The Sealing Performance of Cement Sheaths under Thermal Cycles for Low-Enthalpy Geothermal Wells

Abstract

The repetitive process of shut-in and production in geothermal wells promotes thermal stress on the wellbore components, including annular cement. A cement sheath at a relatively shallow depth undergoes the most significant stress change due to the high differential temperature between the geothermal gradient and the production fluid’s temperature. Understanding the impact of cyclical thermal stresses on cement is critical for assessing the barrier integrity at a shallow depth that serves as aquifer protection. A novel large-scale setup simulating a 1.5 m-long casing-cement-casing well section was built to study the changes in cement’s sealing performance of low-enthalpy geothermal wells during production. Using this setup, a cement sheath can be cured similarly to the in situ conditions, and the annular temperature can be cycled under realistic operating conditions. The change in flow rate through the cement sheath before and after cycling is quantified through leak tests. UV dye is injected at the end of the experiment to identify the location and type of damage in the cement sheath. A hydromechanically coupled finite element model was used to estimate the stress evolution in cement during the tests. The model incorporated the impact of cement hydration and strength development during curing. The numerical results were used as a guide to ensure the test design closely mimicked in situ conditions. The results show the presence of a small microannulus immediately after curing due to hydration shrinkage. Thermal cycles reduced the permeability of the microannulus. The size of the micro-annulus was observed to be sensitive to the backpressure applied to the cement sheath, indicating the need for pressure to maintain an open microannulus. Thirty-nine thermal cycles between 80 and 20 °C did not change the permeability of the cement sheath significantly. Tensile cracks in the cement sheath were not continuous and may not be a significant pathway. The new setup allows for measuring cement’s effectiveness in withstanding in situ stress conditions when exposed to thermal cycles such as geothermal and CCS wells.