SPE-187700-MS

Optimum Practices to Mitigate Gas Migration Problems in Deep Gas Wells

Abdullah Al-Yami, Tushar S. Mukherjee, Arris Riskiawan, and Vikrant Wagle, Saudi ARAMCO

Copyright 2017, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE Russian Petroleum Technology Conference held in Moscow, Russia, 16-18 October 2017.

This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents
of the paper have not been reviewed by the Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessarily reflect
any position of the Society of Petroleum Engineers, its officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written
consent of the Society of Petroleum Engineers is prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300 words; illustrations may
not be copied. The abstract must contain conspicuous acknowledgment of SPE copyright.

Abstract
Gas Migration through cement columns has been an industry problem for many years. The most problematic
areas for gas migrations occur in deep gas wells. To control gas migration, cementing practices should
be optimized. The cementing practices include cement composition, drilling fluids composition, spacer
composition and operations such as pumping procedure and pressure testing.
Gas migration can occur due to settling in high-density cement slurries. Cement densities required to
successfully cement the zone could be as high as 170 pcf (Pounds per Cubic Foot). As cement slurry sets,
hydrostatic pressure is reduced on the formation. During this transition, gases can travel up through the
cement column resulting in gas being present at the surface.
Gas migration problems can also occur due to poor displacement. Spacers, cements and drilling fluids
should be designed and tested for compatibility for good displacements and bonding. Different types of
spacer is required for each type of drilling fluid such as salted drilling fluid or oil based fluids. Testing
should include running rheology tests, thickening time tests and compressive strength development tests.
Cement shrinkage is another factor that can cause gas migration problems. Expansion additives are
usually added to overcome this problem. However, attention should be made to optimize the concentration
and type used to avoid over expansion behavior that can cause micro cracks in the cement matrix. Different
cycling effect in temperature and pressure can cause gas migration channels due to creation of micro cracks.
This paper highlights some of the effort to prevent casing/casing pressure leaks from deep gas wells.

Introduction
We use cementing to:

• Isolate zones by preventing fluid migration between formations

• Support and bond casings

• Protect casing from corrosive environments

• Seal and hold back formation pressures

• Protect casing from drilling operations such as shock loads

2 SPE-187700-MS

• Seal loss circulation zones

• El-Marsafawi et al. (2006) discussed that throughout the life of the well, the cement integrity
experience different challenges due to:
• Opening windows for multilateral wells

• Temperature increase in production phase

• Pressure increase due to gas production

• Changing of mud weight after drilling to a lighter weight or switching to lower densities completion
fluids.
• Changing of mud weight during drilling different formations

• Stimulation treatment such as fracturing operations or aggressive matrix acids, Nasr-El-Din et al.
(2007).
• Formation loading if applicable such as creep, compaction, faulting.

Another challenge that can affect wellbore integrity is the long time waiting for cement on TOL (top
of liner). Cement slurries with conventional retarders achieved good thickening time target of 6-8 hours
but not adequate compressive strength development especially at TOL conditions. Al-Yami et al. (2007 &
2015) have developed and deployed retarder combinations that solved this problem.
In multistage cementing, the DV can fail resulting in remedial operations such as perforations and squeeze
or secondary cementing jobs. The weakest point in the casing is the conventional low-pressure stage tools,
which might affect completely wellbore integrity, Al-Yami et al. 2007.
Conventional multistage tools are not high-pressure barriers. They are only used to support cement
placement to minimize hydrostatic pressure or to cement in loss circulation zones. However, the
conventional multistage tools cannot isolate high-pressure formations.
Cementing in narrow mud window is also challenging, we could induce losses while cementing. One
way to avoid that is drill wells utilizing MPD. For wells, drilled using managed pressure operations it is also
recommend to apply managed pressure cementing when possible. Siddiqi et al. (2016) detailed the proper
steps of applying managed pressure cementing.
It is not possible to set a general guideline for range of the concentration of additives required for the
cementing job. Field and lab experience are required for cementing specialists to help drilling engineers
when designing cement slurries, Al-Yami et al. 2010. The objective of this paper is to set cementing best
practices for deep gas wells.

Cementing Additives Background

We use different chemicals or additives when we design cement formulations for example:

• Retarders

• Fluid loss additives

• Dispersants

• Gas migration additives (latex)

• Expansion additives

• Hematite

• Manganese Tetroxide
SPE-187700-MS 3

Retarders function is to retard, or delay the setting of cement slurries to be safely pumped downhole. The
hydration process of C3S increases as temperature increase, hence, reducing setting time, Bensted (1991).
Retarders with hydroxycarboxylic acid group can chelate metal cation such as Ca2+ to increase the setting
time. However, this type of retarders can cause over-retardation for temperature lower than 220 °F. For
higher than 220°F, it is an optimum practice to use blends of the various retarder compounds, for example, a
blend of a lignin amine and a sodium organic salt. This combination affect Ca2+ ions and increase the setting
time. For temperature range of 300 - 350°F, secondary retarders such as lignosulphonate and a gluconate (a
hydroxycarboxylic acid salt) can be used to enhance the efficiency of primary retarders such as blend of a
lignin amine and a sodium organic salt. We could also have inorganic compounds as retarders. Examples
are salt, zinc oxide, borax, boric, phosphoric, and chromic and hydrofluoric salts and acids, and lead oxide.
For temperature, more than 350 up to 600 °F, retarder systems of Borax or Sodium tetra decahydrate are
used to increase the setting time of cement slurries.
Accelerators are used to reduce setting time of cement slurries. We need short thickening or setting time
for conductor pipes or at low temperature. Pure CaCl2 (77%) in concentrations from 1 to 4%BWOC is used.
In addition to that, Sodium chloride is an excellent accelerator at concentrations up to 10% BWOW.
Bentonite is used as extender to reduce density of cement down to 101 pcf. Bentonite can be used to keep
the excess water from separation from the cement slurry. Treated bentonite (with added polymers) are not
recommended to be used with cement since they can alter the performance of other additives such as fluid
loss or retarders. Sodium silicate are also good cement extenders. They produce viscous gel, which allow
more water addition, Stavland et al. (2011) and Al-Yami et al. (2014). To reduce cement slurries densities,
hollow glass spheres can also be a good option. Alternative low-density cement were designed and tested
to eliminate multistage tools when possible at shallow and deep conditions, Al-Yami et al. (2007, 2008 &
2010). Low density cement utilizing hollow glass spheres were designed and tested at different conditions
to see the effect of pH and hydrostatic pressure crushing, Al-Yami et al. 2015 and Alawami et al. 2015. In
addition, the hollow glass spheres were tested under pressure and mechanical crushing to see its suitability
for drilling fluids applications as well, Albahrani et al. 2017.
Silica sand or silica flour are used to prevent strength retrogression in cement up to 40% BOWC. Strength
retrogression is know as increase in permeability and shrinkage when cementing above about 230 °F. At
high temperature, a denser phase is produced in the cement matrix, causing the strength retrogression, Al-
Yami (2015) and Nelson (1990).
To reduce friction pressure while pumping and placing cement downhole, we used cement dispersants.
Any products with anionic groups such as synthetic sulfonated polymers, lignosulfonates with carboxylate
groups, organic acids, and hydroxylated sugars can work as dispersants.
Fluid loss additives are used in cementing slurries to maintain rheology and fluid within the cement. If
we have un-controlled fluid loss we might end up with formation fluids entering the cement slurries, we
could have the following types of fluid loss additives; non-ionic cellulose-derivate such as HEC, non-ionic
synthetic polymers such as PVA or PEI, or anionic synthetic polymers such as AMPS-copolymers, Al-Yami
(2015) and Stiles (1997).
Expansion additives are always recommended to use to enhance bonding between casing and cement and
formation. Some expansion additives used for high temperature such as calcinated MgO that produce good
bonding. However, at lower temperature (below than 140 °F) we need to use lower temperature expansion
additives, otherwise the expansion will be too slow and this might affect the logs’ results if logging was
done after cementing immediately. For optimum logging results, logging time should be done after 30 days
approximately. Other expansion additives are reactive metal powders such as Zn, Al, Fe and Mg. This type
of expansion additives can react with alkalis in the slurry to produce small hydrogen gas bubbles.
Weighting materials are also added to cement to achieve the targeted hydrostatic pressure during cement
placement. Additives such as hematite, barite, and Manganese tetroxide (Mn3O4) are typically used in
4 SPE-187700-MS

cementing operations. Al-Yami et al. 2016 has used an innovative formulation combining Mn3O4 and
hematite and other additives to produce a tight cement to prevent gas migration problems in deep gas wells.

Recommended Specifications for Cement Formulations to Prevent Casing-

to-Casing Annular Pressure in Gas Wells
Fluids (Gas/Water) can create flow channel through un-displaced drilling fluid over time. Drilling fluid
properties change with time.
Cement formulations need to prevent fluid (gas/water) after placement and before cement sets. Recording
mud weights and flows help finalize cement formulation in terms of selecting proper cement density and
chemicals (latex, fluid loss, expansion additive).
Cement formulations need to withstand the wellbore stresses from pressure and temperature cycles. We
need to calculate and model the stresses in casing and cement from pressure and temperature cycles to
determine required material properties of cement (Elastic Modulus, Poisson Ratio, etc.) and design the
formulation accordingly. Earlier studies by Al-Yami et al. 2012 and Yuan et al. 2012 utilizing finite element
method on three different cement densities (72 pcf to 118 pcf) at the variation of bottom hole pressure,
temperature, casing, and cement found out that pressure variation has more effect on wellbore stability than
temperature variation.
Increasing elasticity/ductility of cement will help reduce potential also for micro-annulus formation.
Expansion additives need to be added and designed to expand at the right time.
Cement formulations with improved long-term hydraulic isolation should have the following
characteristics:

• Reduced bulk and chemical shrinkage of cement; during and after setting of the cement

• Increase compressibility of slurry (solid additives or gas)

• No free water / No solids settling or sedimentation

• Low matrix permeability – initial and long-term

• Increased ductility and elasticity (less brittle)

• Anti-gas migration formulations required for gas wells

• Density range: 125 to 160 pcf (16.7 to 21.4 lb./gal)

• Temperature range: 300 F (BHST)/ 275 F (BHCT)

• Total Shrinkage < 2% (as low as possible – prior to any expansion)

• API Fluid Loss: < 50 mL/30 minute (at 300 F, 1000 psi)

• Free water: Zero

• Suspension Stability: < 5 pcf (0.66 lb/gal) between top and bottom samples in API Sedimentation
Test
• Silica content: > 35% by weight of cement

• Weight Agent: ‘as required’ for density and slurry rheology control/optimization

• Critical Gel Strength Development Period: < 45 minutes

∘ Start of gel strength transition may be delayed – but less than 45 minutes after departure from
base line.

• Material Properties: (Measured after 28 days at 300 F)

SPE-187700-MS 5

∘ Elastic (Young's) Modulus: > 650,000 and < 850,000 psi

∘ Poisson Ratio: > 0.2
∘ Minimum Compressive Strength: 1500 psi

Cement qualities of different wells were investigated utilizing logging. The higher the logging score, the
better the wellbore isolation quality.
Adding latex to cement formulations resulted improved quality, Table 1.

Table 1—Effect of Latex on logging

Well Score

Latex;118 pcf-125 pcf 7

Latex;118 pcf-125 pcf 9

Latex;118 pcf-125 pcf 8

Latex;118 pcf-125 pcf 7

Latex;118 pcf-125 pcf 3

Latex;118 pcf-125 pcf 5

Non-Latex-;118 pcf-125 pcf 6

Non-Latex-;118 pcf-125 pcf 7

Non-Latex-;118 pcf-125 pcf 6

Non-Latex-;118 pcf-125 pcf 6

Cement slurries with higher density (125 pcf - 127pcf) used in second stage cementing showed improved
quality compared to second stage cemented with 118 pcf slurries. However, high densities than 125 pcf did
not show that improved qualities, Table 2. The reason might be that in higher densities cements we need
to utilize higher concentration of expansion additive.

Table 2—Effect of density on logging

Wells/Section Score

125 pcf-127 pcf 8

125 pcf-127 pcf 8

118 pcf 7

125 pcf-127 pcf 7

118 pcf 7

140 pcf and higher 7

125 pcf-127 pcf 6

118 pcf 6

118 pcf 6

140 pcf and higher 6

140 pcf and higher 5

140 pcf and higher 5

140 pcf and higher 5

118 pcf 3
6 SPE-187700-MS

Most of the cement slurries have shown good SGS transition time that indicate no clear correlation
between SGS and cement quality. Additional volume of cement of 150 bbl of 125 pcf to first stage showed
good logging results. No clear correlation was established when maximizing density difference between
cement and drilling fluid on logging, Table 3. An obvious reason is that we need to be more focused on the
pressure drop across cement and casing and this require accurate formation pressure information. Another
paper will discuss this in details where modeling will show the effect of reducing drilling fluids’ densities
on cementing performance.

Table 3—Effect of differences between drilling fluids density and cement density on logging

Score Difference between mud and cement density (pcf)

9 22

8 10

8 10

7 11

7 15

7 21

7 21

7 25

7 14

7 12

6 23

6 18

6 18

6 21

6 12

6 10

6 15

5 11

5 10

5 15

4 25

3 16

Increasing the time interval between cementing and logging improve the logging results, Tables 4 & 5.
The reason behind that is the delay expansion. Usually expansion continues after cementing up to few weeks.
High-density cement did not show such improvement in logging, which indicates the need to increase the
concentration of expansion additive beyond normal densities.
SPE-187700-MS 7

Table 4—Effect of Logging Interval in Normal cement (no weighting agent)

Score Interval between cement job and logging (days)

9 30

8 15

8 15

8 19

7 30

7 10

7 10

7 6

7 6

6 7

6 6

6 13

6 6

4 13

3 7

3 19

Table 5—Effect of Logging Interval in high density cements (with weighting agent)

Score Interval between cement job and logging (days)

7 6

7 22

6 22

6 29

6 10

5 6

5 29

5 10

Differences in drilling fluids’ densities used during cementing and drilling fluids’ densities used during
logging do not show agreed correlation from logging, Table 6.

Table 6—Effect from Difference between drilling fluid density and logging fluid density on logging

Score Difference between mud and logging fluid density (pcf)

9 24

8 26

8 26

8 6

7 34

7 24
8 SPE-187700-MS

Score Difference between mud and logging fluid density (pcf)

7 29

7 29

7 28

7 15

7 68

6 17

6 28

6 5

6 15

6 68

6 80

6 35

5 34

5 80

5 35

4 5

3 17

3 6

Based on the above and other information/experience, the following cementing practices were achieved:

• Adding latex to 1st and 2nd stage tails for normal densities (less than 140 pcf)

• Adding latex to 1st and 2nd stage completely for high densities

• Adding more slurry volume

• Using 125 pcf instead of 118 pcf

• Optimizing centralizer placement aiming to achieve 70% or more casing standoff.

• Introducing high performance cements to meet the recommended specifications to prevent casing
annular pressures in gas wells.
The appendix of this paper has some examples of cementing best practices. New packers were developed
to withstand high pressure up to 10,000 psi, Al-Yami et al. 2017.
The high performance cements were also introduced in the past 2 years resulting in great reduction of
casing-casing annulus pressure leaks. The following section, highlight some of these systems

High Performance Cements

Gas Prevent Cement. A new system was designed to prevent gas migration issues in wells requiring high
densities’ cementing. A gas migration equipment was utilized to test many different formulations, chemicals
and different types of cements. The testing conditions were 350 °F and differential pressure of 2,000 psi
during the test.
The test interval takes about 5 hours just to be able to cleanout the equipment after the test; otherwise,
typically the test should remain for much longer time, Al-Yami et al. 2014. The formulation is a combination
of hematite, expansion additive, silica sand, silica flour, and manganese tetroxide at certain ratio for optimum
SPE-187700-MS 9

performance, Al-Yami et al. (2009 & 2016). Manganese Tetroxide was used with hematite in cement to
design cement plugs for side tracking operations, Al-Yami et al. 2006.
Epoxy Resin Based Cements. A another solution has recently been implemented that features a
combination of heavy-weight cement blends greater than 21 ppg and Epoxy resin to enhance shear bond
and prevent CCA pressure, Al-Yami et al. 2017.
Epoxy resin were also utilized in formulating cement designs for lower densities of 118 and 125 pcf
which will be discussed also in details in another SPE paper.
Durable Cement. Al-Yami et al. 2017 discuss a case study where a fit-for-purpose durable cement system
was designed to meet the required mechanical properties as suggested by the stress modeling performed. It
was placed as a Tail slurry on the 9 5/8" Tieback casing to provide 1000 ft. of long-term hydraulic isolation
in the cased annulus should the liner top packer fail to seal the high-pressure water formation below.
A post-job analysis using job data and cement evaluation logs showed that placement was executed as per
design and that the durable cement system provided excellent bonding and annular coverage. The well was
later drilled to total depth, completed, and delivered to production without CCA pressure at the wellhead.
The new approach consists of performing finite elements stress modeling during the well planning phase
to custom design cement systems that will withstand the anticipated loads that the well will experience
during its life.
Self-Healing Durable Cement. This new cement was developed utilizing novel components that results in
a cement with a reduced Young's Modulus. Lower Young's Modulus would make the cement more elastic
in order to resist pressure and temperature cycling, absorb applied stresses and prevent cement cracks.
The developed Self-Healing Durable Cement also provides an additional benefit to mechanical properties
enhancement, which is swelling and sealing capacity when contacted by hydrocarbon fluids. In case we
have cracks in cement, this will be a path for the fluid to trigger the swelling and self-healing mechanism.
Mechanical properties testing was performed for cement samples after 10, 20 and 30 days curing at
representative targeted field conditions. Single stage triaxial tests were performed on dry cement core plugs
to measure static and dynamic properties through ultrasonic and shear velocities. These properties were
determined at confining pressures and included the Young's modulus, the Poisson's Ratio, and Peak Strength.
Offset wells cemented with conventional formulations have shown CCA pressure with slight oil flows.
The developed Self-Healing Durable Cement was applied for 13 3/8" casing covering oil-bearing zones.
The deployment were successful since negative testing and temperature and pressure cycling did not result
in any CCA pressure. Good cementing performance is always measured by having zero psi casing/casing
annulus pressure.

Conclusion
In this paper, best practices to improve wellbore isolation are included. The following list provides few
examples:

• Adding latex to 1st and 2nd stage tails for normal densities (less than 140 pcf)

• Adding latex to 1st and 2nd stage completely for high densities

• Adding more slurry volume

• Using 125 pcf instead of 118 pcf

• Developing and deploying high performance cements

• Introducing high pressure DVs for gas wells

• Using simulation package

10 SPE-187700-MS

• Optimizing spacer fluids

• Optimizing drilling fluids

• Optimizing centralization

• Introducing QAQC program for all chemicals used

• Providing detailed instructions for cementing operations

• Providing detailed contingency plans and proposed remedial operations as required

Abbreviations
API : American Petroleum Institute
BBl : Barrel
Bc : Bearden consistency
BHCT : Bottom Hole Circulating Temperature, °F
BHLT : Bottom Hole Logging Temperature, °F
BHST : Bottom Hole Static Temperature, °F
BHT : Bottom Hole Temprature, °F
BP : British Petroleum
BV : Bulk Volume, inch3
BWOC : By Weight of Cement
BWOW : By Weight of Water
CBL : Cement Bond Logging Tool
CCA : Casing Casing Annulus
CE : Cementing Engineer
DE : Drilling Engineer
DP : Differential Pressure, psig
DP : Drill Pipe
DV : Diverter Valve
ECD : Equivalent-Circulating Density, lb. /gal
GPS : Gallon Per Sack
HT/HP : High Temperature/High Pressure
ID : Inside Diameter, inch
LB : Pounds
LCM : Lost Circulation Material
MPD : Managed Pressure Drilling
MPC : Managed Pressure Cementing
MW : Mud weight
OD : Outside Diameter, inch
POH : Pull-out of hole
PPG : Pound Per Gallon
PV : Plastic Viscosity, cp
PVA : Polyvinyl Alcohol
QA : Quality Assurance
QC : Quality Control
RIH : Run In-Hole
RP : Recommended Practices
SGS : Static Gel Strength
SPE-187700-MS 11

TD : Total Depth, ft.

TDS : Total Dissolved solids, mg/l
TOC : Top of Cement
TOL : Top of Liner
UCA : Ultrasonic Cement Analyzer
USIT : Ultrasonc Imager Tool
VDL : Variable Density Log
WOC : Waiting on Cement
YP : Yield Point, lb. /100 ft.

SI Metric Conversion Factors

in. : Inch
m : Meter
F : Fahrenheit
C : Celcius
Ft : Feet
Gal : Gallon
m3 : Cubic meter
kg : Kilogram
lbm : Pound-mass
pcf : Pound per cubic foot
Psi : Pound per square inch
MPa : Megapascals
S.G : Specific gravity
bbl. : Barrel

in. × 2.54* E−02 =m

(°F-32) /1.8* E+00 = °C
Ft × 3.048* E−01 =m
Gal × 3.785 412 E−03 = m3
lbm × 4.535 924 E−01 = kg
Psi × 6.894 757 E-03 = MPa
lbm/gal × 1.198 26 E-01 = S.G
bbl. × 1.58987 E-01 = m3
* Conversion factor is exact.

References
Alawami, M., Al-Yami, A., and Wagle, V. "Investigation of the Stability of Hollow Glass Spheres in Drilling Fluids in
Diverse pH Environments and Assessment of Potential Field Applications in Saudi Arabia". Presented at the 2015
SPE North Africa Technical Conference and Exhibition, Cairo, Egypt, 14—16 September. SPE-175737-MS.
AlBahrani, H.I., Wagle, V., Al-Yami, A.S.: "An overview of Experimental Studies Examining the Reliability of Hollow
Glass Spheres as a Density Reduction Agent in Oil Field Applications," paper SPE 183681 presented at the 2017
Middle East Oil & Gas Show and Conference held in Manama, Kingdom of Bahrain, March 6-9.
12 SPE-187700-MS

Al-Yami, A.S., Jennings, S.S., Nasr-El-Din, H.A., Khafaji, A. & Al-Humaidi, A.: "A New Cement Developed for High-
Temprature Sidetracks," paper SPE 102596 presented at the 2006 Annual Technical Conference and Exhibition held
in San Antonio, Texas, U.S.A, September 24-27.
Al-Yami, A.S., Nasr-El-Din, H.A., Al-Saleh, S.H., Al-Humaidi, A., Miller, C., Al-Yami, H., El-Marsafawi, Y.: "Long-
Term Evaluation of Low-Density Cement: Laboratory Studies and Field Application," paper SPE 105340 presented at
the 2007 15th Middle East Oil & Gas Show and Conference held in Bahrain International Exhibition Center, Kingdom
of Bahrain, March 11-14.
Al-Yami, A.S., Al-Arfaj, M.K., Nasr-El-Din, H.A., Jennings, S., Al-Khafaji, A., Al-Ariani, M., and Al-Humaidi, A.
"Development of New Retarder Systems To Mitigate Differential Cement Setting in Long Deep Liners," paper SPE/
IADC 107538 presented at the 2007 Middle East Drilling Technology Conference &Exhibition held in Cairo, Egypt,
October 22-24.
Al-Yami, A.S., Nasr-El-Din, H.A., Al-Saleh, S.H., Al-Humaidi, A., Al-Arfaj, M.K., and Al-Shehri, D.A.: "An Innovative
Approach for Long Term Zonal Isolation in HT/HP Gas Wells," paper SPE 109075 presented at the 2007 Asia Pacific
Oil & Gas Conference and Exhibition held in Jakarta, Indonesia, 30 October- 1 November.
Al-Yami, A.S., Nasr-El-Din, H.A., Al-Arfaj, M.K., Al-Saleh, S.H., Al-Humaidi, A.S., Al-Shuker, N.A.: "Long-Term
Evaluation of Low-Density Cement, Based on Hollow Glass Microspheres, Aids in Providing Effective Zonal Isolation
in HP/HT Wells: Laboratory Studies and Field Applications," paper SPE 113138 presented at the 2008 Western
Regional and Pacific Section AAPG Joint Meeting Held in Bakersfield, California, U.S.A., 31 March-2 April 2008.
Al-Yami, A.S., Nasr-El-Din, H.A, Al-Humaidi, A.: "An Innovative Cement Formula to Prevent Gas Migration Problems
in HT/HP Wells," paper SPE 120885 presented at the 2009 International Symposium on Oilfield Chemistry held in
The Woodlands, Texas, USA, April 20-22.
Al-Yami, A.S., Nasr-El-Din, H.A., Al-Humaidi, A.S., Al-Saleh, S.H., and Al-Arfaj, M.K. "Evaluation and Optimization of
Low-Density Cement: Laboratory Studies and Field Application," March 2010 SPE Drilling and Completion, 70–89.
Al-Yami, A.S., Schubert, J., Medina-Cetina, Z., Yu, O.: "Drilling Expert System for the Optimal Design and Execution
of Successful Cementing Practices," paper IADC/SPE 135183 presented at the 2010 Asia Pacific Drilling Technology
Conference and Exhibition held in Ho Chi Minh City, Vietnam, November 1-3.
Al-Yami, A.S., Yuan, Z., Schubert, J.: "Failure Probability with Time Under Different Operational Conditions for Low-
Density System Based on Hollow Microspheres Supported by Long Term Lab Studies and Field Cases," paper SPE
159141 presented at the 2012 Asia Pacific Oil and Gas Conference and Exhibition held in Perth, Australia, October
22-24.
Al-Yami, A., Wagle, W., Nasr-El-Din, H., and Al-Humaidi, A.: "Cement Formula To Prevent Gas Migraiton Problems
in HT/HP Wells," International Journal of Scientific 7 Engineering Research, Volume 5, Issue 6, June 2014, ISSN
2229-5518.
Al-Yami, A.S., Al-Ateeq, A., Vikrant, W.B., Abdullatif, Z., Al-Qahtani, M.: "New Developed Acid Soluble Cement and
Sodium Silicate Gel to Cure Lost Circulation Zones," paper SPE 172020 presented at the 2014 Abu Dhabi International
Petroleum Exhibition and Conference held in Abu Dhabi, UAE, and November 10-13.
Al-Yami, A.S. and Jennings, S.S.: "Development of Innovative Formulations to Mitigate Differential Delayed Cement
Setting in Long Deep Liners in the Red Sea: Lab Study and Field Application," paper SPE-175841-MS presented at
the 2015 SPE North Africa Technical Conference and Exhibition held in Cairo, Egypt, September 14-16.
Al-Yami, A.S., Al-Awami, M., Wagle, V.: "Investigation of Stability of Hollow Glass Spheres in Fluids and Cement
Slurries for Potential Field Applications in Saudi Arabia," paper SPE 175189 presented at the 2015 Kuwait Oil&Gas
Show and Conference held in Mishref, Kuwait, October 11-14.
Al-Yami, A.S. and Al-Humaidi, A.S.: "High Density Cement Formulation To Prevent Gas Migration Problems," USP.
No 9,273,242, 2017.
Al-Yami, A.S., Buwaidi, H., Al-Herz, A., Mukherjee, T.S. 2017. Application of Heavy Weight Cement-Resin Blend
System to prevent CCA Pressure in Saudi Arabia Deep Gas Fields. SPE-185337 -MS. http://dx.doi.org/SPE-185337-
MS
Al-Yami, A.S., Wagle, V., Mukherjee, T.S., Al-Badran, M., Al-Jubran, M.: "Consideration to Batch Mixing Time Improves
API Recommendation for Testing Cement Slurries and Prevents Cement Failures: Lab Testing and Field Application,"
paper SPE 188119 presented at the 2017 SPE Kingdom of Saudi Arabia Annual Technical Symposium and Exhibition
in Dammam, Saudi Arabia, April 24-27.
Abdullah Al-Yami et al.: "Engineered Fit-For-Purpose Cement System To Withstand Life-Of-The-Well Pressure And
Temperature Cycling: A Solution To Casing-Casing Annular Pressure," paper presented at the 2017 Abu Dhabi
International Petroleum Exhibition and Conference, Abu Dhabi, UAE, November 13-16.
Bensted, J.: "Retardation of Cement Slurries to 250°F," paper SPE 23073 presented at the 1991 SPE Offshore Europe
held in Aberdeen, UK, 3-6 September.
SPE-187700-MS 13

El-Marsafawi, Y., Al-Yami, A., Nasr-El-Din, H.A., Al-Jeffri, A., Misran, M., Hasan, A.: "A New Cementing Approach
to Improve and provide Long-Term Zonal Isolation," paper SPE 100558 presented at the 2006 SPE Asian Pacific Oil
and Gas Conference and Exhibition in Adelaide, Australia, September 11-13.
Nasr-El-Din, H.A., Al-Yami, A., and Al-Aamri, A., El-Marsafawi, Y.: "A Study of Acid Cement Reactions Using the
Rotating Disk Apparatus," paper SPE 106443 presented at the 2007 International Symposium on Oilfield Chemistry
held in Houston, Texas, U.S.A., 28 February-2 March 2007.
Nelson, E.B.: "Well Cementing," Schlumberger Educational Services, Houston (1990).
Siddiqi, F.A., Riskiawan, A., Al-Yami, A., Elmarsafawi, Y., Jain, B., Louti, I., Martanto, R., Taoutaou, S.: "Successful
Managed Pressure Cementing With Hydraulic Simulations Verification in a Narrow Pore-Frac Pressure Window Using
Managed Pressure Drilling in Saudi Arabia," paper SPE 182500 presented at the 2016 Annual Technical Conference
and Exhibition held in Dubai, UAE, September 26-28.
Stavland, A., Jonsbraten, H.C. and Vikane, O., Skrettingland, K., and Fischer, H.: "In-Depth Water Diversion Using
Sodium Silicate on Snorre-Factors Controlling In-Depth Placement," paper SPE 143836 presented at the 2011
European Formation Damage Conference held in Noordwijk, The Netherlands, June 7-10.
Stiles, D.A.: "Successful Cementing in Areas Prone to Shallow Saltwater Flows in Deep-Water Gulf of Mexico," paper
OTC 8305 presented at the 1997 OTC in Houston, TX, 5-8 May.
Yuan, Z., Al-Yami, A.S., Schubert, J., Teodoriu, C.: "Cement Failure Probability Under HPHT Conditions Supported by
Long Term Lab Studies and Field Cases," paper SPE 154746 presented at the 2012 Annual Technical Conference and
Exhibition held in San Antonio, Texas, USA, October 8-10.
14 SPE-187700-MS

Appendix
MULTISTAGE CEMENTING PROCEDURE

DESIGN AND PLANNING

1. Drilling engineer (DE) and Service Company Cementing engineer (CE) calculate the required amount
of cement for blending.
2. Calculation is based on the following (as minimum):
a. First stage cementing: MW + 10 pcf with 50% excess over gauge hole OR 20% excess over
caliper data, use whatever gives higher volume. Use 10% casing –casing excess
b. Second Stage cementing: MW + 10 pcf with 10% casing-casing excess.
3. Perform QA/QC for Weighting materials, latex products, and QA/QC for test of of chemicals
(retarders, fluid loss additives, etc.) and make sure that Lot # needs to be confirmed from quality
reports and compared to lot # available in rig sites
4. After completing the blending and transporting to location, service company will take samples of:
a.Water to be used for cementing
b.Cement blend
c.Active mud
d.Additives to be used for cementing. Especially retarders, they need to be sampled from rig
location along with mix fluids and blend to be used for additional testing when required. Rig
foreman should witness this process to ensure that samples are collected from proper sampling
point(s) and source(s) from each cement silo using cement sick catcher or blow and bleed
method
5. DE and CE calculate volume of job as follows:

First stage:
a. Thin mud: : 400 BBL or 4 times OH volume (without excess) whichever is greater
b. Spacer : 150 BBL
c. Cement slurry : (Caliper data + 20 OR gauge hole + 50 %, use whatever gives higher volume) + shoe
track + 300 ft of cement above DV + 20 BBL (to compensate under displacement, for displacement
type plug).
d. Displacement : 10 BBL of slurry behind plug + 10 BBL of spacer behind + mud to DV (under displace
by 20 BBL) + 30 BBL of spacer across DV + mud from top of spacer to surface.
e. DV Company should review displacement procedures.

Second stage
a. Thin mud : 400 BBL
b. Spacer :150 BBL
c. Cement Slurry : DV to surface + 10% excess casing-casing
d. Displacement : 10 BBL of slurry behind + 10 BBL spacer behind + mud from top of spacer to surface
The properties of thin mud are to be discussed with mud specialist to ensure low yield point and
safe mud weight for cementing operations.
6. DE and CE calculate the operation time.
7. Thickening time requirement will be :
SPE-187700-MS 15

a. Minimum: Operation time + two hrs.

b. Maximum: Operation time + three hrs.
8. DE and CE estimate BHST using :
a. If log data is not available, use temperature gradient of surrounding wells
b. If log data is available:
3 - 4 hrs. from last circulation- BHLT×1.08
5 - 7 hrs. from last circulation- BHLT×1.07
8 - 10 hrs. from last circulation- BHLT×1.06
10 – 48 hrs. from last circulation – BHLT×1.05
More than 48 hrs. BHLT = BHST
Notes: BHCT – Bottom hole circulating temperature
BHST- Bottom Hole Static Temperature
BHLT- Bottom hole logging Temperature

9. If other method of computing BHT is available, then substitute as per best available option.
10. CE Calculates BHCT and checks with DE
BHCT = {(BHST-BHCT-API)×(MD (ft)-TVD (ft))/6000} + BHCT-API (all temperature
expressed in deg F)
Numerical temperature simulation might be required to confirm proposed BHCTs depending on
well conditions.
11. Service company starts pilot test using mix water and cement sample from rig with following
parameters:
a. First and second stage slurry-minimum, MW + 10-pcf latex slurry. Second stage slurry is lead
and tail system, the tail slurry with 1000 ft annular length from DV depth.
b. Thickening time (TT)
c. Fluid Loss
d. Free Water (45 degree inclination)
e. Rheology test at surface temperature and 190 °F (or BHCT) whichever is lower
f. Yield point of cement (expressed in Bingham Plastic mode) should be higher than that of the
spacer (i.e. Cement YP > Spacer YP)
g. Rheology test on active mud or proposed thin mud spacer sample to be conducted at 190 F
(or BHCT, whichever is lower) Report to DE/ Mud specialist
h. API procedures are followed for cement lab testing; refer to Al-Yami et al. (2017) for further
details.
Note: Pilot test report should also specify the calcium and chloride content of the rig
water sample.
SERVICE COMPANY CE HAS TO ENSURE THAT PILOT TESTS ARE PERFORMED USING
REPRESENTATIVE ADDITIVE THAT WILL BE USED FOR THE JOB (LOT/BATCH NUMBER
SHOULD BE SAME ALSO QUALITY REPORTS SHOULD BE PROVIDED BY SERVICE
COMPANIES FOR LOT/BATCH NUMBER FOR LATEX).
12. Upon completion of pilot test, CE should present the formulation to DE for approval.
13. For spacers, the following need to be addressed properly:

Design
16 SPE-187700-MS

• Service companies shall use a cementing spacer in which the rheological profile can be engineered
to achieve the following conditions:
• 3 RPM > 10 at BHCT

• Friction pressure hierarchy-plot falls between the mud and cement

○ Plot shall be in every program and reconfirmed prior to job.

• Spacer density is no less than four pcf above the mud weight or four pcf below the cement density
unless well conditions dictate otherwise and is first agreed to.
• If density is not a constraint, then use spacer density midway between mud weights and cement
slurry weight.
○ Compatibility testing shall be performed between the mud and the cement as per API RP 10B-2

• Surfactant and solvents shall not be used in spacers for WBMs unless testing shows that they are
required and have been reviewed and approved
• Minimum volume of weighed spacer ahead will be 150 bbl

• Wettability testing shall be performed as required

• When BHCT > 250 °F, spacer stability and settling tests shall be performed

• Pressurized balance shall be used to confirm actual density in field and record same on treatment log

Simulations

• Service companies shall submit final mud removal simulations within every cementing program
performed to optimize displacement mechanics using suitable software
• The mud removal simulations shall compare displacement rates vs. spacer volumes vs. spacer
rheology vs. possible use of some volume of treated mud pills vs. top of circumferential coverage
in the annulus.
• For the case of a vertical well, the simulators deviation data shall contain no less than 0.25° at TD
to induce a realistic simulation of centralization and mud removal
Delivery

• Program shall include:

• Friction pressure hierarchy plots at BHCT

• Centralization output

• Minimum 2-D cement concentration maps for the annulus

• Spacer lab report with performance testing as required

• Compatibility testing report with/without wettability

• Once spacer formulation is designed then it needs to be reviewed by DE.

14. DE and CE consult mud engineer/mud specialist for thin mud specifications, which include density
and rheology (expressed in Bingham Plastic) at atmospheric and 190 °F or BHCT whichever is
lower. Mud engineer must pilot test proposed thin mud formulation to ensure viability of the
formulation and ensure there is no barite/hematite settling.
15. DE provides centralizer specification as below:
a. Name : i.e. Brand name/SAP number, etc.…..as identification
SPE-187700-MS 17

b. Type : Rigid/bow
c. Maximum and minimum OD of centralizer (in inch)
16. DE provides:
a. Caliper data if caliper log run (preferable with 6 arms caliper)
b. Actual survey data if hole is deviated
c. Gyro Data if hole is vertical
17. CE runs standoff calculation based on data provided by DE using centralization as follows:
a. Use spiraglider centralizer from KOP to shoe in directional well. Use bow centralizer in the
vertical open hole and cased-hole section. Depending on the deviation should dictate when the
transition occurs from bows to spiraglider type. This has a huge impact on the mud removal
and channeling mitigation.
b. In critical wells, consider using zinc alloy centralizers to reduce coefficient of friction.
c. DE will provide improved centralization to achieve minimum of 70% standoff. Based on a
realistic schedule (1 per joint from×depth to y depth, 2 per joint from z depth to y depth, etc.).
d. In case of achieving 70% standoff is not possible (due to hole inclination/wash out, etc.), CE
should consult DE for strategic placement of centralizer.
18. DE and CE consult mud engineer to decide the lowest possible yield point of mud prior to cementing.
19. CE run cementing job simulation.
a. CE should discuss and obtain agreement with DE for Cement slurry pumping rate,
displacement rate and anticipated stoppage time.
20. CE runs mud removal simulation; mud rheology number for initial run should be using actual mud
rheology stated in daily report and proposed thin mud specifications. When necessary, lower mud
rheology until it reaches lowest possible figure as agreed. If mud removal is still not satisfactory
using the lowest possible yield point, CE consults DE/mud specialist.
21. CE prepares program for cementing and send it to DE along with planned scorecard for approval
as first draft.
22. DE reviews program and scorecard. If necessary request revision.
23. CE revises program and scorecard as per DE's correction and sends final job program to the DE.

II. EXECUTION
1. Thin mud has to be prepared in advance by mud engineer.
2. Cement crew should be on location when is RIH for final wiper trip/reaming or POOH.
3. Once on bottom with casing, continue to reciprocate during circulation. Continue to reciprocate
during first stage cementing whenever possible.
4. Cementer spot equipment and rig up cementing line. Rig up should allow cement unit to record
pressure during displacement. (The portion performed by rig pump).
5. Observe any abnormality. If losses /flow observed it has to be cured prior to prepare mix fluid for
cement slurry.
6. In case of partial or total losses, use LCM in spacer.
7. In case of partial losses while running the casing. The service company is required to quickly run
their simulation to decide on recommended pumping rate.
8. Cementer and DE calculate volume based on actual tally, account for dead volume when preparing
mix fluid as follows:
18 SPE-187700-MS

a. Calculate mix fluid requirement = MF1 = mix fluid requirement (gps) x sacks of cement
needed for job.
b. Add the dead volume anticipated to MF2=MF1 + Dead volume.
c. Calculate sacks of cement needed for MF2.
d. Calculate additive needed accordingly.
Mud engineer/foreman on location should advise dead volume of cement mixing tank
provided by rig
9. Cementer and DE calculate spacer volume for entire job, account for dead volume.
10. Once cement tank and batch mixer are clean, transfer water. Take sample of water and measure
chloride and calcium (Ca++) content of water. Compare chloride and calcium content measured
with the one stated in the pilot test report for QA/QC.
11. If location water is contaminated, rig should arrange for a clean water from alternate source.
12. Once authorized rig Forman, Cementer starts mixing spacer. DE has to witness process. Spacer
surface rheology and density should be checked to ensure quality control and documented by Service
Company.
13. When authorized by rig Forman, cementer starts mixing additive for cement slurry. DE has to witness
the process. It is important to add biocide to the bottom of a clean tank before adding water.
14. Once completed, cementer collects the following samples:
a. Cement blend
b. Water Sample
c. Mix fluid of 1st stage
d. Mix Fluid of 2nd stage (lead and tail)
e. Mud Sample (collected by mud engineer)
f. Thin mud sample (collected by mud engineer)
15. Transport samples to laboratory.
16. Laboratories run confirmation test as follows:
A. Rheology (atmospheric and 190F or BHCT whichever lower) for all fluids
B. API Thickening Time
C. Free water
D. Fluid loss
E. Compatibility test between mud-spacer
F. Compatibility test between spacer-cement slurry
G. UCA of 1st stage at DV depth temperature
H. UCA of 2nd stage tail at DV depth temperature
I. UCA of 1st stage at casing shoe depth
J. Additional thickening time tests to simulate batch-mixing time and expected stoppage during
cementing need to be performed.
17. If any above-mentioned parameters does not meet requirement during planning phase, add
additive(s) to rectify the issue. Any additional additive should be communicated to laboratory.
18. If original TT results fall below operation time, test needs to be repeated with additional additive
to lengthen TT in order to teach required minimum TT, Once achieved, additive should be added at
rig site and sample collected for reconfirmation test.
19. If original TT results in longer than operation time but shorter than operation time + 2 hrs., test
needs to be repeated in the lab with additional additive to reach 2 hrs. minimum safety margin. In
this case, reconfirmation is not required.
SPE-187700-MS 19

20. Based on actual results and actual casing Talley, CE recalculates casing standoff and re run mud
removal simulation.
21. Once casing reaches 13-3/8" casing shoe, perform circulation minimum one full cycle.
22. Once casing reaches casing point, perform circulation, minimum 2 bottoms up. Break circulation
at agreed intervals in long open hole section.
23. Mud should be treated to achieve desired properties prior to cementing. Observe any losses /flow
from trip tank. If observed, it has to be controlled prior to cement job.
24. Once mud properties are acceptable and rig pump efficiency has been determined, cementing
operation is ready to commence.

First Stage Cementing

25. As per authorization of Foreman on location, cement starts batch-mixing slurry.
26. Density of slurry should be measured using pressurized mud balance. Pressurized mud balance and
plunger must be inspected to be in good working order and has to be calibrated using water prior
to use.
27. Once accurate density (+/- 0.5 pcf) and volume of cement achieved:
a. Rig pumped thin mud
b. Rig pumps spacer ahead
c. Cement unit pumps slurry
d. Use Cementing head
e. Once plug is dropped; Cement unit pumps slurry behind
f. Verify the plug launching
g. Cement unit pumps spacer behind
h. Cement unit pumps mud between DV and landing collar (under displace by 20 bbls).
Rig has to supply mud to cement unit with rate of minimum 10 bbls/min (if no losses, if
losses then reduce).
i. Drop DV opening plug.
j. Rig Pumps spacer across DV
k. Verify the plug launching.
l. Rig completes displacement with mud. Compare actual pressure and calculated pressure
during this process. Cementing unit should record pressure during displacement.
Note: Take note extra volume required to bump the plug over the calculated displacement
volume. Use this as a reference for the second stage displacement volume.
m. Inflate DV packer and open DV
n. Circulate excess cement out- record volume of excess cement dumped, measure density with
pressurized mud balance to confirm.
o. Record the amount of Spacer and cement dumped. Measure cement density with pressurized
mud balance to confirm density.
p. During the whole process, monitor tank volume to recognize possible losses/gain while
cementing. Ensure enough space available to account for volume to recognize possible losses/
gain while cementing. Ensure enough space available to account of spacer and cement
q. Wait on cement (WOC) as per UCA for 500-psi compressive strength at DV depth unless
otherwise directed.
r. Monitor well during WOC
28. Once WOC is completed, lift BOP stack and set casing slip and prepare for second stage cementing.
Note if plug is not landed at desired volume, pump 20 bbl. additional and half of shoe track.
If plug still not landed, stop pumping wait for further instructions.
20 SPE-187700-MS

Second Stage Cementing

29. Rig pumps thin mud
30. Rig Pumps spacer ahead
Note: Before Pumping spacer, preload DV closing plug.
31. Cement Unit pumps cement slurry on the fly (using two units). The density measurement on mixing
units should not vary by more or less than 1.5 pcf. Tail slurry should be batched mixed.
32. Drop DV closing plug- cementing head is preferred for second stage instead of circulation head
(swage) because it will allow preloading the closing valve.
33. Cement unit pump 10 bbls of cement behind and 10 bbls of spacer/water behind.
34. Verify the plug launching.
35. Rig Continues to displace with mud
Notes:

◦ Use the same rig pump for both first and second stage displacement.

◦ If possible, plan to take the return in a tank different from active system.
36. Observe return, When spacer or cement appeared, verify by measuring density with pressurized
mud balance.
37. Close DV, If DV can't be closed, pump 5 bbl. over displacement volume considering efficiency of
the pump
Note:
a. Use the first stage displacement as reference to compensate for pump efficiency
b. Use landing volume at plug pumping for first stage to check pump efficiency.
c. As per DV specialist recommendation, The DV tool can be closed mechanically by RIH.
38. After second stage cementing, keep the annulus closed.
39. At the end of cement job, DE should ensure that the copies of Geolograph chart during displacement
process by rig should be made available in the well files, both in the rig and in office.

Contingency Plan
Slurry mixing jet or hopper become plugged
■ Stop mixing slurry, remove hopper and clean quickly.
■ Resume mixing at prescribed pumping rates if possible.
Data acquisition system fail
■ Mixing and pumping should continue, if necessary continue to measure density with pressurize mud
balance throughout the job.
■ The final volume will be based on the physical count of the mix fluid.
Sudden pressure increase observed at surface pump truck during the cement job.
■ Cementing company representative should provide a calculated max treating pressure for cementing
operation.
■ In case of a sudden increase in pumping during cementing, this indicates some problem in the well
and/or cement. Possibly bridging due to solids packed off or plugging, Reduce the pump rate if
possible, continue displacement, under no circumstance pumping pressure should be allowed to reach
bottom-hole pressure that will exceed the estimated formation fracture pressure
■ If pumping at slow rate is not possible, then stop pumping.
SPE-187700-MS 21

■ Bleed off pressure and observe return, and decide on appropriate action plan with rig engineer
Sudden pressure loss observed at surface pump truck during the cement job.
■ In case of a sudden pumping pressure loss during cementing, this indicates some problem in the well/
cementing line. Possibly washout, surface line leak, etc. stop pumping, check surface line and pump,
etc. for possible leak source, fix same, resume pumping
■ Reduce the pump rate if possible.
■ In the event of surface cementing equipment is fine, and pumping pressure is sufficient for slurry
displacement, resume cementing operation
■ In the event that pumping pressure loss is due to hydrostatic pressure reduction in the annulus (i.e.,
loss is occurring and fluid level in the annulus is dropping), reduce pump rate or stop pumping,
evaluate the situation, and decide on appropriate action plan with rig engineer
Unable to bump first stage plug and float shoe failure
■ At the estimated pump volume, if not see any sign of plug bump, continue to displace only half the
shoe track volume as calculated before the job.
■ In case the plug still does not bump, STOP PUMPING, do not over displace.
■ Bleed-off pressure, measured the returned volume, if abnormal return is observed, indicating float
shoe failure, pump back the volume and hold pump pressure if necessary, and WOC
Unable to open DV cementing port and set DV packer
■ Abort 2nd stage cementing
■ Proceed to remedial cementing plan.
Unable to bump DV closing plug and close DV
■ DO NOT OVER DISPLACE if plug does not bump after recalculated displacement volume.
■ Close master valve on cement head and WOC.
In case of CCA (Casing to Casing Annular Pressure)
■ Enhance cement design and placement techniques to optimize bonding and physical and mechanical
properties.
■ Use resin based cement or alternatives as a remedial option above the stage tool as a tail slurry in
the second stage to provide additional barrier above the DV packer to control CCA (1000 feet is the
minimum length required) at approximately BHST 220 °F and below.