API 10A Cooperative Testing Report Austin, TX January 2017
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1 API 2017 Exploration & Production Standards Conference on Oilfield Equipment and Materials, January 16-20, 2017 API 10A Cooperative Testing Report Austin, TX January 2017
2 Cooperative Testing Agenda Charge of SC10/TG Cooperative Testing Overview Results Cube Dimension Investigation Free Fluid Flask Investigation 2
3 CHARGE of SC10/TG2 Task Group on Cooperative Testing (Bill Ulrich) Coordinate efforts of the cooperative testing program. Evaluate test results and present results at annual meeting When necessary as dictated by the results, propose changes in the test procedure to insure results are statistically more accurate. Coordinate efforts of the work group on compressive strength. Work Group on Compressive Strength (Gunnar Debruijn) Continue to evaluate the current specification test method by examining elements including mixing time, curing temperatures, curing time duration, curing baths (static vs. circulating) and cement block breaking procedures. Develop and propose a modified test method to yield improved repeatability. 3
4 Charge: Task Group Membership Chair: William Ulrich Members: Mailing List API Robert Beirute Consultant Greg Bernstein LafargeHolcim John Buflod Glen Benge Consultant Jeff Moon Chandler Ben Coco Greg Garrison Consultant Michael Trimble Buzzi Dan Mueller Exxon Heiko Plack Dyckerhoff Scott Podhaisky LafargeHolcim Jamie Hayes - Ofite Scott Saville Chandler Paul Sonnier CSI
5 2016 Cooperative Testing Overview 5
6 2016 Cooperative Testing Overview Shipment Preparation for Cooperative Sample Preparation 5 1-ton Big Bags obtained and tested for consistency. Big bags were blended and randomly tested for consistency. Samples were prepared in 3 KG hermetically sealed bags. 6
7 2016 Cooperative Testing Overview Costs Costs for 2016 API Cooperative Testing Program US $ Labor for Packaging and Homogenization 4,500 Materials: Bags, Containers Labels, Preparation 7,600 Shipping Costs 23,100 TOTAL 35,200 7
8 2016 Cooperative Testing Overview Lessons Learned Opportunities for Future Cooperative Testing Big 3 Service Companies (~2/3 of samples) Ship to one site. (large quantities) One contact vs multiple contacts Copy model from Halliburton Directions not followed (Cooperative Test Cover Letter and Instructions) Feedback needed for improvement of document Opportunity to develop a better reporting tool. 8
9 2016 Cooperative Testing Overview Participation of SC10 group PARTICIPANT PROFILE SAMPLES SUPPLIED RESULTS REPORTED PETROLEUM COMPANIES SERVICE COMPANIES HALLIBURTON SCHLUMBERGER BAKER HUGHES OTHERS CEMENT PRODUCERS INTERESTED PARTIES TOTAL SUPPLIED * * -- More samples results received after reporting deadline 9
10 PARTICIPANTS 2016 Cooperative Testing Overview Participation About 50% of sample results returned. Supplied vs Analyzed * YEAR TOTAL SUPPLIED TOTAL ANALYSIS * -- More samples results received after reporting deadline 10
11 Results 11
12 Results: 2016 Chemistry Lowest standard deviation in years. API Spec CHEMICAL ANALYSIS (%) 2016 (W/O Exclusions) C 3 S C 3 A SO 3 MgO L.O.I. 48 to 65 3 Max. 3.0 Max 6.0 Max 3.00 Max AVERAGE 60.15% 1.58% 2.78% 1.44% 0.82% STD DEV 2.48% 0.46% 0.10% 0.07% 0.13% COUNT *Need to add Insol. Residue in 2018 ASTM C Table 1 Col 2 Duplicate Analyst Requirement 0.10% 0.16% 0.10% Type Count Type Count Type Count Cement Manufacturer 34 Energy/Other 4 Service 2 Excluded samples are samples that were not taken into consideration for analysis Outliers are samples that are more than 2 Std. Dev. These are facilities that should review their test results. 12
13 Results: Chemistry 2016 results near ASTM duplicate sample requirement SO3 Standard Deviation LOI St andard Deviat ion STD DEV SO3 ASTM DUPLICATE MAX DIFF MgO St andard Deviat ion STD DEV LOI ASTM DUPLICATE MAX DIFF STD DEV MgO ASTM DUPLICATE MAX DIFF 13
14 STD DEV COV Results: Schedule 5 Standard Deviation Standard Deviation has almost decreased in half in Schedule SCH STD DEV COV AXIS TITLE Exclusions and 9 Outliers. Exclusions and Outliers in Appendix 14
15 THICKETNING TIME TO 100 BC Results: 2016 Schedule 5 Comparison of Facilities Good agreement amongst all groups with average and Std. Dev SCH 5 Results AVERAGE 117 STD DEV 4.3 COUNT STANDARD DEVIATION SERVICE CEMENT MANUFACTURER Energy/Other/Consult 15
16 STD DEV COV Results: Compressive Strengths Comparison Steady results for all 3 strengths for Standard Deviation. 8HR 38C Standard Deviation STD DEV COV
17 Results: 2016 Compressive Strengths Comparison 8HR 38 C Cement Manufacturer s standard deviation lower 67 A V E R A G E HR 38 o C PSI AVERAGE 420 STD DEV 134 COUNT 117 STD. DEV. 17
18 Results: 2016 UCA vs Cube 8 Hr & 24 Hr Relatively good comparison larger deviation on 24 hr cubes 18
19 STD DEV COV Results: Free Fluid 2016 Lowest Free Fluid Standard Deviation Free Fluid STD DEV COV Exclusions and 9 Outliers. Exclusions and Outliers in Appendix 19
20 Results: 2016 Free Fluid Cement Manufacturers had the lowest Standard Deviation Free Fluid % AVERAGE 2.92 STD DEV 0.64 COUNT
21 Results: Observations Best deviations seen in years Participation numbers down? Preparation method? More precise testing in laboratories? Other? 21
22 Cube Dimension Investigation 22
23 Cube Dimension Investigation Evaluation of whether or not cube dimensions need to be measured? API vs ASTM Standards Every cube measured API Periodic check of cubes ASTM Cubes are not done in EN New In Use 2 in. ± in. ± 0.02 New 2 in. ± In Use 2 in. ± in in. to in. New 2 in in. to in. In Use Cube molds need to be measured and certified every 2 years 23
24 Cube Dimension - Comparison No difference observed on cube strength on the dimension extremes 8 hr 60 C 24 hr 38 C > 2 in < 2 in > 2 in < 2 in 8 hr 38 C > 2 in < 2 in 24
25 Cube Dimension Conclusions and Observations Data indicates an opportunity to eliminate the measurement of cube dimensions. 8 hr and 24 hr shows no major differences. Opportunity to align with ASTM Open Discussion in Work Group meeting in Feb on where we go from here. 25
26 Free Fluid Flask Investigation 26
27 Free Fluid Investigation Asked participant to provide flask used in measurement What type of flasks being used? Opportunity to improve specification? 500mL conical flask ASTM 1404 Type I, Class 2 or ISO Type I general purpose with graduated scale. Class 2 wide mouth (#10 stopper) with heavy duty beaded top. 27
28 Free Fluid Flasks Both meet specification but still different #10 Stopper #10 Stopper 172 mm 175 mm 105 mm 97 mm 28
29 Free Fluid Flasks Free Fluid Flasks does not Meet Specification #10 Stopper # 7 Stopper #7 Stopper 238 mm 176 mm 175 mm 102 mm 101 mm 138 mm 29
30 Free Fluid Investigation Non-Compliant Flasks had larger Standard Deviation 7 NC 10 C 51 NC 21 C 27 C 10 NC NC Non-Compliant Flask C Compliant Flask Number = Population 30
31 Free Fluid Flasks Observations Cement Facilities vs Service No variances observed in populations Cement Manufacturer Entire Population Service
32 Free Fluid Conclusions and Observations Opportunity to improve the specification? Clarify API 10A specification Currently in progress with next 10A re-write Recommendation for a study for FF. variability on flasks. Opportunity of testing a flask 10/20/30 times with same cement. Is same testing standard deviation observed? Small group of testing to verify? Open Discussion in Work Group meeting in Feb on where we go from here. 32
33 Appendix 33
34 Results: Chemistry SiO2 Al2O3 Fe2O3 CaO MgO SO3 LOI AVERAGE STD DEV EXCLUSIONS SiO2 Al2O3 Fe2O3 CaO MgO SO3 LOI API Cement 35 API Service 69 API Cement 70 API Energy 1.94 API Other OUTLIERS API Service API Cement API Service 4.93 API Cement 1.79 API Cement 4.86 API Cement API Cement 1.19 API Energy API Cement 4.12 API Cement 2.52 API Energy 1.13 API Cement
35 Results: Chemistry SO results near ASTM duplicate sample requirement SO3 Standard Deviation SO3 Results AVERAGE 2.78% STD DEV 0.10% STD DEV SO3 ASTM DUPLICATE MAX DIFF Exclusions SO3 Outliers SO3 API Service 3.14% API Energy 1.94% API Service 2.52% API Cement 2.97% 36
36 Results: Chemistry MgO Better than ASTM duplicate sample requirement 0.3 MgO Standard Deviation MgO Results AVERAGE 1.44% STD DEV 0.15% STD DEV MgO Exclusions MgO API Other 0.37% ASTM DUPLICATE MAX DIFF Outliers MgO API Service 1.00% API Cement 1.79 API Service 1.13% API Cement 1.93%
37 Results: Chemistry LOI Stable results over the years LOI Standard Deviation LOI Results AVERAGE 0.82% STD DEV 0.13% STD DEV LOI Exclusions LOI API Service 69.00% API Cement 70.00% ASTM DUPLICATE MAX DIFF Outliers LOI API Cement 1.19% API Cement 1.15% 38
38 Results: XRD/Rietveld With 14 Facilities reporting WIDE VARIATION (not a good statistical analysis) Alite Belite Aluminate Cubic Aluminate Ortho Gypsum Hemihydrate Anhydrite Lime Average STD Dev Count Exclusions API CEMENT 5.05 API SERVICE API CEMENT 1.8 API CEMENT 2.4 OUTLIERS API CEMENT 1.45 API CEMENT
39 Results: Schedule 5 Exclusions and Outliers Exclusions Sch 5 (min) Outliers API Service 158 API Service 174 API Service 129 API Service 126 API Service 127 API Service 135 API Service 130 API Service 127 API Cement 127 API Cement 126 API Service
40 Results: Compressive Strengths Comparison 8HR 38C Standard Deviation STD DEV 8hr HR 38C Standard Deviation HR 60C Standard Deviation STD DEV 24hr 38 STD DEV 8hr 60
41 10 SEC GEL (LBF/100 FT 2 ) Results: Rheology 10 Sec Gel Possible opportunity for cement manufacturers improvement Sec Gel lbf/100 ft 2 AVERAGE 17.2 STD DEV 4.24 # OF TESTS STANDARD DEVIATION Service Cement Manufacturer Energy/Other/Consult Exclusions 10 sec Gel API Service 50.8 Outliers In Appendix 42
42 10 MIN GEL (LBF/100 FT 2 ) Results: Rheology 10 Min Gel Possible opportunity for cement manufacturers improvement Min Gel lbf/100 ft 2 AVERAGE 26.5 STD DEV 8.67 # OF TESTS STANDARD DEVIATION Service Cement Manufacturer Energy/Other/Consult Exclusions 10 min Gel Outliers API Service 72.0 In Appendix API Service
43 Results: Rheology Exclusions & Outliers 10 minute Gel Strength 10 second Gel Strength Rotational Speed 3 Rotational Speed 300 Facilities Excluded: API Service 46.0 API Service 72.0 API Service Facility Outliers: API Cement Manufacturer API Service 8.9 API Service 50.0 API Service 6.5 API Service 49.0 API Service 6.0 API Service 33.0 API Service API Service 27.0 API Service API Service 47.6 API Service 47.6 API Service
44 Results: Cubes (8HR 38 o C, 8HR 60 o C, 24HR 38 o C) Compressive Strengths All of the Exclusions and Outliers are Service Companies 8 HOUR - 38 o C DATA MINUS EXCLUSIONS AVERAGE 420 STD DEV 134 COUNT HOUR C DATA MINUS EXCLUSIONS AVERAGE 1930 STD DEV 369 COUNT HOUR - 38 o C DATA MINUS EXCLUSIONS AVERAGE 2840 STD DEV 612 COUNT 103 EXCLUDED 8HR 38 o C 8HR 60 o C 24HR 38 o C API Service 1320 API Service 770 API Service 750 API Service 1180 API Service 1290 API Service 1620 API Service 420 API Service 980 OUTLIERS 8HR 38 o C 8HR 60 o C 24HR 38 o C API Service 80 API Service API Service 1040 API Service 980 API Service 900 API Service 1150 API Service 810 API Service 1040 API Service API Service 4260 API Service 50 45
45 Results: UCA vs Cube 24 HR cubes showed a Large STD Compared to UCA UCA to Cube Comparison 2016 Cubes UCA 8 HOUR F 8 HOUR F AVERAGE 420 AVERAGE 640 STD DEV 134 STD DEV 214 COUNT 117 COUNT 105 Cubes UCA 24 HOUR F 24 HOUR F AVERAGE 2840 AVERAGE 2670 STD DEV 612 STD DEV 287 COUNT 103 COUNT 104 Exclusion UCA 8HR Exclusion Cubes 24HR API Other 1720 API Service 1320 API Service 1704 API Service 770 API Service 1290 API Service 420 API Service 980 Outliers UCA 8HR Outliers Cubes 24HR API Service 1203 API Service 1590 API Service 1500 API Service
46 THICKETNING TIME TO 100 BC Results: UCA The difference in the 8 HR UCA Cement Producers is more than the STD UCA 8 HR F AVERAGE 640 STD DEV 214 COUNT 105 UCA 8 HR (PSI) STANDARD DEVIATION Service Cement Energy/Consult/Other
47 Results: UCA Time to 50 & 500 PSI Large Standard Deviations on the Time To TIME TO 50 PSI CEMENT OTHERS SERVICE AVG 4:57 3:47 3:58 STD 0:35 0:57 0:55 COUNT Exclusion 50 PSI API Service BAD # TIME TO 500 PSI CEMENT OTHERS SERVICE AVG 8:54 7:09 7:15 STD 1:01 1:03 1:10 COUNT Exclusion 500 PSI API Other 3:19 Oultier 50 PSI API Other 2:06 API Service 1:15 API Service 6:02 API Service 6:09 Oultier 500 PSI API Service 9:46 API Service 4:55 API Cement 9:43 API Cement 9:51 API Service 4:18 48
48 Results: UCA 8 Hr & 24 Hr PSI Large Standard Deviations on the Time To 8 HR PSI CEMENT OTHERS SERVICE AVG STD COUNT HR PSI CEMENT OTHERS SERVICE AVG 2,306 2,733 2,672 STD COUNT Exclusion 8 HR API Other 1720 API Service 1704 Exclusion 24 HR API Cement 785 API Service 4120 API Service 4341 Oultier 8 HR Oultier 24 HR API Service 1703 API Cement
49 Results: Free Fluid 2016 Outliers 50
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