Abstract
In this paper we explore the advancements in well integrity verification in the Kingdom of Saudi Arabia through the digitalization of cementing processes. We highlight the transition to more efficient operations, emphasizing the pivotal role of digital technologies that enable real-time monitoring and evaluation in modernizing cementing practices within the oil and gas industry.
Key variables such as cement pump rate, density, and pressure, integral to the cementing process, are closely monitored in any cement job. The introduction of real-time cement evaluation software (RTCES) has revolutionized the monitoring and live transmission of these critical data. RTCES facilitates live simulations that align acquired pressure and rates with expected values, promptly identifying deviations or anomalies. This can be particularly crucial in managed pressure cementing (MPC) jobs, where monitoring live equivalent circulating density (ECD) ensures it stays within prescribed pore and fracture pressure limits.
In its extensive application over the past year, RTCES has proven to be instrumental in identifying multiple near-miss incidents, thereby significantly enhancing risk mitigation. A notable instance includes the early detection of a deviation in mud weight during displacement. Had this deviation gone undetected, it could have resulted in catastrophic nonproductive time caused by lost well control. This early detection by RTCES allowed for timely intervention and immediate corrective action, effectively averting potential severe lost time. In another significant case, RTCES accurately pinpointed an ECD spike exceeding the fracture pressure limits during an MPC job. The system's prompt alert enabled timely adjustments, including reducing backpressure and pump rate, thus effectively preventing significant losses. These examples illustrate the system's efficacy in not only enhancing well integrity verification, but also in boosting operational efficiency by limiting the need for remedial work to address integrity issues. This positive impact is further proven by the substantial reductions in near-misses and the marked improvements in resource utilization.
While digitalization has permeated many industries, cementing in the oil and gas sector has lagged. RTCES represents a significant leap in this domain, paving the way for more sophisticated, efficient, and successful cementing operations. We will not only demonstrate the immediate benefits of digitalization in cementing, but also open an avenue for future research and application in this critical field of real-time cement monitoring and evaluation.
