FINAL REPORT: WELL STIMULATION EFFECTS ON ANNULAR SEAL OF PRODUCTION CASING IN OCS OIL AND GAS OPERATIONS Prepared for: BSEE 9/28/2015 Contract Number: E14PC00037 Prepared By: Paul Sonnier Position: Research and Development Manager, Lab Manager CSI TECHNOLOGIES • 2202 Oil Center Court • Houston, Texas 77073 • 281.784.7990 • www.csi-tech.net CTMS-TM-PM-03 (2.1) 2 | P a g e CONTENTS 1 Acronyms and Abbreviations ...................................................................................................................................... 8 2 Introduction .............................................................................................................................................................. 10 2.1 Objective ............................................................................................................................................................ 10 2.2 Conclusions and Recommendations .................................................................................................................. 10 2.2.1 Literature Review ........................................................................................................................................ 10 2.2.2 Failure modes ............................................................................................................................................. 11 2.2.3 Small Scale Physical Modeling .................................................................................................................... 12 2.2.4 Large scale modeling .................................................................................................................................. 13 2.2.5 Finite Element Analysis ............................................................................................................................... 13 2.2.6 Design and Performance Topics Considered for Regulation ...................................................................... 15 2.2.7 Recommendations ...................................................................................................................................... 15 2.3 Background and Report Structure ..................................................................................................................... 15 3 Literature Review ...................................................................................................................................................... 17 3.1 Objective ............................................................................................................................................................ 17 3.2 Background ........................................................................................................................................................ 17 3.3 Summary of Selected Literature ........................................................................................................................ 18 3.3.1 Regulatory Information .............................................................................................................................. 18 3.3.2 Annular Pressure Build Up .......................................................................................................................... 18 3.3.3 Industry Trends ........................................................................................................................................... 19 3.3.4 Well Architecture ........................................................................................................................................ 20 3.3.5 Completion Data ......................................................................................................................................... 20 3.3.6 Field Conditions .......................................................................................................................................... 21 3.3.7 High Pressure High Temperature Conditions ............................................................................................. 21 3.3.8 Stimulation Techniques .............................................................................................................................. 23 3.3.9 Frac Pack ..................................................................................................................................................... 23 3.3.10 Cement Performance ................................................................................................................................ 24 3.3.11 Cement Mechanical Properties ................................................................................................................ 26 3.4 Shale Cement Performance Analogy ................................................................................................................. 28 4 Failure Mode ............................................................................................................................................................. 29 4.1 OBJECTIVE .......................................................................................................................................................... 29 CSI Technologies makes no representations or warranties, either expressed or implied, and specifically provides the results of this report "as is” based upon the provided information. 3 | P a g e 4.2 BACKGROUND .................................................................................................................................................... 29 4.3 STUDY WELL CONDITIONS ................................................................................................................................. 30 4.4 FINDINGS FROM TASK 2 LITERATURE REVIEW .................................................................................................. 33 4.5 INVESTIGATION OF POSSIBLE FAILURE MODES AND RANGES OF STRESSES ..................................................... 33 4.5.1 Stress-induced tensile failure of the cement .............................................................................................. 33 4.5.2 Micro-annulus formation from repeated temperature and pressure cycling ............................................ 36 4.5.3 Shear failure of the cement/casing interface ............................................................................................. 37 4.5.4 Inadequate quality control procedures/cementing practices prior to production .................................... 37 4.6 Summary ............................................................................................................................................................ 37 5 Physical Modeling ..................................................................................................................................................... 38 5.1 Objective ............................................................................................................................................................ 38 5.2 Background ........................................................................................................................................................ 38 5.3 Test Conditions .................................................................................................................................................. 38 5.4 Results and Discussion ....................................................................................................................................... 43 5.4.1 Small Scale Physical Modeling .................................................................................................................... 43 5.4.2 Performance Properties.............................................................................................................................. 44 5.4.3 Mechanical and Thermal Properties ........................................................................................................... 45 5.4.4 Annular Seal Testing ................................................................................................................................... 47 5.4.5 Dimensionless Scaling Correlation Development ....................................................................................... 51 5.4.6 Large Scale Annular Seal ............................................................................................................................. 54 5.4.7 Large-Scale Test Results .............................................................................................................................. 55 5.4.8 Dimensionless Scaling Correlation Evaluation ........................................................................................... 57 5.4.9 FEA Results .................................................................................................................................................. 62 6 FEA Report ................................................................................................................................................................ 65 6.1 Summary ............................................................................................................................................................ 65 6.2 Introduction and Background ............................................................................................................................ 66 6.3 Technical Approach ..........................................................................................................................................