saudi Aramco; Eduardo Vejarano R.,
Riefky Abdurrahman, SPE, Schlumberger
Copyright 2012, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE Saudi Arabia Section Technical Symposium and Exhibition held in Al-Khobar, Saudi Arabia, 8–11 April 2012.

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Abstract
Success of Multi-Stage Fracture treatment in deviated cased hole completion largely depends on isolation mechanism of the
previously created fractures in the lower zones under the presence of complex reservoir characteristics and wellbore
conditions. The lower zones need to be temporarily or permanently isolated utilizing cast iron, composite or sand plugs capped
with cement that must maintain integrity and be able to tolerate high differential pressure across the plug during hydraulically
fracturing the upper zones.
The subject paper is a review of the design philosophy, planning, laboratory testing, execution and results of successful
isolation of lower complex zone with high stress, high pressure and high temperature (BHST = 315 deg F) where proppant
fracturing treatment prematurely screened out exceeding maximum bottomhole treating pressure limit of the completion of a
gas well in Saudi Arabia. The high differential pressure (greater than 10000 psi) requirement of the isolation plug eliminated
the mechanical bridge plug options as a result of uncertainty of the liner condition from unprecedented high screenout pressure
and dubious cement quality behind the pipe. The only viable option that remained was a customized plug made up of ceramic
proppant capped with 100 mesh sand and high temperature cement. The objective of ceramic proppant from plug back depth to
top of perforated interval of the lower zone and capped with 100 mesh sand was to work as base for cement and controlling
leak-off of cement into the lower fractured zone. The short distance between the perforated intervals of lower and upper zones,
maintaining balanced condition during placement of proppant and cement plugs and controlling leak-off of cement across the
fractured lower zone required high level of scrutiny in the selection of proppant type, designing cement properties in the
laboratory, quality control and ultimately placement of the slurries utilizing high pressure coiled tubing (HPCT). The real time
monitoring of temperature and pressure data from permanent downhole gauges enabled to maintain balanced to slightly
overbalanced condition that significantly contributed the set a plug in target depth with desired strength. The plug was
successfully pressure tested to a bottomhole pressure of 15000 psi. The plug maintained it’s integrity during the DataFrac
performed in the upper zone after perforation. The successful application of this isolation method enabled two additional
fracture treatments in layers at the shallower depths of the same well.

Introduction
Zonal isolation is one of the most critical operations in cased hole completion where multi-stage fractures will be performed.
This is primarily to withstand high differential pressure across the plug during fracturing treatment in the upper zones. This
becomes very challenging if the upper zone is highly stressed and lower zone produces formation water as was the case in
Well “A.” It is also important to ensure that the plug is successfully set in the first place, to avoid multiple additional HPCT
interventions and deal with the added wellbore complexities as a result of being more restricted on the available space to set
plugs for isolation. The Lower “X” interval of Well “A” prematurely screened out exposing the completion to 19,000+ psi of
bottom-hole pressure that can easily create ovality in the liner, where cement quality behind the pipe might be poor. Setting a
mechanical plug across such an oval pipe section would compromise required differential rating on the plug during the
fracturing treatment in the Upper “X” interval. The only feasible option to isolate the Lower “X” interval sand plug capped
with cement utilizing HPCT. The 20/40 ceramic proppant was spotted and capped with 100 mesh sand to act as a base for the
2 SPE 160853

cement plug above it. Scrutinized placement strategy and slurry design under the harsh bottom-hole conditions are the keys to
have successful isolation.

This paper describes a field application of innovative approach by using the HPCT with the assistance of utilizing the
Permanent Downhole Measurement System (PDHMS) that allowed the operator to get reliable real-time bottom-hole data
measurement, while setting a sand/cement plug under challenging bottom-hole conditions. The availability of real-time
bottom-hole pressure and temperature reading ensured slight overbalance condition throughout the HPCT intervention period.
The approach mentioned in this paper reduced the engineering assumptions for the zonal isolation resulting perfect isolation of
Lower “X” formation that was proppant fractured and produced formation water.

Reservoir and Wellbore Complexities

Lower and Upper “X” is a Sandstone formation in the pre-Khuff stratigraphic section in Saudi Arabia in which gas resources
are present within a sequence of sandstones, siltstones, mudstones and shales.

Sandstones, with widely varying porosity and permeability has engendered a search for engineering solutions to the problem
of production optimization from both relatively high and low permeability intervals. The average gas rate from the Lower and
Upper “X” is in the range 10 – 30 mmscf/d. Though this rate is achievable, given the formation permeability characteristics
and formation pressure, the nature of the reservoir sandstones gives rise to a risk of sand production. Tip screen out fracture
treatment is designed using combination of ceramic proppant and ceramic resin coated proppant and executed through indirect
and oriented perforated interval to achieve desired solids free rate. The average formation temperature and pressure are 315
F and 7500 psi, respectively. The closure pressure ranges from 11,000 psi to 14,000 psi (0.78 psi/ft to 0.95 psi/ft). Higher
stress is observed in Lower “X” than in Upper “X” formation. Desired fracture treatment is often difficult to place under harsh
bottom-hole conditions.

Well “A” was drilled as a deviated well with 1.45 km lateral displacement showing 107’net pay and 12% average porosity
across the Upper “X” and 91’ net pay and 9% average porosity across the Lower “X” formations. The well was drilled to
15,700’ and completed monobore with 4 ½” cemented liner and production tubing. The well has 30 deg deviation at the
reservoir sections and drilled almost towards the minimum horizontal stress direction. Hydrajetting (high pressure water
cutting) technique was considered to perforate 15,360’ to 15,390’ as conventional perforation technique often failed to bypass
the nearwellbore high induced stress. High near wellbore pressure loss was observed (greater than 2000 psi) after the Step
Down test. The Near Wellbore Pressure was still 1300 psi (Mainly tortuosity) after the Calibration test (with some proppant
slug) with borate crosslinked based fracture fluid. The Closure Pressure and fracture fluids efficiency were determined to be
11300 psi (0.794 psi/ft) and 21%, respectively.

There was a premature near wellbore screen out during fracturing in Lower “X” formation of Well “A” (Fig 1).

20000 45
BHP Measured(psi)
Treating Pressure(psi)
Annulus Pressure(psi) + 40
BHP(psi)
Slurry Rate(bbl/min)
Proppant Conc(PPA)
Prop Conc (BH)(PPA)
35
15000

30
S lu rry R ate, P P A

25
PSI

10000
20

15

5000
10

0 0
140.0 145.5 151.0 156.5 162.0 167.5 173.0 178.5 184.0 189.5 195.0
Treatment Time(min)

Figure1: Premature screenout of proppant fracture treatment in Lower “X” formation of Well “A.”
"BH measured pressure" in the Figure 1 is a direct measurement from PDHMS (Permanent Downhole Monitoring System) at
TVD of 10975' which is 3247' (tvd) above the perforated interval. 24,000 gals of Borate Crosslinked based Pad was pumped
followed by 446,000 lbs of 30/50 HSP + 41,000 lbs of 20/40 HSP in 896 bbls of crosslinked gel during slurry stages before it
screened out. There were no abnormalities during the Pad stage, however, net pressure started to drop at a faster rate once
SPE 160853 3

proppant started to go through the perforations. Severe bridging occurred once 3 PPA 30/50 was going through perforations
due to loss of width. Finally, the treatment screened out instantly with 20/40 HSP at 4 PPA at the perforations. No RCP was
pumped on surface. Total proppant injected in the formation was about 48,500 lbs (44,600 lbs of 30/50 and 4,000 lbs of
20/40). The high tortuosity, creation of multiple fractures in slanted well, and limited rheology of borate based crosslinked gel
under the extreme bottom-hole conditions are primary causes of the premature screen out in the Lower “X” formation of Well
“A.” The completion experienced 19,000 + psi bottom pressure as a result of the screen out which is the upper limit tolerance
of the completion.

The well produced formation water with a non-commercial gas rate after cleaning out the wellbore. That made the Lower “X”
formation mandatory to be isolated. The next interval is the Upper “X” which is at 15190’ to 15210’ (MD). The narrow
difference between the two intervals imposed additional challenges considering that top of cement should be at least 70’ below
the bottom most perforations of Upper “X.” Because the liner condition is uncertain in terms of ovality and ballooning due to
excessive pressure from screen out, the mechanical bridge plug option for isolation was ruled out. It was decided to spot
ceramic proppant and 100 mesh sand until slightly above the top of perforation interval of Upper “X” capped with 15’ to 20’
of cement to withstand 10,000 psi to 12,000 psi of differential pressure during fracturing treatment in the Upper “X.” Ceramic
proppant (20/40 ISP) was considered to withstand stress and not lose fracture height due to crushing, whereas 100 mesh sand
was used to plug between the porous spaces to minimize loss of cement filtrate into the fractured Lower “X” interval. A
number of attempts were made to spot cement using the E-line Cement Dump Bailer. During this process, the tool got stuck a
few times and the tool could spot. (Fig 2).

Figure 2: High Drag and Excessive Overpull Observed During Drifting Well “A” using E-Line to confirm Top of Sand at 15,356’.

After exhausting all isolation options, it was decided to set the cement plug top of the existing sand plug at 15,356’ using
HPCT. The high temperature (315 F), high reservoir pressure (~8000 psi), and the short interval — between the top of the
sand and the bottom of the planned Upper “X” — interval made the execution very precise.

Isolation Options

The zonal isolation can be done either permanently or temporarily by using chemical barriers inside the wellbore and/or the
reservoir, inflatable packer, cast iron, composite or sand plugs capped with cement.

In this particular well, several options were analyzed and isolation with ceramic proppant plug capped with 100 mesh sand and
topped with cement was regarded as a last resource.
A fracture performed previously on the lower sandstone interval was unsuccessful resulting in a screen out at 11,376 psi at
surface. For this reason, the first options of mechanical isolation were dismissed due to a possible deformation of the
liner/casing string due to the high pressure. Dumping cement with wireline was tried and it was dismissed do to the high risk
involved after experiencing overpull at the setting depth.
The fact that the distance between the planned upper perforations and the top of the isolation was 60 ft, made the accuracy of
4 SPE 160853

the sand and cement plugs of critical importance.

Cement Slurry Design and QA/QC

In the process of designing cement slurry through coiled tubing, following factors must be considered.

Mixing energy in the lab calculated accounting for:

• Mixing energy for waring blender in the laboratory (API laboratory mixing).
• Energy during batch mixing process.
• Energy during cement placement of cement through coiled tubing.

Rheology of slurry kept at minimum possible to reduce friction pressure during cement placement. At the same time, it was
enough to suspend solid particle in the slurry to avoid settling issue. For this particular job, yield point of slurry (expressed in
Bingham plastic model) is aimed at 5 lb/100 ft2 to 10 lb/100 ft2. Plastic viscosity of this slurry kept below 100 cp.

Thickening time is equivalent to time required to keep the cement pumpable. It is critical that the thickening time exceed the
actual cementing job to avoid cementing: surface pipes, Coiled tubing, tubing or inside of casing.
Thickening time of slurry calculated to have enough safety margins for slurry mixing and placement. (Fig 3.).
The cement slurry is considered not pumpable once its consistency is around 40 BC.

Figure 3: Test Thickening Time Chart

The small cross sectional area and rate during cement placement allow rapid increase in temperature. Therefore, temperature
used in designing coiled tubing cementing is to the bottom-hole static temperature (BHST).
Latex system used to achieve excellent fluid loss control and bonding properties. At the same time, the system is able to
maintain desirable slurry properties.
Compressive strength widely used as an index for quantifying cement strength. Cement with compressive strength of 500 psi
is adequate for most cementing operations. Determined in the lab prior to running in the hole. (Fig 4.)
SPE 160853 5

Figure 4: Compressive Strength Test Chart

Based on above-mentioned factors, laboratory tests were conducted and managed to achieve the following slurry properties:
BHST 315 F
Yield 1.56 ft3/sack
Density 15.8 ppg (118 pcf)
Yield point (80 F) 9.34 lb/100 ft2
Plastic Viscosity (80 F) 75.369 cP
Yield point (190 F) 5.56 lb/100 ft2
Plastic Viscosity (190 F) 64.129 cP
Thickening Time 06:49 hr:mm
Fluid loss (API) 34 ml
Free Fluid Nil
Table 1: Pilot Test Results

Prior to job execution, additives were prepared and mixed at location. Sample of mixed fluid and cement blend were collected
and sent to cementing laboratory, to perform the confirmation test.

BHST 315 F
Yield 1.56 ft3/sack
Density 15.8 ppg (118 pcf)
Yield point (80 F) 5.83 lb/100 ft2
Plastic Viscosity (80 F) 55.10 cP
Yield point (190 F) 4.64 lb/100 ft2
Plastic Viscosity (190 F) 27.86 cP
Thickening Time 06:00 hr:mm
Fluid loss (API) 40 ml
Free Fluid Nil
UCA (500 psi) 32:24 hr:mm
UCA (2500 psi) 40:00 hr:mm
Table 2: Confirmation Test Results

Pumping rate is aimed at 2 bpm maximum, to reduce the friction pressure during cement placement.
Placement pressure throughout the job execution did not exceed 2,800 psi, below CT pressure rating of 10,000 psi.
6 SPE 160853

Execution Strategies and Onsite QA/QC

JOB EXECUTION

The distance between the planned upper perforations and the top of the isolation was 60 ft, made the accuracy of the sand and
cement plugs of critical importance.
Before starting the operation, CT was purged using to make it empty. Water was then pumped using the cementing pump to
calibrate volume using both the cement displacement tank and CT electronic acquisition system. It was agreed to go with the
displacement tank volume, a nozzle with a small orifice should be used to minimize the error once fluid is at the nozzle while.

Sand Plug

The first part of the operation was to top the sand plug which was found 21 ft lower than expected at 15,341 ft.
To ensure that the sand was set accurately, two things were performed: sand amounts for the small 5 bbl plug were carefully
measured on location and the wellhead pressure was controlled after the sand plug was set, thus ensuring no sand migration up
the wellbore.
Once settling time was up and the new sand plug top was confirmed at 15,322 ft (planned to be 15,320 ft), the cement
operation was started.

Cement Placement

Volumes need to be accurate due to the small amount of the cement, and no fluid contamination may occur in the surface lines.
To achieve this purpose, a sampling point was rigged up on the CT reel. Before any fluid is pumped into the CT string, the
sampling point is used to ensure that a clear sample of the desired fluid (spacer or cement) is emerging from the sampling
point. Once the fluid at the sampling point is confirmed, the valve to the CT reel is opened to account for accurate volumes.
The cement operation required a careful slurry design, complemented by the use of heavy Sodium Bromide (NaBr) brine to
keep the high reservoir pressure of the well under control. Execution of the job started with the dissolution of the NaBr brine to
10.9 ppg (81.5 pcf) and the mixing of the cement slurry. Once the desired properties of the cement were achieved, the
execution of the pumping schedule was started. The cement was pumped as follows:

1. Spacer (5bbls) was pumped ahead the cement to avoid cement contamination while it passes through the CT string,
and also to clean up the well bore, where the cement was placed.
2. Cement (5 bbls) was pumped to cover 75 ft of 4 ½” liner.
3. Spacer (5bbls) was pumped after the cement to avoid cement contamination of the cement slurry from the
displacement fluids, and also to account for the U-tubing effect in the wellbore to balance the hydrostatic inside and
outside the CT.

Once the fluids reached the end of the CT, steps were followed to ensure that the cement was placed in the wellbore without
contamination. After half barrel of cement was out of the nozzle, cement pumping was continued and the CT was pulled out of
hole slowly, at a speed matching the cement pump rate, so that the top of cement was above the end of the CT. This was timed
so that the last of the cement exited the nozzle at the same time the nozzle pulled above the top of the cement.

Fig 5. details when the coiled tubing (CT) was parked a few feet off the top of the sand plug and was picked up at around 33
fpm while the cement was being spotted at 0.5 bpm. Once the cement was out, speed was picked up to 40 to 14,200 ft, to stop
and achieve a squeeze pressure of 1,000 psi. At that point, the CT was run in to wash with contaminant across the new
perforation depth 15,190 ft– 15,220 ft, and down to the desired top of the cement at 15,280 ft. Contaminant was spotted from
15,280 ft up to 15,200 ft, to ensure no cement leftovers, which would later interfere with perforation guns.

Careful timing was required to switch between the cement pump and the CT pump used for displacement and kill well fluid
placement, to avoid losing prime and therefore having cement free-falling.
Pre-job planning and communication on the wellsite were the key factors that enabled the operation to go as planned.
SPE 160853 7

Figure 5: Cement Plug Chart

1. Displace well with kill brine at 15,300 ft.

2. Adjust WHP to 800 psi, to be maintained during the cement job.
3. Displace cement to CT tip.
4. Start spotting cement at 0.5 bpm and PU CT at 33 fpm to 14,200 ft.
5. Reduce WHP to 300 psi once cement slurry in spotted in the wellbore.
6. Squeeze to 1,000 psi.
7. Start washing and spotting with contaminant.
8. Displace wellbore 10.9 ppg (81.5 pcf) pcf brine.

The CT was parked 14,200 for the final well displacement to NaBr brine to maintain the well at slightly overbalanced
conditions to allow for cement setting time.

Cement Tag and Pressure Test

Fig 6.details after the designed setting time of 36 hr, the cement plug was pressure tested up to 7,000 psi at surface and tagged
at 15, 285 ft, which was deemed satisfactory for the upcoming perforation and fracture operation of the upper Zone.

Figure 6: Pressure Test on Cement Plug Chart

Fracturing Upper “X” of Well “A”

The top of cement (TOC) was found to be at 15285’. The Upper “X” of Well “A” was perforated between 15190’ to 15,210.
A Data-frac treatment was performed (Fig 7) in the Upper “X” of Well “A” with 193 bbls of 6% KCl brine for hole-fill,
Mini-Fall-Off (MFO) tests and step rate tests, and 425 bbls of 45# crosslinked fracture fluid for the calibration injection test.
The Closure Pressure, Fracture Extension Pressure, Fracture Extension Rate, and Fluid Efficiency were found to be 10,900 psi
8 SPE 160853

(0.76 psi/ft), 11,776 psi, 4.6 bpm, and 23%, respectively. High near wellbore pressure (~1475 psi from tortuosity) existed after
the Calibration Injection test. The maximum surface and BH treating pressures and pumping rate were 9,270 psi, 14,005 psi
and 35 bpm respectively. The BH ISIP after the Calibration Injection test was 12000 psi. The plug maintained its integrity at
all times during the fracturing treatment.

16000 40.0
PDHMS Measured(psi)

Treating Pressure(psi)
+
Annulus Pressure(psi)
12000 BHP Calculated(psi) 30.0
Slurry Rate(bbl/min)
P r e s s u r e ( P s i)

R a te ( B P M )
8000 20.0

4000 10.0

0 + 0
0 100.0 200.0 300.0 400.0 500.0
Treatment Time(min)
Figure 7: First Fracturing Upper “X” after successful isolation of Lower “X” with sand/cement plug

Operational Challenges

The various challenges that were overcome during the cement placement operation are listed below:

‐ Short clearance between lower perforation top, isolation top and upper perforation bottom required accurate
placement of sand plug and cement, to allow proper isolation of the lower perforated interval and enough rathole for
upcoming perforating of the upper interval. This situation was tackled by the use of excess cement, which was
subsequently contaminated and careful physical measurement of surface volumes against electronic counters.
‐ High reservoir pressure which needed to be controlled to accurately set the sand and cement plugs. A combination of
the use of the choke to maintain enough WHP during the sand plug and cement setting, followed by the use of the
heavy brine to maintain static control of the pressure while waiting for the cement, allowed the successful operation
to be performed.
‐ High BHT in the well, close to 315 deg F, required careful cement slurry design. Rigorous QA/QC measures were
taken to ensure that the actual cement quality on location matched the designed laboratory results.
‐ In cement plugs pumped through CT volume is critical. To minimize uncertainties with volumes and mix of fluids in
pipelines on surface a special procedure was done. Before pumping cement inside the CT reel, the reel isolation valve
was closed and cement slurry was circulated out to the surface lines, until it reached the reel manifold, then the
isolation valve was opened and the exact volume of cement was pumped inside the CT. Once the final cement volume
was reached, the same procedure was done with post-flush fluid. This procedure guaranties an accurate volume of
cement pumped.
‐ Certain operational precautions were taken, including: Pumps were properly primed; pre- and post-levels (fluids and
cement) were visually checked, and compared with monitored data during pumping.
SPE 160853 9

Conclusions and Recommendations

‐ Pre-job planning and communication on the wellsite were the key factors that enabled the operation to go as planned
as well as a rigorous QA/QC measures taken during the entire operation, to ensure that the cement quality matched
the designed results, fluids pumped as planned and adequate procedures for pumping and placement of fluids.
‐ Several options were analyzed but due to well conditions — such as screen-out with high BHP pressures possibly
creating deformation in tubular and limiting options with mechanical plugs, overpulling experiences while running
tools with wireline — isolation with ceramic proppant plug capped with 100 mesh sand and topped with cement was
regarded as a last resource.
‐ Finally, the top of the cement was tagged at 15,285 ft, just 5 ft below the desired top. It indicates the high degree of
accuracy achieved as a result of adequate design and rigorous QA/QC before and during the entire operation.
‐ Real time pressure and temperature data enabled precise placement. The BHP and temperature data was also used to
validate the cement recipe.
‐ A total of 3 days of operating time were spent on the location. No HSE incident or Injury was recorded. The job was
executed as designed; the procedures followed ensure that the different stages involved in the operation serves their
purpose. The combined plug proved its reliability and designed functions efficiency. The sand plug worked
effectively and as per design with the cement to isolate the perforated zone.
‐ Purge CT with N2 is not the most efficient way of calibrating the CT volume but gives a good degree of certainty.
‐ Wait at least 36hrs for the cement to set, because once cement reaches downhole, the cement’s thickening time could
change due to the well status. Please note that 24 hours is not enough.
‐ It is always recommended to use the cement pump with the displacement tank, volume status is easily verified in case
of anomalies with the pump and the electronic monitoring system.
‐ The 20/40 ISP capped with 100 mesh worked very well as a base and 100 mesh was effective to control the leak-off
of cement filtrate into the formation.
‐ A pressure of 500 to 1000 psi overbalance throughout the intervention was optimum to ensure cement stays in place.
‐ Usage of NaBr was effective to minimize the choke operation to have the desired well head pressure to return the
contaminated fluids.

Acknowledgement
The authors would like to thank the management of Saudi Aramco and Schlumberger for their support and permission to
publish this article. In addition, we would like to thank all personnel who participated by engineering and operational support
during the design, execution and evaluation.

References

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Khateeb, Ahmed H. Muhammadi, Saudi Aramco, Vsevolod Bugrov, Wassim Kharrat, Simeon Bolarinwa, Schlumberger,
all SPE
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Optic Services with Tension-Compression sub.: Jorge E. Duarte, Surajit Haldar, Rifat Said, Saudi Aramco Anton Burov,
John Stuker and Wassim Kharrat, Schlumberger All SPE
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Mohammed H. Buali, Alaa A. Dashash, Halder X. Surajit, Jorge E. Duarte Olarte, Saudi Aramco, Anton Burov,
Schlumberger, all SPE
4. Vidick,B., “Critical Mixing Parameters for Good Control of Cement Slurry Quality,” paper SPE18895,1989
5. Orban, J.et.al., “Specific Mixing Energy: a Key Factor for Cement Slurry Quality,” paper SPE15578, 1986