Cross-Scale Design of HPHT Cement Plugging for Fractured Deepwater Wells
Keywords:
HPHT Wells, Cement Plugging, Lost Circulation, Cross-Scale, Nano-SilicaAbstract
Severe lost circulation in fractured deepwater formations under high-pressure high-temperature (HPHT) conditions remains a major challenge in drilling operations, often causing substantial non-productive time and high remediation costs. This study proposes a cross-scale design framework integrating fracture-scale flow modelling, cement-matrix durability analysis, and multi-objective optimisation for HPHT cement plugging applications. Laboratory experiments were conducted using artificial fracture-cavity cores under conditions up to 210 °C and 130 MPa. A modified Brinkman–Forchheimer model was calibrated to evaluate slurry injectability, while cyclic loading tests assessed long-term sealing durability with nano-silica reinforcement. The integrated NSGA-II optimisation identified an optimal ultrafine cement–geopolymer ratio of 1:0.7 with 3 wt% nano-silica. Validation tests demonstrated improved plugging performance, achieving an 83% success rate and extending sealing life from 18 to 62 hours compared with conventional Class G cement. The framework provides a practical basis for improving HPHT lost circulation control and cement design reliability.
Abstrak
Lost circulation parah pada formasi deepwater berrekahan di kondisi high-pressure high-temperature (HPHT) masih menjadi tantangan utama dalam operasi pengeboran karena menyebabkan waktu non-produktif dan biaya remediasi yang tinggi. Penelitian ini mengembangkan kerangka desain lintas skala yang mengintegrasikan pemodelan aliran skala rekahan, analisis durabilitas matriks semen, dan optimasi multiobjektif untuk aplikasi penyumbatan semen HPHT. Eksperimen laboratorium dilakukan menggunakan inti rekahan-rongga buatan pada kondisi hingga 210 °C dan 130 MPa. Model Brinkman–Forchheimer termodifikasi digunakan untuk mengevaluasi injektabilitas slurry, sedangkan pengujian beban siklik menilai ketahanan penyegelan jangka panjang dengan penguatan nano-silika. Optimasi NSGA-II menghasilkan komposisi optimum rasio semen ultrafine–geopolimer 1:0,7 dengan 3 wt% nano-silika. Hasil validasi menunjukkan peningkatan kinerja plugging dengan tingkat keberhasilan 83% dan umur penyegelan meningkat dari 18 menjadi 62 jam dibandingkan semen Class G konvensional. Kerangka ini memberikan dasar praktis untuk meningkatkan pengendalian lost circulation HPHT dan keandalan desain semen.
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