Cement Lab Data Management System. Version 2.2. User s Manual

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Cement Lab Data Management System

Version 2.2

User’s Manual

Pegasus Vertex, Inc.

6100 Corporate Dr., Suite 448

Houston, TX 77036

Tel: 713-981-5558 Fax: 713-981-5556

E-mail: [email protected]

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I. Introduction

I-1. Background

The design and test of slurries are integral parts of every cementing job. Variability between wells can make this process time-consuming and expensive. Traditionally, cementing engineers and lab technicians used paper files to record test results. The introduction of spreadsheet software, like Excel, greatly enhanced the reporting quality and speed of filing. Yet organizing numerous reports and searching those reports proved to be very difficult.

Without an interactive cement lab database, engineers and technicians face:

 Difficulty designing cement slurries

 Wasted resources when repeating similar tests

 Lack of proof of the design flaws while job problems occurred

 Difficulty maintaining standards across labs within the same company

 Extra work transferring designs and testing data to other people

 Difficulty keeping track of all in-process and finished design tests

PVI developed CEMLab® to streamline the cement lab operations. CEMLab® is an integrated database management application that formulates the slurry blend, calculates the amount of ingredients (cement, dry and liquid additives, salts and water), generates weight sheets, stores test results and generates lab reports.

This web-based application allows users to quickly access their slurry formulations and check testing status from anywhere, at any time. The advanced search function enables users to find the formula and the test they need based on past jobs in no time.

I-2. Engineering Features

CEMLab features include:  Web-based application

 Compatible with IE8, IE9, IE10, IE11, Firefox, Chrome and Safari.  Cement slurry formula designs

 Density/porosity input  7 API standard tests

 Up to 5 sets of data for each test  Test sheet

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 Final reports  Combined search  Various search criteria

 Centralized master database  Job tracking

 Design history  Cost calculations

 Lab management and user management (admin only)

I-3. Copyright and Disclaimer

CEMLab and its user’s manual are copyrighted (2012) by Pegasus Vertex, Inc. All efforts

were made to insure the proper operation and calculation of the CEMLab program. However, due to the inherent complexity of the analysis, Pegasus Vertex, Inc. makes no warranties or representations (expressed or implied) about the suitability of the software. This also includes the validity, merchantability, or fitness for a particular purpose from any results obtained from the CEMLab program. Pegasus Vertex, Inc. will not be liable for any damages suffered by licensee as a result of using, modifying, and distributing this software and its derivatives.

I-4. Technical Support

For any questions, comments, or suggestions about CEMLab, please contact: Pegasus Vertex, Inc.

6100 Corporate Dr., Suite 448 Houston, TX 77036 Tel: 713-981-5558 Fax: 713-981-5556 E-mail: [email protected] Web: www.pvisoftware.com

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II. CEMLab Structure

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III. Getting Started

III-1. Hardware and System Requirements

Server requirements:

Processor 1 GHz (x86), 1.4 GHz (x64)

Operating System Windows Server 2003 with .Net Framework 3.5 and 4.0 IIS Version 5.0 or higher

Database SQL 2005 or higher

Memory 1 GB RAM

Disk Space 5 GB Client requirement:

Web browse IE7, IE8, IE9, IE10, IE11, Firefox, Chrome, Safari Download speed 1Mbps

Display: Resolution: 1280 x 720

III-2. Server Configuration

CEMLab is shipped on a CD containing the necessary files to install the software. Before installing the CD, please go through the following configurations.

1. Install .Net Framework 3.5 and 4.0

2. Install SQL Server and SQL Management Studio (version 2005 or higher) 3. Install IIS (version 5.0 or higher)

4. Install Microsoft Office (version 2000 or higher)

After the setup is complete, the CEMLab icon will appear on the desktop.

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III-3. Interface

The user interface can be divided into 3 major sections: Title, Menu and Main page. 1. Title Section

The CEMLab® logo is on the left side and user’s information on the right side.

Click on “User Setting” to open a window where you can set up your personal information and change your password.

Click on “Log out” to exit the program.

2. Menu Section

The menu has four choices:

A. “Slurry Design” – where you can start a new design, by clicking on “New”. All

active slurry designs are also listed in this panel. To select an active design, click on it.

B. “Search” – brings users to a search page where users can search all designs,

whether active or archived (for more detail on searching, see Chapter V).

C. “Master Database” – displays eight (8) databases. Within each database, you will

find the ingredients’ information which you can select when working on a slurry design (for a more detail on databases, see Chapter VI).

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D. “Management” – has features that are only available for administrators (for more

details on administration, see Chapter VII).

Clicking on a section title will open a panel displaying the choices for that section. In the example above, the “Management” section is open and the choices (Lab, User, General, Bulletin Board and Test Manual) are displayed.

3. Welcome Window

The main page contains Lab Information, Quick Links, Bulletin Board and Job Tracking. The Lab Information section shows the current user’s lab name and lab code and a logo for the lab.

Quick Links can direct users to create new slurries or search for existing slurries.

Bulletin Board section lists all the notifications that are sent by either a system administrator or a lab manager. User can click on the hyperlink to open a window which shows the detailed contents of the message.

Job Tracking has 4 sections:

A. “Designing” – slurry designs that are currently in the design process. B. “Testing” – slurry designs that are currently ready for testing.

C. “Returned” – slurry designs that have completed all the required tests and are returned to the original designer.

Job Tracking

B

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D. “Finalized” – slurry designs that have been completed and archived.

The items in 4 columns are sorted by time order; the new coming slurry design will always appear at the top.

Users with administrator privilege can see all the slurry designs of multiple labs; and users with lab manager privilege can see the slurry designs of their own lab. The slurry designs that directly relate to themselves will have a start symbol (*) on the side.

The main page allows you to have multiple tabs opened at one time so that users can switch among the different designs easily. Clicking “X” on a tab will close the tab.

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IV. Slurry Design

IV-1. General

The General section (as shown above) provides 5 buttons and specific information about the current cement slurry design.

“Collapse All” and “Expand All” buttons are used to collapse and expand all panels in this window. Users can also click on the round icon with a triangle inside to collapse or expand a certain panel.

“Save” button is used to save the input data. If users try to exit the window without saving, a pop-up message will automatically open as a reminder.

“Duplicate” button is used to generate a new slurry design and copy slurry formula data from the current slurry design to the new one. Note: only general information and formula will be duplicated; test and other data will not be duplicated.

“Refresh” button is used to refresh the web page. In the unexpected event that the web page becomes suspended or loses connection with the server, users can click on this button to refresh the web page.

“Report No.” is a unique number that identifies each cement slurry design. Whenever a new slurry is created, the system automatically assigns a default number. Users can then modify the number. Clicking on this button will revert back to the default number.

“Report date” is the date when the slurry is created. The system uses the current date as the default date. It can be changed if needed.

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“Project No.” is a number for reference purposes.

“Operator” is the operator company name.

“Analyst” is the person who started the slurry design. This field is filled with the current user’s name by default.

“Client” is the client company name. This field is a drop down list. The contents of this list can be edited in the General Management section (see Chapter VII-3).

“Well” is the name of the well.

“Field” is the oil field name.

“API Well No.” is the API serial number of the well. "Rig" is the rig name or rig model.

"Job" is the operation that the slurry is designed for. The drop-down list includes casing, liner, squeeze, plug, coil tubing and others. The contents of the list can be modified by a system administrator (see Chapter VII-3).

"Casing size" is the diameter of the casing, represented in inch. (See Chapter VII-3) "MD" is the measured depth.

"TVD" is the true vertical depth.

“Mud weight” is the mud density.

"BHST" is the bottom hole static temperature. "BHCT" is the bottom hole circulating temperature. "Surface T." is the surface temperature.

"BHP" is the bottom hole pressure.

"T. gradient" is the temperature gradient. Users can manually input the value, or they can click the button next to it to let the system calculate the value on the given data.

"Blend type" is a field to input the blend type.

"Notes" is for users to input some comments or notifications about the current slurry design.

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IV-2. Blend

1. Add button

The drop-down box and the Add button are used to add a row in the blend table below. The correct operation is to select an item in the drop-down list first, then click on the Add button. The drop-down list includes silica, fine, medium, coarse and solid additives.

2. Blend name, Save and Load blend

The Blend input field is for users to define a name for the current blend formula. The Save Blend button is used to save user’s defined blend name and blend formula, and the Load Blend button is used to load an existing blend.

3. Blend table

The Blend table contains all the information about the blend formula. Users can insert up to 10 rows in this table.

(1) “Category” column shows which category an ingredient belongs to.

(2) “Code” column is for users to select the ingredients from the master database

(3) “Component” column shows the name or description of the selected ingredient.

(4) “SG” is the specific gravity.

(5) “Price” is the unit price of the selected ingredient.

(6) “Conc.” is the abbreviation of concentration. This column is for users to input

concentration values.

(7) “Unit” column is a drop-down box for users to select. There are 2

options: %BVOB (by volume of blend) and %BWOC (by weight of cement). Note: if %BVOB is selected, the value in the Conc. column should be less than 100, and the summation of the Conc. column should be less than 100 as well.

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(8) “Wt.” is a calculated result. It indicates how much of an ingredient is required to

make a sack of this type of blend.

(9) “Lab Wt.” is a calculated result. It indicates how many grams for each ingredient

are required to make a 600 ml sample of the cement slurry.

(10) “Cost” is the cost of each ingredient for making one bbl of cement slurry.

(11) “Lot #” is the lot number of the ingredient. Users can only input lot numbers in

the ‘Lot #’ window. 4. Average SG

This field shows the average specific gravity of the whole blend. This value is computed by the SG and concentration of the ingredients.

5. Total weight and total lab weight

The two numbers after “Total” are the total blend weight of one sack of cement slurry and the total laboratory blend weight of a 600 ml slurry sample.

Note: the field with white background is editable. The field with grey background is not editable.

IV-3. Solid Additive

The solid additive table contains information about selected solid additives. The Add button on the left side is used to add a new row to the table. Users can delete it by clicking on the trash icon.

The content of the solid additive table is similar to the blend table. The Unit column has two options: %BWOB (by weight of blend) and %BWOC (by weight of cement).

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IV-4. Liquid additive

The Add button on the left side is used to add a new row to the table. Users can select an ingredient in the Code column. The Unit column has 2 options: gal/sk (gallons per sack) and gphs (gallons per hundred sacks).

IV-5. Base Fluid

The Base Fluid has 2 sections. The upper section is for base fluid, and the lower section is for salt. Users can select which base fluid is used in the Code column, and the system will do calculation for all other columns. In the Salt section, users can select either KCl or NaCl to be used for this slurry and define the salt concentration by entering a number in the %BWOW (by weight of water) column. Note: the reasonable range of NaCl is between 0 and 37, and KCl is between 0 and 31.

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IV-6. Slurry property and results

The floating panel on the right side contains slurry properties and some calculated results. 1. Slurry density and porosity

There are 2 options: slurry density and porosity. Users can select either one. The selected one will become an input, and the other one will become a calculated result. Porosity is the percentage of the liquid-phase ingredient volume (including base fluid, liquid additives, and salt if applied), divided by the total slurry sample volume (which is always 600 ml). SVF (solid volume fraction) is the percentage of the volume of all solid-phase ingredients divided by the volume of total slurry sample.

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2. Yield

There are cement yield and blend yield. The cement yield is always used more frequently.

3. Mixing fluid

Mixing fluid is the mixture of liquid additives, base fluid, and salt. “SG” is the specific gravity of mixing fluid. “Per sk of blend” shows the number of gallons of the mixing fluid required for mixing with one sack of blend. “Per sk of cement” shows the number of gallons of the mixing fluid required for mixing with one sack of cement. If the blend consists of cement only, and no other solid additives, then the latter value will be equal to the former one. “Lab Wt.” and “Lab Vol.” are the laboratory weight and volume of the mixing fluid for making a 600 ml slurry sample.

4. Cost

This section shows the cost of blend, additives, base fluid, and the total. 5. Super sack

This section can be used when users want to mix a larger amount of this kind of slurry. Users can input either the required slurry volume or the required blend sacks. Then the system will calculate how much of each ingredient is needed for making such amount of slurry and the results will be displayed in an Excel report.

6. “Calculate” button

This button is used to perform calculations. If some key parameter is missing or out of a reasonable range, the system will pop up a message to notify users.

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IV-7. Comments

The Comments section is used to leave comments and send the slurry design to others. 1. Comments

The large box allows users to type in comments or suggestions for the lab technician. 2. “Assign to” and Submit button

In the “Assign to” box, users can first select other users whom they want to submit this formula design to. Then click on the “Submit” button to submit the data. Please note: after the data is submitted, no one can make any changes to the submitted slurry formula. Users can assign a slurry design to one person or to an entire lab. If a slurry design is assigned to a lab, then all users working for this lab will receive this design, and they all can open the test section at the same time.

3. “Lot #” button

Clicking this button will open the “Lot #” window where users can enter the lot numbers for each ingredient.

4. “Test Sheet” button

Clicking this button will generate a test sheet in Excel format. It includes general information, slurry formula, and a blank test page for the lab technician to record the test results on (see Chapter VIII).

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V. Test

V-1 Test

The Test section has 7 API standard tests and one user defined test. Mark the checkbox in front of the test icon to activate the test, then clicking on the icon will open an individual window for the test. Each test has up to 5 sets of data. Only users who create this slurry and the users who receive the test request can have the authority to open the test windows. Other users are not able to open them.

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1. Density

The Density test is used to measure the cement slurry density.

“Test name” is for users to enter an identification number or name for this test.

“Show on report” is a checkbox which can control whether you want to show this test in the report or not.

At the bottom of each test window, there is a “Test manual” button, which can open a pre-uploaded test manual file. On the right side there is an “Add” button which is used to add a set of test data. The “OK” button can save the data and exit this window.

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2. Rheology

In the Rheology window, users can input the viscometer readings in the table and then select a desired rheology model. By clicking the button, the system will calculate and show the results and plot the shear rate vs. shear stress graph on the right side. The system has 4 models: Bingham plastic, Power law, Herschel Bulkley and Auto pick. When selecting a different model, the system will give relative results. If Auto pick is selected, system will compare the results of the Bingham plastic model and the Power law model and pick the model that fits the best.

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3. Compressive strength

On the top left side, there is a schedule table for the input of initial conditions, final conditions, and ramp time. In the “Compressive strength” table, users can enter the time points and the strength at that time. The UCA table is for the input of testing data observed from testing equipment. On the right side of this window there is a picture box that allows users to import a picture by clicking the Load button. Users can also select the crush type, which can be either ‘cube’ or ‘puck’.

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4. Fluid loss

The Schedule section is for recording the experimental conditions. The “API fluid loss” table is to input the filtrate volumes measured at different times. The system will calculate the final API fluid loss volume once the button is clicked. If a blowout occurs, the fields on the right side should be used. Users are required to enter the time and volume at the moment of the blowout, and the system will calculate the fluid loss volume under the blowout situation.

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5. Thickening time

The Schedule section is for recording the experimental conditions. If the testing slurry is mixed before the test starts, users can enter the mixing time and temperature in the “Batch mixing” table. The “Time to” table is for recording how long the slurry takes to achieve a certain consistency. On the right side of this window there is a picture box which allows users to import a picture that was generated from testing equipment.

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6. Free fluid

The Free fluid test is used to determine the static stability of a cement slurry. After users enter the temperature, time, inclination angle, initial volume and free fluid volume, the system will calculate the free fluid percentage based on the numbers input.

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7. Compatibility

The Compatibility test is in standard API format. Users can input viscometer readings for different mixtures. In the “Compatible” column, users can select either Yes or No to indicate whether this component is compatible or not.

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8. Other

This window is for some user-defined tests. Users can define a test name and column title and input the test data. A picture can be uploaded if needed.

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V-2. Attachment and Finalize

The bottom section below the Test contains an attachment list and three buttons.

The Attachment box is a list of all attached files. The file can be in any format, such as a picture, a pdf document, a chart, or an Excel spreadsheet. Attached files can be opened or downloaded to the local disk.

The “Upload” button opens a diagram window from where users can select a file to upload. The “Finalize” button is used to finalize a slurry job. After clicking on this button, all data in the job will be locked and protected. No one can make any changes on a finalized job. The “Report” button is used to generate a final report including slurry formula, test data, and charts (see Chapter VIII).

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VI. Search

The Search window has 2 sections: the upper section is general search and the lower section is advanced search.

As to the search criteria, users can type in a key word in the field and search for one or multiple slurry designs with this key word. If users want to search by some numbers, such like slurry density, then users can set a minimum limit and a maximum limit, and the system will search for all the slurry designs with a value in this given range. If only a minimum limit is given, then the system will search all slurry designs with a value larger

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than this limit. Similarly, if only a maximum limit is given, the system will search all those with a value below this limit. Users can also do a search by giving a code of a certain ingredient, such as “ClsA”, and then the system will search all slurry designs that contain ClsA cement.

After clicking the Search button, a window will pop up. This window shows all slurry designs that meet the search criteria. Clicking on any of the blue-colored Report No. will open a slurry page.

Users can click the column head to sort the data by alphabetical order. Users also have the capability to select what column they want to show in this window, this way, users can ignore some unimportant data. The Formula column shows an abbreviated slurry formula with ingredient code and percentage.

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VII. Master Database

There are eight master databases: cement, silica, fine, medium, coarse, solid additive, liquid additive, and base fluid. All users in the system share the same master database. Users can add new records to the master database, edit or delete existing records generated by them. However, users are not allowed to modify others’ records and only the administrator can do so.

All eight master databases have eight separate pages. The following example shows you the cement database; the others are similar.

Clicking the Add button will open a new window where users can add a new chemical ingredient to the master database. The window is shown below.

“Code” is the unique ID of one specific ingredient. It consists of letters and numbers. The same code cannot be used for two different ingredients.

“Component” is the explanation or description about that one specific ingredient.

“SG” is the specific gravity of that one specific ingredient. The SG is required for slurry calculation.

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“Abs. Vol.” is the absolute volume. Users do not need to input this value; it will be calculated by the system automatically after the SG has been entered.

“Bulk density” is the mass per unit volume of a dry material. This number is required for all solid ingredients.

“Price” is the unit price of that one specific ingredient. Note: the price of solid material is dollar per unit mass, and the price of liquid material is dollar per unit volume.

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VIII. User Setting

Clicking on the User Setting link at the right top corner will open a pop-up window.

In this window, users can change their passwords. If users do not want to change the password, these two fields can be left unchanged. Users’ personal contact can be provided here as well.

Some fields are locked to prevent from being changed by mistake. If general users want to change the locked information, they have to contact the system administrator who has the privilege to do so.

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Clicking on the Change button right behind the Unit Setting can open a pop-up window where users are able to switch units between US oil filed unit and SI unit. Users also can set up customized units by selecting Customized, where they can select a unit for each parameter.

Users can also select a currency symbol for the system, as well as up to three characters as currency symbols, such as USD. Please note that, changing the currency symbol will only change the appearance of the currency unit, it doesn’t exchange any prices or costs. The server will memorize all the personal settings no matter which computer is logged in.

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IX. Management (admin only)

IX-1. Lab

The Lab management page is for the administrator to add, modify or delete a lab. Clicking the Add button will open the Add Lab window as shown below.

“Lab name” is the name of the lab. The name will be shown in the report heading.

“Lab code” is the two letters that will be referenced to create a report number.

“Info” is the information about this lab. Users can type in the address, phone number, email address, etc. Lab info will be shown on reports as report head.

“Logo” is a picture box. Users can click the Upload button to open a dialog window and import a picture. The logo will be shown on reports as well.

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IX-2. User

The User page is for adding a user or modifying an existing user’s information.

The Add User window is for adding a new user.

“User name” is the user ID used to log into the system.

“Password” and “Confirm password” are to set up a password. The password can be made up with letters, numbers, and symbols. It must have at least 6 characters.

“Real name”, “Email”, and “Phone” are real information about the user.

“Lab” is a drop-down list showing all the labs in the system. The administrator needs to select which lab the current user is working on.

“Access level” is a drop-down list. It has 4 options: administrator, Lab manager, user, and guest.

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 Administrator has the highest privilege. The administrator can manage labs and users, and modify users’ data. It is recommended that each system should have less than 3 administrators.

 Lab manager is the person who takes charge of the whole lab. A lab manager can see all on-going jobs under his lab.

 User can be any general user of the system. A user can be a specialist, an analyst or a lab technician.

 Guest has the lowest access level. A guest can only review the existing data in the system, but cannot make any changes.

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IX-3. General

In the general page, there are 3 tables - Job, Casing size, and Client. These three tables are related with the fields in the General section of the Slurry Design page. Only the administrator has the privilege to edit the information in this window. Any line items added into these three tables will become a valid option in Slurry Design.

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IX-4. Bulletin Board

Only the administrator and lab manager can access to the Bulletin Board. This section is for them to distribute a message, they create a message and save it in the system, and then other users who log onto CEMLab will receive this message. The message sent by the administrator will be received by every user in CEMLab, and the message sent by the lab manager will be only received by the people of his own lab.

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IX-5. Test Manual

The Test Manual page is only open to the administrator. An administrator can upload a document file to guide the users how to run a test.

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X. Reports

CEMLab can generate two types of reports. One is a test sheet and the other is the final report.

A test sheet has cement slurry formula for lab technicians to use when mixing the slurries and blank tables for lab technicians to write the test results.

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The final report is a total summary of the slurry job. It contains the slurry formula, test results, some test graphs and the super sack sheet if applicable.

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Cement Lab Data Management System. Version 2.2. User s Manual