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Acknowledgements
This manual was prepared under the direction of the ExxonMobil Development
Company - Drilling Technical Applications Group.
All Mar 2004 Replaces EPR Cement Slurry Design, May 1985; Mobil Primary
Cementing Course Manual; and EPR Primary and Remedial
Cementing, December 1984
13.1.2 Oct 2004 ISO 10426-4: Cements and Materials for Well Cementing - Part 4
Methods for Atmospheric Foamed Cement Slurry Preparation and
Testing
Primary Cementing
Cement Basics
Scope
1.2. History....................................................................................................... 6
1.3. Manufacturing .......................................................................................... 7
1.3.1. Manufacturing Processes .............................................................................. 7
1.3.2. Wet Process.................................................................................................. 7
1.3.3. Dry Process................................................................................................... 8
1.3.3.1. Kiln Operations ....................................................................................... 8
1.4. Composition ............................................................................................. 9
1.5. Chemistry................................................................................................ 10
1.5.1. Material Consistency ................................................................................... 10
1.5.2. Reactions .................................................................................................... 10
This Section lists Practices and Standards that are generically referenced and assumed
part of this document. Unless otherwise specified herein, use the latest edition.
1.2. HISTORY
The use of cements or cement-like materials can be traced back to early times in
Greece, Egypt, and Italy. Early brick making relied on forming and drying out clay
materials held together with straw. The straw was used to give the "brick" strength and
resistance to cracking. Between bricks or other building materials, like wood, mortar
was added to seal the buildings. The mortar also consisted largely of clay materials.
During Roman times, it was discovered that by heating the clay, the resulting brick was
much stronger and would last much longer. It was also discovered that by using a
mixture of calcium oxide, silica, and water, the brick would be much stronger. The
calcium oxide was obtained by burning limestone. Pozzolan or flyash was obtained
from near the town of Pozzuli, Italy, thus the origin of the name.
Prior to finding that the heating process increased the strength of bricks, Rome had
laws limiting the height of buildings to no more than one story. Following the discovery,
building surged in Rome to include many structures that are still standing and in use
today. The Roman Coliseum and the Aqueducts are examples of structures
incorporating the newly discovered "cement."
The knowledge of how to make cement died with the fall of the Roman Empire. Mortar
was still in use, but burning brick to improve strength was largely lost.
In 1824, Joseph Aspdin, an English brick mason, filed a patent for a process to
manufacture "Portland Cement." The material he patented was named Portland
Cement after the Isle of Portland, off the coast of England, due to its resemblance to the
1.3. MANUFACTURING
The technical definition of cement is "a powder of alumina, silica, iron oxide and
magnesia burned together in a kiln, finely pulverized and used as an ingredient of
mortar and concrete." The manufacture of cement takes limestone (or other source of
lime) and mixes it with clays and iron oxide. The mixture is burned together in a rotary
kiln at temperatures between 2600-3000°F (1427-1649°C). The components literally
melt and as they exit the kiln, cool and form clinker. The clinker is then ground together
with gypsum (to control the setting) and Portland Cement is formed.
1.4. COMPOSITION
Cement is composed primarily of four components: C3S, C2S, C3SA, and C4AF.
Table 1.2 lists the composition of cement and the relative concentrations of the
components along with the other minor materials found in a typical cement. The four
major components and their relative reaction rates and contribution to strength is also
included.
In Table 1.2, the abbreviations for the four major components of cement use C as an
abbreviation for calcium. Depending on a number of chemicals and manufacturing
variables, the concentrations of the four main components can vary.
1.5.2. Reactions
Cement does not dry out as it sets, but reacts with the water in the system to form a
variety of crystalline structures. This chemical reaction is exothermic (gives off heat),
called the heat of hydration. The heat generated by the chemical reaction can be used
to identify top of cement in a well using temperature logs. Depending on the mass of
the cement and amount of water and other diluents in the cement, the heat generated
can vary from a few degrees to as much as 75°F to 100°F (24°C to 38°C).
C3A is the fastest reacting of the constituents of cement. This reaction is controlled
through the addition of gypsum in the manufacturing process. The reaction of the small
amount of gypsum with the C3A forms ettringite crystals that control further hydration of
the C3A. Adding more gypsum to the cement can result in high concentrations of
ettringite, which leads to thixotropic behavior in cements.
Cements are classified by how finely the material is ground, and to a lesser extent, the
chemistry of the cement. The American Society of Testing and Materials (ASTM)
classifies cement by Type, from Type I to Type V. Type I is the most common
construction cement. Type III is more finely ground, and is often considered the winter
grade cement because of the faster setting times. The API uses letter designations for
cements (currently from Class A to Class H).
Most ASTM Type I cements will meet the requirements for Class A cement. Type III
cements correspond somewhat to Class C, although there can be slight chemistry
differences. There are no ASTM types corresponding to API Classes D through H.
These classes are specifically manufactured for the oilfield.
Oilfield cement is also classified within API based on the chemistry of the cement. A
component known as C3A (tricalcium aluminate) is one of the fastest reacting materials
in cement. This compound is linked to gel strength - the ability for a cement to be
thixotropic, and resistant to sulfate attack. Cements with a C3A content less than 3%
are considered to be high sulfate resistant (HSR). Cements with less than 8% C3A are
classified as moderate sulfate resistant (MSR) cements. The majority of Class G and H
The API and ISO specifications for cement are found in API Spec 10A or ISO 10426-1.
These specifications list the tests to be performed on neat cement with no additives.
The purpose of the specification test is to evaluate the "raw" cement for specific
chemical and performance requirements. It is through this testing that cement is
classified as Class A, Class G, etc. The tests are highly specific and no variance from
the testing protocol is allowed. Specification testing is only performed on the base
cement with no additives. There is no one test used for a particular well.
Most day-to-day cement testing is based on testing standards developed by API. The
standards are found in API Recommended Practice for Testing Oil Field Cements, API
RP 10B. This same document has been adopted as an international standard through
ISO (ISO 10426-2). These documents contain standard recommended testing
procedures for evaluating cements and cement slurries. The test methods differ
considerably from specifications for cement because they allow the use of cement
additives, encourage changes to the test, and make some attempt to follow field
conditions.
It is not the intent of API to simulate well conditions. The goal of the API is to develop a
standard set of test procedures to allow comparison of results between various labs.
API procedures may be modified to match the particular well conditions and mixing
methods used. While the tests outlined in the API and ISO publications are applicable
to field work, it is the responsibility of the engineer to determine the applicability of a
particular test and to determine if the results have meaning to a particular well.
Slurry Density
API Class % Mix Water (lb/gal)
A 46 15.6
C 56 14.8
G 44 15.8
H 38 16.4
Table 1.3 does not imply that Class H cement cannot be mixed at a density other than
16.4 lb/gal. It states that for specification testing, the cement must meet the
performance criteria when mixed with that amount of water. It further means that
cements mixed at the API water content will have some free water development, unless
treated with an additive to eliminate the free water.
Mixing an API cement with more mix water (thus reducing the slurry density) will result
in the following:
• Increased free water
• Slightly reduced strength
• Increased pumping time
None of these effects are necessarily bad, depending on the well requirements.
Sufficient strength to perform any well operation can easily be obtained from slurries
mixed at below the above densities, provided appropriate additives are used to modify
the slurry properties.
A cement that meets API or ISO specifications should serve as the base for all of the
slurries pumped by ExxonMobil. This gives the assurance that at least the base starting
material has been manufactured to a set of standards. It also provides the operations
with a base material that will require fewer additives and should be more predictable.
Most Service Companies do not list API cements, but rather generic terms such as
"Standard, Premium, or Premium Plus." These generic terms can be linked back to a
particular cement. A Premium cement at one location will not necessarily be the same
Class of cement at another location. The Service Companies, as a legal method to limit
liability, have adopted these generic terms. If a service company offers an API cement,
then the cement would be required to meet the API specifications at their facility. This
cannot always be assured, so generic classifications have been incorporated to limit
this liability.
Note: There is nothing wrong with the cement, simply the service company is not
guaranteeing the material will meet the API specification at the time of sale. This is not
of particular concern - the concern is for performance of a cement system that has been
designed for the well rather than the base cement performance.
API cements are available globally, though not all cements are available in all locations.
API Class A cement is usually available globally, as it is usually manufactured as a
construction Type I cement. Class C cement is found primarily in West Texas. Class H
Primary Cementing
Cement Additives
Scope
This Section covers the various families of cement additives. Specific service
company's additive names have not been included, but where appropriate, a
generic classification of the additive family is noted.
This section is intended to give an overview of common additives, usage, and
interactions with other additives. Important points are made when to use silica in
slurry design (see Section 2.13).
This Section lists Practices and Standards that are generically referenced and assumed
part of this document. Unless otherwise specified herein, use the latest edition.
2.2. GENERAL
Basic cements have limited properties. Depending on the water ratio, the cement will
have a fixed thickening time and strength development. Modifying the properties of the
cement to meet the requirements of the well is basic to the design of a cement job.
There is considerable mystique generated by the service companies around cement
additives. Knowing the "code names" of the various additives is not important, but
understanding the general function of the various materials should improve the
understanding of why a particular additive is being used.
Regardless of the additive, there must be a technical reason to use the material in
a cement slurry. There are some situations when one material may be required to aid
the functionality of another. An example of this would be the use of a dispersant with a
fluid loss additive. The two materials have a synergistic effect when used together,
allowing for a reduction in the amount of each to achieve a particular property.
2.4. ACCELERATORS
Accelerators function to shorten the thickening time of a cement slurry and can aid in
early strength development. Accelerators do not have any effect on the ultimate
strength of a cement. In general, almost any inorganic salt will accelerate the set of
cement. The exact mechanism is not well understood, but it is believed the salts act as
a catalyst rather than being incorporated into the chemical reactions of the cement.
2.4.3. Seawater
Most seawater reacts much like a 3% NaCl solution. Seawater contains more salts
than just NaCl. Seawater salinity can change seasonally due to increased runoff from
nearby rivers. It is always advisable to obtain a sample of seawater from the rig for
cement testing. Seawater will also vary dramatically depending on the source. For
example, the water in the Caspian Sea has a much lower salt content than found in the
open oceans. The water in the North Sea tends to have a higher magnesium content
than found in more southerly areas.
For offshore work, it is often useful to use seawater in combination with calcium
chloride. The resulting slurries will have a short thickening time and rapid strength
development.
Using seawater at higher temperatures will require the addition of excess retarder. This
situation can be avoided by using drill water or freshwater at temperatures above 150°F
(66°C). Note: NaCl concentration is based on the weight of water rather than by weight
of cement (BWOC).
Heating the mix water will accelerate the set of the cement. This can be necessary in
cold climates where the dry cement temperature may be below freezing and the
resulting slurry temperature is too cold to properly hydrate. Hot mix water can be a
hazard in warmer climates if the water temperature has not been taken into account
during testing.
2.6. RETARDERS
Retarders will extend or lengthen the thickening time of a cement slurry. These
materials are critical for proper placement of cements in most wells. The retarders can
effect the early strength development of a cement.
Retarders are broken into several general classes. These include the following:
• Low temperature - used generally below 200°F (93°C)
• High temperature materials - for use above 200°F (93°C)
• A variety of other retarders designed for a specific purpose
Usually, retarders are sugars or lignin-type materials. Other retarders include NaCl in
concentrations exceeding 25%, many organic compounds, fluid loss additives,
dispersants, and some gelling agents. Newer synthetic retarders allow for long pump
times while still obtaining compressive strength. This can be especially important when
cementing long liners when the temperature at the top of the liner may be less than the
bottomhole circulating temperature.
Retarders will act in synergy with many other additives and care must be exercised
when designing the slurry to account for all of the interactions of the various additives.
Thickening Time
Additive Concentration
2.7. DISPERSANTS
Dispersants modify the rheology of the cement by reducing the viscosity of a cement
slurry. This allows mixing a system with less water, thereby increasing the density of
the system. Dispersants are often referred to (incorrectly) as turbulence inducers.
Cement rarely is placed in turbulent flow, and dispersants should not be used to attempt
to modify the slurry viscosity to allow turbulent flow.
Several materials act as dispersants, such as salt, and lignin-type retarders. The
primary dispersant used in cements is a formaldehyde condensate of lignosulfonic acid.
Dispersants can enhance the effectiveness of fluid loss additives and can reduce the
amount of fluid loss additive needed. These materials also act synergistically with
lignosulfonate retarders.
Unless reduced water, as with a kick off plug, or fluid loss is needed, dispersants are
usually not required. Dispersants are one of the most over used cement additives, and
are generally sold to make the cement mix easier. Many service providers will sell
dispersants as giving the ability to mix a particular slurry at a higher rate. While this
may accomplish that goal, excessive dispersant usage will result in high free water and
solids settling in the cement.
Fluid loss additives are used to reduce the flow rate of water out of a slurry into a
permeable zone. This helps prevent slurry dehydration, which can lead to a buildup of
cement particles across from a permeable zone. Depending on the application, fluid
loss values can range from 1,200 (no control) to less than 50 mL/30 min.
Fluid loss additives are very expensive, and are one of the most over sold materials in
cementing. A common mistake with fluid loss control is the design of a lead slurry with
no fluid loss control, followed by a tail slurry that contains very good fluid loss control.
Unless there are concerns over gas migration, or other technical design considerations,
this practice should be avoided. Except in the case of gas migration, there is no benefit
to very good fluid loss control in a tail system, if there was no need for it in the lead
slurry.
Polymeric fluid loss additives have been developed that require much lower
concentrations, and can have a minimal effect on slurry rheology. These fluid loss
additives are usually run in combination with a dispersant.
Figure 2.2 is an illustration of cement fluid loss across a permeable zone, illustrating
the build up of cement filter cake.
Primary Cementing
Permeable
Zone
Heavy Cement
Filter Cake
Thin Impermeable
Cement Filter Cake
2.8.1. Bentonite
A very common fluid loss additive is bentonite. While bentonite is used primarily as an
extender, when used in lightweight slurries it will also impart some fluid loss control. A
system containing 4 - 6 % bentonite will have an API fluid loss below 400 mL/30 min. If
the same slurry were extended with a silicate extender, the fluid loss would exceed
1,200. The advantage of fluid loss control in bentonite extended slurries is often
overlooked in favor of more convenient silicate extenders. If fluid loss is required,
additional materials must be added, increasing both the cost and complexity of the
slurry.
2.8.2. Cellulose
Cellulose derivatives are common fluid loss additives. These materials will lower the
fluid loss, but will viscosify the cement and will also retard the set of the slurry.
Cellulose derivatives such as hydroxyethyl cellulose (HEC) or other long-chained
polymers derived from cellulose are widely used. These materials function by
2.9. EXTENDERS
Extenders are materials and systems that allow the cement slurry to be mixed at a
lower density without excessive free water development. They also function to increase
the yield of the slurry, thus requiring less cement for a given volume. Because using
extenders essentially "dilutes" the cement, properties of strength development, fluid
loss, thickening time and free water will be effected.
2.9.1. Bentonite
The most common extender is bentonite, which functions by taking up excessive water
in the system. This will reduce the slurry density, but will also result in lower strength
and longer pump times. Fortunately, bentonite can impart fluid loss control, thus
reducing the effect on fluid loss. Bentonite can be used as a dry material blended with
the cement, or can be pre-hydrated and used in the mix water. If pre-hydrated, the yield
obtained from the bentonite is greatly increased. As a general rule, 1% pre-hydrated
bentonite is approximately equal to 4% dry blended. Bentonite should be pre-hydrated
in fresh water to obtain the full yield from the material. Use of salt or seawater is not
recommended for pre-hydrating bentonite.
Not all bentonite sources are the same. Some bentonites will not meet the API
requirements and have additional materials added to improve the water absorbing
ability of the bentonite. These are called beneficiated bentonites, and should not be
used in cement. The small amounts of beneficiating agents can adversely effect
cements, and have led to cement failures in some systems. Only non-beneficiated
bentonite should be used in cementing.
2.9.2. Attapulgite
Also called saltwater gel, attapulgite can be used as an extender in cements.
Attapulgite does not absorb water like bentonite, and obtains viscosity by shearing into
thread-like pieces. The yield of attapulgite is independent of salinity, but is highly
dependent on shear. Unlike bentonite, attapulgite will not impart fluid loss control to the
slurry.
2.9.7. Nitrogen
The final extender in the group is nitrogen or other gas. While used for a variety of
other purposes, introducing gas into a slurry will reduce the density and extend the
slurry. The complexity of design and other properties of these systems are covered in
Section 6, Specialty Cement Systems.
The specialty extenders and foam offer several advantages because they do not require
additional water, and thus do not dilute the base cement as much as conventional
extenders. Because of this, compressive strength development will be much better with
2.10.1. Barite
Most commonly used to weight mud systems, barite has limited use in cements. Barite
requires large amounts of water to wet the surface, and therefore has limited use in
cement slurries. Barite can be used in combination with other weighting agents to help
limit free water development and settling.
2.10.3. Sand
Sand, not silica flour, can increase slurry density up to one (1) lb/gal without adverse
effects. At high temperatures, the incorporation of 35% sand will aid in prevention of
strength retrogression.
2.10.4. Micromax
Micromax is essentially a liquid weighting agent. Consisting of very finely ground
magnesium oxide, the material is sold in liquid form and can be used to weight cement
slurries. This material has been used successfully in many remote locations where dry
blending is not available, and on exploration wells where slurry density had to be
increased unexpectedly.
2.14. SILICA
At temperatures exceeding 230°F (110°C), the crystalline structure of cement changes.
The resulting structure will be higher in permeability and have lower strength. This
reaction is called strength retrogression. To prevent strength retrogression, silica is
added to cement, which reacts to form more stable crystalline forms at high
temperatures.
Many sources quote 230°F (110°C) as the initiation temperature for strength
retrogression. Many cements do not exhibit strength retrogression problems until well
above 260°F (127°C), while others may show signs of degradation below 230°F
(110°C). For the purposes of design, a 230°F (110°C) is used, however, specific well
conditions and designs that reduce the water content of the cement can be successfully
used up to 250°F (120°C).
Silica sand (70 - 140 mesh) and silica flour (less than 200 mesh) are used to prevent
strength retrogression. Silica flour will react faster due to the higher surface area of the
material. For most systems, a concentration of 35% is required to prevent strength
retrogression. The 35% concentration will give a calcium-to-silica ratio in the final
cement of approximately 1:1. For systems incorporating pozzolans, the silica
concentration can be dropped to 20%. This is because the pozzolan contains silica.
Below 230 - 250°F (110 - 120°C), silica acts as a filler, diluent and slight weighting
agent. At one time, silica was added to cement for kick-off plugs, but it has been
determined this gave no benefit to the cement, and in many cases resulted in a more
friable system.
Strength retrogression does not necessarily cause operational problems due simply to
the loss of compressive strength. Over time, the cement strength may retrogress from
3,000 psi to as low as 500 psi, but even this low strength is sufficient to maintain casing
support. The problem begins to arise due to the increase in the permeability of the
cement. Permeability can increase from 0.001 mD in a standard cement, up to 0.5 mD
in a fully strength retrogressed slurry. This can lead to problems with zonal isolation,
fluid movement and other well problems.
2.15.1. Antifoams
An antifoam works by changing the surface tension of the water and preventing foams
from forming. As such, it is added to the mix water, or dry blended into the cement prior
to mixing. The materials will prevent the formation of a foam, but once a foam is
generated in a system, will do little to disperse or eliminate an existing foam. Most of
the agents used in cement are antifoam materials.
If not used properly, antifoam agents can become foam stabilizers at high
concentrations. As noted, an antifoam will do little to eliminate a foam that is in place.
The tendency in the field is to add large amounts of antifoam directly to the mixing tub
to eliminate a foaming problem. The high concentration in the mixing tub can result in
stabilization of the existing foam. One of the reasons the foam appears to reduce is no
new foam is being generated in the tub, and the existing foam is gradually dispersed.
2.15.2. Defoamers
Defoamers work by eliminating existing foams. As noted, these are not readily
available and not normally used. In the event of a severe foaming problem, a SMALL
spray of diesel onto the surface of the foam will generally result in elimination of the
foam.
2.19.1. Metering
Liquid additives, when used in a continuous mix operation, must be properly metered
into the mix water. This is accomplished either through dump tanks, where a given
volume of additive is added to a tank of mix water, or through metering the additive
directly into the water as it is mixed with the cement.
The liquid additive pump systems must be properly calibrated and checked prior to the
job. Many service companies depend on a pump stroke counter from the additive
pump to calculate additive flow rate. This method of metering is not acceptable
in ExxonMobil operations. Experience in Eastern Canada offshore showed this
method of additive metering can be off by as much as 30%, due to the limitations of
counting pump strokes on a pump. If the line is plugged, additive viscosity is too high,
or the suction of the pump is plugged, there will by no indication to the operator that the
additive is not being delivered to the mix water. The pump will continue to cycle, but no
material will be delivered.
The preferred method is to use either a dump tank, where the additive is seen
going into the water, or by using a mass flow meter to measure the additive flow
when the additives are being directly pumped into the mix water line.
2.19.3. Storage
Liquid additives need to be protected from cold temperatures. Depending on the
additive, freezing of the additive can destroy the function. This is particularly true with
latex type materials. Other additives can crystallize out and settle in the container.
Very high temperatures can lead to additional reactions within the liquid additive,
especially if it is a mixture of several components. In one instance, the manufacture
temperature of the additive was 110°F (37°C), but the location temperature exceeded
125°F (51°C). (The additives were stored near a flair on a platform.) This resulted in
continued polymerization of the additive, rendering it too viscous to remove from the
drums.
Liquid additives, if stored in buckets, should be regularly mixed to prevent settling. A
better alternative to small buckets is to store the material in a larger tote that can be
circulated with a small pump.
Extenders (Bentonite,
Weighting Agents
Pozzolans, etc.)
Gas Migration
Accelerators
Dispersant
Retarder
Effect
Sand
LCM
Salt
Density Increase = = = x
Decrease =
Water Requirement More = = x
Less =
Viscosity Higher x x = x
Lower x = = x
Shorter = x
Early Strength More = x
Less = = x = x x
Ultimate Strength More =
Less = x
Durability Better = =
Worse x x
Primary Cementing
Cement Testing
Scope
3.15. Rheology.............................................................................................. 27
3.15.1. Information Needed to Perform Test............................................................ 27
3.15.2. Test Description .......................................................................................... 27
3.15.3. Data Interpretation....................................................................................... 27
3.15.4. Test Limitations ........................................................................................... 28
3.15.5. Considerations ............................................................................................ 29
This Section lists Practices and Standards that are generically referenced and assumed
part of this document. Unless otherwise specified herein, use the latest edition.
3.2. INTRODUCTION
This document attempts to take the aspects of common cement testing and presents
them in a simplified format. The document is not intended to be a definitive treatise on
cementing or cement testing, but as an informative resource on testing.
API and ISO specifications for cement are found in API Spec 10A or ISO 10426-1.
These documents present the tests that are to be performed on neat cement with no
additives. The purpose of the specification tests is to evaluate the "raw" cement for
specific chemical and performance requirements. It is through this testing that cement
is classified as a Class A, Class G, etc. The tests are highly specific, and no variance
from the testing protocol is allowed. Specification testing is only performed on the base
cement with no additives. These are no tests used for a particular well.
Most day-to-day cement testing is based on a set of testing standards developed by the
American Petroleum Institute (API). The standards are found in the API Recommended
Practice for Testing Oil Field Cements, API RP 10B. This same document has been
adopted as an International Standard through ISO as ISO 10426-2. These documents
Using the API standards as a base, performance testing determines if the properties of
a particular slurry meet the requirements of the well. As well conditions merit, it may be
necessary to modify or custom design a test to properly evaluate a slurry for a particular
application. A test example would be stirring a slurry at atmospheric conditions for
some period of time to simulate batch mixing on surface.
Several tests outlined in the API Recommended Practices are reviewed. Each test
identifies the information required to properly run the test, a description of the test, test
limitations, data interpretation and important considerations. Also included are some
tests, while not having an API or ISO procedure, are common enough to be included in
the table. This information is not meant to limit any specialty testing required for actual
well conditions.
Description of Individual Cement Tests - A more detailed description of individual
cement tests follows. Each explanation includes a brief description of the purpose of
the test, the required information needed to perform the test, and a detailed description
of the test. Limitations of the test are described along with a summary of important
factors.
The thickening time of a cement is the time required for a slurry to no longer be
pumpable at a particular temperature and pressure. This test is required for every
slurry to be pumped. A slurry that has obtained 70 Bc should be considered set. A
Bearden Unit of Consistency (Bc) measures of the consistency of a cement slurry when
determined on a pressurized consistometer (see Section 3.5.2).
Slurry Cup
Paddle
120
100
80
Bc
60
40
20
0
0 10 20 30 40 50 60 70 80 90 100 110 120
Time (min.)
The laboratory personnel are the only ones that routinely see the thickening time curve,
and are, hopefully, sufficiently skilled to recognize a slurry that gels with time. The
graph is normally not included in any of the laboratory reports. To address the problem,
it is preferred the lab report the time to 30, 50 and 70 Bc. In this way, an approximation
of the thickening time curve can be made. The shorter the time between these values,
the more "right angle" the set of the cement is said to be. Most labs report the time to
70 Bc as the thickening time. Some laboratories will take the test to 100 Bc, which is in
line with the specification test of neat cement. For ExxonMobil operations, the time
to 70 Bc should be reported as the thickening time.
During the thickening time test, the motor may be turned off for 5 -10 minutes after the
cement reaches test conditions. This is to simulate the dropping of the plug and can
indicate if there is a gellation problem with the slurry. Following the shut-down period,
the viscosity of the slurry should not go above 50 Bc. The shut down is not part of the
standard test, is not contained in the API procedure, but is part of the standard
ExxonMobil testing procedure given to the service companies. The shut-down period
need only be applied where applicable during the job. For example, when pumping a
tail cement, the cement will not have reached test conditions when the plug is dropped.
Including a shut-down period in this test would not be necessary.
Lightweight slurries, particularly those containing silicate extenders, may have a very
long thickening time. The true thickening time of these slurries is related to the point in
time when the slurry begins to thicken, called the point of departure. The point of
departure is where the viscosity of the slurry begins to move away from the baseline.
With silicate slurries, it is possible to continue to pump the slurry beyond its "thickening
time" because the crystals formed in the cement are not strong enough to prevent
breakage by the consistometer blade. The results of pumping one of these slurries well
beyond the point of departure will be a reduction in the strength development. An
analogy to this would be in making whipped cream. Initially, the system will be thick,
but if mixing continues, butter will be formed and the remaining liquid will separate. If a
silicate extended system is mixed too long, the resulting slurry will have the consistency
of cottage cheese. The slurry will also be very thixotropic, and any shut down of the
120
100
80
Point of Departure
Bc
60
40
20
0
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180
Time (Min)
Note: The point of departure is only critical for slurries containing silicate extenders.
If the job calls for batch mixing the slurry, the thickening time test can be modified to
simulate surface mixing of the slurry. The test is performed in the same instrument, but
for the anticipated mixing time, no heat or pressure is applied to the cement. The
surface mixing time is not figured into the thickening time. The thickening time is
reported as the time the temperature and pressure is applied to the slurry until it sets.
3.5.5. Considerations
1. Temperature, pressure, and heat-up rates are very important for a valid test.
Always calculate the rate to bottom and do not depend on the API tables.
2. Request the time to 30, 50 and 70 Bc from the lab.
3. Use caution with silicate extended slurries. Request the point of departure be
reported.
This Section covers "normal" strength testing for wells with static temperatures at or
above ambient temperature. Additional consideration is given to cold temperature
testing and is covered in Section 6, Specialty Cement Systems.
The compressive strength test determines the force required to break an unconfined
cement sample after it has been cured at temperature for a given time-period. The test
may also be performed in an ultrasonic cement analyzer that utilizes sonic signals and
calculates an equivalent strength from the signal. This is referred to as the sonic
strength, but in field practice there is normally no distinction made between the two test
results. Because of the difference in the conventional compressive strength test and
the non-destructive test, the description that follows is in two parts. The non-destructive
test has become more common. Normally, the test is performed by field laboratories,
except where cooling of the slurry below room temperature is required.
Strength testing of cement has the largest standard deviation of any cementing test.
The variability in the test results can be as much as +/-75% and normally runs about
50%. Due to this variance, performing a direct comparison of two slurries based only
on strength development is highly suspect, and is not recommended.
3.6.6. Considerations
1. Test the tail slurry at 85% of BHST. Do not use BHST (see Section 4.3.3).
2. Test the lead at the temperature of the midpoint of the lead, or at the top of the lead,
if strength development at the top of the lead cement is important.
3. If strength development is a problem, consider performing the test following a
preconditioning period on a consistometer at the BHCT of the well following API/ISO
procedures.
4. Do not pay more money for incremental strength gain.
5. Always request a strength test be performed at the top of a liner.
Also known as free fluid, the test is an indication of water separation from a slurry. This
test is particularly important for higher angle wells where gas migration may be
encountered. The free water test will give an indication of the slurry stability under
static conditions.
3.8.5. Considerations
1. Request zero free water for any slurry across a productive interval.
2. Test at well angle or 45° from vertical for high-angle wells.
The fluid loss test measures the amount of fluid (mL) that can be forced out of a cement
slurry at 1,000 psi differential pressure across a 325-mesh screen at the bottomhole
circulating temperature of the well.
Cement
Slurry
Filtrate
For example, if 50 mL is collected in 16 minutes and the test blows dry at that point, the
API fluid loss is calculated as:
5.477
2 * 50 * = 547.7 ÷ 4 = 137 mL
16
The cement fluid loss test is very different from the mud fluid loss test. While both tests
measure the amount of filtrate from a fluid sample, the standard mud fluid loss test is
done at room temperature against filter paper and 100 psi differential pressure. There
is a mud test that is performed at a higher temperature and 500 psi differential, but still
uses filter paper as the filter medium. The cement fluid loss test is performed at 1,000
psi differential against a 325-mesh screen and is performed at the bottomhole
circulating temperature of the well.
Fluid loss additives are second only to gas migration materials as the most expensive
additives used in cement. It is common to see tail cement slurries with very good fluid
loss control following a lead slurry with little or no fluid loss control. The practice should
be avoided. Fluid loss is important for gas migration control, squeeze cementing, and
narrow annular gaps.
1400
1200
1000
800
600
400
200
0
1 2 3 4 5 6 7 8 9 10 11 12
Increasing Cost
3.9.6. Considerations
1. Check to make sure the test is run at circulating temperature.
2. Fluid loss below 100 mL is quite expensive and usually not necessary. It should
only be specified if technically required, as with liners, some squeeze work, or gas
migration control.
3.10. SETTLING
This test measures slurry stability by taking a sample of cement and allowing it to set in
a standard cylinder. The sample is removed, sectioned, and the density of each section
measured. The data is reported in lb/gal for each section.
3.10.5. Considerations
Watch for excessive density variations from top to bottom of the sample. Temperature
can have a major effect on the test. This test is primarily a screening test used for high-
density slurries and those being used for high angle and extended reach wells.
3.11. DENSITY
The long-term properties of cement are controlled by the water to cement ratio. The
easiest method to test for this is by measuring the density of the slurry. This test is
most commonly performed in the field to ensure the cement has been mixed to the
proper density. The test should also be performed in the lab if new sources of major
additives are being used. This would include previously unused flyash sources, etc.
3.11.5. Considerations
1. Assure the balance is calibrated.
2. Use only a pressurized fluid balance, not an atmospheric balance for measuring
cement density.
3.12.5. Considerations
1. Do not confuse this test with the transition time measurement.
2. Due to variability in the tests, understand how the test is performed and what the
data actually means.
3. See Section 7 for recommendations on techniques to minimize gas migration.
3.13.5. Considerations
1. Look for short (less than one hour) transition times.
2. Temperature will have a major effect on gel strength development.
3. Do not confuse the transition time test with high shear measurements from
consistometers or conventional rheometers.
3.14. WETTABILITY
This test attempts to measure the effectiveness of a surfactant system to water wet
metal surfaces. The test evaluates spacer systems mixed with non-aqueous fluids
(NAF) and the ability to remove that fluid from a metal surface, therefore, this test
cannot be performed with water-based drilling muds.
3.15. RHEOLOGY
Spring
Rotating
Sleeve
Bob
Figure 3.8 shows a plot of data from a typical rheology test. Depending on the shape
of the curve, and data interpretation, calculations can be made for estimated friction
pressures, pump pressures, effects on equivalent circulating density (ECD) and any
other calculation related to fluid viscosity.
300
250
200
Reading
150
100
50
0
0 100 200 300 400 500 600 700
RPM
3.15.5. Considerations
1. Watch for very high readings at 300 rpm and very low readings at 3 and 6 rpm.
2. Test at room temperature and BHCT or 180°F if BHCT > 180°F (82°C).
3.16. COMPATIBILITY
This test evaluates the rheological compatibility of two or more fluids. Normally, the test
is run on spacer and mud combinations to determine the compatibility of the fluids. The
test can also be performed on mixtures of the spacer and cement, cement and mud,
and all three fluid mixtures.
100 0 87 45 30 18 4 3
75 25 92 52 33 23 6 4
50 50 100 60 42 32 7 5
25 75 107 68 49 35 9 7
0 100 118 73 58 40 12 9
3.16.5. Considerations
1. Look for large increases in viscosity of the fluid mixtures.
2. Make sure the test was performed at BHCT or 180°F (82°C), whichever is lower.
3.18.5. Considerations
Properly condition the slurry at BHCT before running the test.
Thickening Gives an indication Test does not +/- 15 min. Temperature Rapid set. Time
Time of amount of time measure effects between 30 and 70 Bc
for a slurry to of fluid loss, Pressure should be short.
remain pumpable contamination,
Time to
at test temperature etc. Total time - time to
bottom
and pressure. 70 Bc must be more
Dynamic test - Minimum job than job time.
does not time
normally test gel Lightweight silicate
build up systems should report
point of departure.
Compressive Unconfined crush Cement +/- 50% Temperature 500 psi minimum
Strength strength at a mechanical
particular properties down Time Test temperature for
temperature and hole. lead should NOT be
given time period. BHST.
How the cement
will drill. Tail should be tested
at 85% of BHST.
That the annulus
is sealed.
Sonic Strength based on Same as +/- 30% Temperature At least 100 psi for
Strength sonic velocities. compressive data to be accurate
strength. Pressure
Data is
conservative by
20%.
Free Water Fluid separation Ability to prevent +/- 2%; Hole angle Always below 2.5%,
from the slurry. gas migration. zero for slurries
More with across producing
Settling of solids. higher zones and in angled
values wells.
Fluid Loss Amount of filtrate Effects of mud +/- 10% BHCT Requirements
pressed out of a filter cake depend on type of
slurry. cement job.
Density Density of finished Non-pressurized +/- 0.1 Desired slurry Normally, not run in
slurry. test will not give lb/gal density lab. Check for
proper data. complicated slurries
Confirms validity of or specialty cements.
lab calculations.
Gas No API/ISO test May not be able Depends Temperature Get explanation of the
Migration/ protocol. to compare on test test and what factors
Gas various service Well pressure influence the results.
Tightness Generally listed as company
pass/fail. systems. Fluid loss will be a
key.
Transition Time for a slurry to Ability for a slurry +/- 20 min Temperature Short transition times
Time go from - to control gas or are generally required
2
500 lbs/100 ft gel fluid migration for gas migration
strength. control.
Wettability Gives an indication Only used with +/- 20% Mud sample Effects of changing
of efficiency of non-aqueous surfactant
surfactant muds. Temperature concentration and
packages for use in type on results.
spacers. Does not
address rheology
effects.
Rheology Determines Mud removal +/- 10% Temperature Very high rheology
viscosity profile of efficiency indicates a problem
the fluids.
Compatibility Tests rheological Does not Generally, Temperature Fluids should not gel
compatibility of address bulk pass/fail or increase in
spacer, muds, and mud removal - test Mud sample viscosity when mixed
cements. only chemical together.
compatibility
Check compatibility of
spacer mud and
cement.
Cold Indication of setting Effects of thermal +/- 50% Temperature Look for when the
Temperature properties of mass and heat of cement sets.
Testing cement at cold hydration are Time to
temperatures. ignored bottom Do not be concerned
about the amount of
strength in a given
time.
Strength Evaluates the Same as +/- 50% on Temperature Look for when the
Development strength compressive actual at TOL cement gains
at TOL development at a strength strength strength at TOL
colder temperature Job schedule temperature.
than BHST.
May need to
precondition cement
at BHCT prior to
running test.
Primary Cementing
Cementing Service Company
Laboratory Responsibilities and
Testing Guidelines
Scope
This Section discusses the guidelines developed as the standard procedure for
obtaining consistent, reproducible cement results for use on ExxonMobil wells.
Unless otherwise noted, it is the intent of this document to follow the practices
listed in the most recent issue of the API Recommended Practice for Testing of Oil
Field Cement (API RP 10B) or the equivalent ISO 10426-2. For purposes of this
document, reference to API testing procedures shall also include the ISO
equivalent.
This Section lists Practices and Standards generically referenced and assumed part of
this document. Unless otherwise specified herein, use the latest edition.
Testing of all cement and additives to be used on ExxonMobil jobs is the responsibility
of the service company testing lab. Quality control testing of the cement additives may
be done at the point of manufacture, but the final responsibility for the QA/QC of these
materials lies with the service company.
Quality control of cement testing with liquid additives includes the proper identification of
the additive to be used on the job. As required, this may include sampling of the
additive(s) on the rig, identifying the samples with lot and tank numbers, and the use of
those identifiers on the laboratory test report.
Proper design of the cement systems that best meet the specific requirements of the job
shall be the primary responsibility of the lab. Communication with the service company
coordinator is essential to ensure the design meets the specific well requirements at the
lowest practical cost.
Timely testing of pilot tests and field blend systems is required. No cement system
should be pumped on any ExxonMobil well that has not been laboratory tested unless
specifically agreed by ExxonMobil. Exceptions to this may be granted by the
ExxonMobil Field Drilling Manager or designee.
The goal of these guidelines is to establish a basis for cement testing, and standardize
certain specific tests. It is the intent of these guidelines to establish a basis for
communicating test results and the methods used to arrive at those results. Every effort
should be made to communicate the results and how the results were obtained on the
laboratory report.
4.3.7. Rheology
The rheology of the slurry should be determined at the BHCT of the well or 180°F
(80°C) whichever is less.
A 12-speed rotational viscometer is the preferred method for measuring the rheology of
the cement slurry. It is not necessary to take readings at rpm's less than three (3) rpm.
An initial rheology should be taken on the slurry immediately after mixing to aid in
determining the mixing characteristics on location. It is not necessary to condition the
slurry for this test. This slurry may be used for the subsequent test at elevated
temperature, provided the second test is initiated as quickly as possible.
Notations should be made following the rheology tests of any settling tendencies of the
slurry. Excessive settling can cause mixing and placing problems. Any slurry design
that indicates settling must be redesigned.
Five and 10-minute gel strengths should also be run for all plug cement designs. This
may prevent problems with pulling out of the plug and/or reversing cement out of the
well.
It is the goal of these guidelines to better simulate field conditions in an effort to improve
cementing results. Modification of the API/ISO recommended practices to mirror field
conditions is considered an integral part of cement testing.
Primary Cementing
Factors Influencing Slurry Design
Scope
This Section covers the factors that should be considered when designing a slurry,
including discussions with the service company engineer.
5.10. Equipment............................................................................................ 10
5.11. Volume ................................................................................................. 10
5.12. Strength Development ........................................................................ 10
5.13. Fluid Loss ............................................................................................ 11
5.14. Free Water............................................................................................ 11
This Section lists Practices and Standards generically referenced and assumed part of
this document. Unless otherwise specified herein, use the latest edition.
Most locations have a governing body that sets minimum requirements for well
cementing. Generally, these regulations are present to provide safe drilling parameters,
environmental control of the well, optimize the removal of the hydrocarbons from the
well and ultimately proper abandonment. The requirements for the cement systems
may be simply a minimum volume, or there may be specific slurry performance criteria.
The slurry designs must comply with the specific regulations governing the well.
5.3. TEMPERATURE
One of the most important factors in slurry design is the well temperature. The static
and circulating temperatures are critical for proper slurry design. For upper casing
strings, the production temperatures can also be important.
Well pressures refer to the pore pressure and fracture pressures in the well. This will
determine the required cement densities that will be used for the job. Generally, most
jobs are designed with a lead cement density at least 0.5 lb/gal higher than the mud
weight, and a tail cement at or near the API water requirement. For jobs with
lightweight muds (less than 11.5 lb/gal), the practical lower limit on cement density
would be 11.5 - 11.8 lb/gal. Lighter densities than this are possible, but require the use
of specialty more expensive additives, or processes such as hollow beads or foamed
cement.
Job pressures must also consider the friction pressures when placing the cement.
These pressures can be checked through the service company placement simulators,
and indicate if there is a potential lost circulation problem during the job.
Changes in the wellbore pressures during the job can be made through the proper use
and selection of spacers, lead, and tail cement volumes. For example, if the mud
weight is less than 11.0 lb/gal, water is recommended as a spacer. Using water will
reduce the hydrostatic pressure in the annulus, which can allow higher density slurries
to be used. At the same time, care must be taken that the reduction in the hydrostatic
does not create an under-balanced situation and allow the well to flow.
The density, viscosity, and type of drilling fluid will have a minor effect on the slurry
design. The main effect is in the selection of spacer systems to remove the mud ahead
of the cement. Rarely does the drilling fluid type have a direct effect on the slurry
design. It is the removal of the mud from the hole, and its replacement with cement,
that is key to cementing success.
A discussion of mud removal, spacer design and application is covered in Section 9,
Mud Removal.
The location of the well can effect the base cement available for use, the additive type
and mix water properties. The cement available for use on the well can determine the
amount and type of additives required, and can result in considerable changes to slurry
design.
For many remote operations, cement must be brought in due to either lack of local
supply, or poor quality of local cement. This is typical for West African operations. The
cement is shipped in very large quantities and cement quality may change over time if
not stored properly. Additional laboratory testing of the cement may be required for
these operations.
In some locations, locally available cement does not lend itself for use in oilfield
applications. These cements can require large amounts of additives to make them
function in the well environments. In these instances, it may be more economical to
import a more consistent cement (related closely to logistics).
5.9.1. Seawater
Offshore sites typically use seawater for cement mixing, at least in the upper parts of
the hole. This is less expensive than using fresh water, and allows reducing the amount
of accelerators needed in the upper portions of the well. Using seawater on deeper
casing strings is not recommended as the amount of retarder required to overcome the
accelerating effects of the seawater can be excessive and result in very poor strength
development. Seawater should be limited to mix cement that will not be exposed to a
BHCT of more than 150°F (66°C). At temperatures above this, the acceleration effects
of the seawater make retardation of the cement more difficult and expensive.
The source of the seawater can have an effect on slurry design. Depending on rig
location, the relative concentration of salt in the seawater can vary. Locations near the
mouth of major rivers will change salinity due to seasonal runoff changes in river flow.
Major ocean current changes, as with the Gulf Stream or Labrador Current, can change
the salinity of the water. Small variations in seawater will not have a major effect on
slurry properties, but it is best to obtain a sample of water from the rig for system
design.
5.10. EQUIPMENT
The equipment used can effect the slurry design. Section 14.3.2.1, Equipment, discusses
if a batch mixer is being used, the slurry design must take into account the time at surface.
In addition, certain additives (like gas generating agents) should never be batch mixed
due to the potential for flammable gas generation at surface.
5.11. VOLUME
The total volume of cement to be used on the well is integral to the determination of job
time. Care must be exercised to remember to recalculate the job time if the cement
volume has been adjusted based on open hole calipers. Increasing the volume of
cement will require additional time for mixing, and may effect the total job time.
Two areas where volume changes can result in cement job failures are: 1) large
increases in cement volume due to hole washout, and 2) changing the job from a "stab-
in operation" to a "conventional displacement." Both of these changes will increase the
required time to do the job, and can effect the minimum acceptable thickening time of
the slurry.
A stab-in operation, typical in large casing strings where the displacement is done down
drill pipe rather than the casing string, will have a much lower displacement volume than
if the job were displaced through the casing. For example, at 1000 ft, a 20-inch casing
stab-in job using 5-inch drill pipe has a displacement volume of approximately 18 bbl,
while displacing down the casing would require 350 bbl.
Associated with cement volumes is the amount of lead and tail cement being pumped.
The volume of slurry may be changed to take advantage of the bulk equipment capacity
available at the location. Small changes in tail cement volumes can often eliminate the
need for additional bulk equipment for lead slurries.
Primary Cementing
Specialty Cement Systems
Scope
This Section describes the various types of specialty cement systems. These
include foamed cement, available from all service companies, to specialty systems
available through individual companies.
This Section lists Practices and Standards that are generically referenced and assumed
part of this document. Unless otherwise specified herein, use the latest edition.
6.2. INTRODUCTION
6.3.2. Applications
Foamed cement systems are generally used for one of four applications.
Foamed cement was originally designed as an ultra, lightweight cement system that
allowed for the elimination of stage cementing, by providing high quality, lightweight
cement systems for low fracture gradient wells. Densities below 11 lb/gal were
common with this application.
Due to the presence of the inert gas, foamed cements have a very low thermal
conductivity, and have found use in geothermal and secondary recovery wells. The
density of these slurries need not be low, but the concentration of gas must be high
enough to provide sufficient insulation.
Gas migration and shallow water flow prevention have become major applications for
this technology. Prevention of shallow water flows in offshore applications has
become a major market for foamed cement. A properly designed foamed cement
system is gas tight, thus preventing gas migration in almost any application.
The final area of application has been its use in high-stress environments to prevent
stress failure of the cement sheath. Adding gas to a cement system will have a
dramatic effect on the ultimate rock properties of the set cement. Foamed cement has
been used for this application in high-rate gas wells like those found in Mobile Bay, as
well as gas wells in the Western US, where fracturing treatments are done down the
casing string. (Additional information is found in a 1996 Oil and Gas Journal paper by
Benge, McDermott, Langlinais and Griffith.)
6.3.4. Disadvantages
Foamed cement is operationally more complex than many other systems. It requires
considerable pre-job planning and on-location coordination of the cement and nitrogen
operations. While these are readily overcome, the complexity in design and application
often requires specially-trained cementing crews be used for foamed cementing
operations. When selecting foamed cement over ultra lightweight additives (see
Section 2, 2.9.6), the cost of the nitrogen equipment and additional operational
complexity must offset the savings in ultra lightweight additive costs. As cement
volumes increase, economics tend to favor foam over the ultra lightweight additives.
Computer
Control
System
Pressure Transducer
Check
Valve Foam Generator
Cement Unit
Check Wellhead
Valve
Nitrogen
Liquid Additive Pump
Skid Skid
Nitrogen
Tanks
0 2.52 - - -
100 15.75 14.85 13.95 13.5
1.000 159 148 137 133
2.000 311 288 267 258
3.000 449 415 386 373
4.000 567 527 491 475
A remaining question in foam cementing is "what happens if a foam cement that was
designed for one depth actually winds up in a different part of the well"?
1 871 99
2 1131 105
3 1391 110
From the nitrogen tables, the SCF of nitrogen per barrel for each stage is:
1 144
2 175
3 217
1 144
2 288
1 3 432
4 576
5 720
1 175
2 350
2 3 525
4 700
5 875
1 217
2 434
3 3 651
4 868
5 1085
The annular volume for a 9-5/8 inch casing in a 14-inch open hole is 0.1004 bbl/ft, thus
for each 500 ft interval we need 50 bbl of foam slurry. Since each barrel of cement
pumped will occupy 1.45 bbl of space after the nitrogen is added, the volume of cement
required for each stage will be:
50
= 34.6 bbl
1.45
1 4,982
2 6,055
3 7,508
Total 18,545
The yield of the cement is 1.44 cu ft/sk, so the amount of cement per stage will be
135 sacks of cement. The total amount of cement will be 3 * 135 = 405 sacks for the
foamed cement portion only. (The cement for the tail slurry has not been included.)
Therefore, for the foam cement portion of the job, it will require:
405 Sacks of cement
18,545 SCF of nitrogen
6.4.1. General
The CemCRETE* cement systems are heavily marketed specialty systems from
Schlumberger. These systems are marketed as having superior compressive strength,
improved mechanical properties, and lower rheologies.
While many of the claims may be valid, these systems can be considerably more
expensive than the alternatives, and must be justified on a cost per cubic foot basis. It
is very rare that paying more money for additional compressive strength is justified, and
the high added cost of these systems requires very careful evaluation of the well needs.
As with any cement additive, the use of the system should be justified through well
requirements, not marketing by the service company. With the CemCRETE* systems,
the engineer must realize there are more cement additives than cement in the
"CRETE*" systems.
*Service mark of Schlumberger
6.4.3.2. Porosity
Schlumberger has coined a term "porosity" to define the amount of "open" space in a
cement slurry. This is NOT the same as the porosity commonly defined to describe
rocks, or set cement. The porosity calculation made is only applicable to the slurry
when in a liquid state. This is only a calculation and no physical measurements are
made to determine slurry porosity. The theory is by putting the smaller particles in the
cement, the porosity of the slurry is less, and fewer additives may be needed. Further,
it will push water out of the pore spaces, making the rheology less.
6.4.4. SqueezeCRETE*
Using only the very fine particles and leaving out the Portland Cement will yield
SqueezeCRETE*, which is being marketed as a material that will allow slurry placement
into extremely small openings. Because of the very small particle size, standard fluid
loss cannot be performed, as the material will pass through the API fluid loss screen.
SqueezeCRETE* fluid loss tests are run against filter paper and cannot be
compared to conventional cement fluid loss tests. Cement fluid loss against paper
will always be considerably lower than API tests. For example, a cement with 1,200 mL
API fluid loss will have approximately 25 mL of fluid loss when tested against filter
paper.
Another characteristic identified in the use of SqueezeCRETE* has been poor strength
development. The material does not gain strength quickly and has created some
additional rig problems. Efforts have been made to tail in a SqueezeCRETE* job with
more conventional cement to gain a squeeze pressure and to obtain some type of
strength development.
6.4.7. Summary
The CRETE* slurries can have application in ExxonMobil's operations. These slurries
are more expensive, and require much higher levels of quality control while blending.
As with any cement additive, the use of the system should be justified through well
requirements, not marketing by the service company. If there is justifiable need, the
systems fill a niche and have application. The engineer must be aware that on a per
pound basis, the CRETE slurries have more additives than cement in the system.
Unless specifically required for well conditions, do not pay more money simply for
strength development. High compressive strengths are rarely required, especially with
lightweight slurries.
Many times, there is a need for a cement to be acid soluble. While cement itself is
readily soluble in acid, there is a surface reaction between Portland Cement and
hydrochloric acid (HCl) that forms a gel structure and does not allow the live acid to
continue to react with the cement. Since the live acid can no longer come in contact
with the un-reacted cement, the reaction stops. This is why the cement in wells does
not dissolve out during acid treatments.
To make a cement acid soluble requires either changing the base cement system to a
non-Portland cement, or increasing the reaction sites on the cement by improving the
live acid penetration.
Cements that change the base chemistry to a non-Portland cement include systems
that have a very high magnesium content (like Magne Plus* available through BJ
Services). These systems work well, but cost more than conventional cement.
* Mark of BJ Services
A good alternative to acid soluble cement is to mix 100-200 % calcium carbonate in with
conventional cement. This will reduce the density of the slurry somewhat, but the
addition of the calcium carbonate will make the total system acid soluble. The mixture
consists of one sack of Portland Cement and one to two sacks of calcium carbonate.
Caution must be taken to properly choose the size grade of the calcium carbonate.
Using only the coarse material may not give sufficient acid solubility, and using too fine
a material can lead to mixing problems. To address this issue, the service company lab
CO2 will react with Portland Cement and convert the cement into a calcium carbonate
material. The strength of the system will reduce, but will still retain sufficient strength
and low permeability to provide isolation. The problem in most CO2 applications is the
well eventually is treated with an acid, and this will dissolve the cement from behind the
pipe. This is common in CO2 flood areas and leads to severe problems with loss of CO2
into unwanted zones.
To prevent carbonate conversion of the cement, the solution is to use a system that
does not contain Portland Cement. Another method that has been applied is to attempt
to lower the permeability of the cement to as low a value as possible, thereby delaying
the eventual conversion of the Portland Cement. Depending on the well life and
economics of the field, the later solution will be less expensive, but will not provide a
long-term (>10 year) solution. Because of the chemical reactions, Portland Cement in a
CO2 environment will eventually convert and become acid soluble, regardless of the
permeability.
ThermaLock™ cement is available from Halliburton as a CO2 resistant cement. The
cement is made up of high alumina cement that does not contain any Portland Cement.
The material can be difficult to use, and care must be taken when blending to not have
any Portland Cement contaminate the system. Portland Cement contamination will
accelerate the ThermaLockä to the point it will "flash set."
The high alumina cement is essentially the same material used to make the bricks that
line the fireplace in most homes. Conventional Portland Cement cannot withstand the
high temperatures and harsh chemical environment of a fireplace, and the high alumina
cement has been found resistant to those conditions.
The ThermaLockä slurries are normally mixed at densities between 14 and 15 lb/gal.
Higher densities are available, but will require addition of weighting agents.
In areas where ThermaLockä is not available, an alternative would be the use of a very
low permeability cement. Schlumberger's CRETE* line of slurries would fit in this
category. The CRETE* systems are Portland Cement based, but have very low-cement
content and very low permeability. The Portland Cement content in these systems is
typically 30% by volume. The system will react with the CO2, but at a much lower rate
Coupled with CO2 resistance, wells often contain H2S or will have H2S as part of a gas
injection process.
Studies have shown H2S does not react with Portland Cement; therefore, it is not
necessary to pump any specialty type of cement system. However, if the gas injection
stream contains CO2, then protection from the CO2 is required.
One exception is systems containing salt. High-salt systems tend to be more
susceptible to H2S attack, and should be avoided if H2S is expected.
Portland Cement with no additives will maintain stability up to 230°F (110°C). Above
this temperature, the cement structure will begin to change with time, and the crystals in
the cement will begin to degrade and/or react to form new species. This results in
higher permeability and lower strength. The process is called strength retrogression.
Strength retrogression does not necessarily cause many operational problems due
simply to the loss of compressive strength. Over time, the cement strength may regress
from 3,000 psi to as low as 500 psi. Even this low strength is sufficient to maintain
casing support. The problem begins to arise due to the increase in the permeability of
the cement. Permeability can increase from 0.001 mD (in a standard cement) up to 0.5
mD (in a fully strength-regressed slurry). This can lead to problems with zonal isolation,
fluid movement and other well problems.
Cement systems can experience this temperature at any point in time, not just when
being placed in the well. High production rate wells can have wellhead temperatures
exceeding 300°F (149°C), and because of the high heat at the wellhead, all of the
cement must be stabilized not just the cement in the lower parts of the well.
6.8.2. Alternatives
For wells requiring very high temperature cements, using non-Portland cements is the
simplest solution. These cements are high alumina cements, commonly used to
manufacture the bricks used in fireplaces. These cements are also applicable to CO2
resistance (see Section 6.6).
Care must be exercised when using these specialty cements in the field.
Contamination of these cements with Portland Cement will result in extremely short
pumping times, and can result in a job failure. Care must be taken by the service
company to assure all of their tanks and storage systems are completely cleaned of
Portland Cement before introducing these materials to the system.
6.10.1. Applications
The plastic and resin systems have application in wells used for the disposal of live
acid, or caustic. These systems have found primary use in disposal wells used by
chemical plants and some refineries due to their resistance to many acids and some
organic compounds. Some testing has indicated long-term cracking or embrittlement of
these systems, which could lead to loss of seal.
The systems are solids free, with a base density of approximately 9.5 lb/gal. The
density can be increased by incorporating silica flour, sand, or barite. The solids free
systems have been used to attempt to squeeze casing collar leaks and temporarily seal
wellhead valves.
6.10.2. Limitations
The plastics and resin systems have limits to their use in oilfield operations:
• Placement Temperature Limits - The systems cannot be placed at high
temperatures. The reaction of the resins and plastics is accelerated by
temperature and will set quickly at higher temperatures. This limits the
application to wells with bottomhole circulating temperatures under 150°F
(66°C).
• Application Temperature - Even if the systems can be placed at low
temperatures, the set materials will begin to soften at temperatures exceeding
250°F (120°C). This softening can lead to extrusion of the resin into the
2400 930 890 853 818 785 756 728 702 678 656 635 616 599 583
2500 965 923 885 849 815 784 755 728 704 681 659 640 622 605
2600 999 956 916 879 845 812 782 755 729 705 683 663 644 627
2700 1033 989 948 909 873 840 809 781 754 729 707 686 666 649
2800 1066 1021 978 939 902 868 836 806 779 753 730 708 688 670
2900 1098 1052 1009 968 930 895 862 832 803 777 753 731 710 691
3000 1130 1083 1038 997 958 922 888 857 828 801 776 753 732 713
3100 1161 1113 1068 1025 986 948 914 882 852 824 798 775 753 733
3200 1192 1143 1096 1053 1013 975 939 906 875 847 820 796 774 754
3300 1222 1172 1125 1081 1039 1000 964 930 899 869 842 818 795 774
3400 1251 1200 1153 1108 1065 1026 989 954 922 892 864 839 816 795
3500 1279 1228 1180 1134 1091 1051 1013 978 945 914 886 860 836 815
3600 1307 1255 1207 1160 1117 1075 1037 1001 967 936 907 880 856 834
3700 1334 1282 1233 1186 1142 1100 1060 1024 989 957 928 901 876 854
3800 1361 1308 1258 1211 1166 1124 1084 1046 1011 979 949 921 896 873
3900 1386 1334 1284 1236 1190 1147 1106 1068 1033 1000 969 941 915 892
4000 1411 1359 1308 1260 1214 1170 1129 1090 1054 1020 989 961 935 911
4100 1457 1395 1337 1284 1236 1191 1149 1111 1075 1042 1011 982 955 930
4200 1482 1419 1361 1307 1258 1213 1171 1132 1096 1062 1031 1001 974 949
4300 1506 1442 1384 1330 1280 1234 1192 1153 1116 1082 1050 1020 993 967
4400 1530 1466 1407 1352 1302 1256 1213 1173 1136 1101 1069 1039 1011 985
4500 1554 1489 1429 1374 1324 1277 1234 1193 1156 1121 1088 1058 1029 1003
4600 1577 1512 1452 1396 1345 1298 1254 1213 1176 1140 1107 1076 1048 1021
4700 1600 1534 1474 1417 1366 1319 1274 1233 1195 1159 1126 1095 1066 1038
4800 1622 1556 1495 1439 1387 1339 1294 1253 1214 1178 1144 1113 1083 1056
4900 1645 1578 1517 1460 1408 1359 1314 1272 1233 1197 1163 1131 1101 1073
5000 1667 1600 1538 1481 1428 1379 1334 1292 1252 1215 1181 1149 1119 1090
7400 2116 2043 1976 1913 1855 1800 1749 1701 1655 1612 1571 1533 1496 1461
7500 2132 2059 1992 1929 1870 1816 1764 1716 1670 1627 1586 1547 1510 1475
7600 2147 2075 2007 1944 1886 1831 1779 1731 1685 1641 1600 1561 1524 1489
7700 2163 2090 2023 1960 1901 1846 1794 1745 1699 1656 1615 1576 1538 1503
7800 2178 2106 2038 1975 1916 1861 1809 1760 1714 1670 1629 1590 1552 1516
7900 2194 2121 2053 1990 1931 1876 1824 1775 1728 1685 1643 1603 1566 1530
8000 2209 2136 2068 2005 1946 1890 1838 1789 1743 1699 1657 1617 1580 1543
8100 2228 2156 2086 2021 1960 1904 1851 1801 1755 1711 1670 1630 1594 1559
8200 2246 2170 2100 2035 1974 1917 1864 1815 1768 1724 1682 1643 1606 1571
8300 2259 2183 2113 2048 1987 1930 1877 1828 1781 1737 1695 1656 1619 1583
8400 2272 2196 2126 2061 2000 1943 1890 1840 1794 1749 1708 1668 1631 1596
8500 2285 2209 2139 2074 2013 1956 1903 1853 1806 1762 1720 1681 1643 1608
8600 2298 2222 2152 2087 2026 1969 1916 1866 1819 1775 1733 1693 1656 1620
8700 2311 2235 2165 2099 2039 1982 1928 1878 1831 1787 1745 1705 1668 1632
8800 2323 2248 2177 2112 2051 1994 1941 1891 1844 1799 1757 1718 1680 1644
8900 2336 2260 2190 2124 2064 2007 1953 1903 1856 1811 1769 1730 1692 1656
9000 2348 2272 2202 2137 2076 2019 1965 1915 1868 1823 1781 1741 1704 1668
9100 2360 2284 2214 2149 2088 2031 1978 1927 1880 1837 1793 1753 1715 1679
9200 2372 2296 2226 2161 2100 2043 1990 1939 1892 1847 1805 1765 1727 1691
9300 2384 2308 2238 2173 2112 2055 2001 1951 1904 1859 1817 1776 1738 1702
9400 2396 2320 2250 2185 2124 2067 2013 1963 1915 1871 1828 1788 1750 1713
9500 2407 2332 2262 2196 2135 2078 2025 1974 1927 1882 1840 1799 1760 1725
9600 2419 2343 2273 2208 2147 2090 2036 1986 1938 1894 1851 1811 1772 1736
9700 2430 2355 2284 2219 2159 2101 2048 1997 1950 1905 1862 1822 1783 1747
9800 2441 2366 2296 2230 2170 2113 2059 2009 1960 1916 1873 1833 1795 1758
9900 2452 2377 2307 2242 2181 2124 2070 2020 1972 1927 1885 1844 1805 1769
10000 2463 2388 2318 2253 2192 2135 2081 2031 1983 1938 1896 1855 1816 1779
Primary Cementing
Gas Migration
Scope
This Section briefly covers some of the theories on the causes of gas migration
and proposed slurry and job designs to address gas migration. This is not an
exhaustive discussion of the causes of gas migration, nor the myriad of mitigation
techniques. Rather this Section covers the most common forms of gas migration
and the most common prevention and mitigation methods.
This Section lists Practices and Standards that are generically referenced and assumed
part of this document. Unless otherwise specified herein, use the latest edition.
There are four general types of gas migration distinguished by when the problem is
seen at surface. Summarized here, each type will be examined in detail with slurry and
job design suggestions for the prevention of each type.
An under-balance situation in the well can be the result of either swabbing in the well
during pipe reciprocation, or by pumping excessive amounts of low-density preflush
ahead of the cement.
Performing surge and swab calculations prior to the job can minimize swabbing in the
well. If the margins are very close, pipe reciprocation should be avoided, though the
situation where this is a problem is rare.
Using a cement job simulator will help predict if the hydrostatics in the well does not
allow using water or other low-density wash ahead of the cement. These calculations
should always be made prior to cementing.
In situations where gas is seen at the surface immediately following the cement job, the
annulus must be immediately shut in and the pressures monitored. At this point, there
are three options:
1. Maintain pressure on the well until the cement sets: If no fluid is bled off the
annulus, no additional gas can enter the wellbore. This may help prevent further
channeling of the gas.
2. Circulate out the cement and associated gas: This can only be done with sufficient
pumping time on the slurry; will result in cement slurry in the choke manifold and
BOP equipment on the rig. This is usually the least desirable approach.
3. Pressure up on the annulus and displace sufficient mud to sweep the annulus to the
previous casing shoe. This will ensure a flow path from the surface to at least the
last casing shoe, allowing later placement of high-density mud or additional cement
squeeze jobs.
This situation is one of the most common forms of gas migration, and is the situation
most addressed by specialty gas migration additives.
7.4.1. Theory
Annular gas flow is most commonly caused by a combination of cement gellation,
volume reduction, and lack of total system elasticity. In the end, these result in low
stress between the cement and casing, and/or the cement and borehole. Because of
the low stress, the gas pressure is able to push the two surfaces apart and a
microannulus is created.
When a column of cement begins to set, the chemical bonding between the solids starts
to create gel strength. Simultaneously, the volume of the cement begins to shrink due
to fluid loss to the formation and the uptake of water in the chemical reaction. As
shrinkage occurs, gellation in the column prevents the cement column from moving
downward to maintain hydrostatic pressure.
The loss of hydrostatic pressure was noted in the 1970's. Commonly cited papers are:
SPE 5701, "An Investigation of Annular Gas Flow Following Cementing Operations,"
published in 1976 by J. A. Garcia and C. A. Clark; and SPE 8266, "Annular Gas Flow
After Cementing: A Look At Practical Solutions," by Levine, Thomas, Besner and Toole
in 1979.
These early works noted the pressure loss problem, but did not identify shrinkage as a
contributing factor for the loss of internal column pressure. It was assumed that as the
cement hardened, the solids began to support their own weight. Because the liquid
phase no longer carried the weight of the solids, the pressure would revert to that of the
mix water gradient. This resulted in the operational practices recommended in
SPE 8266, which included the use of a 9-ppg-gradient line to predict the occurrence of
annular gas flow.
Field data presented in the August 1983, JPT, "Field Measurements of Annular
Pressure and Temperature During Primary Cementing," written by Cooke, Kluck, and
Medrano of Exxon showed this assumption to be incorrect.
The pressure in the fluid phase does fall, but not to a water gradient. Cement lacks the
vertical permeability to be able to transmit pressure over long distances. Because the
interstitial water is not connected vertically, the internal pressure can theoretically fall to
zero (0) psi as the column sets and the water is drawn out of the interstitial spaces by
the hydration process. In reality, field data shows the pressure falls until it equals that
of the adjacent rock, whether it is normally pressured, abnormally pressured, or drawn
down. The pressure can fall no further because the water phase in the cement is in
communication with the fluids in the rock. There may actually be no measurable flow,
only fluid-on-fluid pressure at the interface. In one interval where a sensor was placed
across from a shale, the pressure fell well below formation gradient. This can also
occur in a liner overlap where the cement is between steel strings.
7.4.2.1. Latex
The preferred product for normal and higher density slurries is latex at 1.0 - 1.5 gps. A
concentration of 1.0 - 1.5 gal/sk will normally yield a FL < 50 cc's, regardless of BHT.
Schlumberger will recommend latex concentrations of 2.5 - 3.5 gal/sk based on the
"porosity" of the slurry. This porosity number is a calculation of the amount of solids
and liquids in the liquid slurry, and is not related to porosity of a set cement. Latex has
been used in ExxonMobil operations for over 18 years and field results do not support
these higher levels of latex.
If latex is not available, other systems designed to achieve a fluid loss less than 50 cc's
will normally be effective. This can be accomplished by using several different
materials, the more common being polyvinyl alcohol (PVA) based additives. While
these materials have been effective, latex is preferred in more severe situations
because it provides elasticity in addition to fluid loss control.
Gas migration following several days or weeks can be due to a number of reasons, from
dehydration of the mud filter cake to the formation of a microannulus. Changes in
wellbore stresses, as discussed above, play an important role in this type of gas
migration. The elasticity of the cement is a key parameter in resolving this situation.
Often, this type of gas problem presents itself as pressure on the annulus that cannot
be bled off, or will bleed down to zero and return in a few days. Generally, attempts to
This problem is the result of the sealing ability of the cement, brought on by stress
failure of the cement sheath. The stress can come from the pressurization of the casing
through a fracture treatment, or an increase in the mud weight for drilling deeper.
Temperature changes have a major effect on the stress environment of the well.
Increasing the temperature will place radial loads on the cement sheath as the casing
attempts to expand, and can lead to tensile failure of the cement. This will lead to the
loss of isolation, but casing support will still remain.
Prevention of the failure of the cement to maintain isolation has centered on
development of more flexible cement systems. These have included latex slurries,
foamed cements, Schlumberger's FlexStone, and the incorporation of flexible fibers into
the system.
One of the least expensive techniques to increase the flexibility of cement is to simply
reduce the cement density. Diluting the cement, in this case with water, reduces the
rigidity of the set cement, and will improve its resistance to cracking.
7.7. SUMMARY
It is important to understand the full life-cycle requirements for the well for proper
cement design. The best way to prevent long-term problems is to properly address gas
migration in the initial design.
Gas migration prevention should be considered with:
• Gas zones with pore pressure greater than 13 ppg.
• Any gas zone in the surface hole, regardless of pore pressure.
• Any gas zone below a liner top packer.
These conditions are arbitrary, and experience in a particular area, or knowledge of
future operations can dictate the use of gas migration prevention slurries on any
particular well.
Primary Cementing
Lost Circulation
Scope
This Section covers the use of lost circulation materials in primary cementing, how
the materials work, and the limits of the systems. It is specific to primary
cementing operations, and is not intended to supercede or replace the lost returns
response plan.
8.2. General...................................................................................................... 4
8.3. Additives and Systems ............................................................................ 5
8.4. Flakes ........................................................................................................ 5
8.4.1. Cellophane Flakes......................................................................................... 5
This Section lists Practices and Standards that are generically referenced and assumed
part of this document. Unless otherwise specified herein, use the latest edition.
8.2. GENERAL
Controlling lost circulation with cement is often a futile effort. Depending on the cause
of the losses, the response to the losses is several-fold. The lost returns response plan
is intended as the basis for lost circulation response. This plan should be followed for
lost circulation response, with cement playing a minor role in that response.
The current edition of the Lost Circulation Response Plan can be found on
GlobalShare (located in the library folder of the Drilling Technical Share) and the
EMDC Drilling Technical Intranet website.
Major lost returns occurs when the wellbore pressure exceeds wellbore integrity and a
fracture is created. The integrity is equal to the rock stress holding the two faces of the
fracture closed (minimum stress). Integrity is built by pressing the fracture wider to
increase the closing stress, then packing the fracture with solids to sustain the width. If
the width achieved is adequate so the increased stress exceeds ECD, losses stop. If
not, the ECD will press the fracture wider and losses continue. For more information,
refer to other ExxonMobil documentation on Fracture Closure Stress.
Cement is not effective in stopping losses unless the required increase in integrity is
small. Cement particles are essentially the same size as barite so it flows into the
fracture as freely as mud. In contrast, LCM pills become very resistant to flow down the
fracture because of their high fluid loss rate. As the pill dehydrates, the solids
remaining in the fracture become unpumpable and the fracture tip cannot grow. Fluid
loss is the key to this process. The fluid loss of most cements is low enough that it does
not dehydrate significantly as it flows down the permeable face of the fracture. Cement
Discussed briefly in Section 2.13, Additives, most LCMs for cement are large flakes or
large granular materials. It should be noted that because of the dimensions of most
laboratory test equipment, cement blends are not tested with lost circulation additives
present.
8.4. FLAKES
8.5.2. Gilsonite
More common than ground coal, Gilsonite is the other common granular lost circulation
material. It is used in similar concentrations of 10 - 12 lbs/sk. One limiting factor to
Gilsonite is the material will begin to soften at temperatures above 180°F (162°C).
8.6. FIBERS
8.6.1. CemNet*
Marketed by Schlumberger, CemNet* is a fiber that is added at a concentration of 1 - 2
pounds per barrel. (Note the concentration is in pounds per barrel and not pounds per
sack.) The material cannot be dry-blended, as it will not allow bulk transfer of the
cement. The material can also be added to the spacer ahead of the cement.
CemNet* is added to the mixing tub by hand, therefore the actual concentration will vary
with addition rate and pump rate. Care must be taken to prevent adding too much
material, as this will cause mixing problems.
Of the currently available lost circulation materials for cement, it appears fibers are
more effective at preventing lost circulation. ExxonMobil experience is quite limited for
CemNet* fibers. The operations that have utilized the material have had success,
though the high cost has limited the use.
Primary Cementing
Mud Removal
Scope
This Section covers the main considerations for optimizing mud removal. Included
is discussion on spacer selection, compatibility evaluations, and chemical
compatibility. Mechanical aspects of mud removal covered include centralization,
pipe movement, spacer volumes, and fluid velocities.
This Section lists Practices and Standards that are generically referenced and assumed
part of this document. Unless otherwise specified herein, use the latest edition.
9.2. INTRODUCTION
Parameter Consideration
General characterization of mud removal involves two areas: fluid systems and
properties, and mechanical actions to be taken. Fluid systems and properties deal with
mud properties and conditioning, spacer selection and usage, volumes and chemistry.
Mechanical actions include pipe movement, centralization, casing hardware and flow
rates.
While not a controllable factor during the cement job, the annular gap in the well will
effect the annular velocities, flow regimes and centralization.
Primary fluid considerations center around the physical removal of the drilling mud,
chemical compatibility of the selected spacer with the mud and the cement, and the
maintenance of pressure control in the well.
9.4.2. Centralization
Discussed in more detail in Section 14, Cementing Equipment (Centralizers), moving
the pipe toward the center of the hole will improve cementing success. Good
centralization becomes more important in the absence of pipe movement. At least 80%
standoff is recommended where isolation is required in the well.
Selection of centralizer type (bow spring or rigid/solid) should be made based on well
requirements, side loads, and casing running parameters. For vertical wells, bow spring
centralizers are recommended.
Primary Cementing
Cement Calculations
Scope
Tables
Table 10.1: Mix Water ................................................................................................... 7
Table 10.2: Absolute Volumes of Salt Concentrations (By Weight of Water) ............... 15
10.2. TERMS
Sack - A sack of cement weighs 94 pounds and has an absolute volume of 3.59
gallons.
Yield - The yield is expressed in cubic feet per sack of cement. This volume includes
all of the additives and mixing fluid.
Water Requirement or Water Ratio - This is the amount of water required to prepare
one sack of cement slurry to the design density. It is measured in gallons per sack.
Density - Calculated as the final weight in pounds per gallon of the slurry when mixed
with all additives and mixing fluids.
Percent Additive - This is the amount of dry additive added to the cement, expressed
as a percentage based on the weight of the cement (BWOC). For example, 1% additive
would equate to 0.94 pounds of additive added to a sack of cement:
0.01 * 94 = 0.94 lbs
Gallons per Sack - Liquid additives are expressed as gallons of additive added per
sack of cement.
Total Fluids - This is the total volume of water plus liquid additives used to mix the
cement.
By Weight of Water - Salt (NaCl) is normally expressed as a percentage based on the
weight of the mix water (BWOW) rather than as a percentage by weight of cement.
Cubic Foot - Standard volume used for reporting cement yields - equal to 7.48 gallons.
Slurry Density
When additives are used in the system, the water concentration may change. For
cement calculations, the important considerations are the slurry density, the yield, and
the amount of water required per sack of cement. All of these values are related to the
amount of water in the system, and will reflect in the water to cement ratio. As this ratio
changes, the permeability, strength, and other properties of the cement will change.
Density =
åWc + Wa + Ww
åVc + Va + Vw
Where:
Wc = Weight of cement
Wa = Weight of all additives
Ww = Weight of water
Vc = Volume of cement
Va = Volume of additives
Vw = Volume of water
Note: Often the absolute volume may not be known, but the specific gravity is known or
can be measured. To convert from specific gravity to absolute volume, the following
formula can be used:
1
Absolute Volume =
Specific Gravity * 8.33
The actual units of the calculation for density are not important as long as they are
consistent throughout the formula. Weight can be in pounds, grams, or kilograms.
Volume can be in gallons, liters, cubic meters, etc., but must be an absolute volume
value. The final answer of density will be in a weight/volume ratio.
Yield =
åVc + Va + Vw
7.48
For this equation, the yield is expressed in cubic feet/sack, and the volumes must be
expressed in gallons. The 7.48 constant is a conversion factor of gallons to cubic feet.
There are no conversion constants required for metric calculations if the units are
consistent. For the purposes of most of the examples, fresh water is used in the
calculations, and an assumed weight of water is 8.33 lb/gal.
10.3.6.1. Example 1
Absolute
Component Weight Volume Volume
(lbs) (gal/lb) (gal)
137.82 8.85
Density = = 15.6 lb / gal Yield = = 1.18 cu ft/sk
8.85 7.48
In Example 1, the components are known, including the water. In most of the
calculations, the density is known along with the required additives, but the amount of
water and the yield must be determined.
Absolute
Component Weight Volume Volume
(lbs) (gal/lb) (gal)
94 + 8.33X
Density = 15.8 =
3.59 + X
Solving for x :
Absolute
Component Weight (lbs) Volume Volume
(gal/lb) (gal)
126.9 + 8.33X
Density = 15.8 =
5.09 + X
Solving for x :
Absolute
Component Weight Volume Volume
(lbs) (gal/lb) (gal)
94 + 8.5X
Density = 15.8 =
3.59 + X
Solving for x :
Absolute Volume
2 0.0371 0.310
4 0.0378 0.316
6 0.0384 0.321
8 0.0390 0.326
10 0.0394 0.329
12 0.0399 0.333
14 0.0403 0.336
16 0.0407 0.340
18 0.0412 0.344
20 0.0416 0.347
22 0.0420 0.351
24 0.0424 0.354
26 0.0428 0.357
28 0.0430 0.359
30 0.0433 0.361
34 0.0439 0.366
37.2 (saturated) 0.0442 0.369
Cement 94 3.59
18% Salt 0.18 * (8.33X) 0.0412*(0.18(8.33X))
Water 8.33X X
OD 2 − ID 2
Annular Volume =
1029.4
Where :
OD = Outside Diameter (inches) :
ID = Inside Diameter (inches)
8.535 2
Csg Volume = ∗ 80 ft = 5.66 bbl
1029.4
5.66 bbl = 31.8 cu ft = 28 sacks
8.535 2
Displacement Volume = ∗ 9920 ft = 702 bbl
1029.4
Using the example, the job time for this cement job would be:
Cement volume 356 bbl
Mixing rate 5 bpm
Time to mix cement 71 min
Displacement volume 702 bbl
Displacement rate 6 bpm
Time to displace 117 min
Total job time 188 min (approximately 3 hours)
Safety factor 1 - 1.5 hour
Requested thickening time 4 - 4.5 hours
The requested thickening time for the cement design incorporates the job time, plus the
safety factor. A wider range for thickening time is given to allow the cement service
Primary Cementing
Liner Cementing
Scope
This Section covers the types and purposes of liners, common liner cementing
problems, design considerations and liner cementing techniques.
Part of this Section contains a separate report on liner top packers. As liner top
packers are commonly used in many liner applications, it is included here as the
use of a liner top packer affects the design of the cement system.
11.2.4. Tieback
A liner tieback is run to connect the top of a production liner back to surface. A tieback
is run to protect previous casing strings that may not be adequate for production loads,
to provide added protection for pressure or corrosion.
Depth
Temperature
Figure 11.1 is an example of multiple gradients in a well. While the temperature at the
bottom of the well is identical in both situations, assuming a constant gradient
throughout the well would result in over-estimation of the temperatures in the
intermediate portions of the well. As noted above, this can result in over-estimation of
the temperature at the top of a liner.
As with other cement designs, accurate temperature prediction is critical. Use of
temperature data from the well, use of temperature simulators, or other means of
estimating the wellbore temperature will improve cementing results.
11.4.7. Centralization
Small annular gap calls for good centralization as any offset can prevent placing cement
around the pipe. Centralizers will also aid in preventing differential sticking of the liner
and aid in getting the liner to bottom.
Primary Cementing
Plug Cementing
Scope
This Section contains design and placement of cement plugs. Included in this
Section are calculations to properly balance a plug in the well.
12.2.1. Abandonment
Every well will eventually be plugged and abandoned. There are a number of
regulations that address the proper abandonment of wells, and are generally written to
ensure proper isolation of hydrocarbon zones, protection of fresh water areas, and
pressure isolation of the wellbore. It is imperative that local regulations be checked for
the proper plugging requirements.
12.4.1. Abandonment
BHST < 230°F (110°C)
Slurry: Cement + retarder if required
Thickening Time: Placement time + 30 - 45 min assuming drill pipe can be
extracted in less than 30 min.
Fluid Loss: None Required
Free Water: Zero at BHCT and well angle
Strength: Minimum 500 psi
12.6.2. Temperature
The temperature where the plug will be placed will be different than that used to design
a primary cement job. The amount and rate of fluid circulation prior to placing the plug
will effect the temperature, generally reducing it. If possible, run a temperature
simulation to determine the proper temperature for the plug placement.
12.6.6. Mixing
Batch mixing is preferred, and is a simple operation if one of the larger 25-bbl
recirculating units is used. Otherwise, mix as slow as required to assure density
control. Do not batch mix slurries that contain an accelerator. For systems that do not
contain a retarder, the thickening time begins when the cement mixes with the water at
surface.
12.6.7. Spacers
Use an appropriate spacer for the drilling fluid. Plug failures in non-aqueous fluids are
common and a result of failure to remove the mud, or a failure to leave the formation or
pipe water wet. Mud contamination is a major cause of plug failures and is especially a
problem in wells drilled with NAF.
12.6.10. Displacement
When displacing a cement plug, it is common practice to under-displace the plug by a
few barrels to allow the cement to fall out of the pipe as it is being pulled out of the plug.
This practice helps prevent mudflow up the drill pipe in the event the cement was over-
displaced and essentially puts a small slug in the pipe.
This practice is not effective in high-angle or horizontal wells. The angle of the well
does not allow the under-displacement to act as a slug. If the pipe is pulled out of the
plug in a high-angle situation, the cement will not fall out of the pipe, and the plug will
become more contaminated.
To address this problem, it is recommended the pipe be pumped out of the plug. As
each stand of pipe is pulled up, the equivalent pipe volume of mud should be pumped.
Vcmt = L ∗ Vh
where :
L = Required length of cement plug (ft)
Vh = Volume of hole (bbl/ft)
Vcmt
Lcmt =
Vann + Vws
where :
Vann = Volume of the annulus (bbl/ft)
Vws = Volume of the work string (bbl/ft)
To properly balance the plug, the volume of spacer (in bbl) behind the plug should be
calculated to balance the volume pumped ahead of the plug.
Vsp1
Vsp 2 = *Vws
Vann
where :
Vsp1 = Volume of spacer pumped ahead of the plug (bbl)
Vsp 2 = Volume of space pumped behind the plug (bbl)
The displacement volume (in bbl) for the plug is calculated as:
Vdis = Vws ∗ [ D − ( Lcmt + Lsp 2 )]
where :
D = Depth to the bottom of the plug (ft)
Lcmt = Length of the cement plug (ft)
Lsp 2 = Length of the spacer behind the plug (ft)
Note: in the calculations for cement plugs, the units may be changed to any required
units provided there is consistency in the units throughout the calculation. For example,
if the volumes are calculated in cubic feet, the annular capacities should be converted
to cuft/ft.
8.5 2
Volume of Cement = 500 *
1029.4
Volume of Cement = 35 bbl
Length of Plug with the work string in place:
35
Lcmt = = 515 ft
0.0622 + .00579
Volume of spacer behind:
20
Vsp2 = * 0.00579 = 1.86 bbl
0.0622
This calculation assumes the top of the spacer in the annulus is below the transition
between drill pipe and tubing. This is not the case in this example because of the
volumes.
Further, the volume of spacer to balance the plug behind will be slightly less than that
calculated. This is because the top of the spacer will be located inside the drill pipe
rather than the tubing.
The length of the spacer in the annulus is actually:
Length of cement: = 515 ft.
Length of tubing string: = 750 ft
Volume of tubing x OH: = 0.0622 * (750 - 515) = 14.6 bbl
Remaining Spacer: = 20 - 14.6 = 5.4 bbl
Length of spacer in drill pipe x open hole: = 5.4 / .0408 = 132 ft
Top of spacer in annulus: = 10,000 - 750 - 132 = 9118 ft.
Primary Cementing
Operational Requirements and
Specifications for Cementing Services
Scope
This Section contains the technical specifications for equipment, materials, testing, and
personnel for providing cementing services on ExxonMobil wells. Each requirement is
outlined within the Section as it pertains to each of these areas.
Exceptions to these requirements are outlined in 13.2 and may be granted by the Field
Drilling Manager except where safety issues are involved. Exceptions to 13.3 #8 on
pressure relief devices and 13.3 #17, maximum rates through 2-inch treating lines can
only be granted by an Operations Manager.
13.2. EXCEPTIONS
Exceptions to these technical requirements are allowed, but shall be documented in
writing by the service company and approved the Field Drilling Manager or designated
representative. Documentation shall include proposed change, reason for exception,
and impact on operations.
Exceptions to the use of pressure relief devices on cementing equipment and maximum
allowable rates through treating lines require approval of the Operations Manager. All
other exceptions can be made by the Field Drilling Manager
1. The cement unit contracted to perform the cementing work shall be capable of
carrying out all aspects of the proposed work. This includes the cementation of the
proposed casing strings, blowout preventer pressure tests, casing pressure tests,
formation integrity tests, and required well testing operations.
2. The cementing unit is to be a dual diesel or electric-powered design driving dual-
triplex pumps rated to a minimum 10,000 psi working pressure, and having a
recirculating type mixing system.
3. The Recirculating Mixing System (RCM) is to provide density control and slurry
consistency over a wide range of slurry weights and is required to mix cement within
0.2 ppg (plus or minus) of the designed slurry weight. The RCM volume is to be
sufficient to allow continuous or batch mixing and provide for homogeneous slurry.
4. The recirculating mixing system shall have the capability of computer-controlled
mixing for the control of cement density and rate.
5. The displacement tank capacity shall be a minimum of 20 bbls divided into two (2)
10 bbl compartments.
6. The cement unit shall be capable of functioning to full capacity at all times. Regular
maintenance and correction of equipment faults shall be performed. The Contractor
shall operate and maintain the cementing unit, equipment, consumables, and
provide sufficient spare parts.
7. The cement unit shall be outfitted with a downstream densitometer, or equivalent
device for accurately measuring and recording the density of fluids as they are
pumped into the well.
8. The cement unit shall be fitted with an automatic pressure relief device or over-
pressure shut-down capable of being set to the maximum pressure allowed for the
job. Exceptions to this requirement must be approved by the Operations Manager.
9. The cement unit shall be fitted with electronic data and recording equipment to
analyze and record pertinent job parameters for post-job analysis.
10. Real time remote display of electronic data shall be available at the location if
requested. This may be accomplished through a hard-wired remote display located
away from the main work area of the unit.
11. Electronic data shall be captured and recorded at a minimum rate of once every four
(4) seconds. The preferred recording rate is once each second for all parameters.
12. The minimum acceptable data to be recorded shall be time, downstream density,
and liquid additive rate, if applicable, cement pump rates, displacement rates where
displacement is done by the cement unit, and pressure throughout the entire job.
13. Pressure shall be recorded throughout the entire job. If the rig pump is performing
the displacement, this will require the line to the cement unit be left open, or an
additional pressure transducer installed in the treating line to allow pressure
recording for the entire displacement period.
1. The nitrogen unit and associated equipment shall have the capacity to accurately
deliver nitrogen at rates up to 2,500 scf/min.
2. Nitrogen volume capabilities shall support projected foamed cementing operations
and shall include additional volumes for anticipated storage, equipment cool down,
etc.
3. Contractor shall be able to meter injection of liquid foaming agents and stabilizers
into the suction side of the downhole triplex pump. Contractor shall provide a
method for monitoring flow of additives through appropriate metering. Monitoring
liquid additive pump strokes is not considered appropriate metering.
4. Separate tanks for liquid foaming agents and liquid foam stabilizers are required.
For systems where foamer and stabilizer are supplied as a single material, this
requirement will not be applicable.
1. Contractor shall provide Material Safety Data Sheets (MSDS) for all products to be
used on the well or job.
2. Contractor shall maintain a cement-testing lab in the service area capable of running
required tests with samples of water, cement, and chemicals sent in from the rig.
Primary Cementing
Cementing Equipment
Scope
14.2. General................................................................................................... 7
14.3. Surface Equipment ............................................................................... 8
14.3.1. Cement Bulk Blending, Transportation and Storage ...................................... 8
14.3.1.1. Blending.................................................................................................. 8
14.3.1.2. Bulk Cement Transfer - Cement Losses ............................................... 11
14.3.1.3. Bulk Cement Storage............................................................................ 11
14.3.1.4. Bagged Cement .................................................................................... 12
14.3.2. Cement Slurry Mixing .................................................................................. 13
14.3.2.1. Batch-Mixing Equipment ....................................................................... 13
14.3.2.2. Continuous-Mixing Equipment .............................................................. 14
14.3.3. Pump Systems ............................................................................................ 18
14.3.4. Density Measurement ................................................................................. 19
14.3.5. Data Recording ........................................................................................... 19
14.3.6. Inventory Control ......................................................................................... 20
14.3.7. Sampling ..................................................................................................... 20
14.3.8. Other Surface Cement Equipment............................................................... 20
14.3.8.1. Cement Plug Containers or Cement Heads .......................................... 20
14.3.8.2. Wiper Plugs .......................................................................................... 21
14.4. Subsurface Equipment ....................................................................... 22
14.4.1. Casing Centralizers and Stop Collars .......................................................... 22
14.4.1.1. Centralizer Performance Standards ...................................................... 22
14.4.1.2. Where to Use a Centralizer ................................................................... 22
14.4.1.3. Where Not to Use a Centralizer ............................................................ 23
14.4.1.4. Centralizer Type - Bow-Spring, Rigid or Solid ....................................... 23
14.4.1.5. Standoff ................................................................................................ 23
14.4.1.6. Flow Diversion ...................................................................................... 25
14.2. GENERAL
Cementing equipment can be broadly defined as surface equipment (those items
devoted to mixing and pumping in the well), and subsurface equipment (those items
that attach to the casing and will remain in the well following the cement job). The
recommended surface equipment for performing a cement job consists of:
• Appropriately-sized bulk equipment with sufficient dry air for the entire operation
• Computer-aided mixing system (Automatic Density Control (ADC) or equivalent)
• Dual pump cement unit
• Double-plug cement head
• Pressurized mud balance
• Downstream recording densitometer
• Pressure recording through the entire job to include displacement
14.3.1.1. Blending
Located at the service company facility will be a bulk blending plant. This will consist of
storage silos and a batch blending tank or weigh batch blender. The weigh batch
blender will be on scales, and is used for dry blending additives into the cement.
Normally, these blending tanks are 350 - 450 cu ft, but are not completely filled to allow
for blending. One method of blending involves adding 1/2 of the cement, introducing
the additives, and then the remainder of the cement is added. A better and preferred
method is to take 1/3 of the cement, 1/2 of the additives, 1/3 of the cement, 1/2 of the
additives, then the remainder of the cement. This method has been shown to give
improved and more consistent cement blends.
Regardless of the blending method, the cement should be transferred a number of
times between an intermediate tank and the weigh batch blender (or the intermediate
tank and the bulk transport). This process of "boxing" or transferring the cement is
critical to quality cement mixing. The cement should be moved at least three (3)
times before going to location to ensure proper cement blending. Some systems
(Schlumberger's CRETE* blends for example) can require at least five (5) transfers to
ensure proper blending.
Figure 14.1 is a picture of a bulk plant. A bulk plant is used both to blend cement and
to confirm the volume of cement loaded. For locations where liquid additives are used,
while no bulk blending is occurring, the cement will still be run through the bulk plant to
confirm the number of sacks of cement being sent to the location. The only change is
multiple moves of the neat cement are not required.
Understanding bulk cement storage limitations aids in designing cement volumes for a
particular job. If the calculated cement job requires 2-1/2 bulk tanks of lead cement and
1/2 tank of tail, it may be better to redesign the amount of lead and tail cement allowing
for two tanks of lead and one tank of tail cement. Of course, this would depend on well
requirements and hydrostatics, but often the bulk system can be optimized simply by
changing the relative amounts of cement to be used.
Optimizing the use of the bulk system will improve the results of the cement job. The
operation will be simplified and the quality of the cement mixing improved.
For offshore operations, large jobs may require spotting additional cement bulk tanks on
the rig. When this is required, it is normally best to fill these tanks with lead cement,
and mix from these tanks first. This is due to the lower technical requirement of a lead
cement system, and if there is a mixing problem, normally the lead cement has a longer
thickening time, which could allow more time for problem resolution.
Some cement units have very large (± 25 bbl) recirculating tubs that allow for batch
mixing small volumes of cement. This is convenient for setting plugs and squeeze
operations.
Batch-mixing equipment is recommended for some critical cementing operations.
These include production liners, high-density slurries, and other high-risk operations. If
batch-mixing equipment is to be used for the cement job, the cement tests should be
modified to include the mixing time for the slurry. Normally, this is estimated at one
hour and simply involves stirring the cement for the mixing time prior to starting the
thickening time test (see Section, 3, Cement Testing).
Often a single-batch mixer will not be large enough to hold all of the required cement.
In these cases, one tank on the batch mixer can be filled with slurry, and as it is
emptied, additional slurry is mixed in the remaining tank. In this process, the batch
mixer is being used as an averaging tank. The large residence volume of slurry will
even out the swings in slurry density seen in continuous operations. The disadvantage
to this type of operation is if one tank has the wrong density, there is a large volume of
cement that must be dealt with before the correct density can be achieved.
A generic batch-mixing tank is shown in Figure 14.3. A typical unit has two 50-bbl
mixing tanks, an operator station in the middle, and the power system on the end. This
tank allows for mixing the dry cement with the mix water, recirculating the blend until the
cement is at the proper density, then discharging to the downhole pump unit. The
centrifugal pump on the unit is responsible for both mixing and transferring the cement
slurry to the downhole pump.
Turbine Agitator
Baffles
Batch-Mixing Tank
Water
Inlet To Displacement Pumps
Centrifugal Recirculating
Pump Cement Suction
Mixing Water
Surge Tank or (from the mixing manifold)
Atmospheric
Slurry
Tank
(to pump(s))
Dry Cement
Hopper Gooseneck
Grating
Water Jets
Slurry
Bowl
Bulk Cement
Mixing Water
Water Metering Valve
Slurry
Centrifugal
Recirculation
Pumps
Line
Mixing Tub
De-aeration
Partition
Slurry
(to pump(s))
14.3.7. Sampling
Samples of all cement blends, mix water, and additives should be collected and
retained until the cement job is considered a success. Samples of mix water should
include the mix water with any additives included. Individual samples of liquid additives
should be collected and retained. The service provider should provide appropriate
sample containers for all cement, additives, and mix fluids.
Lifting Ring
Bull Plug
Connection to Casing
Flow Line to Cement Units
A final method of determining if the top plug has left the head is through the use of a
radioactive tag placed in the top plug. The radioactive tag can be easily tracked with a
sensor and if the plug hangs up in the cement head, it is easily identified by the sensor.
This is the most reliable method of assuring a cement plug has left the head, though it
does require handling radioactive tags. (Note these tags have a very low level of
radioactivity and do not pose a health problem if handled properly.)
14.4.1.5. Standoff
There is no such thing as an API recommended standoff. It is common to quote that
API recommends 67% standoff ratio. The API makes no recommendation as to the
amount of standoff required. The source of the 67% number is for performing a
centralizer specification test. At a 67% standoff, the centralizer has to show a particular
amount of force.
1. For most applications, 80% standoff (when isolation is needed) will give good
cementing results. Above 80%, the incremental gain can become very expensive.
Lower standoff may be acceptable if there is sufficient distance above and below the
area requiring isolation. If isolation is required within a 100 - 200 ft interval, higher
8.5 0.75 83
8.75 0.875 71
9 1 63
9.5 1.25 50
10 1.5 42
10.5 1.75 36
I 8 1500 (10,300)
II 12 3000 (20,700)
I 2 8 1500 (10,300)
II 4 12 3000 (20,700)
Float equipment will be designated as III-C or I-B, depending on how it has been tested.
Generally, larger casing sizes are not tested to III-C requirements, as they will not be
used under these extreme conditions.
Other types of float valves include flapper or ball type. These valves depend on the
fluid flowing back up into the casing, to keep the valve closed. These types of valves
are not recommended for high-angle or horizontal wells because the valve may not
close properly.
Figure 14.9 shows a typical float shoe on the left. The valve has been pre-cemented
into the casing, and the end threaded to allow screwing it onto the casing string. The
shoe has a rounded nose to ease running into the well.
Figure 14.9 also shows a typical float collar. Much like the float shoe, the same valve is
pre-cemented in place, but in this case, the equipment has been threaded on each end
to allow for placement within the casing string.
The distance from the float shoe to the float collar is typically two to four joints of pipe
(80 - 160 ft). This area is called the shoe track. At least one joint of casing should
When performing a stab-in job, care must be exercised to calculate the collapse loads
on the pipe. As cement is brought up the annulus, the casing x drill pipe annulus is not
exposed to pressure and will experience a collapse load. It may be necessary to fill the
casing with weighted mud to prevent excessive collapse loads during a stab-in cement
job. As a precaution, after stabbing into the collar, the drill pipe x casing annulus should
be filled and monitored to detect any leaks in the stinger seals.
Stage
Collar
Cementing
Basket
First-Stage
Plug
Float
Collar
Shoe
With the tool open, the well can now be circulated from the stage collar up, effectively
isolating the bottom portion of the well. The second stage is then performed, and the
closing plug pumped behind the cement job. When this plug lands, pressure is applied
to close the stage collar. After the cement sets, the stage collar is drilled out and
operations continued.
If necessary, more than one stage collar can be run in a single well. Generally, the
bottom tool will be a hydraulic opening tool, with the upper collar being mechanical.
Running more than one hydraulic tool in a single casing string is not recommended.
Primary Cementing
Design Checklist
Scope
This Section lists items for consideration in cement design. Not all items will be
applicable to all jobs or all wells.
Tables
Table 15.1: Recommended Cement Tests .................................................................. 12
ExxonMobil Requirements
Section # ExxonMobil Requirement
There are no ExxonMobil requirements in this Section.
15.2. PLANNING
The document is broken into sections dedicated to various parts of the design. While
not exhaustive, each section should have some application to most wells and cement
jobs. As noted in Section 5, in a slurry design, there are a number of generalized areas,
such as regulatory compliance, that apply to all wells.
15.4.1. Spacers
• Density - If mud weight is above 11 lb/gal, use a weighted spacer. Otherwise,
use water if well hydrostatics allow.
• Volume - Sufficient for 500 annular feet.
Transition Time
Gas Migration
TOL Strength
Compatibility
Temperature
Free Water
Wettability
Fluid Loss
Rheology
Strength
Settling
Casing
Cold
String or Job
Parameter
Conductor R R X X
Surface R R X X
Intermediate R R R R X
Long String R R R R X
Liner R R R R X R
NAF Mud X R
Mud > 10 ppg R
Gas Migration R X X X
Deepwater R
Deviated Well R X
R - Required Test X - Recommended Test
Primary Cementing
On Location Guidelines
Scope
This Section outlines the items that should be checked prior to performing a
cement job. The assumption is that the design requirements for the cement
system will meet the requirements of the job and no additional design work is
required to develop a cement slurry or spacer system.
16.2.1.3. Additives
• Liquid
• Identified and proper lot numbers - Should match lab report.
• Order of addition - May be important if water is batch mixed - otherwise liquid
add goes directly into mix water and is not a concern.
• Volume - Sufficient for job.
• Confirm liquid additive pump can meet job requirements.
• Solid - Normally, will be either spacer mix, bentonite or calcium chloride.
• Identified and lot number checked.
• Volume sufficient for job
16.2.1.4. Spacers
• Mixing procedure given to responsible person - Offshore, this will normally be the
mud engineer.
• Density
• Volume sufficient for job including any required for loss in tanks
• How pumped - By rig or service company
16.2.2.2. Centralizers
• Proper installation location
16.2.3.1. Liners
• Darts and balls correct and in proper order
• Witness loading head
16.2.4. Operations
There are several operational checkpoints before and during the cement job. These can
be included in the pre-job operational meeting to assure the job is properly executed.
16.2.4.1. Mechanics
• Pipe movement
• Rotation - rpm and max torque, when to start and stop
• Reciprocation - distance and rate, when to start and stop - note that hook load
will increase when cement is in pipe.
• Test pressures for lines to cement head
• Pressure limit of cement head
16.2.4.4. Personnel
• Identify person dropping plug - Assure when plugs are dropped with a two-plug
head that the top valve is opened, then the bottom valve closed to drop the plug.
After the plug dropped, it is acceptable to open both valves, but not before the
plug leaves the head.
• Identify person monitoring returns
16.2.5. Calculations
There are several calculations that should be confirmed.
• Double check the yield of the cement used for the volume calculations matches
that on the lab reports and other documents.
• Cement volumes - Compare to volume on location.
• Water volume - Sufficient for cement mixing, spacers and clean up.
• Displacement - Confirm with at least two other people.
• Job time - Confirm and check that slurries have sufficient pump time.
• Pressures
• Check differential pressure at the shoe at end of job.
• Check that casing will not be pumped out of the hole - particularly important
on large casing strings.
• Differential pressure at top of liner at end of job - Will determine if well will U-
tube when stung out of liner top.
16.2.6. Sampling
Samples should be taken in the event of a well problem. The samples can be discarded
once it is determined the job was a success.
• Dry cement - Collect at least 1 gal or 20 lbs
• Mix water with no additives - 1 gallon
• Liquid additives - 1 quart
• Mix water with all additives - 1 gallon (only if adds are put into the water)
Throughout the job, several samples of cement are normally taken from the mixing tub.
These may be useful in estimating when the cement is set if the slurry was not retarded.
Cement systems designed for high well temperatures will not normally set at surface
16.2.7. Records
Good records of the activities during the cement job are invaluable in the event of a
cementing problem. Most of the pertinent records from the job should be available from
the service company. The service company should record the density, rate and
pressures throughout the job.
Primary Cementing
Good Cementing Practices
Scope
Note:
Exceptions to this requirement may be made by the Field Drilling Manager
or designee.
Putting energy into the wellbore by maximizing pumping and displacement rates will
enhance mud removal. This appears to be independent of flow regime. Most wells
benefit from maximizing the displacement rate.
There are situations where fluid velocity is ineffective in displacing the mud. In some
areas, displacing the cement at slower rates may enhance the results. In these areas,
special consideration must be paid to the viscosity of the various fluids and the density
Recording the density, rates and pressures during the entire job will enhance job
evaluation and any problem resolution. The data can be essential in the event of a job
problem.
It is critical the pressure be recorded for the entire job, including the displacement,
regardless of which pump system is displacing the cement job. On many jobs, the rig
pumps are used to displace the cement. If the cement unit is isolated from the well, the
pressures during displacement cannot be recorded.
It is an ExxonMobil requirement the cement service company record the pressure
during the entire cement job.
Primary Cementing
Cement Sheath Evaluation
Scope
This Section covers cement evaluation through use of sonic and ultrasonic logs.
Figures
Figure 18.1: Tool Configuration ...................................................................................... 9
Figure 18.2: Waveform Nomenclature ............................................................................ 9
Figure 18.3: Waveforms ............................................................................................... 11
Figure 18.4: Free and Fully Cemented Pipe ................................................................. 12
Figure 18.5: Intermittent Cement Coupling to Casing and Formation............................ 12
Figure 18.6: Microseismogram ..................................................................................... 14
Figure 18.7: Amplitude vs. Cement Thickness.............................................................. 16
Figure 18.8: Eccentering Effects................................................................................... 17
Figure 18.9: Transit Time.............................................................................................. 18
Figure 18.10: Critical Transit Time................................................................................ 19
Figure 18.11: Basic Configuration of Tool..................................................................... 24
Figure 18.12: SBT Configuration .................................................................................. 25
Figure 18.13: SBT Presentation.................................................................................... 26
Figure 18.14: Signal Path (Part 1) ................................................................................ 28
Figure 18.15: Signal Path (Part 2) ................................................................................ 28
Figure 18.16: Acoustic Impedance of Mud.................................................................... 29
Figure 18.17: Acoustic Impedance of Cement .............................................................. 30
Figure 18.18: CAST-V Segmentation............................................................................ 33
Figure 18.19: Liquid in the Annulus .............................................................................. 36
Figure 18.20: Cement in the Annulus............................................................................ 37
Figure 18.21: Cement in the Annulus #2....................................................................... 38
Figure 18.22: Lightweight Cement ................................................................................ 39
Figure 18.23: Gas Cut Cement in the Annulus.............................................................. 40
Figure 18.24: Eccentering............................................................................................. 43
18.2. INTRODUCTION
The objective of a cement sheath analysis is simply to confirm the cement has been
successfully placed around the casing so it will provide support for the casing and
assure all zones of interest are hydraulically isolated. Casing support requires the
presence of any solid material in the annulus, but not necessarily 100% circumferential
coverage of the casing. Sand, borehole collapse, barite, hematite, or any similar solid
material will provide casing support providing it fully occupies the annulus. Hydraulic
isolation, however, requires 100% annular fill of an ultra-low to non-permeable material.
Some of the factors that create a good cement job include:
• Adequate circulation and cleaning of the hole prior to cementing
• Centralization of the casing
• Casing movement during circulation and cementing
• Use of a cement slurry that exhibits no free water separation or solids
segregation
• Placement of the cement in the entire annulus without losing circulation
The high-quality cement mixed at the surface does not always yield what is perceived as
correspondingly high-quality cement in the annulus. This apparent loss of cement
quality can be a result several factors:
1. Contamination of the cement with mud and/or gas decreases density and strength,
which creates a corresponding decrease in the acoustic properties of the cement.
These events decrease the ability of the cement sheath (by decreasing the shear
strength) to control the "ringing" of the casing during cement evaluation logging
which relates to increases in bond log amplitude (or decreases in bond log
attenuation rates).
Travel Time
E1 E3 E5
Amplitude
E2 E4
Material ∆T (µ
µ sec/ft) Vel. (ft/sec) Miles/Hour
18.4. WAVEFORMS
The composite waveform detected at the receiver is illustrated in Figure 18.2. In this
composite waveform, the first positive peak is referred to as E1, with subsequent
positive peaks denoted as E3, E5, E7, etc. The first negative peak is referred to as E2,
with subsequent negative peaks denoted as E4, E6, E8, etc. The receivers detect the
sum of all the waveforms generated by reflection of the sonic signal from the casing, the
formation, the cement sheath, and the casing fluid. Generally, the signals reflected from
the cement and the formation are indistinguishable. The signal detected at the receiver
is transported to the surface to an oscilloscope for generation of a waveform.
Figure 18.3 illustrates the typical waveforms that can be generated from each of the
travel paths, i.e., from the mud, the casing, the cement, and the formation. Assuming
set cement is acoustically coupled to the casing and the formation, the signal received
and the waveform generated is a composite of all travel paths. The magnitude
(amplitude) of the waveform is greatest in free casing. If the casing is not acoustically
coupled to the cement, the only signal detected by the receiver will be the ringing of the
casing caused by the pressure surge of the sonic signal travelling down the wall
thickness of the casing. This can be caused by:
1. Mud in the annulus
2. Unset cement in the annulus
3. A microannulus between the set cement and the casing
4. Weak cement fully coupled to thick wall casing
Cement with at least 250 psi compressive strength and complete acoustic coupling is
required for transmittal of the signal through all of the conductors. The transit time of the
signal from the transmitter to the receiver is relevant to the casing size, the casing fluid
Mud
Casing
Cement
Formation
Composite
Figure 18.5-A illustrates intermittent cement coupling to the casing and to the formation.
In this situation, the composite waveform will indicate both formation and casing
responses. This configuration may be attributable to one of two causes, i.e., cement
channeling or a microannulus at the cement-casing interface. The only method for
differentiating between the two is to run a pressured and a non-pressured pass with the
logging tool. With the casing under pressure, the casing signal will disappear in the case
of a microannulus. The casing signal will remain if a channel exists and is in contact
with the casing. To date, no logging tool will provide identification of an outside channel,
i.e., a channel between the formation and the cement sheath.
where
r = Casing Radius, in
P = Pressure, psi
tw = Casing Wall Thickness, in
E = Young's Modulus of Elasticity of Steel
Channeling during cementing can be the result of:
• Poor casing centralization
• Failure to move the casing while circulating and cementing
• Dynamic solids settling from the mud or cement to the low side of the annulus
(low side of the casing)
• Free water separation from the cement slurry after placement (high side of the
casing)
The amount of pressure required to expand the casing to the cement sheath varies with
the cause of the microannulus. Whatever internal pressure existed in the casing at the
time the cement hydrated, must be duplicated, plus approximately 500 psi to
compensate for casing expansion caused by the heat of hydration during cement set.
Another activity that contributes to the formation of a microannulus, or the creation of
stress cracks in the cement sheath, is pressure testing the casing after the cement has
set. If possible, pressure testing the casing immediately after bumping the top wiper
plug, while the cement is still liquid, can eliminate many stress failure problems of the
cement sheath. This requires the plug land and the landing collar or float collar and
cement head and related equipment must withstand the required test pressure.
Raw Waveform
Stacked Shading
The size of the waveform precludes the use of more than one data point per foot.
Whereas, the linear presentation permits printing of hundreds of data points per linear
foot, thus yielding a more solid definition of the casing cement coupling. Methodology
for creation of the linear presentation involves deleting the negative peaks and recording
the width of the positive peaks from the top rather than the height of the peaks. This
creates a two-dimensional log in which variations of shading indicate peak height
(highest peaks are dark and wider, with decreasing intensity shading to lighter and
narrower bands at low-peak heights, to white at the negative or zero peak height). Thus,
dark bands on the linear presentation represent the positive peaks and the white bands
occupy the position of the negative peaks.
Once a basic understanding of the linear or waveform presentation is achieved, one
should be readily equipped to delineate cement or non-cemented sections of the
annulus, assuming the cement sheath is non-contaminated and has reached a sufficient
strength to provide dampening of the casing vibration as well as carry the refracted sonic
signal to the formation. For interpretive purposes, the basic responses of the waveform
to the diverse downhole cement sheath conditions have been illustrated in Figures 18.4
and 18.5. When analyzed in conjunction with knowledge of borehole enlargements and
borehole lithology, a fair judgement of cement sheath quality can be made, as long as
the cement is not contaminated with gas. The infusion of gas from any source into the
cement column, whether designed into the cement system or as a result of influxes from
The major problem with this concept is changes in cement density and strength from a
tail slurry to a lead (filler slurry), change in the cement strength due to decreasing static
temperature up the hole, and/or decreases in cement strength and density created by
gas influx into the cement column will effect ALS and A100%. Another factor that will affect
the bonding index is borehole lithology. Softer, less dense rock will yield lower
amplitude, which may be interpreted as better bonding.
Hard limestone and dolomites will yield higher amplitudes, which may be interpreted as
poor bonding. Eccentering of the tool within the casing will also create lower amplitude
readings (better bonding); therefore, one must be certain the tool is centered during the
run (Figure 18.8).
It is important to realize the expected value for 100%-bonded pipe is part of the bond
index calculation. If the well has been cemented with lightweight slurry, and the tool has
not been reset to represent the lower expected value, the bond index calculation will be
wrong.
Changes in casing size and weight will effect the free pipe calculation, and must also be
adjusted, particularly in wells with mixed casing strings. Often changes in bond index
can simply be a result of a change in casing.
1.0
0.8
0.6
0.4
0.2
4300
11950
4350
When the transit time suddenly increases as illustrated in Figure 18.9-B, it is due to
"cycle skipping." This phenomenon occurs when E1 has become too small to detect in
the "gate" and a subsequent peak such as E3 or E5 (or sometimes even later arrivals) is
detected for amplitude and transit time purposes. When the transit time cycle skips, the
curve is no longer valid for indicating tool eccentering.
In cases of liner laps, or other situations involving casing/casing cement filled annuli, if
uncontaminated cement occupies the space, it is not uncommon to experience a "cycle
skip" as the transit time increases from the inner casing to the outer casing travel time.
As the amplitude of the E1 decreases in well-bonded casing, the transit time begins to
increase due to signal stretch. This appears as a somewhat erratic value of transit time
over the critical transit time just prior to cycle skipping.
The "Critical Transit" time, Figure 18.10, is the transit time measured at the 3-ft receiver
in uncemented casing. Figure 18.10 illustrates the cause of stretching of the transit time
curve. This type of erratic behavior should not be mistaken for tool eccentering. Both
cycle skipping and signal stretch can be an indication of excellent cement well bonded to
the casing. Due to the value of the transit time curve, it is recommended it be displayed
on all bond logs on a magnified scale.
E1 Poor Bond
Good Bond
Detection Level
Time
Transit Time
Stretch
Additional quality control parameters (beyond the transit time curve) for cement
evaluation include the repeatability of the tool and the presentation of the log. Make
certain the tool repeats itself by checking the repeat section of the log. Make certain the
log is printed "on depth" by comparing the lithology represented by the gamma ray to the
lithology represented by the sonic formation signal on the rnicroseismogram.
Log Examples 18.2 and 18.3 illustrate the response to a microannulus when the log is
run with and without pressure. In this case, 2,000 psi casing pressure was used to
expand the casing into contact with the cement sheath. Compare the two logs for the
disappearance of the casing signal and the significant change in the amplitude curves.
This is typical of a microannulus, i.e., the casing signals will disappear with sufficient
casing pressure. In the case of a channel, the casing signals will not disappear with
pressure.
In this example, there are formation arrivals, but the casing signal is a straight line and
there are chevron patterns in the microseismogram. This can indicate either a channel
or microannulus depending on a second pass under pressure.
After pressurizing up to 2,000 psi, Log Example 18.3 shows excellent coupling over the
same interval. Note the transit time curve exhibits cycle skip, again indicating excellent
coupling.
Log Example 18.2 can also illustrate an annular channel between the casing and the
cement sheath. Strong casing signals (with collar chevrons) and strong formation
signals are typical on the log. The appearance of the microseismogram will not normally
change whether casing pressure is applied or not when a channel is present. It is
emphasized an annular channel must be in contact with the casing for detection by any
cement sheath logging device. Channels existing between the cement sheath and
the borehole wall are not detectable with current bond logging tools.
"Noise" logs and/or temperature logs are generally required for identification of exterior
channels (channels between the cement sheath and the borehole wall), which assumes
that inter-zonal fluid or gas flow is occurring during the measurement. If no flow is
occurring, these measuring devices are not effective.
Log Example 18.4 is from a horizontal well that was not centralized. The log is showing
essentially free pipe, yet there are some formation arrivals on the microseismogram.
This is an indication of either, a microannulus or, the pipe lying on the low side of the
hole and no cement around the pipe. This log was run with no pressure, and there was
no subsequent pressure pass to confirm whether there was a microannulus or a severe
cement channel.
T Upper Transmitter
Lower Transmitter
T
One of the later innovations using the fluid-compensated logging technology is the
Segmented Bond Tool (SBT). Basically, the tool (Figure 18.12) consists of six pads
placed in direct contact with the casing wall that measure the 1-ft average signal
1 3 5 1 Upper
Signal Path Transmitters
Upper Receivers
1 2 3 4 5 6 Signal Attentuation Rate Measurements
Lower Receivers
2 4 6 Lower
Transmitters
Figure 18.13 illustrates the attenuation measurements (db/ft) recorded by each of the
six pads. The recommended scale range for these tracks is 0 - 10 db/ft so more
accurate values can be obtained for the lower strength cements and for better
delineation between liquids and crystalline cement in the annulus. Attenuation rates
greater than 10 db/ft indicate excellent cement and it is felt that it is not necessary to
obtain an accurate value of attenuation rate over 10 db/ft. For delineation between a
liquid and a crystalline material like cement, regardless of its compressive strength, the
"line character" will define the material. If a liquid exists against the casing at one or all
of the pads, the attenuation rate will not change. Consequently, a liquid-filled channel at
any of the pads will describe a straight line for attenuation rate except at the collars. If
cement is bonded to the casing, the density and strength of the cement changes
sufficiently that the line will not be straight. In fact, it can radically deviate from minimum
to maximum values of attenuation depending on the amount of gas contamination in the
cement sheath. Determination of the "line character" is the primary reason for the
expanded scale for the six-segmented measurements.
The log also contains a cement map that sets the color of the map based on the
amplitude from the pads. As with any cement map, the coloring is highly dependent on
how the operator has set up the computer and not the data itself.
The high frequency transmitted pulse minimizes the dissipation of the sound wave in the
borehole fluid, thus assuring direct reflection of the pulse to its source, at the same time
limiting the distance of penetration. The ultrasonic tools are heavily centralized. The
transducer used on these tools is a rotating-type transducer found at the bottom of the
tool. Since the signal is focused, the active spot on the casing is essentially the same
diameter (see Figure 18.14). The percent of casing circumference investigated will vary
A tw B
Transducer
Accurate measurements of these and subsequent signal energy levels infer prediction of
the acoustic impedance of the materials in contact at each of the reflective surfaces.
They also may be used to provide very accurate measurements of casing ID and casing
wall thickness. Since acoustic impedance is a measurable physical property, identity of
the materials at each reflective surface is also inferred.
Acoustic Impedance
Material 106 kg.m2 sec
Figure 18.16 illustrates the acoustic impedance of various density drilling muds.
18
Mud Density, lb./gal.
16
14
12
10
8
1 2 3 4
6 2
Acoustic Impedance, 10 kg/m sec
Cement Density 9 10 11 12 13 14 15 16 17
3000
2500
Compressive Strength
2000
1500
1000
500
0
1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5
Acoustic Impedance
Figure 18.17 illustrates the acoustic impedance of various density cement systems.
Note the impedance value for the cement is dependent on both the cement density and
the compressive strength of the set cement.
Comparing this chart with a conventional sonic bond log is similar to taking a single
value for cement and equating it to all cements, regardless of density or strength. As
noted in the discussion of bonding index (see Section 18.4.3), the bond index is
dependent on the expected value of the amplitude of the cement. The ultrasonic tool
and its corresponding map will also be dependent on the expected impedance of the
cement. This chart can be used to estimate that expected value. Note this chart is for
conventionally extended slurries. Use of foam or hollow beads or spheres can have a
major effect on the impedance value.
5° 6.0 3200
5° 3.0 800
5° 1.6 300
5° 0.6
The USIT* scans the entire circumference of the casing, emitting a pulse that strikes the
casing at normal incidence and causes the casing to resonate. The transducer operates
in a variable frequency range of 195 - 650 kHz. The variations of frequency are for
changes in casing wall thickness from 0.18 - 0.59 inches, and changes in the casing fluid
density, are tuned from the surface to optimize variations in downhole conditions. The
transducer excites the casing by repeatedly emitting short pulses of ultrasound. The
same transducer, acting as a receiver, detects the echoes from the casing.
Four measurements are made by analyzing the echoes:
1. Echo amplitude (an indication of casing condition)
2. Casing ID (calculated from the transit time of the pulse and echo)
3. Casing wall thickness (calculated from the resonant frequency)
4. Acoustic impedance of the material at the casing OD
The amplitude of the reflected signal is a function of the acoustic impedance of the fluid
in the casing, the casing steel, and the cement at their respective interfaces. Most of the
incident transmitted energy is reflected at the mud-casing interface, typical to the
Coefficient of Reflection previously discussed. The small fraction of the energy refracted
through the casing thickness is reflected multiple times between reflective surfaces,
releasing a transmitted pulse into the cement or mud each time the energy strikes a
reflective surface. Thus, the impulse echo consists of a large initial energy level
reflected for the casing ID, followed by an exponentially decaying series of inverted
pulses. Processing the reflected waveform involves only the initial reflection and the
very early part of the wave (immediately beyond the casing OD arrival time) to avoid
later reflections from outer casing, borehole, or formations.
The color imaging used for the presentation of the USIT is somewhat of an improvement
over the older CET Cement Map. However, color imaging can be very misleading.
Color imaging works well when a relatively large difference in acoustic impedance exists
between the materials being measured (e.g., neat cement and water). Measurement,
coloration, and interpretation become a severe problem when a gas-contaminated (or
foamed) cement exhibits an acoustic impedance value equal to or less than annular
fluids such as mud or water which, in practice, is prevalent across and above most oil
Section I Section A
Section H Section B
Section G Section C
Section F Section D
Section E
The presentation is oriented so the high side of the hole, on the presentation, is at the
intersection of Sections A and I. The low side of the hole is at Section E. See also
Figures 18.19 through 18.24.
Tool Specifications
Temperature Rating 350°F (175°C)
Pressure Rating 20,000 psi (137.9 MPa)
Tool OD 3.625 inches (92 mm)
Casing Size Range 5-1/2 - 13-/8 inches (130 - 340 mm)
(Variable Sizes of Rotating Heads)
Maximum Water Based Mud Weight: 15 lb/gal (1797.4 kg/m3)
The tool has been run in 16-lb/gal (1917.2 kg/m3) water based mud (low solids) and
16.3-lb/gal (1953.2 kg/m3) Zinc Bromide brine.
Maximum Oil Based Mud Weight: 14-lb/gal (1677.6 kg/m3).
Vertical Sampling Rate: 6 inches (152.4 mm) 13 inches (330.2
mm) 11 inches (279.4 mm)
Logging Speed, ft/min (m/min): 60 (18.3) 130 (39.65) 110 (33.55)
5 1.75
5-1/2 1.92
7 2.44
9-5/8 3.36
13-3/8 4.67
The CAST-V tool makes 100 measurements at each depth segment (1, 3, or 6-inch
samples) in each of the sections defined. (The tool also provides 40 real-time calipers
for inspecting the casing or the borehole.) From the incoming data, the computer can
select one signal, or any combination of the signals from each segment. The signals
that can be retrieved include:
1. Minimum Z (acoustic impedance)
2. Maximum Z
3. Average Z
4. Each of the 100 measurements of Z
5. Any percentage of the 100 measurements of Z desired
For the purposes of differentiating between a liquid and a solid at the casing cement
interface, the recommendation is to select the minimum and maximum acoustic
impedance curves in each of the nine (9) segments on the final log presentation (the
"Altcastave" presentation). The minimum and maximum acoustic impedance
measurements are selected by the computer from the 100 signals/segment, and
represent the lowest and highest value of acoustic impedance calculated in each
segment. The assumption is made that as long as the minimum value of acoustic
impedance illustrates a "solid" in the annulus, as opposed to a liquid, the remainder of
the segment will contain harder or denser solids. The average value is a meaningless
number representing only the average of the minimum and maximum measurements in
each segment.
The log in Figure 18.19 shows the minimum, maximum, and average acoustic
impedance for each of the nine tracks. Note that all readings are straight, low in value,
and very consistent. This is typical of a liquid-filled annulus.
The log in Figure 18.20 shows good quality cement throughout the interval. Throughout
the log the impedance values are over 5, and have pegged out the plot. The coloration
on the left shows black and brown colors, indicating the difference in the impedance
values of the material in the annulus. Regardless of the color of the cement map, this
interval is fully cemented. There are no straight lines on the impedance curve, and all
show much higher values than the mud. The "lower" impedance material may be due to
slightly contaminated cement, lower strength cement as in bypassed lead slurry, etc.
The log also shows the lower strength material circling around the casing rather than
being isolated to only one side of the pipe.
Figure 18.21 is another example of cement in the annulus. In this example, the fully
cemented annulus has more consistent material than in Figure 18.20, and is a fully
cemented interval.
Figure 18.22 is an example of well-cemented pipe, with the cement in the annulus being
very lightweight cement. There is very little difference in the density of the mud and the
cement on this well. There are no straight lines, indicating a solid in the annulus. (The
scale on this particular plot is 0-10 rather than the recommended 0-5, which makes
evaluation more difficult.)
Figure 18.23 is an example of gas cut cement. This is characterized by very low values,
lots of "movement" or wiggling of the signal, and no straight lines. The interval still has
isolation, and has cement with gas contamination.
Once cement has set in the annulus, regardless of gas contamination or compressive
strength development, it cannot be removed and replaced with (what may be
considered) "good" cement. Remedial cementing operations (squeezing) will not
change the quality or quantity of that type of cement. This can be confirmed by running
evaluation logs before and after remedial squeeze treatments.
Each track of the acoustic log should be presented on a scale of 0 - 5 (acoustic
impedance) for more definitive measurements of the weaker cements and liquids.
Greater values of acoustic impedance are academic. It is irrelevant whether the cement
in the annulus exhibits 500 psi or 5000-psi compressive strength once it is set. All that is
necessary is that the material be identified as cement.
Numerous situations exist downhole or can occur in the processing of log data that can
cause considerable confusion in interpretation of the quality and quantity of a cement
sheath.
Microannulus Size
It is quite common to displace top wiper plugs with drilling mud following the cement
placement, then displace that mud with a lower-density completion fluid prior to logging.
Sometimes, due to float failure following cement placement, it is necessary to leave the
casing shut in. To compensate for pressure change effects, it is recommended the
casing be expanded to the cement sheath for logging by placing the equivalent pressure
in the casing that was present while the cement was setting, plus a minimum of 500 psi
to compensate for the casing expansion caused by the cement's heat of hydration. Non-
pressure passes are more effective for collar depth reference for perforating, but
pressurized passes are absolutely necessary for cement evaluation. To satisfy both
requirements, it is recommended both passes be made. It is also recommended the
"Tension" curve be placed on the presentation of the pressurized pass to ascertain line
drag problems. The microannulus size may be calculated by:
(OD2 * ∆P)
r=
(E * tw)
where:
r = Microannulus size, in
OD = Casing OD, in
∆P = Pressure change, psi
E = Young's Modulus of Elasticity of Steel
tw = Wall thickness of Casing, in
0.8
Relative Eccentering
0.6 Response
0.4 +
+
0.2
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presented at the 34th Annual Technical Meeting of the Petroleum Society of CIM, Banff,
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Broding, R. A., "Application of the Sonic Volumetric Scan Log to Cement Evaluation,"
APWLA Twenty-Fifth Annual Logging Conference, June 1984.
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Cements Using the Pulse Echo Tool," Southwestern Petroleum Short Course, Lubbock,
TX, 1988.
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Engineer International, April 1991.
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Primary Cementing
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Scope
1. Books by Subject
Cement Sheath Evaluation API Technical Report 1996
10TR1, First Edition
Cementing Technology and Procedures Editions Technip, 1993
Paris
Cementing, SPE Monograph Volume 4, Henry L Dougherty Series Smith, Dwight K. Society of Petroleum 1990
Engineers,
Richardson, TX.
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Drilling Mud and Cement Slurry Rheology Manual Éditions Technip, 1982
Paris
Lost Circulation Messenger, Joseph U PennWell Publishing 1981
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Petroleum Well Construction Economides, M. J., John Wiley & Sons, 1998
Watters, L. T., and Ltd. West Sussex,
Dunn-Norman, S. England
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Recommended Practice for Performance Testing of Cementing Float Equipment API Recommended 2002 ANSI/API 10F/ISO 18165-2001
Practice 10F, Third Ed
Specification for Bow-Spring Casing Centralizers API Specification 10D, 2002 ANSI/API 10D/ISO 10427-1-2001
Sixth Edition
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Twenty-third Edition
Technical Report on Temperatures for API Cement Operating Thickening Time Tests API Report 10TR3, 1999
First Edition
Testing of Deep Water Cement Formulations ISO 10426-3-2003 2003
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Houston TX
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Bold denotes a significant information resource.
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Shallow Gas Migration Control in Southeastern Alberta and Pipchuk
The Effects of Excess Retardation on the Physical Properties of Sabins, Sutton and SPE 10221 1981 Additives
Cement Slurries Crook
The Quality of Bentonite and Its Effect on Cement Slurry Grant, Rutledge & IADC/SPE 19940 1990 Additives
Performance Gardner
Use of Liquid Cement Additives in Offshore Operations Calvert & Gandy 1986 Additives
Casing Vibration
Primary Cementing Improvement by Casing Vibration During Cooke, Gonzalez and SPE Production 1988 Casing Vibration
Cement Curing Time Broussard Engineering
The Rheological Properties of Cement Slurries: Effects of Chow, McIntire, Kunze SPE Production 1988 Casing Vibration
Vibration, Hydration Conditions and Additives and Cooke Engineering
Displacement
Tide Flow: A Low Rate Density Driven Cementing Technique for Kroken, Sjaholm and IADC/SPE 35802 1996 Displacement
Highly Deviated Wells Olsen
Environmental
Air Emissions Testing at an Oil Field Service Company Bulk Turner SPE 46835 1998 Environmental
Storage Facility
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A Comparison of Cementation Logging Tools in a Full Scale Hayman, Gai and Toma SPE 22779 1991 Evaluation
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Application of the Sonic Volumetric Scan Log to Cement Broding SPWLA 1984 Evaluation
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Assessment of Foamed Cement Slurries Using Conventional Frisch, Graham and SPE 55649 1999 Evaluation
Cement Evaluation Logs and Improved Interpretation Methods Griffith
Cement Bond Log: Determining Wait-on-Cement Time Jordan and Shepard SPE 14200 1985 Evaluation
Cement Bond Logs - A New Analysis to Improve Reliability Gai and Lockyear SPE 23729 1992 Evaluation
Cement Evaluation - Past, Present and Future Pilkington JPT 1992 Evaluation
Cement Evaluation and Casing Inspection with Advanced Graham, Silva , SPE 38651 1997 Evaluation
Ultrasonic Scanning Methods Leimkuhler and de Kock
Improved Evaluation of Neat and Light Cements Dennis and Uswak CADE/CAODC 91-04 1991 Evaluation
Investigation of Ultrasonic and Sonic Bond Tools for Detection of Griffith, Sabins and SPE 24573 1992 Evaluation
Gas Channels in Cements Harness
New Technique Provides Better Low Density Cement Evaluation Harness, Sabins and SPE 24050 1992 Evaluation
Griffith
Ultrasonic Cement Evaluation in Inhomogeneous Cements Gong and Morris SPE 24572 1992 Evaluation
Foam Cement
A Case Study of Ultra Lightweight Cementing Practices in the Edmondson and Benge SPE 12318 1983 Foam Cement
Northeastern United States
A Novel Lightweight Cement Slurry and Placement Technique for Kulkarni and Hina SPE 57449 1999 Foam Cement
Covering Weak Shale in Appalachian Basin
A Unique Experience with Foam Cement Piot, Ferriere and SPE 28820 1994 Foam Cement
Fraboulet
Advances in Metering and Control Technology Improves Judge and Benge IADC/SPE 47831 1998 Foam Cement
Design and Execution of Foamed Cement Jobs
Application of Foam Cement and the Stringent Quality Control Antonovitch. Birch and Proceedings 1983 Foam Cement
Techniques Basic to the Use of this New Oil Field Cementing Murphy Indonesian Petroleum
System Association
Application of Foam Cement in the Williston Basin Bour and Vennes SPE 18984 1989 Foam Cement
Application of Foam Cements in Alberta Olanson CIM 84-35-72 1984 Foam Cement
Applications of Foamed Portland Cement to Deep Well Conditions Bozich, Mountman and SPE 12612 1984 Foam Cement
in West Texas Harms
Automation Brings Foamed Cements Under Control Flatern Offshore 1997 Foam Cement
Calculation of Pressures for Foams in Well Completion Processes Buslov, Towler and SPE 36490 1996 Foam Cement
Amain
Cementing of Fragile Formation Wells with Foamed Cement Harms and Febus SPE 12755 1984 Foam Cement
Slurries
Cementing Through High Pressure Coiled Tubing on HTHP Khuff Mazen, Rouatbi and Zaki SPE 53244 1999 Foam Cement
Gas Well Offshore Abu Dhabi
Dynamic Characteristics of Nitrified Cements Mueller, Franklin and Southwestern 1990 Foam Cement
Daulton Petroleum Short
Course
Evaluating Neat and Foam Cements Uswak and Dennis Petroleum Engineer 1991 Foam Cement
International
Horizontal
Cementation of Horizontal Wellbores McPherson SPE 62893 2000 Horizontal
Problems in Cementing Horizontal Wells Sabins JPT 1990 Horizontal
HTHP
Cementing Steamflood and Fireflood Wells - Slurry Design Nelson and Eilers CIM 83-34-23 1983 HTHP
Evaluation and Improving Thermal Cementing Practices Chmilowski, Frankiw and CIM 84-35-115 1984 HTHP
Ford
Improved Cement Slurry Designed for Thermal EOR Wells Nelson Oil & Gas Journal 1986 HTHP
New Design Guidelines for Geothermal Cement Slurries Koons, Free and Geothermal Resources 1993 HTHP
Fredrick Council Transactions
Lab Studies
Characterization of the Initial, Transitional and Set Properties Mueller, Lacy and Go SPE 36475 1996 Lab Studies
of Oilwell Cement Boncan
Characterizing Curing Cement Slurries by Permeability, Backe, Lile, Lyomov, SPE Drilling & 1999 Lab Studies
Tensile Strength and Shrinkage Elevbakk and Skalle Completion
Laboratory Study on Oilwell Cement and Electrical Conductivity Backe, Lyomov and Lile SPE 56539 1999 Lab Studies
Removing Subjective Judgement from Wettability Analysis Heathman, Wilson, IADC/SPE 59135 2000 Lab Studies
Aids Displacement Cantrell and Gardner
Thickening Time Test Apparatus Provides Method of Simulating Purvis, Mueller, Dawson SPE 26576 1993 Lab Studies
Actual Shear History of Oilwell Cements and Bray
Liners
An Assessment of the Performance of Liner Hanger Bearings Archer, Jacobs and SPE 22572 1991 Liners
Rabia
An Expandable Slotted Tubing, Fiber Cement Wellbore Lining Setwart, Gill, Lohbeck SPE Drilling & 1997 Liners
System and Baaijens Completion
Distributed Load Liner Hanger and Method of Use Thereof Garcia US Patent 4,010,804 1977 Liners
Innovative Way to Cement a Liner Utilizing a New Inner String Fuller, Littler and Pollock SPE 39349 1998 Liners
Cementing Process
Productive Innovations for Cementing Liners in Deep Wells Valles and Gonzalez SPE 69621 2001 Liners
Rainbow Lake Liner Setting and Cementing Practices Teichrob and Saponja CADE/CAODC 93-604 1993 Liners
Rotary Liner Drilling for Depleted Reservoirs Sinor, Tyberoe, Eide and World Oil 1998 Liners
Wenande
Rotating Liner Hanger Development and Cement Garcia 1986 Liners
Improvement
Lost Circulation
Cement Surface Casing after Drilling Without Returns Long and Long World Oil 1999 Lost Circulation
Design of Special Cement Systems for Areas with Low Fracture Wieland, Calvert and SPE 2556 1969 Lost Circulation
Gradients Spangle
Light Cements Take Durability Test Lyle Hart's E&P 2001 Lost Circulation
Lost Circulation Control: Evolving Techniques and Strategies to Bruton, Ivan and Heinz SPE/IADC 67735 2001 Lost Circulation
Reduce Downhole Mud Losses
New Solutions for Subsalt Well Lost Circulation and Primary Sweatman, Faul and SPE 56499 1999 Lost Circulation
Cementing Ballew
New Solutions to Remedy Lost Circulation, Crossflows and Sweatman, Kessler and SPE/IADC 37671 1997 Lost Circulation
Underground Blowouts Hillier
Primary Cementing Across Massive Lost Circulation Zones Turki and Mankay SPE 11490 1983 Lost Circulation
Successful Squeezing of Shallow and Low - Pressure Formations Grant, White, Smith and IADC/SPE 19937 1990 Lost Circulation
Miller
Unique Crosslinking Pill in Tandem with Fracture Prediction Model Caughron, Renfrow, IADC/SPE 74518 2002 Lost Circulation
Cures Circulation Losses in Deepwater Gulf of Mexico Bruton, Ivan, Broussard,
Bratton and Standifird
Unique Ultra Light weight Cement Slurry Compositions for Use in Tanner and Harms SPE 11486 1983 Lost Circulation
Unique Well Conditions, Laboratory Evaluation and Field
Performance
Mechanical Properties
A Soil Mechanics Approach to Predict Cement Sheath Thicerelin, Baumgarte SPE/ISRM 47375 1998 Mechanical Properties
Behavior and Guillot
Cement Design Based on Cement Mechanical Response Thicerlin, Dargaud, Baret SPE 38598 1997 Mechanical Properties
and Rodriguez
Mechanics
A Proven Technique for Economic, In Place Casing Lining and King, Vloedman, Ford SPE 38758 1997 Mechanics
Repair and Westermark
An Extraordinary Drilling Challenge in the Anadarko Basin Koenig SPE 22575 1991 Mechanics
Application of Very Heavy Mud and Cement in a Wildcat Ezzat, Jennings, Al- SPE 62802 2000 Mechanics
Abdulgader and Al-
Hammad
Buoyancy Assist Extends Casing Reach in Horizontal Wells Rogers, Bolado and SPE 50680 1998 Mechanics
Sullaway
Casing Shear: Causes, Cases, Cures Dusseault, Bruno and SPE Drilling & 2001 Mechanics
Barrera Completion
Critical Mixing Parameters for Good Control of Cement Slurry Vidik JPT 1990 Mechanics
Quality
Development of an Open Hole Sidetracking System Stokley and Seale IADC/SPE 59201 2000 Mechanics
Drilling and Production of Kuhff Gas Wells, Saudi Arabia Turki SPE/IADC 21975 1991 Mechanics
Effect of Mixing Energy Levels During Batch Mixing of Cement Hibbert, Kellingray and SPE Drilling & 1995 Mechanics
Slurries Cidik Completion
Expandable Liner Hanger Provides Cost-Effective Alternative Loheofer, Martins, IADC/SPE 59151 2000 Mechanics
Solution Brisco, Weddell, Ring
and York
Mud Displacement
A New Method of Evaluating the Filter Cake Removal Efficiency Miranda, Leite, Lopes SPE 74502 2002 Mud Displacement
and Oliveira
A Quantitative Investigation of the Laminar-to-Turbulent Brand, Peixinho and SPE 71375 2001 Mud Displacement
Transition: Application to Effect Mud Cleaning Nouar
All Purpose Cement-Mud Spacer Beirute SPE 5691 1976 Mud Displacement
An Evaluation of a Primary Cementing Technique Using Low Parker, Ladd, Ross and SPE 1234 1965 Mud Displacement
Displacement Rates Wahl
Cement Spacer Fluid Solids Settling Carney JPT 1974 Mud Displacement
Cement Spacer Fluid Solids Settling Moran and Lindstrom SPE 19936 1990 Mud Displacement
Design Rules and Associated Spacer Properties for Optimal Mud Couturler, Guillot, SPE 21594 1990 Mud Displacement
Removal in Eccentric annuli Hendriks and Callet
Field Data Demonstrate Improved Mud Removal Techniques Kelessidis, Guillot, SPE 26982 1996 Mud Displacement
Lead to Successful Cement Jobs Rafferty, Borriello and
Merlo
Field Study of Offshore Field Spacer Mixing Benge SPE 19864 1990 Mud Displacement
Improved Primary Cement Jobs Through the Use of Unique Schumaker, Bell, SPE 36486 1996 Mud Displacement
Spacer Design Technology: Gulf of Mexico Case History Study Morrison, Chan and
Wydrinski
Improving Cement Bond in the Rocky Mountain Area by the use Waremburg, Kirksey and SPE 9031 1980 Mud Displacement
of Spacer, Wash and Thixotropic Cement Bannister
Other
An Investigation of Factors Contributing to the Deposition of Sabins, Smith, IADC/SPE 19934 1990 Other
Cement Sheaths in Casing Under Highly Deviated Well Broussard, Talbot and
Conditions Olaussen
Case Histories and Laboratory Studies of Cement Sheath Griffith and Osisanya SPE 29476 1995 Other
Deposition Inside Casing Strings
Plug
Issues and Techniques of Plugging and Abandonment of Oil and Calvert and Smith SPE 28349 1994 Plug
Gas Wells
Novel Technique for Open Hole Abandonment Saves Rig Time - Chong, Butterfield and SPE 64481 2000 Plug
A Case History Conwell
Stress Failure
Cement Sheath Stress Failure Goodwin and Crook SPE Drilling 1992 Stress Failure SPE 20453, 1990
Engineering
Field-Scale and Wellbore Modeling of Compaction Induced Hilbert, Gwinn, Moroney SPE Drilling & 1999 Stress Failure
Casing Failures and Deitrick Completion
Stresses
Burst-Induced Stresses in Cemented Wellbores Fleckenstein, Eustes SPE Drilling & 2001 Stresses
and Miller Completion
Evaluation of Collapse Strength of Cemented Pipe in Pipe Casing Marx and El-Sayed SPE/IADC 13432 1985 Stresses
Strings
Laboratory Tests on Collapse Resistance of Cemented Casing Evans and Harriman SPE 4088 1972 Stresses
Temperature
A Cementing Temperature Simulator to Improve Field Practice Guillot, Boisnault and SPE/IADC 25696 1993 Temperature
Hejeux
A Circulating and Shut In Well - Temperature Profile Simulator Beirute JPT 1991 Temperature Also SPE 17591,
1988
A Joint Industry Project to Assess Circulating Temperatures in Ward, Granberry, SPE 71364 2001 Temperature
Deepwater Wells Campos, Rausis, Sledz,
Weber, Guillot, Nazri
and Romero
A Theory Relating High Temperature and Overpressures Lewis and Rose JPT 1990 Temperature
A Two - Dimensional Simulator to Predict Circulating Bittleston SPE 20448 1990 Temperature
Temperatures During Cementing Operations
Foamed Cement for Shallow Water Flows Reddy, Griffith, Faul, Offshore 1998 Water Flow
Fitzgerald and Waugh
Guidelines for Cementing Deepwater Conductor Strings Griffith Offshore 1995 Water Flow
How One of the Biggest Fields in the US Gulf Almost Got Away Furlow Offshore 1999 Water Flow
Identification of "Flowing Water Sand" Drilling Hazards in the Byrd, Schneider, OTC 7971 1996 Water Flow
Deepwater Gulf of Mexico Reynolds, Alberty and
Hafle
Industry Zeroes in on Shallow Water Flow Problems/Solutions Snyder Deepwater Technology 1997 Water Flow
Mechanisms of Shallow Waterflows and Drilling Practices for Alberty, Hafle, Mingle SPE Drilling & 1999 Water Flow
Intervention and Byrd Completion
Mud Management, Special Slurries Improve Deepwater Griffith and Faul Oil & Gas Journal 1997 Water Flow
Cementing Operations
Panel Urges More SWF Detection, Pre Drill Planning Furlow Offshore 1999 Water Flow
Redefining the Static Gel Strength Requirements for Cements Mueller OTC 14282 2002 Water Flow
Employed in SWF Mitigation
Seismic Interpretation, Identification of Shallow Water Flow McConnell and Offshore 2000 Water Flow
Potential Campbell
Shallow Water Flow Database Energy Research Clearing House 1999 Water Flow
Primary Cementing
Glossary of Terms
Scope
This Section covers the terms used for the Primary Cementing Manual.
Absolute Volume The volume per unit mass, reciprocal of absolute density.
This is the volume of a material with no air.
Annular Gap The distance from the outer pipe to the inner surface of
either the formation or the previous casing string.
Automatic Density A field mixing system that utilized computer control to help
Control (ADC) maintain cement density and slurry rate.
Blow Dry When nitrogen gas blows out of a fluid loss test sample.
No additional filtrate is obtained from the sample.
Bulk Loading Factor A factor applied to the volume of cement to account for
entrained air in a bulk system.
Bulk Volume The total volume of solids and air. The bulk volume of a
sack (94 lbs) of cement is one cubic foot.
Carbon Dioxide Gas The same gas found in carbonated drinks. When in the
(CO2) presence of water will convert Portland Cement to calcium
carbonate.
Cement Class API designation for A through H cements that meet the
requirements of API Specification 10A.
Diesel Oil Bentonite, 2 A lost circulation formulation and technique for dealing
Cement (DOB2C) with severe lost circulation problems in wells drilled with
water-based mud systems. The system consists of one
sack of bentonite blended with two sacks of cement in a
diesel or oil carrying fluid.
Filtrate The fluid forced out of a cement sample in a fluid loss test.
The filtrate will contain only water and soluble additives,
but no cement particles.
Free Water Fluid that has separated from cement when left quiescent
for a period of two hours, and is normally expressed as a
percentage.
Gas Invasion Formation gas entering the matrix of the cement, but that
does not move up the wellbore. Gas invasion does not
usually result in well problems.
High Temperature High Term applied to particular wells or projects that have
Pressure (HTHP) temperatures and pressures exceeding some
predetermined number. There is no standard point above
which a well is deemed HTHP. It will vary with operator.
Hydrogen Sulfide (H2S) A poisonous gas that forms an acidic solution when
dissolved in water. Normally it is not a problem for
cementing, as H2S will not react with Portland Cement in a
dry environment.
Job Time Job time is the amount of time required to mix and pump
all of the cement, plus the time to displace the cement into
the well. Estimation of job time requires assuming a
particular mixing rate as well as a displacement rate.
Landing Collar A plate placed in the casing string that allows plugs to
land. Unlike a float collar, there are no valves associated
with a landing collar. Its purpose is only to provide a
landing point for plugs, darts or balls.
Lead Cement Slurry The first slurry pumped in a well that typically is lighter
weight and has a longer thickening time.
Liner Any string of casing whose top is below the top of the well.
Liner Overlap The distance from the top of the liner down to the
previously set casing string. This area will have a pipe x
pipe annulus.
Liner Top Packer A device that is set at the top of a liner following a cement
job to provide an additional mechanical seal in the
wellbore. A liner top packer can be either integral to the
liner, thus is set immediately following the cement job, or a
two trip system where the packer is run and set at a later
date.
Portland Cement The most common form of cement; also called hydraulic
cement.
Pressure Up Rate On a thickening time test, the rate at which the slurry is
taken from atmospheric pressure to the test pressure.
Rheology The study of fluid flow. For cement slurries, the rheology
is normally measured on a rotating sleeve viscometer.
Silicate extenders Materials that tie up water by a reaction with calcium and
silicate to form a gel.
Standard Cubic Foot The volume of one mole of gas at standard temperature
(SCF) and pressure (20°C and one atmosphere of pressure).
Time to Bottom The amount to time required to displace the first sack of
cement to the bottom of the casing string. The time to
bottom is calculated by taking the total displacement
volume and dividing by the anticipated pump rate.
Transition Time The amount of time for a cement slurry to go from 100 to
500 pounds per 100 square feet gel strength when
measured at a shear rate of less than 0.005 sec-1. The
transition time can not be measured on a consistometer or
conventional rheometer.
Waiting on cement time The time required for cement to gain adequate strength to
(WOC) continue operations.
Wash A thin fluid, usually water or base oil that has additional
surfactants to help with mud removal.
Zero Gel Time The time required for a cement slurry to get to 100 pounds
per 100 square feet gel strength when measured on the
same device as the transition time. This is the starting
point for the transition time measurement.
Primary Cementing
Subject Index
job time
calculating, see Sections 10.4, 10.4.6, 16.2.4.3
safety factors, see Section 10.4.8