Chemo-Poro-Elastic Fracture Mechanics of Wellbore Cement Liners: The Role of Eigenstress and Pore Pressure on the Risk of Fracture MASSAC HLISETTS INSTITUTE OF FECHNOLOLGY by JUL 02 2015 Thomas Alexander Petersen LIBRARIES B.S., North Carolina State University (2011) Submitted to the Department of Civil and Environmental Engineering in partial fulfillment of the requirements for the degree of Master of Science at the MASSACHUSETTS INSTITUTE OF TECHNOLOGY June 2015 @ Massachusetts Institute of Technology 2015. All rights reserved. Signature redacted Author ............... Department of Civil and Environmental Engineering May 21, 2015 Certified by...... Signature redacted ......... Franz-Josef Ulm Professor of Civil and Environmental Engineering Supervisor I IThesis Accepted by ... Signature red acted Z. .. .20 ( Heidi Nepf Donald and Martha Harleman Professor of Civil and Environmental Engineering Chairman, Department Committee on Graduate Theses 2 Chemo-Poro-Elastic Fracture Mechanics of Wellbore Cement Liners: The Role of Eigenstress and Pore Pressure on the Risk of Fracture by Thomas Alexander Petersen Submitted to the Department of Civil and Environmental Engineering on May 21, 2015, in partial fulfillment of the requirements for the degree of Master of Science Abstract Between 2001 and 2010, United States natural gas wells have been drilled at a mean annual rate of 24,500. Moreover, an investigation in the Marcellus region revealed a 3.4% incidence rate of well-barrier leakages that were caused primarily by casing and cementing problems. Considering the detrimental consequences even a single failed well can have on the health of vast expanses of ecosystems, the quality of groundwater aquifers, and the production efficiency of fossil resources, ensuring the integrity of cement liners is of utmost importance. While much attention has been devoted to the mechanical analysis of the cement sheath during temperature and casing pressure cycles in the hardened state, modeling efforts of the early-age shrinkage and porepressure developments have thus far proved inadequate. This motivates us to study the cement sheath as a poro-elastic media under growth and stiffening of its solid structure, and connect bulk stress and pressure development to worst-case fracture scenarios. Specifically, a bottom-up approach is herein developed to incorporate the microscale behavior of the hydrating cement phases into a predictive risk-of-fracture model. We incorporate recent findings of the driving mechanism of eigenstress development in CSH-gel and connect it, via Levine's theorem, to pore-pressure changes in the sheath. Coupled to the boundary conditions of an inner steel casing and an outer rock formation, the bulk stress in the sheath is calculated incrementally with reference to the growing solid skeleton. The added risk due to the off-center placement of the casing is quantified in a novel Laurent series solution to the stress state. Finally, energy release rates are derived for (i) the micro-annulus formation along the steel-cement and rock-cement interfaces, and (ii) the occurrence of a single radial fracture emanating from the steel-cement interface. Thesis Supervisor: Franz-Josef Ulm Title: Professor of Civil and Environmental Engineering 3 4 Acknowledgments I am incredibly grateful to have found an environment in the MIT community in which I am challenged academically and supported personally. Thus, I must firstly express my sincere gratitude to Professor Franz Ulm for his breadth of knowledge in cement science and poromechanics, and his continued effort to engage me in interesting and novel research topics. He has an innate ability to communicate the broader impacts of our work. After research meetings, I always left his office more motivated than when I arrived. Additionally, I must give thanks to the hard working engineers and scientists at the Schlumberger-Doll Research Center inn Cambridge, MA and the SchlumbergerRiboud Product Center in Clamart, France. Through weekly phone conferences and a summer internship I gained invaluable insight into the research challenges of the oil and gas drilling industry. Their expertise and generous aid has allowed the X-CEM project to reach targeted solutions otherwise not possible. Funding for my graduate studies was generously supplied by the National Science Foundation Graduate Fellowship program and Schlumberger. I thank these organizations much for their investment in science and engineering; to enabling the work of many inspired students and researchers. Next, I wish to thank the Civil and Environmental Engineering Department as a whole. I have fostered numerous professional and personal relationships that will last far into the future. Both the Parsons' Lab and Building 1 are filled with diverse, intelligent and passionate people that contribute to my scientific and personal growth in this collaborative community. Both within and beyond my life in Cambridge, friends and family have made the last three years of my life some of the most enjoyable. In particular, I wish to thank my dear friend, Fatima, who taught me much about the way of life at MIT from her experiences as an undergraduate. She is an invaluable confidant, and is someone I care for deeply. My immediate family has had the greatest influence in shaping my success. I wish to thank my sister Becky and my brother Karl for their constant availability and for sharing their insights and perspectives on my life's conundrums. I am most appreciative of the continued sacrifices made by my parents Kim and Martin to maintain my wellbeing and happiness; their support is immeasurable and their influence is recognized in all facets of my life. 5 6 Contents 1 21 Introduction 1.1 Industrial Context . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 1.2 Research Motivation and Problem Statement . . . . . . . . . . . . . . 23 1.3 The Primary Cementing Process . . . . . . . . . . . . . . . . . . . . . 26 1.4 T hesis O utline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 31 2 The Microstructure of Hardening Cement Paste 2.1 2.2 Structure of Hardened Cement Paste (HCP) . . . . . . . . . . . . . . 31 . . . . . . . . . . . 32 . . . . . . . . . . . . 33 . . . . . . . . . . . . . . 34 . . . . . . . . . . . . . . . . . . . . . . . . . . 35 2.1.1 Calcium Hydroxide Crystals (Portlandite) 2.1.2 Calcium-Silicate-Hydrate Gel (CSH gel) 2.1.3 Anhydrous Cement Grains (Clinker) 2.1.4 Pore Structure Classification of the Characteristic Length Scales in Hardening Cement P aste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 2.3 37 2.2.1 Level '0'. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.2 L evel I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 2.2.3 Level II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 2.2.4 Level III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Modified Powers-Brownyard Model For the Calculation of Volume Fractio ns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 . . . . . . . . . . . . . . . . 40 . . . . . . . . . . . 45 Sample Model Output: The Evolution of Volume Fractions. . 46 2.3.1 Partitioning of Volume Fractions 2.3.2 Characteristic Time of Cement Hydration 2.3.3 7 2.4 . 48 . . . . . . . . . . . . . . . 48 . . . . . . . . . . . . 49 Continuum Micromechanics: A Three-Level Cement Thought-Model 2.4.1 The Principle of Scale Separability 2.4.2 Concepts in Continuum Micromechanics 2.4.3 Homogenization schemes for elastic properties composite materia ls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2.4.4 Three-Level Homogenization Scheme for Hardening Cement Paste 53 2.4.5 Sample Model Output: Evolution of Poroelastic Constants. . . 57 2.4.6 Chapter Summary . . . . . . . . . . . . . . . . . . . . . . . . 61 63 Bulk Eigenstress Development 3.1 On the Origin of Cement Eigenstresses During Hydration . . . . . . . 64 3.2 Upscaling the Microscopic Driving Forces . . . . . . . . . . . . . . . . 66 . . . . . . . . . . . . . . . . . . . . . . . . . 66 3.2.1 3.3 Levin's Theorem An Incremental State Equation for the Mass Balance of Hydrating Cem ent Paste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 3.3.1 Mass Balance of the Water . . . . . . . . . . . . . . . . . . . . 72 3.3.2 The Simplifying Assumption of Uniform Bulk Eigenstress Developm ent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.3 3.4 4 51 76 Sample Model Output: Comparison with the Down-Hole Pressure of an Oil W ell . . . . . . . . . . . . . . . . . . . . . . . . 80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Chapter Summary Stress Developments for Concentric and Eccentric Steel Casing Place83 ments 4.1 4.2 An Introduction to the Method of Complex Variables for Problems of the Plane Theory of Elasticity . . . . . . . . . . . . . . . . . . . . . . 84 4.1.1 Derivation of the Airy Stress Function in Complex Variables . 84 4.1.2 The Kolosov-Muskhelishvili Equations . . . . . . . . . . . . . 88 4.1.3 The Kolosov-Muskhelishvili Equations in Polar Coordinates . 90 Elements of Poromechanics: A Three-Phase Poro-Composite Cylinder under Eigenstress Loading . . . . . . . . . . . . . . . . . . . . . . . . 8 92 4.3 4.2.1 Poromechanical Constitutive Relations . . . . . . . . . . . . . 92 4.2.2 The Boundary Conditions . . . . . . . . . . . . . . . . . . . . 93 The Stress State in a Cement Sheath with a Concentrically Placed C asin g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.1 94 Sample Model Output: Stress Evolution for a Concentrically Placed Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 4.4 Stress State in a Cement Sheath with an Eccentrically Placed Casing. 4.4.1 102 Constructing Coordinate Systems for the Steel, Cement, and Rock Dom ains: . . . . . . . . . . . . . . . . . . . . . . . . . . 104 4.4.2 The Bilinear transformation . . . . . . . . . . . . . . . . . . . 104 4.4.3 The Kolosov-Muskhelishvili Formulas for the Mapped System 106 4.4.4 Matching the Boundary Contours Using the Chebyshev Polynom ials 4.4.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Sample Model Output: The Stress Evolution for an Eccentrically Placed Casing. 4.5 5 Chapter Summary . . . . . . . . . . . . . . . . . . . . . . .111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 119 Fracture Criteria . . . . . . . . . . . . . . . . . . 120 5.1 Fracture Mechanics in Porous Media 5.2 Microannulus Formation . . . . . . . . . . . . . . . . . . . . . . . . . 122 5.3 5.2.1 Microannulus Along the Steel-Cement Interface (SC) . . . . . 123 5.2.2 Microannulus along the rock-cement interface (RC) . . . . . . 125 5.2.3 Sample Model Output: Energy Release Rate due to Interfacial D ebonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Radial Fracture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 . . . . . . . 130 5.3.1 Connection to the Chemo-Poro-Mechanics Solver 5.3.2 Method of Continuation . . . . . . . . . . . . . . . . . . . . . 132 5.3.3 Green's Function for an Edge Dislocation . . . . . . . . . . . . 134 5.3.4 Singular Integral Equation for the Crack Surface Boundary C ondition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 145 5..35 Calculating the Stress Intensity Factor and the Surface Displacem ent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.6 Sample Model Output: Evolution of Energy Release Rate due to Radial Fracture 5.3.7 6 . . . . . . . . . . . . . . . . . . . . . . . . Chapter Summary . . . . . . . . . . . . . . . . . . . . . . . . . . 159 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 Conclusions and Perspectives 6.1 6.2 156 Sample Model Output: Energy Release Rate due to the Loss of Shear Traction 5.4 154 167 Review and Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 6.1.1 Problem Synopsis . . . . . . . . . . . . . . . . . . . . . . . . . 168 6.1.2 Modeling Contributions and Findings . . . . . . . . . . . . . . 168 N ext Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 A Effective Stiffnesses of Steel Casing and Rock Formation 171 B Laurent Series Representation of Analytic Functions in the Complex Plane 173 C Upscaling Poroelastic Constants 175 C.1 Level I: CSH Gel with Gelpore Pressure C.2 Level II: CSH Gel with Macro-Pores . . . . . . . . . . . . . . . . 175 . . . . . . . . . . . . . . . . . . 176 C.3 Level III: Reinforcement by Rigid, Slippery inclusions (Anhydrous Cement Grains and Non-Reactive Additives), CSH Gel+Macropores D Analytic Functions with Branch Cuts 10 . . 178 181 List of Figures 1-1 Energy sources for United States electricity generation measured in trillions of kilowatthours. The reference case for the projected energy sources assumes a 'business as usual' scenario. (Source of figure: [3]). 1-2 An illustration of the primary cementing procedure for an oil or gas well. The figure has been adopted from Ref. [40]. 2-1 22 . . . . . . . . . . . Scanning electron microscope images of (a) the CSH phase - 29 adapted from Constantinides and Ulm [20]-, and (b) a portlandite (CH) crystal precipitated in a CSH matrix - 2-2 adapted from Nelson and Guillot 1601. 33 The Voigt-Reuss-Hill bounds of the a) bulk and b) shear moduli of CSH solid sheets as calculated by the atomistic simulations of Qomi et al. [6 9]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Illustration of the nano- to micro-scale structure of CSH. This figure is adapted from [871 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 34 38 Depiction of the three-level upscaling scheme utilized to arrive at the bulk poroelastic constants and the bulk eigenstress. . . . . . . . . . . 11 39 2-5 (a) A snapshot of a simulation box filled with spherical CSH particles for a polydispersity 6 = 0.47. The polydispersity is a measure of the standard deviation of the particle sizes used in the mesoscale colloidal simulation. 6 is quantified in units of 0.5(rM + rm), the average of the maximum rm and minimum rm sphere radii and the color code signifies the particle sizes. (b) The packing density r as a function of the polydispersity 6; the shaded region highlights the range of jamming volume fractions 7j (adapted from Ref. [531). . . . . . . . . . . . . . . 2-6 43 (a) The time evolution of the hydration degree measured against values calculated from calorimetry data for Class G oil well cement. The modeled values are calculated by Eq.(2.14), where a = 5.3 s-, b = 6.4, c = 230, and d = 4.3. (b) The hydration affinity plotted against the degree of hydration. (Data provided by Schlumberger-Doll Research C enter.) 2-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 The volume fractions in a hydrating cement sample are plotted as a function of the degree of hydration . The results are based on our modified Powers and Brownyard model (see Table 2.1 for input parameters). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 The microstructure of 100-day old cement paste with a w/c of 0.30 (from R ef. [261). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 47 55 The evolution of the bulk modulus of the cement is plotted for an REV at the three characteristic length scales defined by Level I (CSH-gel), Level II (CSH-gel + macropores), and Level III (CSH-matrix + rigid inclusions) (see Table 2.1 for input parameters). All values have been normalized by the bulk modulus of the CSH-solid. . . . . . . . . . . . 12 58 2-10 The evolution of the Biot modulus of the cement is plotted for an REV at the three characteristic length scales defined by Level I (CSH-gel), Level II (CSH-gel + macropores), and Level III (CSH-matrix + rigid inclusions) (see Table 2.1 for input parameters). The modulus has been normalized by the bulk modulus of the CSH-solid. The secondary axis offers a comparison of the CSH-gel packing density. . . . . . . . . . . 59 2-11 The bulk elastic properties properties of the cement, K and G, and the biot coefficient of the cement are plotted as a functino of the degree of hydration (see Table 2.1 for input parameters) . 3-1 . . . . . . . . . . . . The relation between eigenstress development and packing density for cement hydrating at constant pressures of 1 MPa and 10 MPa 3-2 60 [86J. 65 Levin's theorem is used to upscale the eigenstress in the microstructure to the macroscale (the volume phases are not drawn in proper proportion and scale). 3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . 68 (a) The pressure evolution is plotted against the evolution of the ratio between the characteristic times of hydration and fluid mobility. The time ratio is plotted in log scale on the secondary axis. (b) The evolution of the bulk eigenstresses, decomposed the stresses acting in the CSH-solid (1 - b)-* and the porespace -bp. 3-4 . . . . . . . . . . . . . . 78 A comparison between the model simulated pressure and the pressure in the pressure in an oil well. As the pressure data is proprietary, the curve has been smoothed and the input parameters to the model have been om itted. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 81 A diagram of the wellbore geometry for the case of a casing placed concentrically w.r.t the hole. The cement sheath is bounded at its interior by a steel casing and at its exterior by a geologic formation. The inner, circular boundary of the steel is located at a distance RO from the origin. The interfaces SC and RC are located at distances of R1 and R 2 from the origin respectively. 13 . . . . . . . . . . . . . . . . . 94 4-2 (a) The effective radial stress and (b) the effective hoop stress development along the interfaces of the steel and cement (blue) and the rock and cement (red) is plotted in function of the degree of hydration. The input parameters have been summarized in Table 2.1, and the scenarios of a stiff (solid lines) and soft (dashed lines) are plotted. 4-3 . . . . . . . 101 Three-dimensional plot of the effects of the fluid exchange coefficient A and the rock Young's modulus ER on the radial stress (top row) and the hoop stress (bottom row) at complete hydration. Stresses are plotted for SC (left column) and RC (right column); E( = 1) ~ 23 G Pa . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 103 Contours in the reference coordinate system (z-plane) are mapped via the bilinear transformation into a conformal image ((-plane); the eccentric boundaries SC and RC are mapped into the concentric boundaries S C and R C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 106 Panel of (a),(b) the radial and (c),(d) the hoop stress evolution for a cement sheath with an eccentrically placed casing (4, = 0.8) as a function of the hydration degree for the material parameters provided in Table 2.1 and the borehole dimensions provided in Table 3.1. The plots separate stresses that evolve along (a),(c) the steel-cement interface (SC) and (b),(d) the rock-cement interface (RC). Thick (thin) lines correspond to stresses along the thickest (thinnest) portion of the sheath; colors represent different fluid exchange coefficients between formation and sheath; ER = 40 GPa. . . . . . . . . . . . . . . . . . . 112 14 4-6 Panel of (a),(b) the radial and (c),(d) the hoop stress evolution for a cement sheath with an eccentrically placed casing ( 6e = 0.8) as a function of the hydration degree for the material parameters provided in Table 2.1 and the borehole dimensions provided in Table 3.1. The plots separate stresses that evolve along (a),(c) the steel-cement interface (SC) and (b),(d) the rock-cement interface (RC). Thick (thin) lines correspond to stresses along the thickest (thinnest) portion of the sheath; blue (orange) lines present model output for a soft formation; A = 1 x 10 4-7 5 s/m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 (a) The effective radial stress and (b) the effective tangential stress at complete hydration for a wellbore hole geometry with an eccentric casing plotted as a function of the angular component 0 along the steelcement interface (red) and the rock-cement interface (blue); ER = 40 GPa. The line thickness indicates the degree of eccentricity, which has been varied between 0.2 and 0.8 . . . . . . . . . . . . . . . . . . . . . 4-8 114 The shear stress along the SC (red) and RC (blue) interfaces plotted (a) as a function of the degree of hydration and (b) as a function of the angular coordinate 0 at complete hydration; A = 1 x 10- and ER = 40 GPa. The line thickness indicates the degree of eccentricity, which has been varied between 0.2 and 0.8 . . . . . . . . . . . . . . . . . . . . . 4-9 114 Three-dimensional plot, investigating the influence of the stiffness ER and Newton coefficient A on the magnitude of the maximum shear stress experienced along SC and RC. The degree of eccentricity is set at 6 e = 0.8 and the remaining input parameters are gathered from T able 2.1. 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Dominant fracture scenarios for the plane geometry of the cement sheath. 121 15 5-2 The evolution of (b) the energy release rate and (c) the stress intensity factor for micro-annulus formation along the steel-cement (SC) and rock-cement (RC) interfaces calculated from the results of the chemoporomechanics solver shown in panel (a). Solid lines indicate a stiff formation (ER =40 GPa) and the dashed lines indicate a soft formation (ER = 5 G Pa). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 127 The (a) the energy release rate and (b) the stress intensity factor for micro-annulus formation along the steel-cement (SC) and rock-cement (RC) interfaces are plotted for different ratios of the rock and cement bulk moduli KR/KC. The bulk modulus of the of the cement, the porepressure, and the radial stress along the interfaces have been calculated by the chemo-poromechanics solver and are evaluated at complete hydration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 5-4 Regions of continuation. 5-5 Shapes for the fundamental function for the dislocation density p(t) Oc aU under the loading of a uniform surface pressure for (a) an embed- . . . . . . . . . . . . . . . . . . . . . . . . . 135 at ded crack, (b) a closed crack with the left tip ending at a bi-material interface, and (c) an edge crack. . . . . . . . . . . . . . . . . . . . . . 5-6 152 The evolution of the (a) (c) energy release rate ((b) (d) stress intensity factor) for a radial crack emanating from the steel-cement interface. The top panel (a)(b) corresponds to the open crack geometry, and the bottom panel (c) (d) corresponds to the closed crack geometry. Values are consistent with the stress state shown in 4-2b for ER = 40 GPa. . 5-7 156 The evolution of the (a)(c) energy release rate ((b)(d) stress intensity factor) for a radial crack emanating from the steel-cement interface. The top panel (a)(b) corresponds to the open crack geometry, and the bottom panel (c)(d) corresponds to the closed crack geometry. Values are consistent with the stress state given by the input parameters in Table 2.1 and lowering the permeability to A = 1 x 10' s/m. 16 . . . . 157 5-8 Diagrams depicting (a) the fracture toughness and (b) the critical stress intensity factor for white ordinary Portland cement with a water-tocement ratio of w/c = 0.4. These results were obtained by the study of Hoover and Ulm [37]. 5-9 . . . . . . . . . . . . . . . . . . . . . . . . . 158 Diagram depicting the potential energy stored in the shear connection between the steel casing and the cement sheath upon developing a radial crack of closed shape. . . . . . . . . . . . . . . . . . . . . . . . 5-10 The surface displacement nO(r) = 160 juo] for p, < r < P2 plotted along the line of the crack pi < r < P2 for (a) the open geometry (the edge crack; x = 0) and (b) the closed crack (x -+ oc) for a crack that has propagated the width of the sheath. The thickness of the lines are proportional to the penetration depth of the crack (P2 -pi)/(R 2 - R1 ). Values correspond to complete hydration of the cement = 1 and are consistent with the stress state shown in 4-2b for ER = 40 GPa. . . . 163 5-11 A comparison of the surface displacement uo(r) = 1 uo] along the crack p, < r < P2 between the open crack geometry (blue) and the closed crack geometry (red). Values correspond to complete hydration = 1 and are consistent with the stress state shown in 4-2b for ER = 40 GPa. 164 5-12 The energy stored in the elastic shear bond between the steel and the cement AE plotted in relation to the normalized penetration depth of the crack (r - Pi)/ (P2 - Pi). Values correspond to complete hydration = 1 and are consistent with the stress state shown in 4-2b for ER = 40 G P a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 5-13 The crack surface displacement bounded by steel Es = 200GPa and rock ER = 40 GPa. The y-axis has been elongated to show the effect on the surface displacement as the crack tips terminate at bimaterial interfaces with varying stiffnesses. . . . . . . . . . . . . . . . . . . . . 165 17 18 List of Tables 2.1 Material input parameters (slurry density: 1.9 g/cc). The constants used for the hydration affinity have been optimized in a non-linear regression with calorimetry data for Class G oil well cement. . . . . . 2.2 48 Phase volume fractions and homogenized poroelastic constants for an REV at the characteristic length scales, Level I-III. The Biot coefficients and Biot moduli at the three scales are derived in Appendix C. 57 3.1 Borehole input parameters . . . . . . . . . . . . . . . . . . . . . . . . 80 5.1 Restrictions on the parameters I, and I2 that ensure an effective hoop stress in the tensile regime . . . . . . . . . . . . . . . . . . . . . . . . 5.2 131 The first root of the characteristic equation describing the singular behavior of the crack tip terminating at the RC bi-material interface; assuming v = vR = 0.27 . . . . . . . . . . . . . . . . . . . . . . . . . 19 150 20 Chapter 1 Introduction 1.1 Industrial Context The extraction of oil and gas from underground reservoirs will continue to rise in the upcoming decades to meet the demands of human life and prosperity, and to help industrialize emerging economies. In fact, the U.S. Energy Information Administration estimates that the world's energy consumption will rise from 524 quadrillion (1015) British thermal units (Btu) in 2010 to 820 quadrillion Btu in 2040, where 85% of the increase is to occur in developing nations [751. In order to satisfy the global energy demand, petroleum and other liquid fuels are expected to contribute the majority of the energy supply. On the domestic front, the largest growth in energy supply is expected from previously inaccessible natural gas sources. The underlining prediction of the 2014 Annual Energy Outlook is the disruptive transformation of the American energy landscape by unconventional gas production. Fig. 1-1 shows the anticipated, dominant growth of natural gas as a source of electricity generation for the United States. Two advantages to its increased utilization are cleaner electricity generation, and a domestic stimulus to the job market [381. Additionally, because it is estimated that the U.S. shale source rocks contain 42 trillion cubic meters of natural gas - approximately 65 times the current annual domestic consumption-and vast supplies of 'tight' oil, domestic natural gas production can ensure long-term energy security and a reduc21 6 History Projections 2012 5 4 3 2 1 0 1990 2000 2010 2020 2030 2040 Figure 1-1: Energy sources for United States electricity generation measured in trillions of kilowatthours. The reference case for the projected energy sources assumes a 'business as usual' scenario. (Source of figure: [3]). tion in the net import of petroleum. From an environmental standpoint, the recently released report by the Intergovernmental Panel on Climate Change identifies natural gas as a promising bridge technology [43]: "Greenhouse gas emissions from energy supply can be reduced significantly by replacing current world average coal-fired power plants with modern, highly efficient natural gas conibiiied-cycle power plants ... provided that natural gas is available and the fugitive emissions associated with extraction and supply are low or mitigated." Under safe and regulated practices, natural gas power plants reduce CO 2 emissions by 50% compared to coal-fired alternatives [381. Because the production of conventional and unconventional liquid fuel sources is directly related to the rate of new well completions, and because unconventional wells require a high density of drilling sites to maximize the yield of a shale formation (up to 16 wells are drilled in a 2-hectare area [381), the practice of constructing wells for oil and gas extraction is assured to increase for decades to come. Furthermore, to ensure that the benefits of natural gas as a transitional energy source are maximized, production wells must establish safe, efficient extraction methods. The engineering 22 challenge thus posed is the design of production wells that eliminate uncontrolled fluid loss and unintended fluid migration by properly sealing the well and reducing the risk of mechanical failure during construction and operation. Otherwise, the potential of natural gas as a "clean" carbon emitting alternative may not be harnessed. This thesis is concerned with the loadings and the mechanisms of failure incurred by the wellbore cement liner as it sets during the construction process. 1.2 Research Motivation and Problem Statement In the construction of an oil or natural gas well, the cement sheath is placed between the geologic formation and the steel casing for the purpose of zonal isolation, including the sealing of the reservoir from the fluids of overlying and underlying strata. Loss of the sealing function carries harmful environmental consequences, creates potential hazards in rig and oil-well operations, and assumes loss of revenue due to decreased production capacity and expensive repair operations [231 1321. Nonetheless, recent evidence suggests that current design practices are insufficient in safeguarding against interzonal flow. For instance, studies have indicated that leakages of methane into groundwater aquifers during unconventional gas production (i. e., gas production by hydraulic fracturing) are the result of impaired cement casings [451 [621 [77]. In Pennsylvania, a region noted for its high incidence of methane leakages, Ingraffea et al. (2014) estimate that 6.2% (1.0%) of unconventional (conventional) wells drilled between 2000-2012 have compromised casings [411. It is known that early-age shrinkage phenomena and pore pressure developments are primary contributors to sheath failure 113], yet contemporary modeling efforts rarely and inadequately incorporate their effects. For a set cement specimen, pressure and temperature cycles of the well entail stresses that can cause failure along the casing-cement and rock-cement interfaces termed microannulus formation; and excessive tensile stresses may initiate radial cracks in the cement that emanate from the inner casing surface [321 14]. At early ages, before the cement is subjected to loadings of the testing and production cycles, 23 the setting cement induces pore-pressure changes and chemical shrinkage phenomena that cause bulk volume changes. Under constraint of the steel and rock boundaries, these volume changes can lead to stresses that impair the integrity of the sheath. The ensuing formation of microannuli and radial cracks produce fissures that drastically increase the permeability of the cement liner. An accurate, predictive design tool must reproduce the physico-chemical behavior of setting cement. Current work at the molecular and meso-scales is revealing the fundamental driving forces of the cement volume changes and their relation to the calcium-silicate-hydrate (CSH) packing-density [53] [54] 1861, and potential improvements of cement strength and fracture toughness through fine-tuning its chemical structure [69] [8]. However, the integration of these findings into predictive engi- neering models has yet to be explored. Additionally, the classification of confined water into free, constrained, and chemically bound water molecules 182] has elucidated the details of the H 2 0 kinetics during hydration and lends opportunity for improvements in modeling the hydrating cement phase morphology. Thus, this work aims at connecting these recent discoveries at the engineering scale of the materials to the structural scale of wellbore cement liners. Utilizing a bottom-up approach to the chemo-poro-mechanical evaluation of early-age cement, we represent CSH as a composition of gel-solid and gel-porespace and homogenize the elementary phase properties of the cement to the macroscale. Hence, the stiffening behavior and shrinkage caused by self-balancing eigenstresses can be tracked in time and may utimately be linked to the boundary conditions of the wellbore system. At the engineering scale, additional challenges remain. An important design parameter, yet to be studied in connection with the early-age driving forces of cement volume change, is the eccentricity of the production casing with respect to the wellbore hole. In an experimental setup, Albawi investigated the fraction of interfacial debonding due to thermal cycling of specimens containing a centrically and an eccentrically located casing [4]. Using Computer Tomography, the eccentric casing (with a degree of eccentricity 6, = 0.5; at its thinnest portion, the sheath thickness is half the thickness of an equivalent concentric sheath) showed a greater fraction of debonding 24 and subsequent creation of fluid channels. To the best of our knowledge, no analytic or semi-analytic solution exists for the boundary value problem of a material domain confined by two eccentric, elastically deforming circular contours. Here, the loss of axisymmetry will cause amplification of the radial and hoop stresses and give rise to shear stresses otherwise not present. In this work, we solve the boundary value problem and analyze the severity of stress amplification for various stiffness ratios of cement and rock formation and fluid exchange coefficients between the cement and the rock. Finally, the physico-chemical model of cement hydration and the bulk stress developments must be associated to the liner's risk of failure. Though the debonding of the interfaces and the cracking of the sheath provide the most ostensible pathways for fluid migration, failure criteria have yet to be defined in the context of fracture criteria. Albawi offered an empirical investigation of cement fracture of set specimens subjected to thermal cycling [41, whereas Bonnett and Parfitis identify one of the primary culprits of crack initiation: the decrease of the pore-pressure below the formation pressure leads to an absolute volume reduction of the cement [131. Bois et al. added that micro-annulus formation is critically affected by the dynamics of cement hydration 112] - findings that necessitates an accurate coupling between pressure, eigenstress, and stiffening mechanisms. In the analysis of the failure criteria, industry continues to relate the cement's yield strength rather than fracture toughness to its resistance to fracture. For instance, Bois et al. consider a tensile criterion in designing against radial cracking 1121. Ravi et al. simulate debonding and fracture using a finite-element-analysis, but their smeared-crack model is poorly described and it is uncertain whether the worst-case-scenario of a single radial crack is considered [711. In response to this deficiency in the mechanistic response modeling of the sheath, work in this thesis adds analytic solutions to the energy release rates (resp. stress intensity factors) of micro-annulus formation along the steel-cement and rock-cement interfaces and a single radial fracture emanating from the steel-cement boundary. The integration of a chemo-poro-mechanics and a fracture model provides a novel, holistic approach to identifying the functional design requirements of a wellbore 25 cement sheath. 1.3 The Primary Cementing Process Since 1903 Portland cement has been used in drilling wells to separate oil and gas horizons from each other and overlying water aquifers. In the last century, the primary cementing operation has continued to improve the seal between the steel-cement and rock-cement interfaces, where new cement formulations have provided more durable options that can be tailored to the cementing job at hand. Nonetheless, the most commonly used cement type is the Class G oil well cement, the product of grinding ordinary Portland cement clinker with calcium sulfate additives. Primary cementing commences after the wellbore hole has been drilled and is filled with drilling mud. After running a string of steel casings down the hole, the two-plug method replaces the drilling mud with the freshly mixed cement slurry (Fig. 1-2 provides a diagram of the mechanical devices used to complete a two-plug cementing job). Guided by a bottom and a top plug, the cement is pumped down the interior of the steel casing. The plugs reduce the contamination of the slurry by drilling mud and remove any residual cement along the interior surface of the steel casing. Once the bottom plug reaches the depth of the well and makes contact with the guide shoe, an increase in pressure punctures the plug diaphragm and allows the cement to escape around the bottom of the casing. The continued application of pressure using displacement fluid, pushes the cement up the annular column between the formation and the steel casing. Centralizers are often used to reduce the offset of the steel casing with the borehole center and allow uniform flow of the cement around casing; in Chapter 4 it will be shown that a centered casing also reduces the risk of fracture. Once cement reaches the entire length of the annular gap, the cement is allowed to set. In the event of deep wells the primary cementing operation is completed in segments. 26 1.4 Thesis Outline The completion of the cement placement, described above, is the point at which we commence our analysis of the early-age stress and pressure developments in the cement sheath. Hence, this thesis is organized in the following manner: Chapter 2 gives a description of the dominant phases of the cement microstructure, and adopts the now classic Powers and Brownyard model to partition their volume fractions in function of the degree of hydration1 . Novel to this thesis is the incorporation of a recent finding that links the fractions of low-density and high-density CSH to its polydisperse packing density. With this description of the cement phase morphology, three characteristic length scales are identified and the poro-elastic properties are upscaled using the Mori-Tanaka and self-consistent homogenization schemes. Next, Chapter 3 offers insight into the origin of the eigenstress developments of the CSH-solid and, by means of Levine's Theorem, offers a device to connect these to the bulk scale. Additionally, this chapter constructs a pressure state equation that allows the chemical demand for water to be related to the porespace changes due to the mechanical loadings and the growth of the solid skeleton. Hence, the drained nature of the sheath promotes a fluid exchange with the formation. Moving on to Chapter 4, the bulk eigenstress is linked to the boundary conditions of the steel casing and the rock formation. Whereas the elastic stress state for a steel casing placed concentric with the wellbore hole is solved by classical means, the eccentric case invokes complex variables and the framework pioneered by Muskhelishvili [58] to resolve the loss of axisymmetry. Finally, in Chapter 5 the macroscopic stress evolution is connected to the most prominent in-plane fracture scenarios. We define our failure criteria in terms of linear elastic fracture mechanics, and devise solutions to the energy release rates caused by micro-annulus formation (MA) along the steel-cement and rock-cement interfaces 1The degree of hydration quantifies the fraction of cement clinker undergone reaction. In other words, it defines the extent to which the cement reaction is complete. 27 and radial fracture (RAD) emanating from the steel-cement interface. In the case of RAD, complex variable theory handles the loss of axisymmetry, and the solution to a singular integral equation measures the crack opening displacement. With the energy release rates of MA and RAD at hand, failure criteria can be defined in terms of the toughness of the cement and the bonds along the interfaces. In Chapter 6, we conclude with a review of our findings, recommendations for more robust cement sheath designs, and an outlook onto future work to improve the predictive power of our chemo-poro-mechanics solver. 28 Casing Displacement Fluid Cement Slurry Top Plug Bottom Plug Fboat Collar Centralizwr Guide Shoe Job In Procms Figure 1-2: An illustration of the primary cementing procedure for an oil or gas well. The figure has been adopted from Ref. [40]. 29 30 Chapter 2 The Microstructure of Hardening Cement Paste The first part of this chapter introduces the primary constituents of hardened cement paste and provides the qualities and dimensions pertinent to the modeling of its microstructure. We continue by describing the segmentation of the constituents as a function of the degree of hydration, which is based on the framework of the Powers and Brownyard model. Novel findings in the meso-scale simulations of CSH packing density by Masoero et al. [53] are incorporated to reproduce the transition between the formation of low-density CSH and high-density CSH at early and late stages. Where previous endeavors have incorporated an aspect ratio of the solid CSH phase [74] [76] [63], this work utilizes the results of the colloidal cement model to fit a power-law relation between the packing density of CSH and the degree of hydration. Finally, the homogenization of the elastic material properties to the macroscale is achieved in a three-level construction using the self-consistent and the Mori-Tanaka schemes. 2.1 Structure of Hardened Cement Paste (HCP) Cement is a heterogeneous material, with a complex structure. It is composed of phases or zones of materials with distinctive physico-chemical properties. Here, we employ the term "phase" not in a chemical sense associated with uniform chemical 31 composition, but as a material subdomain that behaves uniformly at the length scale of investigation. Indeed, cement exhibits distinctive phases at multiple length scales that serve as fundamental, intermediate, or bulk levels of structural and chemical characterization. For instance, the calcium-silicate-hydrate gel, often described as the "glue" in cementitious materials, behaves as a random composite at the nanoscale, yet attains the characteristics of a homogeneous medium at the scale of micro- to milimeters. At the latter scale, the characteristic dimension of a heterogeneity I is much smaller than the characteristic dimension of the representative elementary volume (REV) Y -- < Y. For HCP, the volumetrically dominating phases are calcium-silicate-hydrates (CSH), calcium hydroxide (CH; also referred to as portlandite), residue of unhydrated particles, and pore space (water or air filled). Additional minor compounds, such as calcium sulfates, aluminates, and ferrites also constitute a significant portion of the solid volume, though they exhibit limited influence on the mechanical performance of hydrated cement paste. In this section, we provide a brief description of the phases that most influence the structure and mechanical behavior of Class-G cement, the most unibiquitous well cement in use. The last section classifies three characteristic length scales or levels that serve as a basis for the poromechanical modeling of the cement paste behavior. 2.1.1 Calcium Hydroxide Crystals (Portlandite) Calcium hydroxide (CH or portlandite) is a crystalline precipitate that forms in the water-filled pores of hydrating cement. After hardening, it constitutes up to 25% of the solid volume fraction of cement, and adds considerably to its stiffness. At the micrometer scale. it may be considered a stiff inclusion in the CSH matrix [18]. As seen in Fig. 2-1b, CH has a layered structure with weak interlayer forces and negligible hydrogen bonding that give rise to cleavage patterns along well defined planes. Within the modeling efforts of this thesis, we do not distinguish CH from the remaining hydration products. This will be noted in the multiscale model of the cement volume fractions to come. 32 (b) (a) Figure 2-1: Scanning electron microscope images of (a) the CSH phase - adapted from Constantinides and Ulm 120]-, and (b) a portlandite (CH) crystal precipitated in a CSH matrix - adapted from Nelson and Guillot 160]. 2.1.2 Calcium-Silicate-Hydrate Gel (CSH gel) The primary constituent of cement is the calcium-silicate-hydrate gel which occupies approximately 50-60% of the total volume. Fig. 2-la displays the reticular texture of CSH gel in an image taken by a scanning electron microscope 120]. Studies of fractured surfaces of HCP show that the gel forms two distinctive products: i) the gel that forms around anhydrous grains, termed the 'outer product', and ii) the fibers that grow in the water-filled space between the grains, attach to the grains, and form radiating columns, termed the 'inner product' [171 1801. Similarly, Tennis and Jennings 1811 define low density and high density CSH components. While the presence of two distinct forms of CSH has been known since Taplin [79], the influence of the high-density and low-density products on the bulk elastic properties have only recently been revealed 120]. Strikingly, stiffness was determined an intrinsic property of each component at the scale of hundreds of nanometers, such that the homogenized modulus of the gel depends only on their volumetric contribution. Recent work in the field of computational materials science has described CSH gel as a polydisperse assembly of nano-scale colloidal particles, effectively linking packing density to the elastic properties of the system [541. Here, the packing density r defines the vol33 2 -30 60 S60- 35- ~65- - 25 - (A) Cn .2 1.4 1.6 Ca/Si 1 2 1.8 (B) ,I 20 , 1.2 , 1.4 1.6 CaSi , , 0 55 45 ' ' 70 1.8 2 Figure 2-2: The Voigt-Reuss-Hill bounds of the a) bulk and b) shear moduli of CSH solid sheets as calculated by the atomistic simulations of Qomi et al. [691. ume fractions of the CSH solid and the gel-pores (occupied by non-structure water, i.e. interlayer water) that make up the CSH gel. A transition between low-density and high-density products is observed over the progression of the hydration reaction. Hence, the bulk modulus k, and shear modulus go, intrinsic to the CSH solid, were calculated using atomistic simulations for varying calcium-to-silica ratios (Ca/Si) 1691. The colloidal nature of CSH lends the material a high surface area-to-volume ratio, measured at approximately 700 m 2 /cm 3 using the Brunauer-Emmett-Teller method [80]. In particular, Brunauer and co-workers were able to probe the porespace of the gel using H 2 0 as a sorbate, separating adsorbed water molecules from interlayer water molecules; this separation is critical in determining the densification of cement paste during reaction. Additionally, recent ultra precision data retrieved through small-angel neutron scattering and X-ray scattering have determined the CSH gel density at 2.604 Mg/cm 3 with a water mass fraction of 0.174 and Ca/Si equal to 1.7 [5]. 2.1.3 Anhydrous Cement Grains (Clinker) Before reacting with water, ordinary Portland cement clinker is composed of 50-70% alite (C 3 S) 1 , 15-30% belite (-C 2 S) 2, and 10-30% aluminate, ferrite, or other minor 'Here, we use the notation pervasive in cement chemistry; Ca 3 S = 3CaO-SiO,. 2 C 2S=2CaO-SiO 2; where the compound is wholly or largely found as the 3 polymorph. 34 compounds [80]. Alite reacts rapidly with water, converting around 70% of its mass into CSH gel phase after 28 days of hydrating and nearly all after 1 year. Particularly at early ages, alite is the reactant that adds most to the strength and fracture toughness properties of cement. The belite reaction is comparably slow, having reacted 30% after 28 days and 90% after 1 year. Hence, its early-age contribution to the strength and toughness properties is minor, though the 1-year compressive strength has been found comparable to that of alite [801. Aluminate and ferrite may substantially modify the cement reaction rate, but are of little significance to strength and durability. As can be expected, the rate of reaction is strongly dependent on the particle size distribution of the clinker grains. Diamond [261 reports typical sizes between 2 Am and 80 um in diameter, where the typical mean diameter is around 10-12 Am. Due to the limited space in the pore-structure of cement paste, hydration products typically attach to and coat the clinker grains. While the water-to-cement mass ratio (w/c) is an important control of the cement porosity and strength, where lower ratios typically improve mechanical performance, the Powers and Brownyard model demonstrated experimentally that a ratio of at least 0.38 is required to completely hydrate the mix 1611. 2.1.4 Pore Structure The void space in HCP has a complex structure and manifests itself at a range of length scales. Though the Union of Pure and Applied Chemistry has a system to classify pore sizes 3 , the modeling efforts in this thesis require only to distinguish between gel and capillary pores. The void space in CSH gel is constituted by its interlayer spacing and micro- to fine mesopores. There have been several attempts to model the structure of CSH at the nanoscale. For example, Taylor 1801 reports that the interlayer spacing has been estimated between 0.5 and 2.5 nm and makes up around a third of the gel porosity. A more recent study by McDonald et al. 3 1551 used nuclear magnetic resonance relaxation Micropores: < 2 nm, mesopores: 2-50 nm, and macropores: > 50 nm. 35 analysis to estimate the intra and inter CSH sheet widths and relative specific areas. They report sheet widths of 1.5nm and 4.1nm for the intra (interlayer water spacing) and inter (nano porosity) CSH spacing, respectively, and found the ratio of the specific areas of the two pore types to be 2.4. In this thesis, the interlayer space is assigned as a part of the CSH solid, such that the volume fraction of the remaining gel pores are a primary determinant of the colloidal packing density. The gel pores are responsible for the diminishing stiffness of the CSH gel from its early formation of high density products to its late formation of low density products. Even more pronounced, the capillary pores have a considerable impact on the mechanical performance of cement. They are defined as the water or air filled residue of space between cement grains; the initial space available is controlled by the w/cratio. Hence, the fraction of capillary porosity remaining in a set specimen determines much of the change in bulk volume, and, consequently, influences properties such as fracture toughness and compressive strength. For low w/c-ratios and at late stages of hydration, the capillary voids have sizes from 10-100 nm, while high w/c-ratios and early ages of hydration produce voids at sizes of 3-5 pm [18J. The mechanism for the transport of water through the cement structure is strongly dependent on size and the degree of saturation. Recently, quasi-elastic neutron scattering was used to divide the water in Portland cement into free, chemically bound, and constrained populations [821. The constrained portion was associated primarily with water adsorbed onto the surfaces and contained in the pores (<10nm) of the CSH solid. For ultra-confined H 2 0, located in the interlayer spacing of the nanogranular CSH, molecular dynamics simulations calculated the diffusivity of water to be 1/ 1 00 0 th of the bulk quantity over a rang of Ca/Si ratios [68] The mobility water was reduced largely due to the hydrophilicity of the calcium-silicate sheets. In the mesopores (the CSH pores), Feldman and Sereda showed for the unsaturated system that phase changes must be accounted for by differences in the chemical potentials of the gas and liquid states and the change in free energy due to surface adsorption [31]. They concluded that the water in pores up to 10nm in diameter are influenced by surface forces. On the other hand, fluid transport at the macroscale 36 and in a saturated medium is principally determined by gradients in pressure. 2.2 Classification of the Characteristic Length Scales in Hardening Cement Paste The heterogeneity of cement-based binders manifests itself at different scales. In a bottom-up approach, one identifies the smallest length scale at which the fundamental phases of the material do not change from one cement material to another. By rearranging and re-proportioning these fundamental 'ingredients' the microstructure of any binder, of similar chemistry, can be constructed. In a step-wise approach, these phases are upscaled to resolutions that identify a new characteristic morphology. The levels of resolutions used in the upscaling of our oil well cement system are described below. 2.2.1 Level '0' Recently, Jennings provided evidence that the fundamental building block of the CSH solid has the structure of an amorphous colloidal 'globule', containing nano-porosity (structural water) 1461. It is illustrated in Fig. 2-3. While the structure of CSH at Level '0' can be speculated, it has thus far evaded access by mechanical testing equipment. Nonetheless, Ulm et al. [871 were able to backcalculate the moduli of the CSH solid from nano indentations performed at Level I. By deducing the statistical means of two phases (HD and LD) that became apparent in the probability density function of the indentation modulus, and knowing their respective gel porosities, the bulk and shear moduli were calculated to be k, = 31.8 GPa and g, = 19.1 GPa. These values correspond well with the bounds indicated in Fig. 2-2, determined from molecular simulations, once the nano-porosity has been accounted for. 37 LEVEL I: m C-S-H matrix <I rnh Two types of C-S-H LEVEL '0': C-S-Hl solid Gel porosity 'Globules': Basic Bldg. Block Nanoporosity d >16.6nm 5.6 nrn- LD C-S-Hl 37% gel porosiqt B~asic Bluiling Block 18% nanoporosity (structural water) SEM image H D C-S-H4 24% gel powosity Figure 2-3: Illustration of the nano- to micro-scale structure of CSH. This figure is adapted from [87] 2.2.2 Level I At Level I (10-1 m to 10-6 m) at least two phases of CSH have been detected, high-density CSH (HD) and low-density CSH (LD) [871 - they are considered the building blocks of a cement binder. In fact, indentation tests have confirmed the presence of both phases and their inherent stiffnesses for mixes with different w/c ratios 121 [21]. Their volumetric proportions in the CSH gel vary during hydration and can be calculated indirectly using a power law described by the meso-scale simulations of Masoero et al. 1531 [54] (see Section 2.3). Instead, direct calculation is made of the gel-porosity, which defines the local density of CSH ; HD and LD differ only in their gelpore volumes. Here, the gel porosity must be distinguished from the structural water at Level '0', which due to its low mobility is considered to be part of the elementary CSH solid phase [68]. For the subsurface conditions of a wellbore, the 38 Self-Consistent Mori-Tanaka 0 * *1 * * 0 * 0a 0 0 0 0 0 0 0o 0 0 0 10 0 0 00 J. 0 0 0 0 00 * go* 0 0 0 0 Level I: C-S-H solid + gelpores D = 10-8 - 10- 7m Level II: C-S-H gel + macropores D = 10-6 - 10-m Level III: Hydrating matrix, C-S-H gel, macropores, nonreactive inclusions D =i1- 3 _ 10-IM Figure 2-4: Depiction of the three-level upscaling scheme utilized to arrive at the bulk poroelastic constants and the bulk eigenstress. gelporosity and capillary porosity (at Level II) are considered saturated throughout the hydration process. 2.2.3 Level II Mechanical effects relevant at Level II are observed at length scales ranging between 10-6 m and 10-' m. Here, saturated capillary pores are surrounded by a CSH matrix. The CSH matrix is composed of HD and LD described at Level I. Though real cement systems contain secondary products, such as portlandite and aluminates, which could be added as additional inclusions in the CSH gel, explicit representation was dismissed to preserve model parsimony. 2.2.4 Level III Level III (> 10-3 m) represents the composite of a porous CSH gel and unhydrated cement inclusions. Additionally, silica fume (SiO 2 ) is often added to improve the com- 39 pressive strength, fracture toughness, and bond strength of the cement; these silica particles are typically smaller than 1 pm in diameter with average diameters ranging between 0.1 pm and 0.2 pm - 50 to 100 times smaller than the size of the cement particles. Their fineness greatly improves the cement packing density, decreasing the volume fraction of capillary porosity that degrades the cement's mechanical performance. Similarly, the permeability is reduced, a quality desired in wellbore cements to prevent or reduce the inter-strata migration of formation fluids [60]. Commonly, cement slurries used in oil and gas well applications use blends of silica fume and silica flour. While silica fume improves the strength and lowers the permeability of the mix, silica flour less than 75 pm of the mix [33]. pulverized quartz with a typical particle size improves the particle size gradation and reduces the water demand At temperatures up to 85'C, silica flour behaves as an inert filler [50j. Though silica fume has a propensity to react with calcium hydroxide, our model introduces the silica mix as inert, rigid inclusions and it is typically added by an amount of 0-40% by weight of cement (BWOC). 2.3 Modified Powers-Brownyard Model For the Calculation of Volume Fractions 2.3.1 Partitioning of Volume Fractions Work by Powers and Brownyard [151 [671 in the late 1940s resulted in a model of hydrating cement that continues to be applied to the reaction process of the chemically reactive porous media. The core of the Powers and Brownyard model is based on the mass balance of a water-cement mixture. Careful accounting of the morphology of the cement constituents enables a link between volume changes and texture parameters as a function of the hydration degree [86]. The Powers and Brownyard model acts as the foundation of our chemo-poro-elasite modeling framework. Following their method, the constituents of a cement paste sample are described 40 by the phase volume fractions, (2.1) f = where V, is the volume of phase r and V is the overall/ reference volume of the sample. Therefore, a unit volume of our composite material is partitioned into free (evaporable) water and unreacted cement, reaction products, and gel and capillary porosity: fw. + fc, = fw + fc + fhp + fs 1 (2.2) fhp = fg + fhc where fw0 (fco) and fw (fc) represent the initial and instantaneous volume fractions of the water (cement clinker), respectively; fhp stands for the volume fraction of the hydraction product, which is further separated into gel water fg and hydrated cement fhc. Finally, the chemical shrinkage is quantified by f,. Since our system is considered to evolve under saturated conditions of the pore spaces, fw and fg respectively quantify the capillary and the gel water porosities. It is important to recognize that the volume fractions are provided in reference to an initial unit volume; that is, quantities are defined in a Lagrangian manner. The initial volumetric water fraction no may be written in terms of the watercement mass ratio w, w no = fwO c C + PPC and is equal to the initial volume of water occupied before reaction. (23) It is a key design parameter, influencing the strength and fracture toughness of the hardened material. pw and pc designate the mass densities of the water and the cement clinker, respectively. It follows that the initial volume fraction of the cement clinker is provided by fco = 1 - no and the initial mass per unit volume of the system can be written as, 41 Mo = no pw+ (1n- pO)pc. (2.4) The instantaneous mass evolves as a function of the degree of hydration = (1 - mc)/nmcO - the mass fraction of cement clinker undergone reaction - (2.5) such that the phase densities and volume fractions are related to the water influx of a drained specimen by: M( ) - M = pc (-Afc( )) (2.6) + Pw (-Afw( )) + Php fhp( ) + Pw Here, Afc (Af,) refers to the volume of cement (water) per unit volume of sample that has reacted to form CSH gel-fhp= Afc+Afw -fs. Per definition, the volume fraction of cement clinker evolves linearly as a function of according to f, ( ) = (1 - no) (1 -). Hence, the change in mass of the system is directly linked to the chemical shrinkage of the cement. Having categorized the cement phases using the framework pioneered by Powers and Brownyard, one degree of freedom lies in bridging the intrinsic properties of cement clinker and water with those of CSH. In this work, the composition of the CSH is idealized as a mixture of early-stage, low-density gel and late-stage, highdensity gel [20] [461'. These dynamics indicate a nonlinearity between the packing density of CSH and the degree of hydration, such that the ratio between the volume of cement reactant and hydration product increases with . Here, the packing density r, defines the fraction of solid CSH in the hydration product, and can be modeled as a colloidal cement system based on the meso-scale simulations of Masoero et al. [53] [54]. 'This deviates drastically from the original Powers Brownyward model, which assumes fhp as a linear function of [67] 42 a)b) 0.78 - 0.75 - 0.69 - 0.72 0.66 0.63 0 0.1 0.2 0.3 0.4 0.5 Figure 2-5: (a) A snapshot of a simulation box filled with spherical CSH particles for a polydispersity 6 = 0.47. The polydispersity is a measure of the standard deviation of the particle sizes used in the mesoscale colloidal simulation. 6 is quantified in units of 0.5(rM + rm), the average of the maximum rM and minimum rm sphere radii and the color code signifies the particle sizes. (b) The packing density rj as a function of the polydispersity 6; the shaded region highlights the range of jamming volume fractions tlj (adapted from Ref. [53]). The exponential relation, with fitted parameters a and 0, is given by Vhc (1/ Vh =lnQ( im= G Herein, O(2.7) p /ln(77m ); Io ' a=- = 7O Tiim o is the percolation threshold, identified as the hydration degree at which the hardening cement first forms a continuous solid phase and begins to resist shear deformation. Its accompanying packing density is denoted as 7o. Moreover, the asymptotic behavior may be described by a maximum density of the CSH constituent rllim, which depends on the polydispersity of the CSH particles (r7um ~ 0.64 for lowdensity CSH, rlum ~ 0.74 for high-density CSH; confirmed experimentally [20] and through simulation [53]). Figure 2-5b portrays the relation between the limit packing fraction rilm and the polydispersity of the colloidal CSH model. 43 Utilizing the relation in Eq.(2.7), the volume fractions for the constituents of the hydration product are calculated via, fhc( ) = (1 - fg = (2.8) Ahp (0) (2.9) T1( ))fhp()- Indeed, we note that the packing density 77 is the additive inverse of the gel porosity. - Furthermore, we can write the density of the hydration products as Php = r1 PCSH+(I T)pw. Next, noting a mass balance of the reactants and products - Phpfhp- pcAfc +pAf = the fraction of the hydration products becomes fhp = Pw - Pc fco Pw - Php Pw Pw - (2.10) fs Php and the fraction of the saturated capillary pores is obtained by fW = fW "+ Pc - Php fco Pw - Php + Php s (2.11) Pw - Php Finally, the chemical shrinkage drives an external water supply whose volume may be represented as fs In the above, #3 =--+(1 - PO)( =3efK. (2.12) denotes the effective sink term coefficient, the second degree of freedom of our model; it is a tool to predict the influx of water required to saturate the H2 0 demand of the reaction and the surface adsorption and thus determine, under zero effective stress, the densification of the constituents. Finally, we recognize that the above volume fractions assume a statistically homogeneous mixture of hydrating cement. In many cases, however, it is of interest to modify the mechanical properties of a cement mixture without influence on its hydration kinetics. The addition of non-reactive inclusions permit such changes. Admitting these inclusions, whose standard of measurement is by weight of cement (BWOC), 'In other words, the packing density q and the gel porosity o 44 1 - 77 must always add to 1. 1.0 model 0.8--0C 0.6 data .2.5 >)4-' - 2.0 O 1.5 0.4 W .01., 0.2 0.5, 0.0 10 10 time - t [s] 10 0.8 0.6 0.4 0.2 degree of hydration - [-] 1.0 (b) (a) Figure 2-6: (a) The time evolution of the hydration degree measured against values calculated from calorimetry data for Class G oil well cement. The modeled values are calculated by Eq.(2.14), where a = 5.3 s--1, b = 6.4, c = 230, and d = 4.3. (b) (Data provided by The hydration affinity plotted against the degree of hydration. Schlumberger-Doll Research Center.) the components of Eq.(2.2) must be rescaled by (1 - fNR); with: - -BWOC fNR where 2.3.2 PNR (2.13) PNR W+ C PC 1I+ PC BWOC) PNR is the density of the non-reactive inclusions. Characteristic Time of Cement Hydration As the mechanics and chemistry of the cement are principally affected by the growth of the solid skeleton, it is advantageous to replace the time dependence of variables By doing so, the stiffness and eigenstress evolutions in the sheath will be shown to have a close to linear relation with . with a degree of hydration dependence. Correspondingly, we define a characteristic time of hydration Thyd that measures the time required to react an additional mass fraction of cement dt/d. It is governed by an Arrhenius type kinetics law [24]: 1 -e- dg dt A()e-Ea/RT = hQZT); 45 AQ ) = a 1 -'eb In the above, the hydration affinity, A( ) = de E,/RT = dt , (2.15) (1 measures the change in the Helmholtz free energy T of the system as the reaction progresses. It is an intrinsic material function of the cement and is independent of heat flux boundary conditions. As such, it depends exclusively on the stoichiometry of the chemical cement phases and the molar masses and chemical potentials of their reactants. Nonetheless, the advancement of the hydration affinity A( ) may be captured by the empirical relation given in Eq.(2.14). This necessitates the non-linear regression of four constants a, b, c, and d that depend on the type of cement 1351. The factor Ea/RT accounts for an activation controlled reaction; here, Ea, R, and T are the activation energy, the ideal gas constant, and the absolute temperature (i.e., measured in K), respectively. Fig. 2-6a displays the relationship between the curing time and the hydration degree of a Class G oil well cement. Here, the hydration affinity well represents the calorimetry data of a representative cement sample curing at 85'C (see Fig. 2-6b). 2.3.3 Sample Model Output: The Evolution of Volume Fractions. Throughout this thesis, we connect the varying components of our modeling effort by providing the results of a comprehensive simulation. In doing so, we choose to restrict the input parameters to typical conditions encountered during a primary cementing operation. Our idealized model for the evolution of the volume fractions as a function of the hydration degree is illustrated in Figure 2-7. All material properties and mix design parameters have been written into Table 2.1. Per definition (see Eq.(2.5)), one observes that the clinker vanishes linearly as the reaction progresses, while the pronounced formation of low-density CSH at the early stages and high-density CSH at the latter stages evokes the non-linear relationship of hydration products. As defined 46 1.0. clinker 0.5 0.0 0.2 0.4 0.6 0.8 1.0 Figure 2-7: The volume fractions in a hydrating cement sample are plotted as a function of the degree of hydration . The results are based on our modified Powers and Brownyard model (see Table 2.1 for input parameters). by Eq.(2.7), the decrease in the instantaneous packing density of the CSH gel is due to a loss in the void-to-solid ratio. Therefore, the volume of the hydrated cement (i.e., the CSH solid) is still linearly related to . Finally, the green segment near the top of Fig. 2-7 evidences the chemical shrinkage, measuring the densification of the reactants for an unloaded system with incompressible fluid and incompressible solid phases: fs) M dM (2.16) Pw For an unloaded, saturated, and incompressible cement paste, it measures the mass of water absorbed into the paste. Here, the mass of water that is chemo-physically bound into the CSH structure and the mass adsorbed onto the gelpore surfaces have a smaller volume than the mass of water that previously occupied the macropore space; i. e., the change in capillary pore volume due to the growth of hydrated matter dqo/dk (see Section 3.3.1). 47 Table 2.1: Material input parameters (slurry density: 1.9 g/cc). The constants used for the hydration affinity have been optimized in a non-linear regression with calorimetry data for Class G oil well cement. Mix Design (Class G) Hydration Kinetics Param (Class G) w/c 0.45 a[1/s] = 3.231 b NR-BOWC 0.35 c = 95.191 d Pc [g/cc 3.15 Ea[kJ/mol] 31.472 PNR[g/cc] (SiO 2 ) 2.65 Molecular Scale Prop. of CSH PCSH [g/cc 2.43 ks[GPa] 49 gs [GPa] 23.5 - 3.930 0.402 Mesoscale Prop. of CSH O= 0.263 fL Bulk Water Prop.: 2.4 20.505 0.15 0.01 pw[g/cc] = 1.0 0.640.7 e* 3/1000 kfl[GPa] = 2.0 Continuum Micromechanics: A Three-Level Cement Thought-Model This section of the chapter reviews concepts that allow a heterogeneous cement material to be treated in a continuous manner. More succinctly, we recount the most successful techniques that predict the macroscopic constitutive behavior from a material's microscopic structure and apply them to the three-level cement model using the relations devised by Constantinides and Ulm [20]. 2.4.1 The Principle of Scale Separability Classical homogenization techniques wish to replace the complex, heterogeneous material behavior at the microscale by a representative, homogeneous medium at the macroscale. A key concept in the development of homogenization techniques is the representative elementary volume (REV): A material sample that contains a statistically sufficient number of inhomogeneities that are evenly distributed within its 48 volume to construct a fictitious, and homogeneous material equivalent. In order to ensure that the REV can be replaced by such an equivalent homogeneous material body, we must introduce the relevant characteristic length scales and ascertain relevance of the principle of scale separability'. For an inhomogeneity of characteristic length 1 and embedded in the matrix of an REV of characteristic length 2 , we require 1 < Y. Similarly, for the scale of the overall structure 9, it is necessary that Y < -9. For instance, the anhydrous clinker grains and capillary pores of HCP are pervasive throughout its microstructure and have a discernible influence on the bulk material behavior, yet are not perceived by an observer at the structural level. A second condition requires that the applied mechanical loading varies over sufficiently large distances. Thus, the fluctuation length of the loading A should be large compared to the dimensions of the REV, Y < A. This makes accessible the mathematical tools of differential calculus. These conditions ensure, from a material perspective, that continuum theory can be applied at the structural level of an REV 191]. 2.4.2 Concepts in Continuum Micromechanics In our bottom up approach, the smallest relevant scale is identified, after which we progressively coarsen the granularity of our model, identifying all 'levels' at which new phase can be identified. As alluded to earlier, a phase is defined as a spatial fragment of the REV that behaves uniformly according to its on-average stress or strain state. It need not be homogeneous in composition. Apportioning volume fractions to the phases of a level, the Hashin boundary conditions 7 allow the macroscopic strain and stress states to be approximated by the volume averages of the microscopic strain 6Here, we assume a static system, unaffected by percolation phenomena and in which long-range correlation effects are not present. 7 See, for instance, the Ph.D. thesis by Georgios Constantinides for a complete description of the Hashin conditions {191; It also contains a more in depth review of continuum micromechanics herein utilized. 49 and stress states: E = (E(z)) = = (or(z)) = fj E(z)dV (2.17a) fj a(z)dV. (2.17b) These relations only hold if a regular stress or strain boundary conditions apply: on V: u = E -n; or t = E -n (2.18) Here, V and aV denote the volume and boundary surface of the REV. E and E are the homogenized macroscopic strain and stress, and E(z) and o-(z) are the localized strain and stress at position z. Finally, u and t are the displacement and traction vectors acting on a surface perpendicular to the unit normal n. Naturally, one may wish to write explicitly the relation between the local microscopic strain and stress states and their upscaled quantities. Hence, linear micromechanics theory has devised strain A and stress B concentration operators, that map the macroscopic states to the local microstates: o-(z) E(z) = A(z) : E; = B(z) : E (2.19) where the assumption of linear elasticity has reduced the concentration operators to forth-order tensor fields, and we have adopted dyadic notation. Whence, it follows that E = (c(z))v = (A(z) : E)= E = (a-(Z))V = (B(z) : (A(z)) : E -+ (A(z))v = I (2.20a) (B(z)) :E -+ (B(z))v = ] (2.20b) = and I is the diagonal 4th-order identity tensor. It is now possible to express the linear elastic constitutive relations for the homogenized medium in terms of the localization laws. Taking the material properties at the microscale, i.e. the stiffness tensors c', and the volume fractions of the microphases r, the macroscopically effective stiffness 50 tensor C can be calculated from Eq.(2.20) and Eq.(2.17) as (c, :r(z))v = (c, : A(z))v : E = C: E E = (c 1 : -(Z))V = (c 1 : (Z))V : E = C 1 (2.21a) E (2.21b) which implies C = (Cr : A(z))v C- = (c;1 : B(z))v. (2.22a) (2.22b) The expressions for C in Eq.(2.22a) and Eq.(2.22b) become equivalent in the limit 1/Y -+ 0 - i. e., the operation of localizing the macroscopic strain to the microstrain via A and localizing the macroscopic stress to the microstress via B become equivalent. 2.4.3 Homogenization schemes for elastic properties composite materials We wish to use common techniques in micromechanics to deconstruct our complex poro-mechanical system into a mathematically accessible problem. Many efforts in the past have made it possible to make accurate estimates of the macroscopic behavior of linear elastic materials by simplifying the complex morphology of its microsystem. For example, the famous result by Eshelby [30] proved that the strain in an ellipsoidal inclusion, which is embedded in an infinite medium and is subjected to a uniform eigenstress - a self-equilibrating stress that is not caused by an external loading8 -, is constant. Hence, by simplifying the geometry of the inhomogeneities in an REV to ellipsoids, several upscaling schemes have been devised that relate the strains in the inclusion phases E cin and the strain in the matrix Emat. For the case of a single 8 It derives from the German word Eigenspannung and refers to a residual or "self"/materiallygenerated load, such as is present in thermal expansion. For more information on eigenstresses see e.g., the book by Mura [57]. 51 inclusion one may calculate directly from Eshelby, I"ind = [ + Pr : (Cinci - cat)] -1 Emat, (2.23) where the loading of an eigenstress has been replaced by an equivalent far-field matrix strain. In the above, Cinc and Cmat refer to the stiffness tensors of the inclusion and matrix, respectively, and Pr is the forth-order Hill tensor - it depend on the shape of the inclusions and the elastic properties of the matrix [19]. One recognizes immediately that the strain concentration tensor field for the inclusion is uniform and given by Ainci - [i + p(Cincl - Cmat)] -1. The rapid attenuation of the stress gradient near the inclusion often allows the result to be applied directly to dilute systems. However, for materials densely populated by particles, additional consideration must be taken to account for their interaction. Using the strain averaging relation in Eq. (2.17b) and considering the volume fractions Jr = V/V of a multiphase composite, the strain in the matrix is calculated as 'r [11 + IPr : ((Cind ci Jmt ma)] i) )-1 E (2.24) where E is the strain applied to the REV. It follows directly from Eq. (2.23) that the strain concentration tensor for an individual phase r is estimated as Aes t = [I + Pr : (Cr - Cmat ) 1 : f [J+ Pr : (Cn - Cmat)] (2.25) Next, we elaborate on two options of how to chose the matrix and inclusion phases and expound upon the circumstances under which they are best utilized. The Mori-Tanaka Scheme (MT) The Mori-Tanaka upscaling procedure chooses a distinct phase as the reinforcing medium [56] [10]. It is well appropriated to cases for which there is a dominant matrix morphology, and the difference in stiffness between the matrix and the inclusions 52 is great. Hence, it is often chosen to model stiff/rigid inclusions or pore space embedded in an elastic, continuous matrix phase (e.g., aggregate embedded in a matrix of bitumen or entrained air infused into a cement mixture). In Eq.(2.25), we assign r = 1 as the matrix phase and r > 1 as the inclusion phases, such that the strain concentration operator is written as: AMI = [I + Pr : (C, - C 1 )]- : ( f [1i + Pr : (Cn (2.26) C)]-) Because the stiffness properties of the matrix phase are known, the Mori-Tanaka scheme can be solved in an explicit fashion. The Self-Consistent Scheme (SCS) The second upscaling procedure of note is the self-consistent scheme, where Cscs is chosen from the overall moduli, dependent on the properties of the phases composing the REV 1361 151]. SCS has been utilized successfully on polyerstals, where the phases are dispersed in the medium [911. Geomechanics provides another prominent appli- cation, as granular materials, such as clay or shale, often have a disordered structure in which none of the phases mimic dominant matrix or inclusion characteristics [88]. Consequently, the implicit nature of the REV homogenization is transformed into an as the matrix stiffness: integral equation by choosing the composite stiffness Cc'm ASCS 2.4.4 - [RI + IPr : (C, - Ccop : fn [1[ +n ]Pr : (Cn - )-1 CcornP)P1) (2.27) Three-Level Homogenization Scheme for Hardening Cement Paste In the following, we utilize the upscaling schemes previously introduced to measured the homogenized bulk and shear moduli for the REVs at the three characteristic length scales identified in Section 2.2. It is demonstrated that the matrix-inclusion morphology plays an important role in distributing the stresses in the microstructure. 53 Level '0': The CSH-solid 'globule' The power-law in Eq.(2.7) fits the proportions of low-density and high-density CSH to the packing density of the colloidal CSH system. Hence, the fraction of CSHsolid (including structural water and nanopores) in the gel is measured by q and the fraction of porespace is given by c = 1 - 7. Though anisotropy exists in the sheet- like orientation of the CSH layers 'globule' - 1691, our elementary building block - the CSH can be modeled as an isotropic solid due to the disordered orientation of the particles. The stiffness tensor of the CSH-solid thus simplifies to Chc where K = 6 ij 41 (2.28) 3ksK + 2gsJ is the volumetric part of the fourth-order unit tensor and J = R -K is its deviatoric part. Level I: CSH solid + gelpores = CSH gel Level I includes the CSH solid and gelpores (V1 = Vhp = Vh + Vg). At this scale, the CSH solid can be modeled as colloidal grains. Upon percolation - the point at which a continuous force path through the solid is able to resist shear stresses - the CSH gel resembles a disordered array of contacting grains intermixed with some porosity. A granular material of this sort was studied by Hershey [361 and Krbner [51], who upscaled the elastic modulus and its bounds for a polycrystalline aggregate. Their self-consistent scheme in Eq.(2.27), has been adapted to the study of cement by Constantinides and Ulm [201 [191. Hence, the Level I stiffness tensor is estimated by: C1 = 77 Ch AsCS + (1 ---) Cg : ASCS(2.29) where C9 = 0 is the modulus of the gelpore space and Ch, has been given in Eq. (2.28) above. Recognizing that IP = Sesh : C om p in Eq.(2.27), where Sesh is the Eshelby tensor 9 of phase r [30], and assuming the shape of spherical inclusions, the bulk and 9 See for instance the review article by Zaoui [91], which provides the form of Sesh for a spherical and isotropic inclusion. 54 Figure 2-8: The microstructure of 100-day old cement paste with a w/c of 0.30 (from Ref. 126]). shear moduli are recovered as, K1 k- 4rG/g, _ (2.30) 4G/g, + 3(1 - r7)rs and 1 2 G, YS 5 4 3 r (2+r) 16 (2.31) 1 + 16 2 /-V1 44 (1 - r,) - 480'q + 40072 + 408rr - 120rsr + 9r2(2 + i/) 2 where rs = ks/gs = 2(1 + vs)/3(1 - 2v,) > 0. It is apparent that the stiffness of the CSH-gel has a direct relation to the packing density of the colloidal grains, since ks and g, are considered intrinsic to the CSH-solid. Level II: CSH gel + macropores = cement binder At Level II, the REV is represented as a matrix of CSH-gel weakened by the random 17 = Vhp + Vw). Thus, the total porosity manifests arrangement of capillary pores (V itself at two levels; gelpores at the sub-micron scale and macropores at the micron 55 scale. The effect of the gelpores on the Level II stiffness is accounted for in the homogenized moduli of the CSH-gel, K and G 1. Furthermore, the clear distinction between phases and the embedded nature of the capillary pores in the CSH-matrix suggest use of the Mori-Tanaka in calculating the Level II homogenized stiffness tensor, Cn = 3K1 K + 2G 1 J: Knl K1 Gil G1 In the above, r1 = K1 /G1 and Oil 4(1 -0#1) K 4+3#%r1 ((2.32) (8 + 9ri) (1 - #i) 8 + 9r1 + 605(2 +r 1 )( = M (2.33) (Vg + Vw)/(V 1 ) is the volume fraction of the large, capillary pores at level I. Level III: Cement binder + anhydrous clinker + non-reactive inclusions + The coarsest resolution of the cement paste is achieved at Level III (V, = Vl Vc + Vnr), for which the length scale of a typical REV is measured in milimeters. A scanning electron microscope image of cement at Level III is provided in Fig. 2-8. Here, we see that grains of anhydrous cement clinker are surrounded by hydrated CSH-gel. In the case that structural additives, such as silica flour, are added to the mix, an additional phase resides in the space separating residual clinker grains. It should be noted, that Fig. 2-8 provides a snapshot of the arrangement of phases in well hydrated cement sample. At earlier ages, the proportions of the cement binder and the inclusions will vary substantially; In fact, the phases playing the roles of the matrix and the embedded inclusions is poorly defined and may switch during the reaction. Consequently, the random arrangement, size, and multitude of phases of the inhomogeneities at Level III suggests the self-consistent scheme as the best suited upscaling procedure. Following the scheme, the bulk modulus is given by 3r1 + 4 Ki1 nm 3(1 - n 11)r(2 56 (2.34) Table 2.2: Phase volume fractions and homogenized poroelastic constants for an REV at the characteristic length scales, Level 1-111. The Biot coefficients and Biot moduli at the three scales are derived in Appendix C. Level III: (hydrating Level I: (CSH solid + Level II: (CSH gel + matrix, CSH gel, gelpores) macropores) macropores, non-reactive inclusions) V1 = Vp Matrix Vii- i=7nn Fraction =ln71 Inclusion 1- 7 0 050 Biot Coefficient1-1- b1 = Solid Biot = 0 bn = y[(1 -L-_ 1- Modulus nm = I/n /VV finc = (V + Vnr)/Vi + n0y#I' = 01(1 - - Knlk, bi - #")(b - #1) + - bJN)-- -(1 ni= = V,VI = - K11k, = VI + Vc + Vnr V VpV = V p/Vn Fraction Total Porosity Vh + Vw - finc) = bi 1 ) Reference Volume and the shear modulus is calculated as 8(3 - 2nrim) (15 - 24rInm)rii ) Gil - 1 1 24 (2 - 3nm11 Gi, 9(8ni - 5) 2r 2 + 48(11nr 1 - 29nm 11 + 15)rl1 + 64(3 - + (2.35) 2n,,I)2 In the above, the ratio of the Level II moduli, r 1 = K11/G 1 , has simplified the expressions. 2.4.5 Sample Model Output: Evolution of Poroelastic Constants. Incorporating the input parameters previously noted in Table 2.1, the upscaling relations derived in the previous section provide access to the stiffening behavior of the cement slurry for an REV at Level I, Level II, and Level III. Thus, we have plotted 57 u.6 0.5- I, C-S-H gel II, C-S-H gel+capillary pore -- d= III, Cement paste+NR inclusions -d= 0.4 0.30.2 0.1 0.2 0.4 0.6 0.8 1.0 Figure 2-9: The evolution of the bulk modulus of the cement is plotted for an REV at the three characteristic length scales defined by Level I (CSH-gel), Level II (CSH-gel + macropores), and Level III (CSH-matrix + rigid inclusions) (see Table 2.1 for input parameters). All values have been normalized by the bulk modulus of the CSH-solid. the model output for the three bulk moduli in Fig. 2-9. Per definition, the cement is able to withstand loads once the hydration reaction has moved beyond the percolation threshold and a continuous solid matrix has been established. We note that none of the moduli exceed the stiffness of the CSH-solid. In fact, the added gel-porespace (at Level I) and macro-porespace (at Level II) act to reduce the stiffness due to the drained character of the cement. However, the comparably rigid behavior of the residual clinker grains and added structural inclusions help to increase the elastic stiffness once the bulk modulus is homogenized to Level III. Interestingly, additives such as silica flour improve cement strength and stiffness by increasing the polydispersity of the cement phase constituents and, consequently, decreasing the capillary porespace. It follows that such non-reactive inclusions, which are incorporated into the homogenization scheme at Level III, indirectly enhance the stiffness of the cement at a smaller length scale. In the succeeding chapter, additional poromechanical constants will be of use in describing the constitutive behavior of the hardening cement paste. In particular, it 58 1 0 1~ - 0.8 - 1.0 d =I, C-S-H gel d=II, C-S-H gel+capillary pore d=III, Cement paste+NR inclusions 0.8 0.6 .0.6 0.4- -0.4 0.2 -0.2 packing density 0.0 0.2 0.6 0.4 0.8 0.0 Figure 2-10: The evolution of the Biot modulus of the cement is plotted for an REV at the three characteristic length scales defined by Level I (CSH-gel), Level II (CSHgel + macropores), and Level III (CSH-matrix + rigid inclusions) (see Table 2.1 for input parameters). The modulus has been normalized by the bulk modulus of the CSH-solid. The secondary axis offers a comparison of the CSH-gel packing density. will be required to relate eigenstresses generated in the microscale phases to each other and the bulk, and applied displacements at the macroscale to the strain localization in the phases. To achieve this, we calculated the relevant Biot coefficients - operators that localize the macroscopic strain to the porespace - and Biot moduli - operators 10 that measure the porosity change due to a microphase eigenstress . Expressions for these constants and the porespace and packing fractions are provided in Table 2.2. Fig. 2-10 depicts the evolution of the scale dependent Biot moduli as related to the eigenstress generation in the CSH-solid (in the graphic, their normalized inverses are plotted); plotted beside is the packing fraction of the CSH-gel. Before solid percolation, the Biot moduli are directly related to the gel packing density; at Level I a 1-to-1 correlation is observed. This is easily explained by the assumption that any induced stress in the CSH-solid induces a subsequent unrestrained volume change thereof. In other words, an eigenstress o-* in the solid phase produces a volume change provided in Ap"A more detailed investigation follows in Chapter 3, and the derivations are pendix C. 59 0.6 K/k, - G/ks Cn- (1-b) - 0.4- 0.2 o A0.2 0.2 0.4 0.6 0.8 1.0 Figure 2-11: The bulk elastic properties properties of the cement, K and G, and the biot coefficient of the cement are plotted as a functino of the degree of hydration (see Table 2.1 for input parameters). o-*/N of the CSH-solid, whose proportion of the REV is measured by r. Once the cement paste has hydrated beyond o and is able to resist deviatoric stresses, the evolution of 1/Nd is determined by the competing processes of the cement stiffening and gel densification. The effect of an eigenstress is attenuated at larger scales as the CSH-solid composes a lessening volume fraction of the REV. Finally, we plot the two macroscopic elastic constants K = Km and G next to the compressibility index (1 - b) = (1 - bm11) in Fig. 2-11. = Gm1 We recall that the Biot coefficient computes the macroscpic change in strain due to a change in porosity. For our drained specimen, b must always be bounded between b = 1 (an incompressible solid) and b = # (the uniform localization of strain). For our cement paste, it is reasoned that applied loads before percolation act to drive fluid out of the system and only rearrange the anhydrous cement clinker. Thus, (1 - b) = 0. For > 0, stresses are concentrated in the compressible solid matrix, reducing the Biot coefficient as the matrix grows. 60 2.4.6 Chapter Summary In this chapter, the relevant phases of a neat cement paste were identified and their properties were tracked down to the nanoscale. Considering these properties as intrinsic building blocks of the cement composite, the representation of an array of mix designs is satisfied without sacrificing model parsimony. Given the typically observed dimensions of the micro phases, three characteristic length scales were identified at which new, homogenized phases were revealed. Introducing the Powers and Brownyard model for the partitioning of the volume fractions during reaction, we incorporated a novel model of the CSH-gel by Masoero et al. [53] to characterize its nanotexture. Finally, the elastic properties of the cement were upscaled using the Mori-Tanaka and Self-Consistent models for the matrix-inclusions morphology. Key results are summarized in Table 2.2, and will provide the important link between the micro and macroscopic material responses to internal and external loadings in Chapter 3. Moreover, the homogenized moduli will be adopted in a continuum linear elastic stress analysis of the cement sheath in Chapter 4 and further utilized for the calculation of the energy release rates for the fracture scenarios in Chapter 5. As a necessary component of the risk-of-failure assessment of the wellbore linear, we have constructed an advanced material model that can assess the stiffening behavior of the cement in function of the degree of hydration. Most importantly, the framework has been set to investigate the dynamics between pore-pressure and eigenstress developments and their impacts on the structural response of the cement. The next step is to relate cement chemistry to poromechanics. 61 62 Chapter 3 Bulk Eigenstress Development Ulm et al. [871 showed that the mechanical behavior of cement is well described by elastic poromechanics models. These models capture the couplings between the eigenstress in the CSH-gel, the pore-pressure development, and the deformation of the porous skeleton. In this work, we incorporate these couplings into the mass balance of the water in the macro- and gel-pores, while considering the reactivity of the media. In the first section of the chapter, we introduce Levin's theorem, which allows us to relate the localized pressure and eigenstress developments in the poroelastic skeleton to the changes in the bulk porosity. We proceed, by introducing novel findings that explain the physico-chemical driving forces of chemical shrinkage. In particular, the water consumption due to the stoichiometry of the cement reaction and the confinement of water in the gelpore cavities are compared to the growth of the solid skeleton. It will be shown that net-attractive interactions of colloidal gel particles and pore-pressure changes experienced as a result of the water demand during the hydration reaction are responsible for the bulk volume changes of the cement paste. Moving on, it is observed that the growth, stiffening, and deformation of the solid skeleton are intimately linked to the pore-pressure and fluid exchange with the formation. Hence, the aim of this chapter is to derive an equation for the discretized pore-pressure development of an REV at the bulk scale and relate it to the boundary conditions of the sheath. At fixed degree of hydration fraction fhp, and fixed solid volume the single-valued pressure in the pores and the eigenstress in the chemoe63 lastic skeleton are upscaled to the mean bulk stress of an unrestrained REV: the bulk eigenstress. Under restraint of the steel and the rock, radial and, in the case of an eccentrically placed casing, tangential stress gradients drive a non-uniform pressure development in the sheath. However, it will be shown for typical hydration kinetics and flow parameters that this gradient is small compared to the overall drop in pressure. 3.1 On the Origin of Cement Eigenstresses During Hydration Chemical shrinkage - also termed Le Chatelier contraction - is best observed when an incompressible cement paste, before solid percolation, hydrates under saturated conditions. Here, the difference in density of the hydration products on the one hand and the cement and water reactants on the other hand is measured by the absorption of water into the cement paste structure. Under these conditions, it is assumed that the cement phases are absent of deformation due to loading. Powers examined the chemical shrinkage of 10 Berkeley cement samples and measured absorption rates between 0.024 g and 0.05 g of H 2 0 per g of cement [65]. While direct evaluation of the "absolute" volume changes - that is, the volume of the additional water mass consumed by the hydration reaction -, sample at early cement ages ( can be made for the incompressible bulk < co), the onset of a continuous solid framework allows the cement slurry to resist the volume contraction arising in the microstructure. For unsaturated pastes, the further diminution of the bulk volume is often attributed to capillary forces that emerge due to the formation of menisci. This phenomenon is often termed self-desiccation [9]. However, recent experimental results for water saturated cement hydrating under constant pressure conditions suggest that the bulk cement specimen shrinks even in the absence of menisci formation [861. This shrinkage is typically one order of magnitude less than that of the chemical shrinkage. In this work, we wish to make a link between the chemo-poro-mechanical testing by Ulm et 64 60 - p=10 MPa 50 .p=1 MPa 40 C)30 20 10 0 0.5 0.55 0.6 0.65 0.7 0.75 Packing Density, q; Figure 3-1: The relation between eigenstress development and packing density for cement hydrating at constant pressures of 1 MPa and 10 MPa [86]. al. 1861 and the colloidal mesoscale simulations by Masoero et al. 153]; the simulations lent evidence that the mean interparticle distance of the colloidal CSH spheres was greater than the equilibrium separation, leading to a net-attractive interaction. This phenomena is in direct agreement with the observation that, though shrinkage was recorded during the experimental test, a positive effective stress was calculated (i.e. internal stresses rather than external boundary loads must be responsible for the volume change). Under comparison with the model generated (positively correlated) relation between packing density and degree of hydration, Fig. 3-1 gives evidence to the linear relation between o* and rq. The difference in the onset of a detectable eigenstress for cement hydrating at 1 MPa versus cement hydrating at 10 MPa is explained by the difference in an initial prestress. In conclusion, there is strong evidence that the colloidal system generates eigenstresses that are directly related to its interparticle potentials. This means that the eigenstress is determined by the packing density of the CSH-gel and must therefore be treated as a phenomena intrinsic to its phase. 65 3.2 Upscaling the Microscopic Driving Forces Our cement liner undergoes internal loading that manifests itself in its microstrueture: The CSH-gel shrinks due to internal eigenstresses that grow in proportion to the colloidal packing density, and the water demand of the hydration reaction decreases the fluid pressure in the pores. While these forces are considered to espouse uniformly in the phases of the microstructure, the inhomogeneities act to redistribute the loads. Hence, we are tasked to build a framework that upscales the local eigenstresses to the engineering scale. In combination with the homogenized elastic constants de- rived in Section 2.4.4, an expression for the homogenized eigenstress facilitates the construction of the continuum level poromechanical constitutive relations. 3.2.1 Levin's Theorem In this section of the chapter we introduce Levin's theorem, a tool that maps the effect of localized driving forces onto the bulk specimen. More succinctly, the theory herein reviewed allows us to connect the pressure acting at the solid-fluid interface dp and the eigenstress developed in the CSH-gel d-* to the homogenized bulk stress state of the REV. Imperative to the formulation of this relation is the stationarity of the phase volumes. Since our mechanical analysis deals with reactive cement, whose solid volume grows continuously, the homogenization must be applied at a constant degree of hydration and for incremental changes in the boundary conditions. Thus, we tailor the approach by Dormieux et al. (Ref. [271, pg. 156-159) to our multiphase chemically reactive porous material. We begin by writing the local constitutive relation, in V : [do(z) = c(z) : dE(z) + doP(z)], 66 (3.1) c(z) 00 in 1nc Ch in Vh" 0 in VO d;a= 0 in V4nc do-*1 in Vh, -dZpl in VO (3.2) were z C V is the position vector for an REV defined in the region V. Herein, the microscopic resolution includes elements of Level I and Level II (see Section 2.2), where the matrix volume consists of CSH-solid and the rigid inclusions - comprised of the anhydrous clinker grains and the non-reactive inclusions - and their volume contributions have been segmented into Vh and Vinc, respectively. In addition, the pore volume Vp consists of the capillary and gel pores, such that: 1ic + Vh + VO = (3.3) V Finally, Chc is the stiffness tensor of the CSH solid and doP defines the local eigenstress. Application of the internal loading at constant hydration degree is carried out throughout the remainder of this thesis and will not be explicitly indicated in the subsequent. The solution to this upscaling problem resides in the linear elasticity of the material skeleton behavior and the self-balanced nature of the eigenstresses. The problem is deconstructed into two sub-problems. " dE1 : The stress state due to a regular displacement boundary condition of the form Eq.(2.18) where the eigenstresses have been set to zero. " dE 2 : The stress state due to the loading of the eigenstresses where the displacement of the REV boundary has been set to zero. Thus, the principal of superposition applies and we can construct the stress of an . REV subjected to bulk deformations and an internal loading, dE = dE1 + dE 2 67 du= dE - z du 1 dE - z sub-problem 1 du2 0 sub-problem 2 Figure 3-2: Levin's theorem is used to upscale the eigenstress in the microstructure to the macroscale (the volume phases are not drawn in proper proportion and scale). Sub-problem 1 This first problem, in which a regular displacement boundary condition is admitted without eigenstresses acting in the microstructure, is stated mathematically as follows: in V: V -da, = 0 (3.4a) in V: doi = c(z) : dEi(z) (3.4b) on av : dui(z) = dE - z. (3.4c) As usual, the local strain increment is related to the strain at the scale of the REV by the strain concentration operator, dEc(z) = A(z) : dE. Substituting this relation into Eq.(2.17b), the homogenized stress dE 1 = (doa-)v reads as dE= (c(z) : A(z))v : dE d,= # 0 1 : (dc1(z))v, = #01 : (A(z))v4 : dE where the change in porosity d 1 (3.5a) (3.5b) , measured in reference to the initial porosity #0 = (V, + Vg)/V, is simply the localization of the change in mean strain onto the pore volume. The operator that relates pore volume changes to the macroscopic change in 68 strain is known as the Biot tensor, here identified as b = #o1 : (A(z))v,. Furthermore, as our poroelastic skeleton is considered statistically isotropic, the stiffness tensor Ch, has a well known form and the relations in Eq.(3.5a) and Eq.(3.5b) are expressed more simply as dE1 = 2GdE' + KdEml or d Ei = 2G(dElj - dEm6itj) + KdEm6ij (3.6a) (3.6b) do1 = b dEm. where dE' is the strain deviator, and dEm, is the mean strain, which equals 1/3 of the volumetric strain dEv = tr(dE). The homogenized values of the elasticity constants K = Km and G = GI, and the biot coefficient b = bm are derived in detail in Section 2.4.4 and Appendix C. Sub-problem 2 The second sub-problem fixes the displacement of the REV boundaries and measures the change in stress due to the drained, incremental evolution of the eigenstresses. Thus, the boundary value problem is posed as, in V : V . dO 2 = 0 in V: do 2 on v: = (3.7a) c(z) : de 2 (z) + do- (3.7c) du 2 (z) = 0 and the zero displacement condition implies (dE2 (z))v (3.7b) = 0. Noting again that the corresponding macroscopic stress is the mean microscopic stress in V, and using the mean strain calculated in the first sub-problem as a virtual displacement, we can write the virtual work of the mixed system as, dE: dE 2 = (dE1(z): do 2 (z))v = (dE1(z) : c(z) : dE 2 (z))V + (dEi(z) : doa(z))v (3.8) 69 Using the Hill Lemmal and the result of the zero displacement condition, the first term on the right-hand side vanishes: (dE1(z) : c(z) : dK2(Z))V = (de(z))v : (c(z))v : (dE 2 (z))V = 0, (3.9) Substituting the strain localization condition for the second term in Eq.(3.8), we incorporate the relation classically known as Levin's theorem, (3.10) dE2 = (A(z) : doa(z))v, which provides a means to upscale the microstress to the resolution of the REV. Next, the localization is separated into the volume portions of the pore space and the CSH solid - the two phases that contain the eigenstresses. Here, it is advantageous to begin our analysis for a system that is absent of rigid inclusions, i.e., finc = 0, with a new porosity denoted by 0o. Thus, Eq.(3.10) is calculated by: dE2 = (1 - q0)1 : (A(z))vh-du* - : (A(z))v,dp (3.11) Similarly, we can seek an expression for the change in porosity. Because the average strain is zero, the change in porosity is equal to the change in the solid 1 The Hill lemma is the remarkable result that, for a statically admissible stress field s and a geometrically compatible strain field e, the work averaged over the microstructure is equal to the dyadic product of the average stress and the average strain: (s : E) = (s) : (e) 70 volume fraction. Noting again that the rigid inclusions do not deform, we can write, 2 d2= -1 (1 o) ((do 2 (z))vh - (o(do = 1 : c- 1 2 (z))V, hc - ld*) - dE 2 + (1 o)ldu*) - (3.12) 1: C-1 oldp + ol : (A(z))v dp + (1 - So)1 (A(z))vcdu* + (1 - Oo)ldu* Finally, the consistency condition I = qo(A(z))v, + (1 - Oo)(A(z))vhC provides the b = 1 - (1 - &)1 : (A(z))v, (3.13) necessary relation to the Biot tensor, and we simplify Eq.(3.12) and Eq.(3.11) for the isotropic case, d E2 d2 = (1 -b)do* -bdp or dE 2 = (1 - b)da*6,j - bdp6ij (3.14b) p + d* NP No' In the above, 1/NP = 1 (3.14a) (-50 1 + b) is the inverse of the Biot modulus with c respect to the fluid pressure and 1/N'* = 1 : c (-150 + b) is the inverse of the Biot modulus with respect to the CSH eigenstress. These two parameters quantify the pore volume change caused by an increase in the pressure or eigenstress while the macroscopic strain is held constant. As a result, and in the absence of rigid inclusions, we have demonstrated that 1 NP|5,nc=O 1 No'*\I fco 1 N\fcO' (3.15) The more general case, for which finc > 0, is derived in Appendix C using the three level homogenization scheme. Thus, under the self-consistent scheme of choice3 , the 2 The stress in the hydrated cement due to elastic strain is sought as: (1 - o)(do2(z))Vhc = - dE2 - (# (d'2W) V, 3 We selected a self-consistent scheme to upscale the properties of the Level II microphase (absent of ridgid inclusions) to the Level III macrophase (containing rigid inclusions; see Section 2.4.4). 71 addition of rigid inclusions rescales the change in porosity and Biot modulus as follows, d#2 = (1 - fim)d 1 (1 - fic) = .finc N|f1,,>o N|5,_o 2; (3.16) Therein, the pore volume change is simply proportioned to the reduction in compressible volume. Combining the results of the two sub-problems, we arrive at the poromechanical constitutive relations for our cement specimen: d = 2GdE' + KdEml + (1 - b)do-* - b dp d= bdEm + 3.3 da-* dp + N N (3.17a) (3.17b) An Incremental State Equation for the Mass Balance of Hydrating Cement Paste By tracing the contents of evaporable and non-evaporable (structural) water over time, the Powers-Brownyard model elucidates the transformation of cement clinker and water into the cement binder (see Section 2.3). The deformation of the porespace due to external and internal loadings and the mass absorption of water caused by chemical shrinkage require the fluid content to be traced in measure of the chemical and physical morphology of the CSH solid. In the following, we present an incremental mass balance of water in the capillary porespace. 3.3.1 Mass Balance of the Water The porespace of cement may broadly be categorized into macropores (capillary pores) and gelpores (formed in the CSH gel). Using the Lagrangian porosity 0 - the total and incremental loading (dp, do-*, dEm) pore volume at a given hydration degree 72 the fluid mass content is defined as per unit initial reference volume -, m= p=fl, (3.18) where pf denotes the fluid mass density 1241. Under drained and saturated conditions, the mass content of an REV obeys, dm dt = MO - (Omhyd + (3.19) fmsurf) where the temporal change in fluid mass dm/dt is driven by the difference in the external water supply, Mo, and the use of H 2 0 molecules in the creation of CSH ( 6 mhyd + 6 rfmsurf)- In particular, the two source terms refer to (i) the stoichiometric water demand of the reaction water 6 mhyd, also termed water of constitution or structural [681; i.e. the specific mass of H 2 0 required in satiating the chemical require- ments of CSH, and (ii) the adsorption of water onto the gel pore surfaces 6 msurf driven by the interaction potential between adsorbed and bulk water in the gelpores. To elaborate: (i) The stoichiometric sink term 6 mhyd refers to the observation that ig of cement requires between 0.2g and 0.25g of water to produce CSH and CH products. Translated into volume fractions, this stoichiometric term thus reads: PC p= < d di 'hyd hyd plfcO dOj =t Ohyd dt(3.20) where pc /pfl = 3.15 is the cement-to-liquid mass density ratio, fco = (1 fnr) - fo) (1 - 6mhyd is the initial cement volume content; where as d</dt is the reaction rate, which is described by a hydration kinetics law (see Section 2.3.2). For w/c = 0.45 the stoichiometric sink term is on the order of Ahyd = 0.27 - 0.33. (ii) The adsorption sink term &msurf was discovered by Powers 1651 and has recently been quantified by reactive molecular simulations that traced the state of water in CSH [70]. The driving force of the adsorption sink term is the interaction 73 potential; that is, the interparticle potential between the water adsorbed on the CSH gelpore surface and the bulk water in the gelpores, which in good approximation can be viewed as constant over the hydration process. On the other hand, given the surface nature of the adsorption phenomena, the rate of water adsorption is scaled by the change of the surface area of the gel-porosity, or more generally, by the specific surface area: 6 msurf pfl ac-wnH 2 0 M dSG <pfl < dt (3.21) surf dt where ac-w is the number of C - w bonds per surface; approximated at 2.4 bonds/nm 2 , rH 2 O is the number of water molecules per bond ( 10H 2 0), Mw = 18g/mol is the molar mass of water, and SG is the gelpore surface, which has been shown to increase almost linearly with the hydration degree [831. A rough estimate of this term is provided by considering that the specific surface of cement paste is SG/I~ 80 - 300m 2 /g, where P = 2g/cc is the average paste density. Feldman and Sereda calculated that the specific surface area of a colloidal cement system is around 200m2/g [31]. It should be noted that most of the measureable specific surface area is due to the gelpores; the macropores contribute little. Thus, !surf ~ 0.11 -0.41, which means that the surface adsorption term is of the same order of magnitude as the stoichiometric sink term. From a mass balance perspective, it is advantageous to separate the chemical and mechanical changes to the water mass. Thus, the change in the mass content accounted for in Eq.(3.19) is likewise obtained by considering the differential variation in the porosity , and the fluid compressibility: dm pfl + dpn q pfl (3.22) (i) The first term, djp,*,Em = dqo, measures the incremental change in the porosity due to the morphology of the REV phases - calculated at constant pressure p, eigenstress o*, and volumetric strain Em,. For chemically reactive materials, 74 this term is coined the chemical porosity [24] 1271. Both the changes in the capillary and the gelpore spaces contribute to this term, such that the evolution of 01p,,*,Em in function of is depicted by the dashed contour in Fig. 2-7. (ii) The second term, dqj measures, at constant hydration degree, the change in porosity due to an incremental loading of the pore-solid system. More specifically, it measures the deformation of the solid skeleton due to an incremental volume strain, pressure and eigenstress loading d(Em, p, a*) [24]. (iii) The final term d# Pfl quantifies the mass change due to the compressibility of the fluid, where, under isothermal conditions, P = g with 1/kf the fluid compressibility; i.e. the inverse of the fluid bulk modulus, kfl. Equating the mass balances described by Eq. (3.19) and Eq. (3.22), one obtains the state equation for the fluid mass content in the cement under isothermal hydration: b dEm dt + 1 do-* ! dp ,pfV 2 P 1 + = k,-__3___(3.23) N dt M dt 7f M Thyd In the above equation, the first term on the left-hand-side (l.h.s.) of the equation quantifies the effect on the porespace due to an incremental bulk volume strain dEm of the REV. The second term on the L.h.s. models the effect of the eigenstress development in the CSH-gel, where N(s) = No* is the corresponding Biot modulus of the solid matrix (Vh, + Vin,). The third term on the l.h.s. accounts for the change in pore-pressure and its influence in compressing both the solid matrix and the fluid in the macro and gel pores, 1/M( ) = 1/NP + #/kfl. Finally, the terms on the right) hand-side of the equation quantify, in order of appearance, the spatial gradient (V 2 of the pore-pressure and the effective sink term. Here, kc, pf, and qfl are the cement permeability, fluid density, and fluid viscosity respectively, while Thyd = (~) is the characteristic time of cement hydration, dictating the rate of water consumption by the reaction. The effective sink term quantifies the combined effect of the physico-chemical changes to the cement system: the stoichiometric water demand, the adsorption of water to the gelpore surfaces, and the growth of the solid skeleton. 75 Hence, 3 (3.24) =hyd - surf - 3.3.2 /ef The Simplifying Assumption of Uniform Bulk Eigenstress Development Once the pressure state equation is applied to the boundary value problem of our cement sheath, the pore-pressure in the cement sheath varies in direct response to the restraints and flux conditions of the steel and the rock interfaces. As the cement undergoes volume contraction, the difference in the resistance of the steel and the rock produces a radial gradient in volumetric strain and consequently pressure. Addition- ally, the case of an eccentrically placed casing will guarantee a tangential gradient perpendicular to the radial direction - due to the non-uniform distribution of hydrating matter around the production well. If, in good approximation, the characteristic dimensions of the state equation allow the driving forces and pressure be estimated as uniform, the coupling of Eq.(3.23) to the stress solver in Chapter 4 is vastly simplified without loss of predictive power. More succinctly, we are enabled to apply the effective bulk eigenstress dE*( ) = (1- b)do-*( ) - bdp( ) along the boundary contours without modification. This is because the volume change of an unrestrained annulus under uniform eigenstress is equivalently achieved by the uniform application of the . stress along the (unrestrained) boundaries 4 In the following, it will be shown that the volumetric strain in the eccentric annulus varies only marginally, despite the significant variations in the radial and hoop stress components across the domain. Since, the eigenstrain development of the CSH-gel phase is assumed an intrinsic and uniform property, it remains only to outline the conditions that render the spatial variations in the pressure negligible to ensure d(o-*, p, Em) as approximately uniform. The assumption of a uniform pressure development requires justification through analysis of the governing scaling relations. The cause of the gradient in pressure is 4 1n the case that the eigenstress is non-uniformly applied to the cement sheath, another approach must be taken to integrate the local response across the volume of the body. 76 the influx or efflux of water along the rock-cement interface (RC), which is incited by the consumption of water by the cement. By showing that the cement sheath is thin with respect to the parameters governing the flow of water through the porestructure of the cement and the rock, it can be shown that the characteristic length scale of the pressure variation extends close to or beyond the domain of the sheath. In the case of the eccentric boundaries, the sheath will assume additional variations of pressure in the tangential direction. However, since the circumference is greater than the thickness of the sheath (i.e., ir(R2 + R 1 ) > (R2 - R1 )) and the flow is principally driven by the pressure differential between between sheath and formation, radial variations generally far exceed tangential variations - 2O9r >> Therefore, it I r a0 suffices to show that the pressure front extends close to or beyond the RC boundary. Isolating the pressure components of Eq. (3.23) and non-dimensionalizing, the diffusion length of the pressure within the sheath is 6p( ) kc(()pflfl, Thyd( - V _hy. ) is the characteristic time of hydration, and 5 pressure to be modeled as uniform in good estimation. Here, Ac(d) = > 1 allows the It must be remembered that the permeability of the sheath k, changes with the microtexture of the cement, and is directly related to the capillary porosity; k characteristic pore size [891 [801 166]. _ 1~F(O) where 1p denotes the Thus, near the beginning of the hydration reaction Ac is large and allows for rapid equilibration of the pressure within the sheath. At later stages of the reaction, the hydration kinetics slows (i.e., Thyd becomes large), minimizing further developments of the pressure variations within the sheath. These dynamics are further investigated by discretizing Darcy's law to model the flow of water between the formation and the sheath and only considering radial flow: U' = Afl(p(r = R2, t) - PF) (3.25) The above Newton coefficient depends on the flow characteristics of the cement and the rock, Afi = n7fl (k+ \l1C 1R ). Moreover, the discretized expression for the fluid velocity allows us to relate the volume of the water consumed during the reaction dQ."" dt ~ Thyd ) and the volume of water entering along the RC boundary 77 1.0 0.9A - - Pressure Time ratio 0.8 1.0 -(1-b)o* 0.5- n n, /PF ((1 b)o-*- bAp)/PF, 0.2 0.8 0.6 0.4 1.0 Figure 3-3: (a) The pressure evolution is plotted against the evolution of the ratio between the characteristic times of hydration and fluid mobility. The time ratio is plotted in log scale on the secondary axis. (b) The evolution of the bulk eigenstresses, decomposed the stresses acting in the CSH-solid (1 - b)u* and the porespace -bp. dI2fiu dt -MR flf 2 27r. Comparison of these two quantities shows that the pressure varia- tion depends on the two characteristic time scales, dQfux 2MAlThyd dQsink pflR 2 (1 - R / R2) such that the characteristic time of hydration acteristic time of fluid influx mf Thyd= Thyd - T.6 dt/d competes with the char- = pnR 2 (1 - R2/R2)/(2MAn). Considering the param- eters governing the fluid mobility in the cement and the formation and the hydration kinetics, several regimes of the pressure development emerge. We study these by considering the output of a sample simulation. Sample Pressure Output of the Poro-Mechanics Model: Table 2.1 provides the input parameters for the sample simulations presented in this study. We chose to restrict ourselves to typical conditions encountered during primary 78 cementing operations. In doing so, several parameters (Afi, PF, and 0) were adjusted within the range of observable values to allow model resemblance with the pressure evolution of typical wellbore measurements. Figure 3-3a demonstrates the dependence of the pressure changes within the sheath on the ratio between the characteristic time of hydration and the characteristic time of mass exchange " (Thyd/Tfl): At early curing times, the rate of the hydration reaction is fast compared to the rate of recharge pressure. Thyd Tfl - 1 - 100, producing a rapid decrease in the cement Here, kc is large and the water entering the cement sheath moves rapidly to equilibrate the pressure in the cement, 1 c -+ oc. It is thus the rock permeability that limits influx of water to the sheath, Afl - . Because Thyd is small, the initial, rapid decrease in pressure is the dominant mechanism of the bulk eigenstress development (see Figure 3-3b). " At a degree of hydration of -~ 0.4, the water demand of the reaction and the changes in the pore space are balanced by the Darcy flux into the annulus, such that a pressure minimum is realized. " At latter maturity, the rate of the hydration reaction slows, such that the pressure changes in the cement are principally affected by the influx of wa- ter Thyd rfl _ 10 _ 107. As a consequence, the decreased permeability of the cement drives variations in pressure. pressure drop attenuates as Thyd -> However, since the chemically induced oc and the pressure profile must adhere to the zero-flux condition along SC, it is reasonable to assume that the pressure gradient is small and concentrated near RC. As kc < kF, the Newton coeffi- cient is again well approximated by A = Pfi'Q. Moreover, Fig. 3-3b shows that the bulk effective eigenstress becomes less dependent on the pressure and more dependent on the eigenstress developed in the CSH-gel phase. Accepting the arguments on the uniform development of pressure and the CSH eigenstress, the state equation in Eq.(3.23) can be simplified to the discrete form P Thyd M d&* bM (dEm) = + + d N d< d -Tf PF 79 (3.27) PF Table 3.1: Borehole input parameters. Geometry Constitutive Properties Inner casing rad., Ro [m] 0.1 Casing modulus, ES [GPa] 200 Outer casing rad., R 1 [m] 0.11 Poisson's ratio casing, vs [-] 0.27 0.16 Rock. modulus, ER [GPa] 40(5) Borehole rad., R2 [M] Poisson's ratio rock, Vu Mass Exchange Prop. 0.04 Exchange coef., AF [s/mi 8 x 10-7 PF 0.3 Cement Placement Conditions Formation pressure, PF [GPa] where P = P/pF; [-] Initial pressure, po [GPa] Temperature, T [C 0] 0.04 85.9 are the normalized, scalar quantities of the pressure and eigenstress of the cement sheath. 3.3.3 Sample Model Output: Comparison with the DownHole Pressure of an Oil Well The red curve in Figure 3-4 shows data for the pressure evolution near the bottom of an oil well5 . As this data is proprietary, the curve has been smoothed and normalized, such that the dimensional information cannot be recreated. The figure serves only to demonstrate the ability of our model to reproduce down-hole pressure dynamics. Hence, our simulated pressure curve is plotted atop the data in blue. Firstly, we recognize distinctive pressure variations prior to the onset of the cement solid percolation, which substantiates around t = 14 hr. Initially, the oil well is filled with drilling mud, equaling the hydrostatic pressure of the formation. As the slurry is pumped up the annular region, the pressure quickly increases due to the applied pumping load, the drag forces along the annular walls, and the difference in densities between the two fluids. Allowed to set, the incompressible cement slurry begins exchanging water with the formation, causing a net reduction in the cement paste mass. During this process, the height of the annular cement column drops. 'Source: Schlumberger-Doll Research Center. 80 5 1.2 1.1- 4 1.0 -3 0.9 9 0.8 2 0.7 0.6 0.5. 0 - modeled pressure - measured pressure time ratio 5 15 10 t 20 [hrs] Figure 3-4: A comparison between the model simulated pressure and the pressure in the pressure in an oil well. As the pressure data is proprietary, the curve has been smoothed and the input parameters to the model have been omitted. However, this drop in height is not enough to substantiate the fairly linear pressure drop observed between t ~ 3 hr and t ~ 14 hr. Instead, the downward flow of the cement paste induces vertical drag forces along the boundaries that relieve the down-hole pressure 1601. It should be recognized that our model does not consider the pressure changes caused by these shear forces (in Figure 3-4 a line was fit for appearance); we are interested only in the stresses succeeding percolation. Thus, all simulations in our work initialize the pore-pressure at the adjacent formation pressure. As was recognized in Figure 3-3a, the temporal pressure variations within the sheath find direct correlation to the hydration rate. The initial severe drop, gradual level off, and eventual recovery of the pressure are attributed to the exponential decay in the reaction rate. At a degree of hydration = 0.57 it is expected that the water demand by the reaction and the changes in pore space are balanced by the Darcy flux into the annulus, such that a pressure minimum is realized. 81 3.4 Chapter Summary The first section of Chapter 3 discussed the origin of the eigenstress development in the CSH solid. Stated succinctly, mesoscale simulations showed that the mean separation of the CSH spheres was greater than the equilibrium separation, causing net-attractive interactions between the particles. Hence, tensile eigenstresses develop in the solid phase at constant volume that are a function of the packing density r1. After incorporating the recent insights into the nature of these self-equilibrating stresses, we produced a mass balance of the water in an REV. Here, changes to the H 2 0 mass were calculated for the chemical demand of the reaction, the adsorption of water onto the gel-pore surfaces, and the change in the pore space due to the growth in hydrated matter, and related to the physical distortion of the pore space due to eigenstresses (dp, do-*) as well as a prescribed regular displacement along the REV boundary. Thereafter, we placed the model of our material element into the setting of the cement sheath, which hydrates along an inner impermeable steel barrier and an outer permeable rock barrier. It was discovered, by investigating several key characteristic length and time scales, that the pressure in the sheath remains approximately uniform. The chapter was concluded by demonstrating the ability of the pressure state equation to reproduce the down-hole pressure evolution of early-age wellbore field data. In the succeeding chapter, we couple our state equation to the momentum balance of the cement sheath under the mechanical boundary conditions of the steel and rock. 82 Chapter 4 Stress Developments for Concentric and Eccentric Steel Casing Placements This chapter of the thesis presents a detailed account of the stress and displacement fields which have been derived analytically for a cement sheath under eigenstress development. After the placement of the cement slurry during the primary cementing operation, net attractive eigenstresses develop in the CSH solid gel. After percolation of the solid skeleton and upon generating compressibility in the system1 , these tensile stresses cause the cement to shrink and produce bulk stresses that risk fracturing the sheath. Placed between two circular boundaries, we link the poromechanical model introduced in Chapters 2 and 3 with the stress state due to the boundary constraints. Two scenarios are considered: i) The case of a steel casing placed concentrically with respect to the wellbore hole, and ii) the case of a casing placed eccentrically with respect to the wellbore. In the case of the eccentric geometry, our solution employs spectral methods in the complex plane that require the stress and displacement states to be approximated by truncating Laurent series. 'Before percolation, the cement slurry is incompressible, b = 1, such that the development of eigenstresses in the CSH gel are not experienced at the bulk scale: (1 - b)do-* = 0. 83 The mechanical solutions assume a linear elastic material behavior, and they are thus linearly related to the pressure and eigenstress driving forces. Consequently, we can linearly superpose the solutions of an unrestrained, reacting specimen and a restrained, inactive specimen. With models that relate the cement stiffening behavior and the pore-pressure changes to the stress evolution of the wellbore geometry, the coupled pressure state equation, Eq.(3.27), is solved incrementally to track the bulk stress as a function of the degree of hydration. Critical stresses at risk of impairing the sealing function of the liner will serve as input to the fracture mechanics model in Chapter 5. 4.1 An Introduction to the Method of Complex Variables for Problems of the Plane Theory of Elasticity Herein, we will make extensive use of the method of complex variables to solve solid mechanics problems in two-dimensional linear elasticity. The method was pioneered by Muskhelishvili [58] and was expanded upon by England [28]. Here, we provide a brief description of the relations relevant to the derivations of the stress states and fracture energy release rates of the cement annulus. 4.1.1 Derivation of the Airy Stress Function in Complex Variables In two-dimensions, an elastic material free of inertial and body forces is considered statically admissible if the stress tensor is divergence free and symmetric. In other words, a static stress field in a Cartesian coordinate system satisfies the equations of 84 equilibrium, aX+ a =0 ax ay (4.1a) 09EY + ""=0 Ox (4. 1b) ay where E is the stress tensor in index notation, respecting the symmetry Eg = Eji. These relations are necessary and sufficient to define two functions A(x, y) and B(x, y), such that a = -E ax aY A EX (4.2a) S- aax = Ex (4.2b) =0 09X1y a2Bs a 0 (4.3a) Oy ay Eyx, and one recognizes a2Aa2A EXX 2 aaaxay 2B (9X x + ay 8E 8 ,a aE+ ax Oy ax It follows that a2A = ayB. - axay OXOy (4.3b) - Herein, it becomes convenient to define a potential, U(x, y), called the Airy stress function, such that A = 8yU and B = 9xU. The stresses are related to the Airy stress function by 2 U a2 a2 u = EaX (4.4a) =E (4.4b) u aa= --EY =-EYX and the biharmonic property of U is revealed V 2 V 2 U (4.4c) = 0; here, V 2 = X + OYY is the Laplace operator. Due to the single-valued and continuous nature of Eij up to its second derivative, U must be single-valued and continuous up to its fourth-order derivative. 85 Moving on, the constitutive relations between displacement and stress for plane strain are expressed as: (2 K--G) 3 ExX= EYY= K- E2X = G ( ay aG +(K+--G', (4.5b) (9X 3 ay 4 (K+-G) 3 __ j+ + Dn (4.5a) , ax 3 ay (4.5c) ax where K and G are the elastic bulk and shear moduli of the body, and un and uY are the displacements in the x- and y-directions, respectively. The above equations can be recast into the more convenient form, EX = A ax+(A+2G) ", (4.6a) ax ay EYY = A + (A+ 2G) ay, (4.6b) Exy = G (and+ an3 ay1 (4.6c) ) ax where we have made use of the constant of Lam6 A = (K - 2G). Utilizing the relations above in conjunction with Eq.(4.4a) and Eq.(4.4b), it can be shown that 2G an ay 2 2Gany au2 ax ay - ax V2U (4.7a) A V2U 2(A + G) (4.7b) 2 (A + G) Next, we wish to develop the Airy stress function in the complex plane, and show that it can be resolved by two analytic potentials o(z) and x(z). As was proceeded by Muskhelishvili [58], one can introduce a function P aU 2G- ax an 2Ga ay a2U --- ax2 + 2U aaU =--+AP aV2 86 = V 2 U into Eq. (4.7), such that A+2G P 2(A + G) A+2G (4.8b) 2(A + G) (4.8a) One may further define a conjugate function conditions, 0_P = DyQ and iByP = - Q that observes the Cauchy-Riemann Q. Remark: For a complex valued function defined by the complex coordinate z = x + iy, the Cauchy-Riemann conditions are summarized by the following single equation: =f(z) 0 (4.9) where an overbar denotes complex conjugation (i. e. f = x - iy) 2 , and the complex partial derivative is referred to as the Wirtinger derivative. If we define a function in the complex plane f(z) whose real and imaginary parts are given by f(z) = P(x, y) + iQ(x, y), the Cauchy-Riemann equations ensure its analyticity: The function is complex differentiable and can be expanded into a power series. Continuing, we define the integral of f(z) as follows, (z) =p + iq = 'Jf(z)dz (4.10) where the 1/4 has been introduced for convenience of notion in future expressions. The analyticity of ib(z) asserts Dp = i9yq = 'P and 0 yp -Dq = Q. After inserting the above relations into Eq.(4.8) and integrating, the local displacement functions are recovered as 2G'~-2G, = 2GuY= U +2G) x + 2(A (A+G)P + CX (A + G) ax &U W Dy + 2 (A + 2 G)q~ (A + G) q + Cy. (4.11a) (4.11b) The constants C, and C, measure rigid body displacement and are irrelevant in the 2 The following important distinctions should be pointed out in the notation of complex functions. For a complex valued function f(z) = p(x, y) + iq(x, y): f(z) = p(x, y) - iq(x, y) f() = p(x, -y) + iq(x, -y) f(z) = f( ) = p(x, -y) - iq(x, -y). 87 determination of the stress field. Since both p and q are harmonic, P can be expressed as: P = V 2 (px + qy) = xV2p + yV2q + 2 O+2 8x ay = 4 ax (4.12) and we find from the definition V 2 U = P, V 2 (U -px - qy) = 0 (4.13) U = px + qy + g(x, y) where g(x, y) is a real-valued harmonic function. Now, as R [7ZA(z)] = px + qy, it is quickly realized that the Airy stress function may be written simply as U = R [-Mb(z) + x(z)] 11 U = 2[(z) (4.14) + X(z) + z4(z) + x(z)] where we must define R[x(z)] = g(x, y). The real parts of f4b(z) and x(z) have been extracted by adding their complex conjugates to the expression and halving the result. 4.1.2 The Kolosov-Muskhelishvili Equations With a simple expression of the Airy stress function at hand, we can seek representations for EiZ and ui in terms of the potentials 4)(z) and x(z). Returning to Eq.(4.11), the relevant partial derivatives are given as (z) + -fb'(z) (Z)~' ~ i z'}-VXz + X'( Z) + _4(z) + z_' (z-) + ')(41) ('Ox I2 2k ay where axz = 1, 2 [-4I(z) + ZV'(z) + X'(z) + Db(z) - zb' (z) - x(z)] ayz = (4.15a) (4.15b) i, a2- = 1, and O.J = -i, and where a prime denotes the derivative' d/dz. Adding the two components above as 9xU + h8yU and noting the 3 1t should be remembered that d/dz = O/z + a/dz. However, for analytic functions, obeying the Cauchy-Riemann equations, a/DT= 0. 88 relation to the displacement in Eq.(4.11), we find, (DU .DU\ 2G(u,, + zu.) = jj) A ++ G = = 2(A +2G) O + i OU Dx Dy 'I(z) ((A + + 2)p(Z) G) - zV(z) - (4.16) q1(z) WA(z) - z1'(z) - X1(z) where the substitution T (z) = X'(z) has been made and K =(A+3G)/(A+G) = 3-4v. The result in Eq.(4.16) allows the x- and y-components of the displacement to be treated as a single complex function and was first presented in a similar form by Kolosov [49]. The displacement vector along with the representation of the stress field to follow, act as the basis for the analysis of mechanics problems in two-dimensional elasticity using complex variables. The formulas will henceforth be referred to as the Kolosov-Muskhelishvili equations. Before explicitly defining the complex functions that define the stress components, we draw attention to another important result: ++ = f1 + if, = 1(z) + zv(z) + T(z) (4.17) which has a relevant mechanical interpretation. It is the resultant force due to the stress applied normal to the arc connecting two points pi and P2: u ) =zD ax In the above, n = n(x) + ay 2 Eijnx) +iEijnY)ds +C. (4.18) P in(y) is the unit vector defining the positive normal to the arc. It should be understood that the resultant force above does not depend on the path traversed from pi to P2, and is unique up to an arbitrary constant C. In this thesis, Eq. (4.18) is used to ensure traction continuity between rigidly bonded material regions4. Taking the partial derivatives of Eq.(4.17) with respect to the Cartesian coordi4 For a more detailed derivation of Eq.(4.18) see Refs. [58] or [28]. 89 nates, the complex functions for the stress components emerge as Exx + i EYY - iE2, = 02U azXy ax2 - 02U (4.19a) &x~y + (4.19b) 2 where EXX + iEZY = O(z) + O(z) + z'(z) + O(z) (4.20a) EYY - iEXY = (4.20b) (z) + O(z) - z#'(z) -(z and we have set O(z) = <'(z) and O(z) = T'(z). 4.1.3 The Kolosov-Muskhelishvili Equations in Polar Coordi- nates As our cement liner is bounded by two circular contours, the wall of the steel casing at the interior and the wellbore hole at the exterior, mechanics solution are best resolved in polar coordinates. For the displacement vector, the following well known relation is established between the Cartesian and the polar displacement components, (4.21) Ux + iUy = (ur + iUO)ei, where r and 0 are the radial and angular components, respectively. ourselves that z = x+ iy We remind = relo where ej0 = cos(O)+i sin(O). Consequently, Eq.(4.16) can be rewritten as, . 2G(u, + iuo) = e-'O rA(z) - zVb'(z) - 1(z)] 90 (4.22) In order to write the stress components in polar coordinates, we recall the transformation equations for plane stress: 2 ZrrEr = - " Z cos(20) - Ey sin(20) (4.23b) Eoo = YY + + 2 " + EY/I _ 2 2 EY cos(20) + Exy sin(20) 2 Z - 2 (4.23c) 2 E" sin(20) + Ex cos(20). Er= - E (4.23a) 2 One recognizes by manipulating Eqn.(4.23) that the following relations emerge: Err + EOO = Exx + EYY = 2 [O(z) + #(z)] (4.24a) EOO - Err + 2iErO = 2e2 0 [z#'(z) + 0(z)] (4.24b) By adding or subtracting the two expressions above, the Kolosov-Muskhelishvili formulas can be written in polar coordinates: Err - ZErO E 00 + = ZErO = z _O(z) z z O(z) + #(z) + zq'(z) + -V(z) z O(z) + #(z) - z#'(z) - (4.25a) (4.25b) Additionally, an important derivative of the displacement vector can be calculated: 2G -_ + ) = Kb(z) - #(z) + z#'(z) + -(z) (4.26) This final relation allows the displacement boundary conditions for a circle to be written in terms of # and V rather than their integrals. 91 4.2 Elements of Poromechanics: A Three-Phase PoroComposite Cylinder under Eigenstress Loading 4.2.1 Poromechanical Constitutive Relations As the cement annulus is governed by the physiochemical evolution of the hydrating matter, the solution is framed within the theory of poromechanics. Linking the incremental solid and pore-pressure changes to the bulk scale, the constitutive relations of the steel, cement and rock are sought as: dEm(r, 0) = Ks dEm(r, 0) dm m(r, 0) +dp =KdEm(r, 0) +(1 - b)(du* +dp) z CC z ES (4.27a) z E R (4.27c) d = {S, C, R}. (4.27d) (4.27b) dEm(r, 0) + dp = KRdEm(r, 0) + dp dSi (r,0) = 2Gd(dE 7 - dEm6nij) Here, upper case symbols denote bulk parameters and states, while lower case symbols denote the subsystem parameters and states. Thus, Kd( ), and Gd( ) denote the bulk modulus and shear modulus of the respective domains of the steel S, cement C, and rock R, though we omit explicit indication of properties describing the cement due to their prevalence in this text. b( ) is the biot modulus of the cement. The stresses have been separated into their volumetric (dEm) and deviatoric (dSij) parts. The bulk elastic modulus K( ), the bulk shear modulus G( ), and the Biot coefficient b( ) of the cement are obtained by considering the microtexture and morphology of the subsystems and vary in function of the degree of hydration, . The early-age behavior of the relevant cement phases and the appropriate upscaling relations have been detailed in Chapter 2. As our solution procedure is placed into a poromechanics framework, consideration of pore pressure effects must be given not only to the cement, but also to the rock. It is quickly realized that this consideration has a fundamental effect on the 92 traction boundary condition along the rock-cement interface. 4.2.2 The Boundary Conditions In this chapter of the thesis we link the incremental bulk eigenstress evaluated at a constant degree of hydration, dE*I = (1 - b) * d-*k - bdpk , to the stresses de- veloped due to the confinements of the rock and either (i) a concentrically and (ii) an eccentrically placed steel casing. While the solution to the linear elastic stress development for the concentric case can be adapted to the well-known problem of a thick-walled pressure vessel under uniform boundary loads (e.g., see Ref. [84]), an analytical solution for the eccentric case with elastic boundary conditions has yet to be described. It should be observed that the eccentricity of the casing causes the steel and rock to produce a tangentially varying resistance to the bulk volume changes of the cement. For both cases, the linear elastic solution must satisfy the momentum balance V - a = 0 with the following boundary conditions: " Constant pressure (or no stress) applied to the inner surface of the steel casing, t(n = -er, r = Ro) = Cn. (4.28) * Traction and displacement continuity along the steel-cement interface, t(n = er, r = R1 )] = 0 (4.29a) u(r = R 1 )j = 0. (4.29b) * Traction and displacement continuity along the rock-cement interface, [t(n = er, r = R 2 + [u(r = R 2 + Ae)j = e)] = 0, where Ae is the magnitude of the eccentricity. 93 0 (4.30a) (4.30b) e A zero far-field effective stress condition, (o-(r 4.3 -+ (4.31) oc) + p1) = 0. The Stress State in a Cement Sheath with a Concentrically Placed Casing. Formatina Ce ent Sh ath AfG K( RO f ) / ) G( \4 XsRR R Figure 4-1: A diagram of the wellbore geometry for the case of a casing placed concentrically w.r.t the hole. The cement sheath is bounded at its interior by a steel casing and at its exterior by a geologic formation. The inner, circular boundary of the steel is located at a distance RO from the origin. The interfaces SC and RC are located at distances of R1 and R2 from the origin respectively. A cement sheath hydrating under saturated conditions, having uniform and isotropic properties, and confined by material boundaries that are uniform and isotropic, 94 may be reduced to a one-dimensional problem. Radial symmetry reduces the stress tensor and displacement vector fields to functions of r. In particular, the hydrating liner, undergoing bulk volume changes, can be evaluated as a thick-walled cylinder confined at its interior and extcrior by elastic springs; the springs represent the equivalent elastic stiffnesses of the steel casing and rock formation. The solution to a cylinder under uniform boundary loading is well known (see for instance the book by Timoshenko [841) and is readily applied to the problem at hand. Hence, the momentum balance needs to be satisfied incrementally or in rate form in order to accommodate the growth of the material system: V OE at = 0 ,)=10 (i)+() a2E Ot at 1 a(M+3zz) r 0 -0 3 = raKaGDr +Kt -GDr (433a) In the above, the constitutive relations of the two-dimensional effective stress tensor can be developed in the form 8(+a2E a &(Zrr + P) (K >)4 Drr+ (K -2G at - at where Dij = aEig/at o 3)3)d a(EO A zz d19*+Z dt +p K( 2 C) Drr+(K A4GDoo +d(Z +p)(43b K - -3 K - -G 3 dt(4 Drr + K - -G 3 Doo E* d dt (4.33a) 3 b (4.33c) stands for the strain rate and dE*/dt is the prestress rate; it is the rate at which the effective bulk eigenstress develops in the cement. The prestress 95 rate is written as: d(E* + D) dl 6E* = = (1- b) du (1 - b) dt dp + d= dt dt do* E* + 6P (4.34b) dt dt (4.34a) In 6P = dt (4.34c) Noting that Eqn.(4.33) assume plane strain conditions, such that dEzz/dt = 0, the remaining components of the strain tensor are found via: Err Dr E00= U'r(r) Ero = 0. (4.35) and it is well known that a velocity solution of the radial displacement can be found by assuming an expression of the form, aUr - (Cir + C r 2 at (4.36) ). The boundary conditions in Eqn.(4.28)-(4.31) are posed as follows: 9 Along the inner surface of the steel casing: dErr(I = Ro) (4.37) dt e At the interface between the steel and the cement SC: (rI=R) dp = dE-(r = RI) rr + dt dt dt du+ (r = R1 ) du-(r = R1 dt dt (4.38a) ) d 96 (4.38b) . At the interface between the rock and the cement RC: dE,(r = R 2 ) dp dE-(r = R2 ) dp + = + dt dt dt d du+ (r = R 2 ) du-(r = R2 dt dt(4.39b) dt dt ) (4.39a) o Finally, the change in the effective far-field stress in the rock formation, d-g dt dt oc0) + dp dt 6-=0 requires the far-field displacement field to remain undeformed dUr (r (4.40) - oc) /dt = 0. In the above, the superscript + indicates the limiting value of the stress (resp. deformation) in approaching a boundary from the left side, where the left side is defined with respect to a counter-clockwise traversal around the contour. Similarly, the superscript - indicates the limiting value of the stress (resp. displacement) in approaching the boundary from the right side. As the pressure in the cement drops upon hydration, it must be recognized that the formation in proximity to RC experiences a pore-pressure change similar to that of the cement. Thus, the pressure drop dp/dt must be accounted for in Eq.(4.39a) when resolving the traction along the wellbore hole aE- /&t. In the event of a micro annulus formation along RC or in the limiting case that the rock stiffness tends toward zero, this condition asserts that the effective stress along the outer interface of the cement sheath is equal to the pressure p. The principal strains are calculated from Eq.(4.35) and Eq.(4.36), via, 2 ) (4.41a) Doo(r) = (C1 + C 2 r- 2 ) (4.41b) Dr,(T) = (C1 - C 2 r- 97 and insertion into the constitutive relations of Eqn.(4.33a) and (4.33b) results in: rr = (2K + 2G C1-2G 3 at = 2K + --G at + 6E* (4.42a) C1 + 2GC + 6 E* (4.42b) )r2 3 )r2 azz 2K - 4-G at C1 +6E* (4.42c) 3) Next, we notice that the linear response of the interfaces allows them to be replaced with pseudo-springs of equivalent stiffnesses, as depicted in Figure 4-1. Specifically, the effective stiffnesses measure the material resistance of the steel and rock due to a unit expansion of the SC and RC interfaces. They have been de- rived in Appendix A utilizing the displacement boundary conditions in Eq.(4.39b) and Eq.(4.38b), and are denoted by xs (steel) and xR (rock). It follows that the constants C1 and C2 can be solved from the two traction boundary conditions in Eq.(4.38a) and Eq.(4.39a): + 6E* = xs(C1R1 + C2 R-) 2K + G C 1 - 2G 2K + G C1 - 2G2 +6 * = -XR(C1R2 + (4.43a) C2R-) - bR 6 p (4.43b) As mentioned above, the drop in pressure along the adjacent lying formation has been incorporated, where we will assume that the rock is incompressible with respect to its fluid pressure (i.e., the Biot coefficient of the rock is set to bR = 1), such that Eq.(4.43b) becomes: 2K + 2 G C1 - 2G +6E* + 6 p = -xR(CR 2 + C2 R- 1 ) (4.44) To solve the system of equations, a two-step approach will be employed to separately account for the effect of i) the bulk eigenstress development in the cement and ii) the pressure drop in the adjacent lying portion of the formation. Hence, C1 (C2) has corresponding contributions of Cl* (C27) and C6P (C 6P) that may be added 98 linearly: C1 =Cg* + C6P (4.45a) C2 =C + C2'. (4.45b) Their explicit solution reads 2G(1 6E* C 26 C 6* 2 R6E* _ Z2) + XS + Z2XR 6* (4.46a) XR - XS _ 2(4G + 3K)(XR + zS) + (1 - 3(XR + xs) W )(3XR(XS - 2K) - 2G(3xs + XR) + 4G(3K + G)) 2 (4.46b) and ( .,;R + 2G ) -c2 c C R 2p - <XS (2G + 6K + 3xR) 3(xR + xs) (4.47b) * XR 1P c, (4.47a) * c6 = = where u = R 2 /R 1 . This allows the stress rate solution to be recast, noting separately D(Zrr + P) at = (2K+ G cl* -2G r2 c6E*+ + the effects of the prestress rate the and pressure drop in the formation: 1(2K + 2G) 6 -2G 1 sp c6+ a(EOO + p) at = 12K + + 2 2G) c, +2G c 1] 6E*+ (2K+ 2G) c6p+ 2G Q ) (4.48a) (4.48b) at 1(2K 4G) c +1 6E*+ L(2K - G) c"p+ 1 1p (4.48c) and the mean stress rate can be calculated by, M = (2KcbE* + 1)6E* + 2Kc'p6p at (4.49) For consistency, we express the solution above in form of the Kolosov-Muskhelishvili formulas given by Eqn.(4.25a,b). Radial symmetry enables us to simplify their ex- 99 C +1 6P pression as follows, O(Zrr +-P) = = 2K + 2G 3 C1 -- 2G C2+ 2K + 2 G 3 C1 + 2G r2 6E* (4.50a) + 6E* (4.50b) ) at 20(z) - ei 2 0v(z) &(Zoo+p) = 2#(z) + ei20v)(z) = ) at r2 where the absence of shear stresses makes O(z) real-valued. We recognize immediately that O(z) =2K + C1 + 6E* (4.51a) 2GC 2 (4.51b) Z2 )(Z) = Finally, remembering that 1(z) G f = #(z)dz, '(z) = f (z)dz, and K = 3 - 4v the radial displacement solution is confirmed: f at -___ 2G - z'(z) - (z)(4.52) . au,(r) + [Cir .r 4.3.1 Sample Model Output: Stress Evolution for a Concentrically Placed Casing The effective radial stress E,, + p within the sheath shows particular sensitivity to the dynamics of the pressure. We see from Fig. 4-2 that the maximum compres- sive stress at both the interior and exterior boundaries coincides with the pressure minimum around = 0.4 (for the related pressure curve see Fig. 3-3). As the pres- sure increases, the radial stress begins to increase and eventually enters into the tensile regime. Toward the beginning of the reaction, the effective stress is strongly dependent on pressure changes, as the solid cement matrix has yet to gain stiffness. Clearly portrayed in Fig. 2-11, the overall bulk modulus advances nearly linearly with and builds much stiffness by ~ 0.5. In consequence, upon advanced hardening 100 0.25 0.15 - 0.10 0.05 stress along SC (ER =40 GPa) -- stress along RC (ER=40 GPa) - - stress along SC (ER =5 GPa) - stress along RC (Et=5 GPa) - 0.00 8 0.20- A 0.10 -- r -0.05 -0.10 -0.15 0.15 0.05 0.00 0.2 0.4 0.6 0.8 1.0 0.05 - -- 0.2 0.4 0.6 0.8 1.0 (b) effective hoop stress (a) effective radial stress Figure 4-2: (a) The effective radial stress and (b) the effective hoop stress development along the interfaces of the steel and cement (blue) and the rock and cement (red) is plotted in function of the degree of hydration. The input parameters have been summarized in Table 2.1, and the scenarios of a stiff (solid lines) and soft (dashed lines) are plotted. ( > 0.5), CSH eigenstresses more drastically influence the sheath's mechanical stress state; whence the boundary restraints induce tensile loads. Additionally, the eventual equilibrium of the pressure to that of the formation pressure places the system into a state of residual tension: Initially, during the period of accelerated hydration, a dramatic pressure drop is imposed on a relatively incompressible slurry; much of the system is still composed of a fluid mixture of water and clinker grains. As the matter hydrates, the growth of porous CSH gel increases the compressibility of the system. As the reaction rate slows and upon re-pressurization, the compressible cement matrix is placed into a state of residual tension. This phenomenon further increases the effective tensile stress in the solid skeleton; beyond effects purely due to the eigenstress in the solid and pore space. In fact, were the system to remain incompressible in course of the pressure evolution, no additional additional Cauchy stresses would be created. Instead, the hardening sheath is most vulnerable to micro-annulus formation during the period of pressure recovery. The top panels in Fig. 4-3 demonstrate the influence of the system's permeability and the rock stiffness on the radial stress along SC and RC. Clearly, greater tensile stresses develop for more permeable systems with a less movable rock boundaries. 101 However, it must be pointed out that the pressure for systems with low A has not yet recovered p < PF when = 1; it is expected that the pressure will increase even once the cement has set. The rock's Young's modulus, ER, has a pronounced impact on the generation of effective hoop stresses Eoo + p within the sheath. Both for stiff and soft formations, the pressure drop due to early hydration induces immediate tensile stresses along the inside of the sheath; the reduction in volume constricts the sheath around the steel casing. A short compressive regime is witnessed along RC for stiff formations, as the exterior bond opposes the inward displacement. Most noticeably, we recognize that robust adhesion to a stiff formation near the late hardening stages promotes substantial increases to the sheath's final-state hoop stress at both r = R1 and r = R2; in the event of a micro-annulus formation along RC we expect the risk of radial cracking to be minimized due to the substantial reduction in the tangential stress. The bottom panels in Fig. 4-3 displays the influence of the rock Young's modulus ER and the Newton coefficient A on the hoop stress generation. In general, a more compliant formation reduces the hoop stresses in sheath. As a final remark, we recognize that Eo is greater along the inner circumference (true nearly everywhere in the A - ER space), prompting radial crack initiation along SC. Because the solid skeleton of the cement grows during the pressure evolution, the stress development in the sheath is path dependent. This means that the incremental addition to the homogenized bulk eigenstress at a constant degree of hydration depends on the instantaneous volume fractions of the pore-space and the CSH solid. 4.4 Stress State in a Cement Sheath with an Eccentrically Placed Casing. In the event that the steel casing is placed eccentrically with respect to the wellbore hole, the stress and displacement states lose their radial axis symmetry. For large eccentricities, the maximal radial and hoop stresses encountered along the two inter102 SC: (Err + Ap)/pF RC: (Err + Ap)/PF 0.2 0.1 1e-06 0.1 1e-06 0 0z 0 1e-07 1e-07 -0.1 -0.1 I 1e-08 10 30 70 50 SC: (Eoo + Ap)/pF -0.2 1 e-08 10 20 30 RC: (EoO + Ap)/pPF 0.3 0.25 1 e-06 0.2 1e-07 0.1 10 20 30 0 0.15 1 e-07 0.1 0.05 1e-08 ER [GPa] 0.3 0.2 0.05 1e-08 -0.2 0.25 1 e-06 0.15 0z 0.2 0 10 ER 20 30 [GPa] Figure 4-3: Three-dimensional plot of the effects of the fluid exchange coefficient A and the rock Young's modulus ER on the radial stress (top row) and the hoop stress (bottom row) at complete hydration. Stresses are plotted for SC (left column) and 23 GPa. RC (right column); E( = 1) 103 faces is significantly amplified. Here, it is important to quantify the added risk of impairment, such that a maximum allowable offset is defined during primary cementing. With an engineering solution in mind, this section derives analytical solutions for the stress field in an eccentric wellbore and constructs maps that indicate the location and maximal amplification of the principal stresses along the steel-cement and rock-cement boundaries. This is done for a range of rock-to-cement stiffness ratios, allowing for quick access to an accurate estimate of the added risk of impairment for on-site conditions. 4.4.1 Constructing Coordinate Systems for the Steel, Cement, and Rock Domains: The first step calls for the calculation of the stress field in an eccentric geometry. We utilize the method of complex variables, introduced by Muskhelishvili [581, and map the cement interfaces onto circular contours centered at the origin. This allows for the complete description of the contours by their radial coordinate. In doing so, it is advantageous to evaluate the stresses and displacements of the steel, cement, and rock in separate coordinate systems, the z-, (-, and v-planes: " The steel casing is placed at the center of the physical system in the z-plane. " The eccentric boundaries of the cement annulus are conformally mapped onto concentric circles in the (-plane. " The geologic formation is mapped to the v-plane by translating the z-plane in the direction opposite the eccentricity, Ae. 4.4.2 The Bilinear transformation A conformal mapping preserves the magnitude and sense of the angle between two linear elements during transformation from the domain to the image region and is univalent. The relevant conformal mapping of the cement domain is the bilinear transformation. By appropriately specifying two parameters ao and a,, the function 104 places the origin of the reference coordinate system - the z-plane - at the center of the steel-cement interface (SC =S C) and the origin of the mapped system - the (-plane - at the center of two concentric circular contours, the mapped steel-cement (RC (SC = S n C) and rock-cement interfaces = R n C). Thus, movement between the reference and the transformed domains is defined by: w(z) 1+z~c~) w(() (4.53b) ao + z =+ = 1 + ce 1z (4.53a) =Oa ( + aoa1)((45b = 1 + ao( '0 where w and w are the mapping and inverse mapping functions, respectively. Within the transformed domain, C = pe" allows the boundary contours SC and RC to be defined solely by the radii p = R 1 and p =R 2, and the angular component varies between 0 < 19 < 27r. The radii of the transformed interfaces are calculated from the geometry of the physical system by Rf 4R = - 1 V I + (2Rjc1)2 2 2R= 2Rja1 - 1,2 (4.54) where (Ry a, O= 2 - - R2) 2 - 2Ae(R? + R2) + A(4.55a) (4.55b) . 2R1 and Ae is the eccentricity. The representation of the region of the cement sheath in the reference and mapped systems is compared in Fig. 4-4. It is apparent that the bilinear function maintains the shape of any circular contour during its mapping. Nonetheless, it is critical to observe that the equally spaced rays emanating from the origin of the concentric geometry in Figure 4-4b provide a curvature in Figure 4-4a, such that 105 (-Plane z-Plane RC SC P 1 0 Figure 4-4: Contours in the reference coordinate system (z-plane) are mapped via the bilinear transformation into a conformal image ((-plane); the eccentric boundaries SC and RC are mapped into the concentric boundaries SC and W. their intersections with SC and RC cluster along the thin section of the sheath. This will require additional attention since the boundary points along SC RC i-4 '-4 SC (resp. RC) must be expressed as 6sc(0) (resp. GRc( 6 )) in order to write the condi- tions of stress and displacement continuity. 4.4.3 The Kolosov-Muskhelishvili Formulas for the Mapped System For the poromechanics boundary value problem at hand, we choose to evaluate the stress and displacement states using the Kolosov-Muskhelishvili formulas defined in Eq. (4.25) and Eq. (4.26). Under conformal transformation, these are rewritten in 106 incremental form as follows: dE, -idEp) = #*(() + #*(() + *( (2 2G w '2j 0 + =*(() - 4,*((), = 0*(() 4*(() #(z) (w(()) = #*(() and = (4.56c) ')(z) though the asterisk shall be omitted in the subsequent. commonly proceeded (see Ref. (d Cw( / #'*(() + The complex potentials are defined such that (w(()) = ___ - (2 W(2) (du,* + iduy,) (4.56a) (2I(*) [58]), we choose to seek a solution for /d = As is and Vd {S, C, R}) in form of Laurent series: 00 00 Os= A Os (z) z = k=-xo Bs Zk (4.57a) Bk zk (4.57b) B z'k (4.57c) k=-00 00 00 q#c = c (z) = A >3 k=-o k=-xo -1 -2 OR k R(Z) 3 = k=-oo k=-cc Because the far-field locations within the rock formation are assumed unaffected by the hydration dynamics of the cement, dE(IV1 -4 oc) = 0 and duR(IVI oc), the series -+ in Eqn. (4.57a) and (4.57b) neglect terms with positive powers. With the above expressions at hand, the boundary equations can be simplified into power series of z, C, and v. In doing so, it is necessary to expand the functional expressions in the transformed Kolosov-Muskhelishvili formulas, ((2 p2 )(w'(() /w'(()) and ((2 /p 2 )(w (()/ w'(()) , into series expansions. Utilizing the mapping function w((), it can be shown that, 2 = -(ocl +cai)p2 + (2a0ac and 107 + 1)p 1 ( - aop 2 2 (4.58) Z=E l nQ( (2 2p if n=0 2 + (n - -2n" 4.4.4 + (n + 1)an 2p 2 if n > 0. 2 p_ 1)a (4.59) Matching the Boundary Contours Using the Chebyshev Polynomials The driving mechanisms of the early-age isothermal stress development within the hardening cement phase are the self-balancing loads due to eigenstress development, and pore-pressure changes. The total stress in the cement sheath is calculated by ) onto the region d = C of the linearly superposing the real-valued stress -E*( boundary value problem. It should be noted that the formation adjacent to RC undergoes the same pressure drop, such that the term -dp( ) must be superposed unto the rock. Complete continuity of traction and displacement ensures that both the normal and shear stresses generated by the shrinking (resp. expanding) cement specimen are transferred to the steel and rock. Solving for a divergence-free stress tensor, the boundary conditions read: " Traction-free conditions along the inner surface of the steel casing (zo = Roe0 ): #s(zo) + #s(zo) - zo#'s (zo) - = zs(Zo) zo 0, r = Ro; 0 < 0 < 27r " Traction and displacement continuity along SC (resp. SC): (zi = R1 ie 1Zien) qs(zi) + #s(zi) - '(1) (4.61) =Oc ((1) + #C () zi#'s(ZI) (2 s 20 21 - r-4's(zi) (1) Q O'(1 21 WO'(1 108 1 dE* (4.60) '-+ (I = 2Gs 5 sOs(zi) - 2C 1 Z10 (ZI-)i) -_- s(zi) S 2Gc =COC((l) - C(1) - where r = RI; 0 < 0 < 27 '-* )2 2 (4.62) 1 ( )(I bi'(1) __ (1 bj(() C o'((G) 0'c((1) 7212 'G p = R 1 ; 0 <,d < 27r. * Traction and displacement continuity along RC (resp. RC): (V2 (2 = R2 ei-* 7 2 e2) O5R(V2) + OR (V2) 2 -(V + A,e (G2 ) + Oc ((2) -Z2 2C 2GR R R(V2) - OR(V2) - - R ( U) ((2) (22 = R 2 ; 0 < 0 < 27r -+ p = dE*Jk 2 OR(V2 W'((2) -22 'C((2) KCC ((2) -OC ((2) -R2 2Gc 22 W'(G) =G where (4.63) (U 2 + Aeei20)O/R(V 2 ) I_ dP V2 'C(( 2 ) - )2 2 W'((2) '(() 12 - '02 -jOR(V2) 2 () 2 =c R (5~V 2) - R2 22 1 (4.64) 'G R 2 ; 0 < 9 < 27. It is then seen that the equalities along the interfaces can be simplified to systems of equations of the form: 00 CseikO= k=-oo -1 k=-oo = C + iC and Dk (4.65a) DiekO (4.65b) 00 Djeik = where Ck Cie ik7 k=-oo k=-oo = DR + iD are complex valued coefficients, and Ck, DR, and D' are expressed as a linear combination of A, and B,. The hat over the angle above, b, indicates the argument of the v-plane. As noted above, the phase angles of z (resp. v) and the mapped coordinate ( do not correspond. Hence, the required conditions of stress continuity in Eqn.(4.61) and (4.63) and displacement contintuity in Eqn.(4.62) and (4.64) must be matched through an additional functional relation. 109 The Fourier series in Eq.(4.65) may readily be decoupled into their real and imaginary components, such that one needs to relate etO to e". Utilizing the inverse mapping function in Eq.(4.53) one can show for z along SC: eo = cos(O) + i sin(O) = 9(19) + Ig(i) + 7r/2) 0 < d < 27 (4.66) 1 ao - (1 + aOai)RieR R1 -1 + a1R1ie01 Similarly, one can show along RC: =cos(0) + i sin(0) e el 0 < 0 < 27 ao - (1 + aoa1)R2e0 1R2 I -1 + a1 R 2 e 0 (4.67) As a reminder, Chebyshev polynomials of the first kind Tk allow the orthogonal functions of cos(kO) to be expressed in terms of the fundamental modes cos(O) = g(7), where Tk(cos(O)) = Tk(g(i9)) = cos(kO). (4.68) and the discrete orthogonality condition for the polynomials reads, { 0 N Z Ti(cos(0m))Tj(cos(0m)) = m=1 7rN 2 ) ir(m - J N/2 if i = j 7 0 j = 0 N Om = if i if i = (4.69) m = 1, 2,3, ... , N Hence, one can relate the reference and mapped phase angles, while maintaining the ability to express the boundary conditions in terms of power series of orthogonal 110 components. In particular, it can be proved along the respective boundary that 00 C eik9 = S knCne (4.70a) n DnRe (4.70b) n=1 00 DceikO = n1=1 where one may truncate the above series to an order N after the desired accuracy has been achieved. The coefficients are calculated by, e 1 EN= T(cos(0m))Tk(g(im)) if k = 0 M 0 Tn(cos(0m))T(g(?3m)) if k > 0 = { =0 Tn(cos(m))Tk(g(5m)) 2 EN=0Tn (cos(m))T(g(dm)) if k = 0 if k > 0 and k < N. Now, the boundary conditions may be written without reference to the arguments of the systems z, (, and v. Upon convergence of the Laurent series in the holomorphic domains S, C, and R, the stress state is approximated by truncating the series in Truncation at the nth-mode, (" = pne i", yields a system of iOn + 5 Eq.(4.57). equations 5 that produce the coefficients Ad and B d for the domains d = 4.4.5 {S, C, R}. Sample Model Output: The Stress Evolution for an Eccentrically Placed Casing. Placing the steel casing eccentrically with respect to the wellbore hole creates an uneven distribution of cement around the casing. Hence the sheath is segmented into thick and thin portions. Herein, we define the degree of eccentricity 6, = Ae/(R2-RI), which measures the fractional reduction of the thinnest section of the sheath when compared with the regular geometry. In order to test the impact of the eccentricity 5 The 10n + 5 equations result from 5 boundary conditions, where the real components - the cos(kt9) modes - contribute 5n + 5 equations and the imaginary components - the sin(k0) modes - contribute the remaining 5n equations. The final boundary condition, the assumption of zero far-field stress, eliminates the positive powers of OR and 1/)R. 111 0.1 (a)-0. ~10.0 - 0.1 (b) + 0.+ -C -0.1 . - -0.2 A thinnest section thickest section 0.2 0.4 - -02 0.6 0.8 1.0 1 s/m x10 A=8 xlI 7 s/m r 0.2 0.4 0.6 0.8 0.2 0.4 0.6 0.8 1.0 0.3 0.3 (d) (c) 30.2- 0.2 0.1 0.1 0.0 0.0 0.0 0.2 0.4 0.6 0.8 1.0 0.0 - 9 1.0 Figure 4-5: Panel of (a),(b) the radial and (c),(d) the hoop stress evolution for a cement sheath with an eccentrically placed casing (6 e = 0.8) as a function of the hydration degree for the material parameters provided in Table 2.1 and the borehole dimensions provided in Table 3.1. The plots separate stresses that evolve along (a),(c) the steel-cement interface (SC) and (b),(d) the rock-cement interface (RC). Thick (thin) lines correspond to stresses along the thickest (thinnest) portion of the sheath; colors represent different fluid exchange coefficients between formation and sheath; ER = 40 GPa. on stress distribution, the boundary value problem was coupled to the pressure state equation and was solved incrementally. Figure 4-5 and Figure 4-6 show the results for the stresses in the radial and tangential direction along SC and RC at the thinnest and thickest segments of the sheath for 6, = 0.8. More precisely, Figure 4-5 displays the evolution of the stresses for low and high rock permeability values; the Newton coefficient A was varied by over an order of magnitude from 8 x 10-7 s/M to 1 x 10-5 s/M. In the highly permeable system, the cement only experiences a marginal pressure drop, as the 112 0.2 0.2 (a) (b) 0.1 0.1 ++ - 0.0 . 0.0 - s= section thickest section -ER -thinnest - -0~-0.1 0.2 0.4 =5 GPa 8 0 GPa ER = 0.6 0.8 0. 1.0 0.3 (c) 0.3 (d) 0.2- 0.2 2 0.2 0. 0.6-7 0.1. 0.8 1.0 0.4 0.6 0.8 1.0 0.4 0.6 0.1 -0.1 0.0 0.0-- 0.0 0.2 0.4 0.6 0.8 1.0 0.0 0.2 Figure 4-6: Panel of (a),(b) the radial and (c),(d) the hoop stress evolution for a 6 cement sheath with an eccentrically placed casing ( e = 0.8) as a function of the hydration degree for the material parameters provided in Table 2.1 and the borehole dimensions provided in Table 3.1. The plots separate stresses that evolve along (a),(c) the steel-cement interface (SC) and (b),(d) the rock-cement interface (RC). Thick (thin) lines correspond to stresses along the thickest (thinnest) portion of the sheath; blue (orange) lines present model output for a soft formation; A = 1 x 10-5 s/i. formation readily supplies the water that is being consumed during reaction. As a results, little variation in the pressure is experienced as the cement paste gains compressiblity and the magnitude of the residual tension in the CSH is curtailed. As a comparison, the final state of the Cauchy stress in the low permeable system is heightened by the cycle of drastically lowering and thereafter recovering the porepressure. In both cases, the magnitude of the stresses depends on the local thickness of the sheath and the thick segment bears a larger load. An important dynamic between the fluid exchange coefficient and the relative importance of the eigenstress development is discerned by comparing the simulation 113 03 0.15. 0.20.10- T SC: - 0.05- 6,=0.2 0.1 SC: 6,=0.4 SC: SC: - 6,=0.6 6,=0.8 RC: ,=0.2 RC: 6.=0.4 RC: 6,=0.6 RC: ni,=0.8 - - -i i/2 0 -r/2 -7t 7t 7r/2 0 -7r/2 7r 9 0 (b) effective tangential stress; low permeability A = 1 x 10- 7s/m (a) effective radial stress; high permeability A = 8 x 10- 7s/m Figure 4-7: (a) The effective radial stress and (b) the effective tangential stress at complete hydration for a wellbore hole geometry with an eccentric casing plotted as a function of the angular component 0 along the steel-cement interface (red) and the rock-cement interface (blue); ER = 40 GPa. The line thickness indicates the degree of eccentricity, which has been varied between 0.2 and 0.8. 0.04 - 0.03 - SC: RC: J,=0.2 RC: 6,=0.4 0.02 RC: 6,=0.6 RC: J,=0.8 - SC: SC: 6,=0.6 6 =0.8 0.00 0.02 -0.02 0.01 0.0 6,=0.2 SC: ,=0.4 0.2 0.4 0.6 0.8 1.0 -7r 7r/2 0r/2 T (b) (a) Figure 4-8: The shear stress along the SC (red) and RC (blue) interfaces plotted (a) as a function of the degree of hydration and (b) as a function of the angular coordinate 6 at complete hydration; A = 1 x 10- and ER = 40 GPa. The line thickness indicates the degree of eccentricity, which has been varied between 0.2 and 0.8. 114 (a) SC: max(Ero)/PF (b) 0.2 1e-06 K: MaXk2r9)/PF 0.2 0.18 0.18 0.16 0.16 0.14 1e-06 0.14 0.12 0.12 0.1 0.1 0.08 0.08 1e-07 1 e-08, 10 1e-07 0.06 l-80 30 50 0.06 0.04 0.04 0.02 0.02 le-081 70 - 10 30 50 70 E11 [GPa ER [GPa Figure 4-9: Three-dimensional plot, investigating the influence of the stiffness ER and Newton coefficient A on the magnitude of the maximum shear stress experienced 0.8 and the remaining along SC and RC. The degree of eccentricity is set at C 2.1. input parameters are gathered from Table results for the high permeable systems in Figure 4-6 and the low permeable system in Figure 4-5 (blue lines). Systems in which fluid is readily exchanged between cement and formation are more susceptible to the eigenstress generation in the CSH solid. Here, the pressure drop during reaction is moderated by rapid fluid recharge, such that the bulk stresses vary according to the increase in o-* and the stiffening behavior of cement. Consequently, the difference in the relative magnitudes of the stresses along the thick and thin segments of the sheath increase during the hardening process. On the other hand, low permeable systems are more heavily dependent on the uniform pressure evolution in the sheath. This is particularly evident when comparing the pressure curve in Figure 3-3 to the respective residual radial stresses along SC and RC plotted in Figure 4-5a and Figure 4-5b, respectively. Here, the residual loading due to the growth of compressible hydrating matter during the pressure recovery enacts a uniform stress development along both thin and thick portions of the sheath. Hence, the curves progress nearly in parallel. In Figure 4-6, the stress solver was run for a high stiffness and a low stiffness formation. As seen in panels (a) and (b), a compliant formation places the radial 115 stress along SC and RC into states of compression and tension, respectively. Such an occurrence is troublesome for drilling contractors that often choose to add expanding agents to the cement to safeguard against the build-up of tensile stresses; for a low stiffness formation, hydrating under the development of a uniform bulk eigenstress, the cement sheath is inevitably placed in tension along one of the interfaces. Nonetheless, the overall magnitude of the stresses is far exceeded for stiff formations. Interestingly, the hoop stress development with a soft rock interface shows accentuated stresses along the thin section (displayed in panels (c) and (d)). Where a formation with a high modulus is well able to resist the residual stresses incurred by the compressible hydrating matter, a soft formation gives way. Instead the stresses are transferred tangentially toward the thin portion of the sheath. At this location, the event of debonding along RC is expected to significantly increase the risk of radial fracture. To better understand the stress profile along the interfaces, Fig. 4-7 plots the radial (left panel) and hoop (right panel) stresses for a range of eccentricities as a function of the angular component 0. For the parameters selected, the thick segment is imparted more pronounced tensile loads upon increasing the eccentricity. More importantly, however, one should recognized that the stresses in the thin segment deviate to a greater degree from the concentric solution than those in the thick segment. It follows that in guarding against the stress amplification due to the casing offset, it is of benefit to seek parameters that locate the stress increase along the thicker portion. Finally, the loss of axisymmetry engenders interfacial shear stresses not present in the concentric geometry. The uneven distribution of hydrating mass acts to pull the thin section of the cement toward the thicker section. Thereby, the cement is sheared along the interfaces. Here, Fig. 4-8 shows (a) the maximum shear stress as the cement hydrates and (b) the angular distribution of stresses at complete hydration. We see that the maximum shear stress is located 450 from the narrowest segment of the sheath. Additionally, the shear stress tends to be greatest along RC and reaches magnitudes up to half the radial stress; this is confirmed for a large space of ER 116 and A values graphed in Fig. 4-9. This addition of shear stress, places the sheath at risk of mixed mode fracture, and complicates the investigation of where along the interface fracture will originate. While this thesis does not make an effort to answer this question, it is a condition important to be aware of. 4.5 Chapter Summary In this Chapter we coupled the boundary conditions of the cement liner to the pressure state equation developed in the previous chapter. As poromechanics theory is only able to reconcile the response of the system due to two mechanical loadings - (i) a regular displacement condition along the REV boundary, and (ii) the pressure acting along the solid-pore interface - the homogenization using Levine's theorem was administered at a constant degree of hydration and the pressure state equation (Eq. 3.27) was advanced incrementally. This implies the path dependence of the stress developments at the bulk scale. Herein, the stresses cannot be obtained from the final values of the constituent volume fractions and the eigenstresses, but instead depend on the mass of the transient state solid system at the time of loading. Once a poromechanical framework for the constitutive relations of the cement was constructed, the stress in the sheath was resolved for the geometry of a concentrically placed casing and an eccentrically placed casing. In general, the stress development in the sheath showed a strong dependence on the interplay between the time of hydration and the ability for fluid to be exchanged with the formation. Compressive stresses in the sheath were accentuated in the case of low fluid exchange coefficients. Of greatest concern, however, was the recovery of the pressure at the latter stages of hydration. For eigenstresses developing under low pressure conditions, the rebound in pressure places the sheath into a state of high radial tensile stress. The solution to the stress state in the eccentric geometry was derived using the Kolosov-Muskhelishvili formulas and the technique of conformal mapping. No analytic (or semi-analytic) solution was otherwise found in literature, such that this 117 novel approach is of industrial benefit in quickly 6 estimating the magnification of stresses along the interfaces. Additionally, the eccentricity of the casing produced shear stresses along SC and RC. With our chemo-poro-elastic stress solver at hand, the chapter to follow derives the energy release rate for the most critical in-plane fracture scenarios: The debonding of the SC and RC interfaces, and radial fracture. 6 Numerical approaches, such as finite-element analysis require much attention to the meshing of the geometry and can be computationally burdensome. 118 Chapter 5 Fracture Criteria Chapter 2 and Chapter 3 characterized the early-age behavior of cement from its microphases. Therein, we measured the transient state stiffening and shrinkage phenomena and upscaled them using a three-level homogenization scheme. Moving on to Chapter 4, our discoveries for the behavior the cement REV were integrated with the boundary conditions for the wellbore system. It was shown that the coupled behavior between the eigenstresses - both in the solid (du*) and the pore-space (dp) - and the growth of the solid mass resulted in a path-dependent final stress state. For a large range of input parameters, a shrinking cement specimen produced radial and hoop tensile stresses along the interfaces, placing the sheath at risk of fracture impairment. This risk will be characterized in the present chapter by developing the most critical fracture criteria for the in-plane geometry. Afforded the fracture toughness of the cement and its interfacial bonds, our work derives energy release rates that predict the advancement of fracture. In particular, we expound upon the following fracture scenarios: o Micro-annulus formation: MA is a small gap that forms between the liner and the casing or the rock (see cases (a) and (b) in Fig. 5-1). Often it is the result of pressure and temperature cycles in the production channel of the casing. However, at early ages, shrinkage and pore-pressure changes are the culprits of the interfacial tensile stresses. Typically, only partial debonding is observed 119 due to the irregularity of the hole geometry and potential eccentric placement of the casing. Nonetheless, we appropriate the worst-case scenario of complete . debonding to our calculation of the energy release rate1 * Radial fracture: Cement shrinkage causes tensile hoop stresses that concentrate along the SC boundary. As formation fluid accumulates in the open fracture, it acts to propagate the crack upward, and by extension, radially outward [92]. In our analysis, we calculate the energy release rate for a unit depth of the sheath due to a single crack emanating along SC and propagating radially outward. Several other studies have solved similar problems. Bowie and Freese provided the stress intensity factor for an edge crack in a circular ring with a uniform tension applied along the external boundary [14]. Delale and Erdogan produced the stress intensity factor for a radial crack in a hollow cylinder [25]. The solution closest to the problem at hand, was given by Luo and Chen, who solved for the energy release rate of a crack in the intermediate matrix of a threephase composite cylinder [52]. Wang and Shen expanded upon their approach by adding a sliding interface [90]. The solution outlined in the following utilizes elements inspired by all of the aforementioned works. 5.1 Fracture Mechanics in Porous Media The fracture approach we herein adopt is linear elastic fracture mechanics, which requires the evaluation of the energy release rate, defined as: (F) =-9 t (5.1) where Epot is the elastic potential energy and F is the area of the crack surface, such that the energy release rate is measured in J/m2 . Consider then a possible fracture process that occurs under drained conditions (P = 0) at a given hydration degree 'In order to account for the increased risk due to casing eccentricity, the stress along the interface may need to be modified by the stress concentration calculated in Section 4.4 120 Ip,r 4- (a) microannulus along the (b) microannulus along the rock-cement interface steel-cement interface (c) radial fracture Figure 5-1: Dominant fracture scenarios for the plane geometry of the cement sheath. (. Such a fracture process will reduce the traction vector along the line of the crack oriented by the outward normal n - progressed value t+(n) = pn. from its initial value t -(n) = E - n to its This stress release is associated with the release of potential energy under constant boundary conditions and is yielded by: - <9cr (5.2) (E-n -pn) - dF (o='p(r)o 2 aF pn) aprd<~ir where uj stands for the jump in displacement as a consequence of the drained fracture propagation. !cr denotes the criticalfracture energy; this threshold must be attained in order to substantiate an advance in the crack. Moreover, in order for crack propagation to proceed stably, the derivative of the release rate must remain negative. This requires the amount of energy released during propagation must decreases as the crack advances. Hence, the stability criterion reads S a2pot < 0 (5.3) By drawing on the law of energy conservation, one may equivalently regard g as the amount of work by external forces required to restore the system to its original physical state, before crack advancement. In doing so, we utilize Clapeyron's formula W(E) = 2 [T(u) + T*(E)] 121 (5.4) where the amount of internal energy generated W(E) equals the sum of the work due to externally prescribed forces T*(E) and externally prescribed displacements T(u). Approaching fracture from this perspective is well suited to the analysis of microannulus formation at the interfaces. Here, the initial and final physical states correspond to completely bonded and debonded interfaces, such that the work necessary to restore the system is readily at hand. For all fracture criteria, the stress state of the sheath E and the pressure in the macro-pores (capillary and gel) p are determined by the chemo-poro-elastic model outlined in Chapters 3 and 4. Thus, it remains only to determine the relevant crack opening vector. Stress Intensity Factor Due to the pervasive use of stress intensity factors in lieu of energy release rates to investigate fracture problems, Irwin [44] proved a straightforward conversion: Kp, = /9E' < (5.5) Ccr 1 Here, direct comparison to the critical stress intensity factor, Acr, of a material is achieved; an intensive property that quantifies a material's resistance to fracture. E' = E()/(1 - 0A) is the reduced Young's modulus under the assumption of plane strain. 5.2 Microannulus Formation In deriving solutions to the energy release during micro-annulus formation it is useful to define two equivalent moduli xs and XR for the casing and the rock. These moduli were previously invoked to calculate the evolution of the stress state in a concentric geometry (see Section 4.3). We recall that xs is the stiffness of the casing with respect to uniform pressure acting against its outer circumference. It associates the stress required to substantiate a unit inward displacement. Similarly, XR is the equivalent 122 stiffness of the formation, measuring the stress along RC required to expand the well by a unit of normalized displacement. These constants are derived in Appendix A. 5.2.1 Microannulus Along the Steel-Cement Interface (SC) To calculate the energy release of complete debonding along the interface of the cement sheath and the steel casing Clapeyron's formula is used to relate the internal energy to the prescribed boundary stresses. Accordingly, the energy released during fracture is equal to the mechanical work required to close the crack and bring the system back to its unruptured state. The symmetry of the problem allows for a simple expression of the energy release rate, gsc 1 2 1 -(E-(R 1 ) + p) ur(Ri)] 2 = (5.6) where the dissipated energy gSC equals the loss of energy due to the release of the prescribed stresses (1/2)(T*(E, p). In the above, E- is the radial stress state preceding debonding and 1[lrl = u- - u+ is the opening caused along SC. In light of the intended use for engineering applications, the above calculates the energy release for the drained poro-mechanics material. In this worst-case-scenario, pressurized water enters the crack volume after rupture and works to further extend the opening displacement. Denoting u+ as the displacement of the steel at R 1 , we find + E=-("P) R, (5.7) The displacement of the debonded, inner surface of the cement u; can also be calculated in a straightforward manner. Here, the constitutive equations (4.33) are used to seek a solution in the form of u; = Cir + C2 /r. Accordingly, the boundary value 123 problem supplies two equations, K+ =K K+ C2 (C1 R 2 ) -XR =K G C1-- + (K ~G) (ci-1 C1 - R 3G 4c (C2- -2G + (K- G C2 (C1 (5.8a) (C1+ (5.8b) ) - (Er-,+P) that define the constants for the radial displacement as C2 R2 where z = (C2 2 6G-3xR ~2G +6K +3>rR 1 (2G + 6K + 3xR) (-(E (R1 ) + p)) 2 2 (2G(G+ K) - xR(3K +G)), -G(2G+ 3xR +6K) ) Cl (5.9a) (5.9b) R2 /R 1 . Substituting these coefficients back into the displacement relation reveals the equivalent stiffness of the cement sheath - the resistance of the exposed cement surface to an applied pressure: (R) Ur + P) = ZC(Ri) _ R, 2xR(3G + (3K + G) (6G - 3xR) ) + 4G(3K + G)(1 - -o2 2 +2G+6K+3xR 2 (5.10) ) rr Hence, we are enabled to calculated the opening displacement along SC by p) (,4R) 1 + N )R /R 1 . iurl = (E;, (5.11) Finally, plugging the above into Eq.(5.6), the energy release rate due to the microannulus formation is given by gsC - + )2 ( + I R (5.12) with (x) = (1/2) (x + Ixl) > 0, indicating the unilateral nature of the crack opening. 124 Microannulus along the rock-cement interface (RC) 5.2.2 Micro-annulus formation along the outer boundary releases the stress that bonds the rock formation to the cement sheath. Mimicking the approach from the above, the energy release rate is found by - (R 2 ) + p) [Ur (R 2 )] _ * gRC (5.13) where E- +p is the effective radial stress along RC before debonding, and Ur(R 2 ) U is the opening displacement (71 U,- = (u-) denotes the displacement at R 2 as one approaches RC from the interior (exterior)). Here, the radial displacement of the wellbore hole after fracture is given by + (5.14) (= XR P) R2 Again, the constitutive relations in Eq. (4.33) allow the radial displacement of the relevant cement sheath to be calculated by assuming a solution of the form U= Cr + C2 /r. In particular, the boundary conditions read KS C1R1 + = (K +4 G) -= K+ (C1 - G) (C1 - + (K + - K - 2G) C+ C ) (5.15a) G C + C2) (5.15b) and the coefficients are evaluated as 6G+3Xs 2G+6K - 3;<s C2 R1 _ 4G 2 (I _ C2) C2(5.16a) R (2G - 3 xs + 6K)(-(E- + p)) + 2G(6K(1 - U2 ) + 3xs(1 + 3; 2 )) + 3xs (2K + xs) 125 (5.16b) Whence, the equivalent stiffness of the cement for a pressure acting against its outer boundary is measured by 4G2 (1 (R 2 ) = C - .2) + 2G(6K(1 - 02) + 3xs +xs( + 3 2 )) + 3xs (2K + xs) 6G + 3xs + (2G + 6K - 3xs)-0 2 (5.17) Hence, the displacement of the outer surface of the sheath, which once adjoined the rock, is calculated by = (R2 xC (5.18) R2. With the opening displacement at hand, we arrive at the following expression for the energy release rate due to micro-annulus formation along RC: gRC 5.2.3 1 2 Rr + (5.19) Sample Model Output: Energy Release Rate due to Interfacial Debonding The fracture energy release rate due to MA is calculated for the stress evolutions given in Figure 5-2a, for the cases of a stiff (ER= 40 GPa) and a soft (ER = 5 GPa) rock formation. The results for 9 and IC as a function of are displayed in Figure 5-2b and Figure 5-2c. Risk of debonding is capacitated once Err + Ap along SC and RC enters into a state of tension at around ~ 0.6 - 0.7. Beyond this threshold, the risk of fracture becomes a function of the competing processes of material toughening/increase in bond strength and the stress increase along r = R, and r = R 2 . From Eqn.(5.19) and (5.12), it is seen that g is linearly related to the build-up of radial stresses and inversely related to the moduli of the separating materials. While 9 along SC and RC is comparable at the early stages of hardening, the disproportionate increase in stress at the outer portion of the sheath promotes a more considerable increase in gRC. Additionally, because 1/xs is small compared to 1/XR, the stiffening of the cement (decrease in 1/xC) more dramatically reduces the energy 126 (a) 0.14 0.12 0.10- - - - stress along SC (ER =40 GPa) stress along RC (ER =40 GPa) stress along SC (ER =5 GPa) stress along RC (ER =5 GPa) 0.080.06 0.04 0.02 0.00 (b) 0.6 120 -- 100 - ~~~~"~~=- ' .--- - - 0.7 0.8 1.0 0.9 along SC micro-a nnulus micro-a nnulus along SC micro-a nnulus along RC 80 6040 -- 20 0.6 0.7 0.8 0.9 1. 0 0.9 1.0 21 (C) - micro-annulus along SC - micro-annulus along RC 1.5 1. 0.5 0.0c 0.6 0.7 0.8 Figure 5-2: The evolution of (b) the energy release rate and (c) the stress intensity factor for micro-annulus formation along the steel-cement (SC) and rock-cement (RC) interfaces calculated from the results of the chemo-poromechanics solver shown in panel (a). Solid lines indicate a stiff formation (ER =40 GPa) and the dashed lines indicate a soft formation (ER =5 GPa). 127 release rate along SC. The stress intensity factor for the case of a stiff formation is generally greater because larger stresses develop under these more rigidly confined conditions. To more thoroughly investigate the effect of the formation stiffness on the energy release rate due to MA, we plot g at complete hydration for a range of bulk moduli in Fig. 5-3. KR The energy release rate for MA along both interfaces increases substantially as ratio between rock and cement stiffnesses increases. Interestingly, though the cement solid experiences bulk shrinkage, both interfaces are at risk of debonding, even after the pressure drop has recovered 2. Here, it must be remembered that (i) the initial pressure drop is administered differently along SC and RC in solving the boundary value problem, as the formation undergoes a similar pressure change; and (ii) the effective stress is calculated incrementally and in function of the solid mass. Hence, while du* places SC in radial compression and RC in radial tension, dp (a pressure increase) places both interfaces into tension. Only for high fluid exchange coefficients, where the drop in fluid pressure in the cement is quickly recovered, is a difference in the sign of the effective stress along SC and RC to be experienced3 . This remarkable result implies that MA is a potential risk along both interfaces, even in the event that expanding agents are used to reverse the sign of the eigenstress in the solid skeleton. 5.3 Radial Fracture A convenient method for evaluating elastic problems lacking axisymmetry is by means of the Airy stress function U and complex variables. This approach was developed by Muskhelishvili [581 and has been described in Section 4.1. It has found widespread application in solving planar problems of fracture mechanics with specific application to the semi-analytical calculation of stress intensity factors for a radial crack in an annular geometry [6] [14] [85]. Of apparent interest, the solution by Wang and 2 For a three-phase cylinder with a uniform bulk eigenstress in the intermediate matrix phase, if one interface is under tension, the other is under compression. 3 This was previously noted in Section 4.3.1. 128 160 . , , , ,2.5 140 2.0- 120 C 100 1.5 80 1.0 60 4040. 0.5- 20 - - 0.5 micro-annulus along SC micro-annulus along RC 05 2.5 0.0 1.5 1.0 2.0 -- - KR/Kc 0.5 1.0 micro-annulus along SC micro-annulus along RC 1.5 2.0 2.5 K1/ Kc (b) stress intensity factor (a) energy release rate Figure 5-3: The (a) the energy release rate and (b) the stress intensity factor for microannulus formation along the steel-cement (SC) and rock-cement (RC) interfaces are plotted for different ratios of the rock and cement bulk moduli KR/KC. The bulk modulus of the of the cement, the pore-pressure, and the radial stress along the interfaces have been calculated by the chemo-poromechanics solver and are evaluated at complete hydration. Shen [901 provides the stress intensity factor for an embedded radial fracture in the intermediate matrix of a three-phase composite cylinder. However, in their approach the inner inclusion is simply connected and does not contain a hollow interior as is the case for our steel casing. Thus, to our knowledge no analytic solution exists that has been adapted to the elastic boundary conditions and geometry prevailing in the casing-sheath-formation system. Below, we follow the approach employed in many of the works of Erdogan (see for instance [25]) and seek a solution to the energy release rate of the system by first finding the Green's function for an edge dislocation in the cement sheath. A boundary condition that relates the shear stress along the steelcement interface to the slip displacement jump is adopted from the solution by Wang and Shen to simulate varying degrees interface damage Eo = x(u (R1 ) - u-(R 1 )). Here, the damage parameter X defines the rigidity of the shear connection. Once at hand, the Green's function may be integrated along the line of fracture to calculate the crack opening displacement. In calculating the energy release rate due a radial crack, the behavior of cement as a multi-level, chemo-poromechanics material is blended with linear fracture 129 mechanics. Hence, we construct the following solution procedure: 1. Connect the cement behavior to the chemo-poromechanics solver: Under reaction the cement paste stiffens, solid eigenstresses develop, and the pore-pressure evolves. Utilizing the solution in Section 4.3, the tangential stress for a sheath . in good quality may be written in the form Eoo + p = I, + I2 /r 2 2. Construct regions of analytic continuity: A well-known simplification allows the regions of steel, cement, and rock to be continued analytically across the SC and RC interfaces. This allows the stress and displacement states to be written in terms of a single potential (Dd. 3. Solve for the Green's function of an edge dislocation: By constructing the potentials bd as Laurent series (see Appendix B), the Green's function for an edge dislocation is solved in a two-step process: First the stress due to an edge dislocation in an infinite medium is calculated along SC and RC. Second, this stress is superposed onto the boundary value problem of the cement sheath. The boundary relations allow the coefficients of the Laurent series to be solved as a decoupled system of equations. 4. Integrate the Green's function along the line of the crack: The Green's function, which represents a delta discontinuity in the displacement of the sheath, may be integrated along the line of the radial crack to resolve the crack opening displacement. Hence, the unknown strength of the discontinuity along the crack p(t) (herein termed the dislocation density) is solved in a singular integral equation by relating the crack surface stress to the tangential stress calculated in step 1. 5.3.1 Connection to the Chemo-Poro-Mechanics Solver The expression in Eq. 5.2 of the energy release rate allows one to employ a linear elastic approach derived through the method of superposition. The cement sheath, undergoing stress and pressure developments, is split into two subproblems: (i) A 130 Table 5.1: Restrictions on the parameters 1, and I2 that ensure an effective hoop stress in the tensile regime. Sign of parameters Restrictions Max. extension of Shape of function enabling radial cracking crack entire sheath I1 > 0 12 > 0 convex none I1 > 0 I2 < 0 concave crack initiation along < 0 12 > 0 convex I1 < 0 12 < 0 concave I1 RC (uncommon) I1 + 12 > 0 entire sheath is in compression in the 0-direction min R, ,R 2} no extension continuous cement annulus, absent of defects, with hoop stresses E00 evolving due to the uniform development of eigenstresses and pressure changes, and (ii) a sectionally holomorphic annulus with a crack of length a, where an effective stress Eoo + p acts on the crack surfaces. The effective stress must be opposite in sign and equal in magnitude (less the added pressure term) to the stress evaluated in the defect-free system. This establishes a hydrostatic pressure along the crack lips after superposing the two subproblems, consistent with the assumed drained nature of the fracture process. The presence of a single radial crack in sub-problem (ii) introduces a loss of axisymmetry, posing the challenge and novelty of the approach. Additionally, it should be noted that the propagation of a crack solely alters the stress state of (ii). The poromechanics model detailed in Chapters 2 and 3 accounts for the interactive effects of hydration and fluid kinetics by evaluating the state equations incrementally. Thus, the macroscopic effective hoop stress in the uncracked cement annulus is sought in classical form EOO + P = I1 ( ) + 12( ), r) R, <r <R2 (5.20) and is related to the effective eigenstress development (dE* + dp = (1 - b)(do* + dp)) 131 by I1 / {1+2 [K( J O = 1 + 2 [K( ) + + 2 (Qt)= {2G( )c + GQ)1 c )+-G( L3< (_)} dZ7 (5.21) G() c()} < ( )} dZ d* (5.22) {2G(d)c *(<)} where it has been remembered that the radial displacement solution implemented in our boundary value problem can be sought in the form u,( ) = C1()r + C2 ( )/r. Within the context of our problem, I1 + I2 (Ri/r)2 must be positive at r = R, in order for crack initiation to find opportunity. Emperical evidence and chemo- poromechanical simulations evince predominant radial fracture initiation along SC. This is due to the disparity in the magnitude of the elastic moduli of sheath, casing, and formation 1111. The contraction of the sheath around a stiff casing localizes the greatest hoop stresses along SC (see Figure 4-2 for the stress at complete hydration). Moreover, if a tension-to-compression transition exists, the crack may not propagate beyond the inner tensile region. The conditions on I1 and I2 to entail a tensile regime are summarized in Table 5.1. In the sequel, we connect the effective hoop stress calculated in Eq.(5.20) and resolve the crack opening opening displacement in sub-problem (ii). This enables us to calculate the work required to advance the radial crack, and thus obtain the energy release rate. 5.3.2 Method of Continuation The primary drawback in constructing solutions for elasticity problems using the Kolosov-Muskhelishvili formulae is that lengthy and complicated expressions typically emerge. For this reason, one often seeks devices that simplify the solution approach. England [281, in his book, presents the particularly favorable method of analytic 132 continuation, which allows the two potentials required to resolve a mechanical state to be reduced to a single potential. Consider an infinite plate with a circular hole of radius r. If we denote the region of the of the plate by V- and the region of the hole by V+, then for every point z in V- we can calculate an image point r2 /2 in the region V+. It is observed along the boundary contour z E (V- n V+) that z = r 2 /-. Now, the stress and displacement of the plate are defined by Eq.(4.25) and Eq.(4.26), where the potentials <b(z) and '(z) are valid in z E V-. Consequently D(z) and '(z) may be defined arbitrarily for z E V+, and we can, for instance, express I(z) in V- in terms of 1D(z) in V+. In the analysis of our wellbore liner, this scenario describes the case of the material region of the rock. Here, the rock, with elastic parameters GR = ER/2(1 + R 1/R) and 3 - 4iR, borders the outer wall of the sheath and extends to infinity (z E R). The regions defining the rock and its image (z E R+) are portrayed in Fig. 5-4c. If we continue the function 4)R(z) across RC as 4)R(Z) = -zA)(R/z) - '(R'/z), z E R+ (5.23) the resultant force along RC is given by (see Eq. 4.17): f, + fy = 4)-(Z) - (D+(z). (5.24) The displacement is obtained as: 2GR(u, + iny) = KR4 -(Z) - The superscripts + and - - '+(z). (5.25) indicate the direction from which the boundary is . being approached 4 Similar arguments follow for the annular domains of the steel casing (z c S) and the cement sheath (z E C). Because these domains are multiply connected, two image 4+ (-) will be used to denote the left (right) side of the boundary contour with respect to a counter-clockwise traversal. 133 regions a piece must be constructed. Take for example an annulus that is bounded by two concentric circles of radii r 1 and r 2 that produce a region V. By continuing the region of analyticity across z to z = r2/r2 (z = = i (z = r 2 ), the thickness of the annulus is extended r2/ri) and the annulus is defined for V- U V U V+. Thus, we can define - '(r2/z) IJ(r2/z), - if (r /r2) z| r1 (Dd(Z) = ; dz'~ for the interior V+ G 2/Z) - if r2 < Iz|I 1XIF~r2/) (r2/r2 < d = S, C (5.26) r2 /ri) continu- (r2/1 IzI < ri) and exterior V- E (r2 z ations of the steel V = S and the cement V = C. The two extended material domains and their boundaries are depicted in Figures 5-4 a,b. Though of little mathematical consequence, one should observe that several domains overlap (e.g., S- overlaps C). By inverting the relations in Eq.(5.26) it is recognized that TId(Z), resolved in the interior region, has two expressions: -diI(z) 5d(Z) (r/z) d- (r'/z) - Yd (z) (5.27) in V in V Consequently, in order to ensure that the mechanical state is well defined, TId(z) must satisfy the compatibility condition: (2)- 5.3.3 (2/(r/z) +T ) (z) =0. - (5.28) z Green's Function for an Edge Dislocation The Green's function, in application for the cement sheath, solves for a divergence free stress state with a delta inhomogeneity positioned at z = t. Here, the delta inhomogeneitiy describes the physical analogy of an edge dislocation. From a mathematical point of view this means that the traversal around the inhomogeneity in C produces a jump in displacement that is proportional to the strength of the dislo134 R" IS Ro R, (a) steel casing ----- R2 R, C W2 (b) cement sheath RR R2 R+ (c) rock formation Figure 5-4: Regions of continuation. 135 cation. However, a single dislocation enacts a mono-valued jump, regardless of the radius by which we circumscribe the dislocation. For our application in solving for the fracture energy release rate we wish the discontinuity to be indicative of the crack opening displacement. Hence, a gradient of dislocation strengths ferred to as dislocation pile-up - sometimes re- is positioned in the sheath to recreate the shape of the crack. The great utility of the Green's function is that, once at hand, it can be used to construct any arbitrarily shaped crack in the region V = C. Again, a solution will be sought by superposing two sub-problems. In the first sub-problem, the stress state due to an edge dislocation embedded in an infinite, homogeneous medium (cement) will be denoted by E(l). By calculating the stress E(1) along the location of the two interfaces of the sheath, SC and RC, the response of the adjoining media can be determined by applying an equal and opposite loading to a holomorphic 5 system. The stress resulting in this second sub-problem will be denoted E(2), such that the superposed result, Edis - E(1) E(2), (5.29) produces the stress due to an edge dislocation for the particular boundary conditions of the sheath. For the purposes of our fracture analysis, the Green's function shall solve the mechanical state of the cement sheath (i.e., produce expressions for <D(z) and 'I(z)) for an edge dislocation with a Burgers vector of unit value Jb2 + ibl = 1 placed at z = t. Because the desired result is a radial crack along a single ray (where 0 is constant) and the displacement jump shall occur perpendicular to the crack, the result is simplified by assuming the position of the dislocation along the real axis a(t) = 0 with a Burgers vector pointing in the y-direction b, = 0. Under these simplifications, the potentials for the first sub-problem (an infinite cement medium) 5Holomorphicity implies single-valuedness in S, C, and R. 136 are well known and given as 1721, (Z) - J(z) = (Z -G(bx+ iby) -- r7(K G log(z - t) i7r(K + 1) z + 1) Z -- t Tr(K + 1) G(bx- iby) i7r(K + 1) log(z - t) (5.30a) G lo~ )=7(K + 1) lo(zf) zNj (gz t)-z - t)f (5.30b) where 3 - 4v has been chosen for the conditions of plane strain. It should be K= noted that 1(z) and T (z) are singular at z = t where z E C, and that additional singularities exist in the image regions at z = R1 /t where z C C+ and z = R/t where z E C-. Substituting the potentials into fX + ify = 1-(z) - D+(z) (5.31) and noting that 1(z) is defined by Eq. (5.26) for the continued regions, the resultant force f E (' - n dz along the interfaces is given as: { - (z) (l G (+z) log(z - t) + log (z- - log(t) + + log(z - t) + log (z-R2/t - log(t) + + ) )-AI/t Z-R/t z along SC z along RC (5.32) Next, it is remembered that any constant term in the above does not alter the stress state. Additionally, with the foresight of developing 4(z) into a Laurent series, only the principal value of the expressions is of importance. This allows the superposed result to be calculated by: I disdz J (1) + E(2) (2 )(z) + Q (log(z - t) + log (z-/t ( 2 )(z) + Q (log(z - t) + log (Z- 137 z along SC + + _ z along RC (5.33) where =(R!- Rt 2 ) t3, and 72 = (Ri -= 2- Rit2/3). Laurent Series As was done in the analysis of the system with an eccentrically placed casing, a solution to the boundary value problem will be sought by developing <P(2 (z) into a Laurent series6 for the three material regions d = {S,C,R}. It must be remembered that the continuation of the casing, sheath, and formation produces additional domains. Consequently, a total of 8 series are required to define the mechanical state of the oil well system7 . In general, these can be written as (p2 (Zc) n= a+Zn if z E V+ an z if Z E n=0a- V if Z E V- n" and we define the coefficients for the three material regions d a+ = A+ = An; aa+ = BBan =B; a = B; for the cement a+ = CZ; a- = (5.34) A- a. = Cn = S, C, R as for the steel (5.35) for the rock. The dash across the summation symbols in Eq.(5.34) indicates that the zeroth-order term in the series is omitted from the sum. These terms describe rigid body displacements that are inconsequential to the stress/deformation states of the regions. As the remainder of the analysis is largely concerned with the response of the boundaries to the dislocation singularity, the indication () to denote the second sub-problem will be omitted unless required for clarity, and all quantities shall refer to the cement sheath unless s or R indicate reference to the steel or rock. The poles in the physical and image regions due to the dislocation are described 'Appendix B provides a brief introduction to Laurent series. 73 series to represent <b(z) in C+, C, and C-, 3 series to represent <bs(z) in S+, S, and S, and 2 series to represent 4bR(Z) in R+, and R. 138 in Eq.(5.33); they are the terms that describe the stress state that must be superposed onto the boundaries SC and RC. As we have opted to resolve the mechanical state by the orthogonal terms of the Laurent series, the effect of the poles must similarly be decomposed into powers of zn in order to measure the contribution of the frequency e"O to the solution. One may readily access the following important power series expansions, log(1- z)= - for jzj < 1 (5.36a) for jzj < 1 (5.36b) n=1 1 1 00 Zzn Z n=O Using these relations and recognizing that zI < t and IzI > R'/t along SC and Iz| > t and jzj < R /t along RC, we can recast the resultant force along the boundaries as Edisdz = <(b(2)(Z) + ( + E(dz 0(_1 [ + (z_ (,)n +-1 E (R )n [ + ( )f z along SC - 2 (t)n+1 zn] z along RC (5.37) With the necessary series expressions at hand, it remains only to define the boundary relations that allow the unknown coefficients A+, An, A-, Bj, Bn, B-,C ,andC to be solved as a system of equations. Boundary Conditions As usual, the boundary conditions ensure the traction and displacement continuity along the SC and RC interfaces, and ensure a stress-free inner surface of the casing and a vanishing far-field stress in the formation. However, because the radial crack emanates from SC, the bond in proximity of the crack origin is necessarily damaged. In this location, we wish to model the interfaces as sliding with respect to one another, while nonetheless maintaining non-zero shear stress. A capable solution is adapted 139 from the work of Wang and Shen [90], where the shear stress is imposed proportional to the tangential displacement jump: E zi = Rie (zi) = E (zi) =xTUo] = x(UO (Zi) - U0(Zi)) (5.38) Thus, the parameter x measures the rigidity of the shear connection. The asymptotic cases x = 0 and x - oc assume a completely sliding and a rigidly bonded interface, respectively. Having continued the regions of definition for across SC and RC, we may 4Dd write the boundary conditions in the following way: e Traction-free conditions along the inner surface of the steel casing (zo = Roe' 0 ): E- (zi)dz = JI (zo) - %s (zo) = 0, r=RO; 0<0<27T (5.39) . Traction continuity along SC (z,1 = R ie): SE(zi) + iE+(z)dz= f E-(zi) + 1E;- (zl)dz (5.40) (zi) - D-(zi) = D-(zi) - @+(zi) * Radial displacement continuity along SC (z, = Rieo): Ur,(zi) = U-,(zi) {z 1 R [Ks(D (zi) + D- (zi)]} = 22G (5.41) {Z-1 [K4D(zl) * Jump in the tangential displacement along SC (z 1 EgO(zi)= E-(z1 ) = X( S{4'I-(zi) - 4b'+(zi) I = {4 '+(zi) - = + 2i 2Gs +(z')]}I Rie): (zi) - uf+(zi)) '() = 2C Xe.- { {I Zi , [K-(Zi) + 4+(z)] [Ks 4(zi) + P -(zi)] (5.42) 140 e Traction continuity along RC (z 2 = R 2eio): I E+(z2 ) + iE%(z 2 )dz = +(z 2 ) - ( J -,(z 2 )+ iE -(z 2 )dz (5.43) r (z2 ) = 4Fj(z 2 ) - 4I(z 2 ), = R2 ; 0 < 0 < 2wr o Displacement continuity along RC (z 2 = R2C 4): ) uf,.(z 2 ) + irO(z2 ) =u (z 2 ) + 11U7(z2 20 ) r r'(2) +'U 2[R(Z2) ' I z2 [WP+ (Z2) + 4)-(Z2)] = 2GI[KR4D-z2) + RR 2GR R+(Z2)] r=R; 1 0<0<27 (5.44) * Zero far-field effective stress condition in the formation. This boundary condition truncates the positive powers of the Laurent series representation of 1 R(z) in z E R and the negative powers in z E R+ in order to ensure a finite value at z = oo and z = 0, respectively. The displacement vector along SC is divided into its real and imaginary parts in order to ascribe conditions on the the radial and tangential deformation separately. In order to avoid decomposing the exponential e' 0 into its cosine and sine terms, we isolate the real part of Eq.(5.41) by adding the complex conjugate to both sides and (z) + ( - /)-(z) + z (z) (r - by simplifying the expression using Eq.(5.40): In the above, the two bimaterial constants are given by q = (5.45) Gs++ KSG Gs GsGs and 0 = KGG For the link between the tangential jump in displacement and the shear stress along the interface, we isolate the imaginary component of Eq.(5.41) by subtracting the 141 complex conjugate terms on both sides. This yields S['s+(z) +Fs+(z) + (7 = +'s+ D'+(z) - )Ps (z) - Z) [+(z) + (n - b)%s(z) (5.46) 4[-(z) -- @-(z) where X = 2GRs 2GGS Matrix Coefficients The task that remains is the assembly of a system of equations that solves for the Laurent series coefficients in 4)d; d = {S,C,R}. Before moving to compose these matrices, we reduce the number of coefficients for the steel casing by applying several relations a priori. In particular, the compatibility condition written in Eq. (5.28) links the coefficients for the steel domain and its image regions by, 2R 2/Z2 s(Rj/z) - @s(R/z) +4(z) = 0 z An- RA + (R - R )(-n + 2)A-n+2 = 0 (5.47) Similarly, the traction boundary condition (5.39) along the inner surface of the steel imposes the relation, A+ = An. (5.48) This reduces the previous relation to an expression for the coefficients of the interior image region, An- = R2n An - (R 21R" - RR 2)) (-n + 2)A-n+2. (5.49) Thus, it suffices to solve An for the steel. It should be recognized that, in general, each of the boundary and compatibility equations only links coefficients of order n to coefficients of order -n + 2 (unlike the previous solution for the stress state in a sheath with an eccentrically placed casing). This fortunate result allows us to provide an explicit expression for the matrices 142 that define the coefficients A,, B+, B,, Bn, CZ, and Cn. In conjunction with the compatibility condition for 1(z) for the cement, 2 <D(Rf /z) 2 R2-R D'4)(z) = 0 - (Ds(RO/z) + -1 (5.50) ( - the previously defined boundary conditions are solved by the following relations: A1 A2 B1 B+ + ( o The coefficients for terms of order n = 1 and n = 2 read as B1 = (A ) 1(by); B2 B- B-2 C1 C2 =(A2) (b2g); (5.51) SAll other coefficients of order n > 2 and -n + 2 < 0 are calculated by An A-n+2 Btn Bin+2 Bn = (An)- 1 (bn) (5.52) B-n+2 Bn B-n+2 Cz ) C-n+ 2 where A 1 , bi, A 2 , b 2 , An, and b, are provided on the following page. This completely defines the Green's function for an edge dislocation in the annular region of the cement sheath. 143 (A 1 ) = +2W2 1 -11G - 1] 1 0 0 s/G R 2 (R -R2) 0 0 0 ( 0 0 0 0 -1 1/G -11GR -1 ( (A 2 ) = 1 -- -1 W4) -Xl 0 X~ - 0 0 0 Q (b)T =0 0 -3t - ] 0 0 0 0 (5.53) -1 1 11G -1GR 4 0 R2 1 i/G R 4-1 0 2 n -- 0 )T = 1-W4 XR s+w4]+2( ) 2(1-W2) 4- rs 0 0 0) 0 1 (5.54) (An)= (2 - n)R( 2 -2n) (2n- 2 -~~~~~~ ~ _ ~ Z2) n ,I- (2 l) [n(1 - Z2) _ I + (6 - (1_ 1 2) - -- -- 0 I Tr - - .2n 1 72 > 1 I (4-2n) - - ~ - ~ - - - ~ -2 2-2n> F -1 0 0 ~~ o 0 0 0 0 0 0 I 0 I 0 - 0 1 0 I - R (-- -(1-C2)(2--n) 0 I o 2 .2n] I-+ -1 - 1 - ----------------------- + R R 2n[(n+X(O-3r)1} 2 (-2-X) - 2 2 0 L 0' 0 ---- - - - - 0- - -- - - - - - -- - - - - - - - - - - - - - -i---- 0 0I 0 I 1 4- -I 0 -1 0 1 0 I- 0 1/G_ 0 -1/GR 0 KIG 0 IIG 0 -KRIGR 0 0 I--- -I 0 - 0 1 -1 o0 I -I - i -1--1 - 0 0 I I (2-n+X(3--n)) 0 0 X8R(2-2n) -X 0 0 n) (1-.2)(2-n)(n+X(O-7)) - - [n-2-X(3-7)] 2 - nw 2 2 2 R X+n[n-l-X(-77)] o - i 0 0 0 0 - oI i i R2n\ -L 0 I I 0 I R R( 0/G 0 0 0 0 L2n) - 4 1-n (n-2)(R2- R - n(R -R 2) I 1 0 L _ __0 1 L 0 _- _ .__- - L -- R 2 4-2n) - oi 0 0 0 0 (5.55) 2 (b)T In the above =rKl u 17 -y _a 2n-4 n n-2 R( nt 2 ) R 2n-4 (n-2)t-2j 0 0 Q [ + _ -- n- the expressions for the parameters r; = 'Gs+G we restate convenience, = R =. For 2GG 2SG3GS' rsG+Gs+1 (Ri - Rlt 2/t, and 'Y2 2R R~ 2 /t 0 0 0 -GSGs 0) (5.56) = XRs Singular Integral Equation for the Crack Surface Bound- 5.3.4 ary Condition The Green's function in the previous section solves the stress state in the cement sheath for a single edge dislocation with a unit Burgers vector pointing in the yDue to the linearity of the response, the influence of a dislocation of direction. variable strength p pydis = /E(1) commonly termed the dislocation density - is measured by + PE(2). The versatility of the function is immediately recognized: by relating the dislocation density to the crack opening displacement, a crack of arbitrary shape may be represented in the cement region. It is noted that the Green's function has presently been limited to discontinuities along the real axis, such that a continuous arrangement of dislocations along the sheath thickness allows a radial crack of any length and origin to be constructed (emanating from the proximal/distal interface, or embedded). While devising the circumstances of a radial crack for a known distribution of the dislocation density p(t) is trivial, the risk of radial fracture for the hydrating cement sheath must be assessed with respect to the poromechanical properties and the eigenstress generation. Consequently, we are tasked with finding the distribution that relates the tangential stress generation in a holomorphic specimen to the crack surface traction in the impaired specimen. From the above, the hoop stress caused by a dislocation at location r = x = t is resolved from the Kolosov-Muskhelishvili formulae as Ed + PE(2 where PE( p(t)E2 ) (r, t)} = pt(t)R {2#(r, t) + r#(r, t) + = P(t)R {24'(r, t) + r"(r, t) + '(r, t)} (5.57) = P(t)H(r,t). Remembering that TJ(z, t) is calculated by either of the cases in Eq.(5.27), we may choose / (z, t) = -D (R2 /-f, t) 145 Z I'(z , t) (5.58) and the potentials read in terms of their Laurent series as 00 <D B, (t)zZ (z, t) = E (5.59a) n= -oo XF 00 ) ~zt) =-1: B() (+j~ n1) Bn (t) z7 -1: . 00 (5.59b) fl-oc( fl-o0 Whence, it follows from Eq.(5.57): 00 H(r, t) B(t) [(n2 + n)rn-1 - (n2 - 2n)R2r"-3 ] + B+(t) [nR 2nr-"-1] . (5.60) = 71=-cO It will be remembered that our solution strategy superposes two elastic solutions: the solution for the holomophic problem, and the solution with a crack whose surface traction is measured by - (I1( ) + I 2 ( )/r 2 ). With the relevant expressions at hand, such a boundary traction is guaranteed by setting -2G er(r + 1) p (t)E((r,t)dt + P(t)E 2 (r, t)dt = - I 12 fP2 fP)2 IP2 d t - + r / I H(r,t)p(t)dt =rs effect of dislocations in an infinite medium I2 (5.61) r2 boundary response We notice that p(t) can be solved as a singular integral equation of the first kind, where pi and P2 are the left and right crack tips, respectively. The integrals must be . taken in the Cauchy Principal Value sense8 Numerical solutions to the singular integral equation. Much work has been devoted to the analysis of singular integral equations [591 and noteworthy contributions by Erdogan et al. [291 [481, give numerical approaches to the The Cauchy principal value of an integral f f(x)dx- also termed the finite part of an integral with a singularity at the end point x = b may be calculated as 8 - f(x) dx P.v. a lim +0+ 1 146 f (x) dx. (5.62) solution of crack-type problems. In particular, they have adopted Gaussian quadrature formulas that utilize the orthogonality of the Jacobi polynomials to provide high-accuracy solutions with a small number of quadrature points. In Appendix D, it is shown that the fundamental function of the dislocation density is that of the weight function for the Jacobi polynomials (Chebychev polynomials in particular), such that the form of p(t) is sought as P(t) = w(t)g(t) = (t - P1)"(P2 - t)'g(t) (5.63) and w(t) is the pre-determined weight function. It depends on two parameters, a and 3, that describe the nature of the crack tip singularities. In order to ascribe meaning to these parameters, we investigate the physical interpretation of P(t). Because a Burgers vector is defined as the integral of &ui/Ds taken counter clockwise around the dislocation, it is readily understood that P(r) = ar". (5.64) defines the gradient of the displacement discontinuity. In other words, the dislocation density p(t) describes the slope of the crack opening displacement. If the crack is embedded in a homogeneous medium, p(t) will be singular at the points t = pi and t = P2. For this scenario, the symmetry of the top and bottom crack surfaces and the elliptical shape requires the opening displacement to terminate at an infinite slope; this demands the negativity of a and 3. Case (a) in Fig. 5-5 shows the idealized shape of a crack embedded in a homogeneous medium. On the other hand, if P(t) represents an edge crack, where one of the end points of the crack, say t = pi, terminates at a zero slope or a finite slope (for instance, if shear forces along the interface subdue an unimpeded opening displacement), then the respective parameter is necessarily non-negative, /3 > 0. Cases (c) and (d) in Fig. 5-5 show the idealized crack shapes for these scenarios. The numerical recipes by Erdogan et al. [291 will now be applied to the various cases of a radial crack in our cement sheath. However, in order to relate the crack 147 of integration must be normalized to (-1,1). Thus, the integral equation is recast as '2~ 7r T _T (T) -p dT + - 1 f(r(p). t(T))f(T)dT = [ p I 2 (5.65) r (p) 2 where H(r(p), t(T)) = - (K+ 1)(P2 - P1) 4G H(r(p), t(T)) (K + 1) 2G (2 2+ 1) 1 2G fA(r) =ptr) and the coordinates r and t have been parameterized using the following relations: P2 2 T +P1 P2-P1 P2-P1 2 P2+P1. P2-P1 _ P2 - P1 + P2 +P1 2 P2P1 + 2 P2-P1 (5.66a) 2 + ) boundary condition in Eq. (5.61) to the general formulae cited in literature, the interval . 2 (5.66b) In the following we provide the numerical solutions to Eq.(5.61) for a crack that originates at SC and propagates radially outward toward RC. Varying assumptions are made for the shear traction continuity along SC. Closed Crack Geometry: Rigid Shear Connection Along SC The first case we consider is that of a rigid connection between steel and cement, for which x -+ oc and an ellipsoidal crack shape ensures displacement continuity at the proximal crack tip r = R1 . It should be noted that a shear stress singularity along SC is necessitated to maintain the closure of the crack. As a result, the Fredholm kernel H(p, T) in Eq.(5.65) becomes singular for p = T = -1. Typically, numerical methods are only designed to accommodate the Cauchy singularity 1/(T - p) in the first integral. Thus, additional attention must devoted in the numerical procedure to deal with ft(p, T). With this in mind, we will first proceed by giving the well known 148 solution for a bounded Fredholm kernel; as would be appropriate for an embedded crack, not in contact with SC or RC. Thereafter, the form of the weight function tb(T) will be modified to provide more accurate results in the case that either of the crack tips terminates at a bi-material interface. As a first approximation, the symmetry of the problem allows us to estimate the fundamental function of the crack by (lT(() = ,\(I 1 - 7) (1 + 7) (5.67) . where a and 3 have been set to -0.5 in Eq.(5.63). Substituting the above expression for ft(T) into Eq.(5.65), a system of linear algebraic equations can be developed by discretizing g(T) and using a Gauss-Jacobi quadrature scheme [29]: S- N 1 g(Ti) 1-1 Ti -Pk + 7rH(pk, Ti) _ = 2- ZI + (5.68) 2 r(P )x2 Herein, the relevant orthogonal polynomials are of the Jacobi type and reduce to Cliebyshev polynomials of the first and second kind - denoted TN(T) and UN 1(p), respectively. Their abscissas define the collocation points, which are given by, Ti - OS 72i -1) Ti = cos 7r 1=1 11..IN (i=1,2,3 ... ,N) N c p)s(k =1,(2, =3,..., N). Within the development of the numerical quadrature, TN(T) provides the N abscissas for ri, and UN-1(p) provides N - 1 abscissas for Pk in the interval -1 < T < 1. Hence, an additional relation is of need to obtain a unique solution. This condition is given by the physics of the problem, where we require the closure of the crack opening displacement - i.e. the condition of single-valuedness of the displacement upon crack traversal: 1 N g(7j) = 0 - (T)dT ~ f222N 149 (5.70) Table 5.2: The first root of the characteristic equation describing the singular behavior of the crack tip terminating at the RC bi-material interface; assuming v = vR = 0.27 m=GR/G -a 0.1 0.753 0.2 0.679 0.5 0.575 1.0 0.500 2.0 0.431 5.0 0.358 10.0 0.320 While the approach outlined above provides a good first estimate of g(T) (and is accurate for an embedded crack), we will now seek a modification to the weight function ')(T) that will allow the effects of the Fredholm singularities to be taken into consideration. It should be pointed out that if the fracture penetrates the entire width of the sheath, Ht(p, p T) will have two singularities located at p = T -1 and T = 1. Fortunately, several authors have investigated the details of this singular behavior 1161 [781, and Cook and Erdogan provide a mathematical formalism for the change in the singular behavior for a crack terminating at the interface of two semi-infinite half planes [22] [42]. By calculating the eigenvalues of a characteristic transcendental function, the values of a and 3 are derived. This function is substantially complicated in the case of our annulus due to the Laurent series expression. But, because the characteristic radial dimension of the sheath is much greater than the characteristic dimension of the opening displacement, adoption of their formalism well approximates the singular behavior for the crack tip ending at our curved surface at RC. Thus, from their analysis a is the first root of [221, 2d, cos(7r(a + 1)) - d 2 (a + 1)2 - d3 150 = 0; 0 < -a < 1 (5.71) where di = (m +Vs) (I + MK) d2 = -4(m + Ks)(I d3 = (1 - m)(m - - m) rs) + (1 + mK)(m + Ks) - m(1 + K)(1 + mnK) and rn = GR/G. Table 5.2 shows the values of a for varying ratios of the shear modulus. As the stiffness of the rock increases in comparison to the cement, the strength of the singularity decreases. The rock is able to absorb more of the stress and the load near the crack tip is dampened. It should be remembered that the stiffening behavior of the cement will vary the ratio of the moduli, m, such that a changes in the course of the reaction. The application of this approach to the crack tip at SC is less justifiable, because the steel casing is not suitable to the idealization of an infinite half space. Nonetheless, we will calculate # from the first root of Eq.(5.71), and are confident that this approximation lends only minor error since (i) the high ratio of the moduli between steel and cement will lead to a large absorption of the stresses by the steel near the crack tip, and (ii) we are principally concerned with the stress intensity factor at the distal tip. Therefore, the inaccuracies of the approximation are expected to decrease as the crack length increases. The fundamental function g(T) must now be approximated by means that utilize the general form of the Jacobi polynomials P() (x), for which Polyanin and Manzhi- rov give a numerical method that is readily adopted to estimate Eq.(5.65)( [64]; Chapter 15): N -i^ wig(Ti) 1 Ti -- Pk + 7TH(r(pk),(r) k(+Pk)2 = I,+ - (k = 1, 2, 3, . . , N) (5.72) 151 G1, t =1 =0 1t t = (a) W(t) = K1 (U1+ W(t) = -0t -t)(1 (1-+ t)1 (G1, i, G2, 2) W (t) = (b) (c) Figure 5-5: Shapes for the fundamental function for the dislocation density P(t) cX of a uniform surface pressure for (a) an embedded crack, (b) a at"U under the loading closed crack with the left tip ending at a bi-material interface, and (c) an edge crack. 71 ~ cos(0); Pk Wi Cos(1k); 2 2N + a +3+1 ei dk 2a - 1 + 4i ~ 7r 2N + a +/ + 12 2a + 1 + 4i 7r 2N + a + + 12 1 - T(1 - T,)"(1 + TF)" The Open Crack Geometry: Complete Loss of Shear Along SC In the event that the shear bond between steel and cement is lost entirely, the radial crack will assume the greatest opening displacement and, consequently, also the greatest stress intensity factor. Where the proximal end of the crack is otherwise restrained from opening, the loss of the interfacial bond allows the crack to open unimpeded. Case (c) in Fig. 5-5 depicts the resulting surface displacements for an edge crack, where x = 0 causes the steel and cement to slide without resistance. Gupta and Erdogan proved analytically that the weight function of an edge crack takes the form [341: = 0. 7b(T) =X 152 (5.73) The equation above ensures the finite slope of the surface displacement upon nearing the steel interface. The square root singularity signifies that the crack tip is embedded in a homogeneous medium. Now. it is desirable to extend the definition of P(t) beyond the physical extent of the domain in order to make use of the Jacobian integration formula with orthogonal polynomials P 1/2 ,-1/ 2 (x) (i.e, the Chebyshev polynomials of the first kind, TN(x)). As was done in [341, we proceed by defining the following normalization of the radial coordinate, r(t) = (5.74) Pi p(r ) = P1 P2 - P2 - P1 such that a continuation across the origin can be made, (TT) (-1< T<1) ; g(T) =g(-T) = 01 ( ) -- (-1< < 0). ) T) (1 + 7-)(5.75) The integral equation in Eq.(5.65) may now be recast as 1 I 2r g(r) _1 gT+ 12 I + H(r(p), t(T)) dr Ir I - p (r(p), t(I )) d (5.76) I2 r(p)2 where H(r(p), t(T)) (rK + 1)(P2 - P1) 2G The procedure for solving the integral equation with H(r(p), t(r)). w(T) = (1-T 2 )- 1 /2 was discussed above with reference to an embedded crack with a closed geometry and may again be adopted'. 9 The symmetry of the extension guarantees the closure of the crack shape. Instead, the first N zeros of T2N+1 and U2N provide the collocation points and produce an N x N system of equations. For additional details see Ref. [34]. 153 5.3.5 Calculating the Stress Intensity Factor and the Surface Displacement The formal definition of the stress intensity factor for a crack whose tip is embedded in the cement is given by Krad _ lim V2w(p 2 r-*P2 where (Eoo(r, 0 = - r) (Zoo(r, 0 = 0) + p), (5.77) 0) + p) is the effective stress acting ahead of the crack. It is well established that the singular stress behavior in proximity of the crack tip may be expressed in terms of the cleavage stress 00, which takes the form [731 Olue(r)] 4G '00(r)1r>b = =1+K Or 2G 1+Kr 2G _ [29], 1+ r<b uo(r) (5.78) r<b 0=0 r) Thus, the stress intensity factor can be rewritten as /rad = lim r-4P2 = 2 1+ 2w(P2 - r)Co0 (5.79) lim r r-+P2 V27(P2 - r) P(r)l and on substituting p(r) = h(r)(j' ) and h(r) = a- g((r)), where ao= P2 -Pi is the crack length, the above equation becomes, Krad = 1+ rK 2iaoI g(1)|. (5.80) The value of a has been left ambiguous and depends on whether the proximal tip adheres to an open or closed geometry10 . In either case, we obtain the same solution. A numerical procedure for solving g(T) was given in the previous section. 10a = -1/2 for the open geometry and a = f(G, Gs, 154 ,, Ks) for the closed geometry Next, we must consider the case in which, the radial crack has fully penetrated the cement sheath, and the crack tip concludes at an interface. Here the stress singularity and the stress intensity factor according to Cook and Erdogan may be has order -, sought as [221, yCad = lim G*V2w(p 2 - r) "Coo lim GY-2wr(p 2 - r) '|p(T(r))| r = P2 (5.81) r-= P2 where G* = Gm (3 + 20)(1 + m) - (1 + 2/3)(m + (m + KR)(1 + m,'K) sin(-F (1 + 0)) We remember that m = GR/G. In the above, the relation y(r) = (-) Pi) 0 (P2 - (5.82) R) ('+8 g(T r))(r+ r) was used". Stress intensity factors were calculated for embedded cracks, and edge cracks where Gs and GR were set to zero to resemble a "hollow" ring. Their solution compared perfectly with the results given in [251. Finally, the surface displacement of the crack is obtained by UO (r, 0) 1f&~[uJJ =-dr= 1 - P2 p(r)dr p < r < P2 (5.83) and is readily calculated at the collocation points for an edge crack by Eq.(5.70): 1 UO(t(Tk)) where T2 = cos k T(r)di - g(Ti) (5.84) k 1- 2Na++ (1 - - (])d + UO(t(Tk)) = - 1 (- 7r). Similarly, the formula for the closed crack yields: 1 where wi 2 1 ~ -Wi g(ri) (5.85) TI . "It is remembered that the open crack was scaled by scaled by (P2 - p1)/ 2 155 (P2 - Pi), whereas the closed crack was 000 800 - 6 (b) x= 0 700. a/(R2 -R )=0.2 a/(R2 -R 1 )=0.4 - 5 ,9 - 4 -600 500 L4 400 a/(R2 -R)=0.6 - a/(R2 -R,)=0.8 - a/(R2 -R 1 )=1.0 2 S300 200 100 0.2 0.4 0.6 0.8 0.2 1.0 3 300 (C) - 250 x-+o 2.5 ,200 2.0 150 1 100 1 .0 1.5 - -- 0.6 0.8 1.0 a/(R2 -R 1.0 F 50 0 0.8 a/(R2 -R , )=0.2 a/(R2 -R , )=0.4 a/(R2 -R , )=0.6 a/(R2 -R , )=0.8 - : 0.6 F 3.0 C4 0.4 0.5 0.2 0.4 0.6 0.8 1.0 0.0 0.2 0.4 Figure 5-6: The evolution of the (a) (c) energy release rate ((b) (d) stress intensity factor) for a radial crack emanating from the steel-cement interface. The top panel (a) (b) corresponds to the open crack geometry, and the bottom panel (c) (d) corresponds to the closed crack geometry. Values are consistent with the stress state shown in 4-2b for ER = 40 GPa. 5.3.6 Sample Model Output: Evolution of Energy Release Rate due to Radial Fracture Two variants to the linear elastic fracture mechanics solution for the radial crack are investigated in Fig. 5-6 by changing the condition of the shear bond between the steel casing and the sheath. In particular, we plot the energy release rates and the stress intensity factors for the limit states of a rigid bond (X -+ oc; red) and a loss of bond (x = 0; blue) along SC. The stress development has been modeled from the input parameters provided in Table 2.1 for stiff formation. The width of the lines indicates the depth of crack penetration. As expected, the loss of shear along SC increases the 156 (a)700 600 - (b) x= a/(R 2 -R 1)=0.2 - 5001 5 - a/(R 2 -R 4 - a/(R 2 -R 1)=0.6 - a/(R 2 -R 1)=0.8 a/(R 2 -R 1)=1.0 1 )0.-4 r__" CA 400 3 - 300 2 200[ 100 0.6 0.8 0 1. 0 20 (d) (c) I x-*o -- 0.2 - 2.5 S2.0 - P 1005 501 - 0.6 0.8 1 0.6 0.8 1.0 0 3 C, 150 9 0.4 . 0.4 . 0.2 1.5 - )=0.2 a/(R 2 -R 1)=0.4 a/(R 2 -R)=0.6 a/(R 2 -R 1)=0.8 a/(R 2 -Ri)=1.0 a/(R 2 -R 1 1.0 0.5 0.2 0.4 0.6 0.8 1.0 (n 0.2 0.4 Figure 5-7: The evolution of the (a)(c) energy release rate ((b)(d) stress intensity factor) for a radial crack emanating from the steel-cement interface. The top panel (a)(b) corresponds to the open crack geometry, and the bottom panel (c)(d) corresponds to the closed crack geometry. Values are consistent with the stress state given by the input parameters in Table 2.1 and lowering the permeability to A = 1 x 10s/m. 157 energy release rate of the radial crack. Here, the system's compliance with respect to a pressure along the crack surface is increased by the absence of a counteracting shear stress. Thus, the crack opens wider, releasing more energy upon advancement 2 ) (grad X 'UO Nonetheless, the same trends for both bond conditions are observed: (i) The stiffening and eigenstress development in course of the reaction lead to an accumulation of elastic potential energy that accelerates toward the latter stages of hydration, and (ii) the fracture process is generally unstable, because the energy release rate increases upon crack propagation. Indeed, the energy release rate grows at a greater rate the further the crack penetrates the sheath thickness. There are a few exceptions. At intermediate ages ( - 0.4), as the pressure in the sheath recovers to the formation pressure and the effective hoop stress transitions from the compressive to the tensile regime, the sheath is temporarily in a stable fracture state. Additionally, simulations not reported here, have shown that soft, permeable formations allow for stable fracture propagation, though the stress build-up and risk of fracture is lower. 500 50(a) 3.5 ,3.0 400 CN1 (b) S 2.5 q 2.0 1.5 200 1.0 100 0.5 0 0.2 0.4 0.6 0.8 1.0 0 0 0.2 0.4 0.6 0.8 1.0 Figure 5-8: Diagrams depicting (a) the fracture toughness and (b) the critical stress intensity factor for white ordinary Portland cement with a water-to-cement ratio of w/c = 0.4. These results were obtained by the study of Hoover and Ulm [37]. Results for a low permeability formation, for which the pressure in the sheath recovers more slowly, are shown in Fig. 5-7 (A has been lowered form 8 x 10-7 s/M 158 to 1 x 10- s/m). Here, one readily notices the delayed response of the pressure in driving the fracture process. Nonetheless, the rapidly hardening cement and continued shrinkage of the solid skeleton continue to drive the fracture process, such that grad increases monotonically. Interestingly, the closed crack shape allows the potential for fracture Crad > 0 to be delayed slightly. Lastly, we make reference of the experimental fracture toughness results by Hoover and Ulm that were obtained from microscratch tests on hydrating white ordinary Portland cement (see Fig. 5-8). Fortunately, the fracture toughness evolves with a concavity, while the energy release rate evolves with a convexity. Initially, the cement rapidly gains a resistance to fracture, while the increase in elastic potential energy is comparatively slow. At later stages of hydration, the trend is reversed: The increase in toughness is small compared to the increase in the energy release rate. For the results of the two sample simulations provided in Figs. 5-6 and 5-7, only a crack with an open geometry and having penetrated over 80% of the sheath thickness is expected to further advance near the end of the hardening process. Sample Model Output: Energy Release Rate due to the 5.3.7 Loss of Shear Traction In this section, we elaborate on the meaning of the two shear bond conditions. As the open crack shape enforces a zero shear stress along steel and cement and the closed crack shape maintains a rigid connection, their potential energy release during fracture can be related to the energy stored in the bond. In particular, the debonding energy for a radial crack that extends from p, to P2 may be written as = P2 goPen - gcloseddr = 1 jP2 (i + (2 n open _ closed1) dr. (5.86) Herein, we have related the energy release rate to the work done by the surface stress, I, + 2/r 2 , to open the crack by an amount [uo1. By integrating the energy release rate along the propagated line of fracture we arrive at the total energy dissipated during fracture. The difference between the energy quantities for the open and closed 159 Figure 5-9: Diagram depicting the potential energy stored in the shear connection between the steel casing and the cement sheath upon developing a radial crack of closed shape. crack geometries measures the energy stored in the rigid shear bond (see the diagram in Fig. 5-9). For the standard model parameters in Table 2.1, Fig. 5-10 displays the crack shapes of the two traction conditions along SC for increasing penetration depths. Fig. 5-13 shows a direct comparison of the crack shape for x -+ oc and x = 0 at complete penetration. (~ The maximum opening displacement of the edge crack 1.2 mm) reaches approximately four times that of the closed crack (~ 0.3 mm). Bachu and Bennion experimented with brine and CO 2 to evaluate the permeability of wellbore liners in the lab. In good quality the liner's permeability was found to be 10-2 m2 , and in the presence of an annular gap and radial cracking, with apertures ranging between 0.01 mm and 0.3 mm, the permeability increased to 10-1 m 2 [7]. Though precise conditions of the mechanics driving the fracture processes in their experimental samples is unclear, it is of comfort that the results of our simulation are of a similar order of magnitude. Additionally, as observed radial fractures of 160 wellbore liners likely preserve a partial bond along SC, only loosing connection locally near the proximal crack tip, we can expect the most accurate model of the opening displacement to lie between the limit cases. Finally, the green line in Fig. 5-12 plots the potential energy stored in the rigid connection along SC for an advancing crack. Remarkably, most of the energy release for the edge crack scenario could be averted by improving the bond between steel and cement. 5.4 Chapter Summary In Chapter 5, we derived the energy release rate and fracture criteria for the failure mechanisms most at risk of impairing the sheath's sealing function at early ages. More precisely, Clapeyron's formula was employed to relate the external work done to open the apertures. By deducing effective elastic stiffnesses for the casing and the formation, the displacement of the interface boundaries was calculated upon complete rupture of SC and RC. In the case of the radial crack, Muskhelishvili's method of complex variables was used to derive the Green's function of an edge dislocation in the sheath. Integrating the Green's function along the real axis, an integral equation was developed for the dislocation density. Here, direct connection could be made to the stress intensity factor of a radial crack covering any portion of the sheath's thickness. Key to an accurate description of the crack propagation, was the incorporation of the drained nature of the fracture process. In this circumstance, the saturated cement medium expels fluid into newly created fissures, which exerts additional pressure onto the crack surfaces, exacerbating the risk of failure. Thus, the effective stress E + pl calculated by the chemo-poro-elastic solver in Chapter 4 was incorporated as the driving mechanism of fracture. As follows from the investigation of the bulk stress development, fracture energy release rates are greatest when the cement sheath is bounded by a low-permeable, stiff rock. A central finding is that the risk of both micro-annulus formation and radial 161 fracture can be substantially mitigated by improving the bond along the interfaces. 162 1 4 1e-3 1.2- 1.0 0.8 ~0.60.4 0.2 0..0 0.2 0.4 0.6 0.8 1.0 r-p, P2 -Pi 3.51e-4 3.0 2.5 2.0 S1.56..J 0.5 0.0 -0.5- X-+00 '..0.2 0.4 0.6 0.8 1.0 r-P1 P2 -Pi Figure 5-10: The surface displacement uO(r) = uoj] for pi < r < P2 plotted along the line of the crack pi < T< P2 for (a) the open geometry (the edge crack; X = 0) and (b) the closed crack (x -+ oc) for a crack that has propagated the width of the sheath. The thickness of the lines are proportional to the penetration depth of the crack (P2 - pi)/(R 2 - R1 ). Values correspond to complete hydration of the cement S= 1 and are consistent with the stress state shown in 4-2b for ER = 40 GPa. 163 (b) 2. 0 4le-3 x-0 - 1.5 L 1.0 0.5 0.8-.0 0.4 0.2 0.6 0.8 1.0 r-p, P2 -P1 Figure 5-11: A comparison of the surface displacement uo(r) = 1 uoj along the crack P1 < r < P2 between the open crack geometry (blue) and the closed crack geometry (red). Values correspond to complete hydration = 1 and are consistent with the stress state shown in 4-2b for ER = 40 GPa. 5 fr gope" 4[ Jr dr gclosed dr Pi 2[ 1J 0 0.2 0.4 0.6 0.8 1.0 r-pi P2 -P1 - Figure 5-12: The energy stored in the elastic shear bond between the steel and the cement AS plotted in relation to the normalized penetration depth of the crack (r Pi) / (P2 - Pi). Values correspond to complete hydration ( = 1 and are consistent with the stress state shown in 4-2b for ER = 40 GPa. 164 4.0 le-4 -"" X-oo 3.5 3.0 2.5 2.0 1.5 1.0 0.5- 0.8.0 0.2 0.6 0.4 0.8 1.0 r-p, P2 -P1 Figure 5-13: The crack surface displacement bounded by steel Es = 200GPa and rock ER = 40 GPa. The y-axis has been elongated to show the effect on the surface displacement as the crack tips terminate at bimaterial interfaces with varying stiffnesses. 165 166 Chapter 6 Conclusions and Perspectives The health of wellbore cement liners is vital to the efficient extraction and ultimate recovery of fossil fuel resources. A failed cement liner can cause an uncontrolled release of pressurized oil and gas from the reservoir into overlying strata, the groundwater aquifer, or to the surface. For natural gas wells, Howarth et al. [39] estimate that between 3.6% and 7.9% of the methane from shale-gas production is lost to the atmosphere due to venting and leaks. The department of energy predicts that by 2035 the domestic production of natural gas will grow by 20% with unconventional drilling techniques accounting for 75% of the total [3]. This means that the rate of oil and gas well constructions will significantly increase from the -35,000/yr produced on average between 2001 and 2010. Moreover, as easy-to-reach oil supplies become depleted, drilling contractors are posed with the challenge of cementing in more extreme temperature and pressure environments. We are thus challenged to continuously improve our design practices by incorporating advancements in science, engineering, and technology. Hence, the design tools introduced in this thesis have expanded the capabilities of current models by (i) incorporating cement as a chemo-poro-mechanics material, (ii) evincing the driving mechanisms of the cement eigenstress developments in the solid and pore phases and connecting them to a pressure state equation, and (iii) calculating the structural failure criteria by utilizing new solutions to the stress and fracture energy release rates. 167 6.1 Review and Results 6.1.1 Problem Synopsis The early-age stress developments of cement pose a risk to the sealing function of a wellbore liner. After the steel production channel is inserted into the wellbore hole, it is stabilized by pumping cement slurry into the annular gap between its outer surface and the hole diameter. As it cures, cement eigenstresses develop. Simultaneously, the stoichiometry of the reaction, and the difference in the chemical potentials of H20 in the porespace and on the gelpore surfaces leads to the mobilization of water into and onto the CSH structure. Consequently, the cement experiences a drop in pore pressure, causing a flux of water into the sheath from the adjacent lying formation. The coupling between the eigenstresses in the cement's solid skeleton and the pressure change in the porespace, place the sheath at risk of fracture once the cement becomes resistive to loading. Under this setting, the bulk reduction in volume acts against the restraints of the steel and the rock to cause potentially fatal tensile loads. 6.1.2 Modeling Contributions and Findings In this thesis, we incorporate the recent elucidations of the CSH constitution and the origin of its eigenstress into a chemo-poro-elastic model of hydrating cement. Molecular and mesoscale simulations, as well as state-of-the-art experiments, have shown that the eigenstress is the result of a net-attractive potential between CSHspheres that remains after the cement has reached its hardened state [86]. Correlated with the packing density, we were able to track the densification and eigenstress in function of the degree of hydration. The core of our material model was described by a poro-mechanical pressure equation, which treated the coupled processes of the internal loading of the CSH solid du*, the pore pressure dp, the densification of the reactants eff, and the prescribed displacement of the REV boundary du (therein linked by the mean strain dEm). This enabled us to bridge the chemical and physical changes to the porosity and 168 empowered the stress evolution to be tracked in course of the growth of the solid skeleton by solving the pressure equation incrementally. It was discovered that the drop in pressure at the early stages of hydration and subsequent increase in pressure - following a significant increase in the solid volume - locked the system into a state of effective tensile stress. Here, the dynamics of the pressure variation were well explained by a time ratio hyd/Trfl that compares the rate of the reaction to the fluid velocity in the sheath. With a material model at hand, the bulk stress development along the interfaces was tracked in function of the hydration degree. The key finding is that low permeable, stiff formations place the sheath at greatest risk of fracture, because (i) low permeable formations delay the pressure recovery, increasing the magnitude of the final tensile stress, and (ii) a rigid rock barrier prevents the cement to shrink in response to its eigenstress generation. Additionally, a Laurent series solution to the stress state in a sheath with an eccentrically placed casing, allowed the added risk of failure due to the casing off-set to be estimated. For large off-sets, the greatest magnification of stresses was found for the hoop stress in soft formations (the stress can be increased by over 100% of the reference, concentric value). Moreover, non-negligible shear stresses develop along SC and RC not otherwise present. Finally, the bulk stress state was linked to the fracture scenarios of micro-annulus formation along SC and RC and a single radial fracture emanating from SC. Due to the role of the pressure evolution in the sheath, it was found that micro-annulus formation is a risk along both interfaces, even for soft formations. Subsequently, the use of expanding agents to negate the shrinkage of the solid skeleton does not guarantee compressive stresses along RC and will further increase the risk of debonding along SC. The loss of axisymmetry for the stress state in a sheath with a a radial crack, prompted use of Kolosov-Muskhelishvili formulae. Here, a solution was found for the derivative of the opening displacement vector p(t), which was linked to the stress intensity factor KIrad. Interestingly, the stress intensity factor was increased substantially by considering an open crack (where the shear bond between steel and cement 169 is lost) rather than a closed crack geometry. More succinctly, much elastic potential energy is stored in the bond along SC and improving the adhesion between steel and cement is expected to significantly decreased the risk of radial fracture. 6.2 Next Steps Finally, we leave the reader with our contemplation of improvements to the model that would enhance its proximity to the physical conditions encountered downhole and during reaction: " As many drilling contractors incorporate expansive agents into the cement mix design to counteract bulk shrinkage, the phase morphology and upscaling schemes should be modified to allow such inclusions. " Due to the heat production during reaction, additional eigenstresses caused by the temperature variation in the phases will be induced. These must be included in the pressure state equation and the formulation of the bulk eigenstress. " While ordinary Portland cement typically requires 7-days to attain 60%-75% of its 28-day compressive strength [471, the high cost of drilling equipment (e.g., drilling rigs) incentivizes contractors to initiate the testing and production processes as early as 3-5 days after placement. Hence, our model output should investigate the effects of pressure cycles applied to the inside of the casing in course of the cement hydration. " As it was concluded that much elastic potential energy is stored in the bond between steel and cement during radial fracture of the closed geometry, it is of interest to determine the effect of partial debonding on the energy release rate. Does guaranteeing the partial adhesion of cement to steel substantially reduce the risk of radial fracture? Or, is a predominance of the elastic potential energy stored locally near the tip at SC? 170 Appendix A Effective Stiffnesses of Steel Casing and Rock Formation In calculating the stress state for the concentric annulus (see Chapter 4), our expressions may be simplified by identifying effective stiffness constants for the steel and rock formation. These measure the uniform stress along the boundaries required to advance the SC and RC interfaces outward by a unit length. We can derive the effective stiffnesses of the two media by considering the displacement solution of an infinite cylindrical tube subjected to an interior pressure po and an exterior pressure Pi: Ur(2 R21 - 1 2(A + G) + Ur (r) = PO2 -U 2Gr ) 1 P21 2-+ 2 J- 1 r (2(A + G) R2 0 2Gr (A.1) where r is the radial coordinate, RO is the radius defining the interior surface, R1 is the radius defining the exterior surface, = R 1 /RO, and A = K - G is Lam6's constant. In the case of the steel casing, we consider a thick-walled cylinder with a zero inside pressure (i.e. po = 0). Therefore, noting that the radial stress on the outside is balanced by the exterior pressure, we can write: 171 )_R R)(A.4) (Trr(r R1) = -p1 = 2 G 2 2 - 1) u, (r = R ) (Gs + 3Ks)(u 1 = fs =(R(r RA U (A.2) In the above, is represents the effective stiffness of the casing. For the formation, we must adapt Eq. A. 1 to the case of an infintely thick pressure vessel (' - 00) whose inner boundary is subjected to a pressure of po: lim zu o0 Urrr- O) Ur(T O) RO RO) =r(rPo 2GR -GRUr(r 0 )R= Ro) = R_ 172 (A.3) _ RUr (r rT = Ro)(A4 Appendix B Laurent Series Representation of Analytic Functions in the Complex Plane Often we wish to represent functions that are analytic everywhere except at some point(s) or region(s) of the complex plane (see, for instance, Section 5.3.3). Here, it may not be possible to employ a Taylor series in the neighborhood of the singularities (It should be remembered that Taylor series contain only the positive powers of z). Instead, we look to Laurent series, which contain both positive and negative powers of z, to resolve these functions. Such a series is analytic in the region and on the boundaries of a circular annulus, where r1 < Izf < r 2 and the center has been placed at the origin. The general expression for a Laurent series of a complex-valued function g(z) = g1 (z) + ig2 (z) in the complex plane is then given as, 00 g(z) = E where ri < IzI < r2. c"z (B.1) n=-oo Herein, Ck are complex-valued coefficients. In the special cases of a cicular disk (lim r1 -+ 0) and an infinite plate with a hole (lim r2 -÷ o) the negative and positive powers of the series are dropped, respectively, in order to ensure convergence. In order to deduce an expression for the nth coefficient, the Cauchy integral 173 formula can be used to show that cn = f)dz 272 c zn+1 (B.2) where C is any simple closed contour in the annulus that circumscribes the inner boundary IzI = r1 (see e.g. Ref. [1], pg. 128 for a thorough derivation). However, in the case that we wish to evaluate the coefficients from a circular contour for which g(O) becomes dependent only on the angular component, a classical Fourier series emerges. Using Eq.(B.1) we can proceed by multiplying both sides by Zn and integrating the series over its interval of orthogonality, noting that 2 zn+k d - 2 rn+ke(n+kOdO = JO {0.if n+ k y 0 27r, if n + k = 0 (B.3) Hence, we recover the coefficients as, Cn= 21 27rrT -ing(z)dO. j21 (B.4) 0 'The Cauchy integral formula states: For a simply connected region D, any holomorphic (i.e. analytic) function f(z) in D can be evaluated at a point a as, f(a) = 27ri jC zf(z)dz - a where C is a closed contour forming the boundary of D. 174 Appendix C Upscaling Poroelastic Constants C.1 Level I: CSH Gel with Gelpore Pressure The Level I state equations define changes in the stresses and the gel-porosity at constant hydration degree. The equations for a basic pore-solid composite are given by Dormieux et al. [271 and read as: dEm = 1 I1I J dorm(z)dz = KjdEv + (1 - bi)du* - bidpg (C.1) V d#l|' = bdE v b1 bidEv + (du-* + dpg) s 1 -(d-* + dpg) -s (C.2) where the gelporosity change (d#' = d(# - 0)) is due solely to the elastic response of the material system. In the above k, is the bulk modulus of the CSH solid, a-* is the eigenstress in the CSH solid, and pg is the gelpore pressure. The poroelastic properties at this scale are well known such that the Biot coefficient and Biot modulus are defined classically as: bi =1 -K, (C.3) 1 b1 0N1 ~ k (C.4) and _ 175 Level II: CSH Gel with Macro-Pores C.2 At the second level, we consider the CSH gel as a matrix for the macro-pores. Here another pressure prevails, denoted p, such that the state equations must be redeveloped, starting from the following distribution of stresses: (C.5) dum(z) = k(z)dE(z) + do&(z). In the above, dcP(z) is the local eigenstress, such that in Vhp K 0 = do(z) = {27 inV, (1 bi)du* - bidpg - k(z) in Vhp (C.6) in V, -dp Application of Levine's Theorem allows the Level II homogenized eigenstress to be sought as, d E*- I1 J )dE* - b( dp A(z) : duP(z)dz = (1 - b(d 11 (C.7) 1 whence, the incremental equations of state are given by: do"l' I = = J dom(z)dz = K 1dE' + (1 - b (1 - #1) 1 = b, dEv' - dE d#"l Herein, d#'l - b )do* - b b, (dE*+ dp) + dvg - b dp (do* + dpg) b)dEv"-+ I (dE* + dp) WI NI, (C.8) (C.9) (C.10) is the change in the gel-porosity at Level II, and d4r j is the change in the macro-porosity at Level II. Moreover, b 176 and b are the Biot coefficients for the gel and macro porespace, respectively. Thus, Knl = (1 - b (C.11a) 1 - -K (C.11b) , 0) (1 1 Nn (b) K, K1 (2))b,= - K:') (C.11c) Kn ) K, b = (C.11d) " b )K1 K, It is convenient to recast the state equations for the changes in porosity as, 11 1 dOg = b()dEv, + NI do* + NI dpg + NIdp 11 do*pg do3"|j = b dE + + 1 I dp (C.12) (C.13) N"udpg21 2 hN where the various Biot moduli can be calculated from 1 (I - #") N1 1 N 1 (1 - bi) N11 (bj + Nl N11 I I N=1 N~1 b, (I -- bl) N, (C.14a) (C. 14b) N) bi (C. 14c) (C.14d) N, 1 (C. 14e) Nil Throughout this thesis, we make the assumption that the gelpore pressure is in equilibrium with the capillary pressure, such that dpg = dp. In this case, the state equations simplify to: = KndEv' + d (1 - bn,)do-* - b,,dp dr,*i 177 (C.15) 1 1 I dE*" (C.16 I dp ) ' + * =b+d d| 101 1 and b = b (1 - b ())b + b + b ()= N" + 1 1 (I - #")(b- = 1 = 1- K 1 (C. 17a) 01) + (1 - bl)(b (2 1 (C. 17b) (C. 17c) Thus, the Biot Modulus with respect to the development of pressure in the porespace or eigenstress in the CSH solid may be approximated by the same formula given in Eq.( C.17b). C.3 Level III: Reinforcement by Rigid, Slippery inclusions (Anhydrous Cement Grains and NonReactive Additives), CSH Gel+Macropores The strain distribution in the system at Level III is written as above in the form do(z) = (C.18) k(z)dem(z) + duP(z) with k(z) =Kil 00 in Vhp +V (C.19) in Vinc = Vnr + V. Here, the rigid inclusions include anhydrous cement grains and non-reactive inclusions, such as silicate particles. Homogenization using Levine's theorem yields, dEl = I dam(z)dz = K,,,dEv"I' + (1 - bl,)du* - b 3dpg - b (2dp d*O 178 (C.20) 1 1 1 d$OII| = (I - finc )d$ |g= bl d Ev"n + N"do* + Nildpg + N d$"lll =(1 - finc)dl|jbw = b W ~ dp (C.21) 1 1 1 dEll + N"w~do-* + N1 N"'l dpg + N dp (C.22) where the Biot moduli are related to their Level II analogues by 1 (1 - finc) 1 __ (1 (C.23a) fm c) - 1 1___(1( c- f) (C.23b) (C.23c) N 1N "-- (1-finc) (C.23d) NjIINII N11I 1 -I (I - Nc) f (C.23e) NI N'I Finally, considering the mass content in the gelpores and the macropores in relation to the fluid state equation (Eq. 3.23), we obtain for a fluid of compressibility kfl: dmg~ P P - d$,' + $" kfldpg bi E + 1 1 =b ld El" + -"do-* + M -dpg =M' dollg + $ Ikfldp E + 1 =bjd El" + -do-* V wI N"' 21 + - (C.24) 1 (C.25) +N 1 -dpg 1 + I where M refers to a Biot modulus of the fluid-solid composite (contrary to the solid Biot ModulusN, M considers volume changes due to the compressibility of the fluid). Therefore, 1 1 M 11 1 M II + $g kfl (C.26) 1 NI + $O kfl 179 (C.27) Lastly, we inform the reader of the simplification in the state equations by considering the gelpore and macropore pressure changes equal dpg d Li = KjdE d#" d# " + do"' dm-b pfl = dp: + (1 - biI)dor* - bldp 1 I du-* + bmdEt" + (C.28) 1 dp. dE"1 Idu*+ 1 Mdp NII (C.29) (C.30) Throughout this thesis the bulk properties often omit the superscript /subscript III. The total porosity is given as # = 11 = (1 - finc)#and the Biot coefficient and the Biot moduli are calculated from 1 1 1 - 1 Ii NvI, 1 1 XJII 1 1P + = b~ + b 1 I= Nw l 1 2III - (C.31) 1 - K1, 11 I (finc)NIa* (C.32a) NI'*MNI 1 N"' + 2N 1 finc) 1 - b 1 N,, (C.32b) (C.32c) The primary results for the upscaling of the poroelastic properties summarized in main text in Table 2.2. 180 Appendix D Analytic Functions with Branch Cuts This appendix gives an insight into why the solution to p(t) in Eq. (5.61) can be sought as k(t)(1 + t)'(1 - t),3 , where a = with general coefficients -1 0.5 and 3 < a < 1 and -1 = 0.5. A more thorough analysis < # < 1 is omitted, but is addressed in Ref. [591. As the topics are fairly complex, additional background information can be sought in Ref. [58], and much of the derivation to follow has been adopted from Ref. [72]. Defining an analytic function f(z) whose value is the solution to the Cauchy integral, 2F i ) dt = f (z), t- z (D.1) where L is a smooth cut in z and g(t) must be H6lder continuous 1 , the Plemelj formulae give the solution to f(to) on approaching a point on L from the left (+) or the right (-): (D.2a) f+(to) - f -(to) = g(to) f+(to) + f -(to) = j g(to dt. (D.2b) These formulas suppose that g(to) is not a point of discontinuity and is not an end point at which g(to) / 0. Isee Muskhelishvili [59]. 181 Now, suppose f(z) is a function analytic everywhere in a chosen domain D, except along an arc L such that: (D.3) fT+(t) - f -g(t) = s(t) Then the more general solution is attained by f(z) = 1 I 27ri IL g t)dt + fo(z), (D.4) t- z where fo(z) is holomorphic in D. As proved by Muskhelishvili [581 we may select a function h(z) defined along the arc L, 1 h(z) = (D.5) (z - p 1 )(z - P2) Since it can be shown that h(z) changes sign upon crossing the arc L, h+ (z) + h-(z) = 0, (D.6) ( f(Z) ) h(z) + the second equality in Eq.(D.2) is written as Sh(z) 7=i (z) IL g(t) dt. t -z zc L (D.7) Making the substitutions f,(z) = f(z)/h(z) and q(z) = fL g(t)/(t - z)dt we arrive at (Z) - (Z) q(z) zcL (D.8) We can then show for Eq. 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