Cementing Manual - Copy Halliburton PDF

WELLS PUBLICATION
CEMENTING MANUAL
Copyright Shell Group of Companies. No reproduction or networking permitted without license from Shell. Not for resale
WS 38.80.31.38-Gen.
Revision 0.0
This manual was developed and approved jointly between the Wells discipline and the PT/PC discipline. Deviations from this
manual may, where noted, require PT/PC approval.
Custodian PTE Cementing

Author Edwards, Joseph H SIEP-PTW/TAWT
Owner VP Wells Discipline
Status Live [with exceptions, see Section (1.8)]
Last Revision May 1st, 2016
Valid To May 1st, 2019
Shell standards and manuals are intended to direct Shell employees in the performance of their duties. They are not intended
for investors, and should not be relied on when considering whether to buy, retain or sell shares in any Shell Company. This
document is classified as Restricted. Access is allowed to Shell personnel, associate companies and contractors working on
Shell projects who have signed a confidentiality agreement with Shell.
Copyright Shell Global Solutions International B.V. 2016.
This document contains information that is classified as EAR99 and, as a consequence, can neither be exported nor re-
exported to any country which is under an embargo of the U.S. government pursuant to Part 746 of the Export Administration
Regulations (15 C.F.R. Part 746) nor can be made available to any national of such country. In addition, the information in this
document cannot be exported nor re-exported to an end-user or for an end-use that is prohibited by Part 744 of the Export
Administration Regulations (15 C.F.R. Part 744).
This document has been supplied under license by Shell to:

Shell Erlend.Finsnes@shell.com 15/08/2017 23:24:14
PREFACE
Because of the diversity, nature, and criticality of cementing activities and the process steps
involved in executing a cement job, this manual has a joint ownership (see cover page). The
PT/PC and Wells disciplines share the responsibilities and requirements in this manual, which
are allocated accordingly.
As stated in Section (1.3), deviations will be handled as per the Discipline Controls and
Assurance Framework (DCAF) of the respective discipline. The DCAF processes for deviation
based on each discipline are indicated below. Because this is a shared document between
PT/PC and Wells, there will be some requirements with dual ownership that will require both
disciplines to approve deviations. To avoid confusion, the ownership of each section will be
stated at the beginning of the section as a note, and the requirements of that section will be the
accountability of the discipline identified as the owner. Sections were assigned based on the
following rationale: for Well Fluids (Wells and PC), Casing Attachments and Hardware (Wells),
Lab Testing and Design (PC), Well Integrity (Wells and PT), Job Simulation and Execution
(Wells), and Lab and Facility Audits (PC).
The responsibility and the accountability for the in-house Shell and external contractor
cementing laboratories shall be held by the PC discipline.
DCAF Deviation Process
• Wells:
• SHALL[WELLS] statements: To deviate, approval is required from the designated
Technical Authority TA1 and endorsement is required from the Global PTE
Cementing Operations. Deviations shall be risk-assessed and logged.
• Small ‘shall’ statements: To deviate, approval is required from the designated TA2
and endorsement can be requested from the Global PTE Cementing Operations at
the discretion of the TA2. The deviation shall be forwarded to the Custodian (PTE)
through the online feedback tool for tracking.
• PC:
• SHALL[WELLS] statement: To deviate, approval is required from the designated
TA1 and the endorsement is required from the Global PTE Well Fluids. Deviations
shall be risk-assessed and logged.
and endorsement can be requested from the Global PTE Well Fluids at the discretion
of the TA2. The deviation shall be forwarded to the Custodian (PTE) for tracking
through the online feedback tool
• PT:
• SHALL[WELLS] statements: To deviate, approval is required from the designated
TA1 and endorsement is required from the Global PTE Well Integrity. Deviations
shall be risk-assessed and logged.
and endorsement is requested from the Global PTE Well Integrity at the discretion of
the TA2. The deviation shall be forwarded to the Custodian (PTE) for tracking
through the online feedback tool
Wells Manual WS 38.80.31.38-Gen. Page 2 of 77

May 1st, 2016 Cementing Manual Rev. 0.0
The controlled version of this document resides online in the DEP system. Printed copies are UNCONTROLLED.

TABLE OF CONTENTS
1 INTRODUCTION .................................................................................................................... 6
1.1 SCOPE ......................................................................................................................... 6
1.2 DISTRIBUTION, INTENDED USE, AND REGULATORY CONSIDERATIONS .......... 6
1.3 REQUIREMENTS STATEMENTS ............................................................................... 6
1.4 DEFINITIONS ............................................................................................................... 7
1.5 ACRONYMS ................................................................................................................. 9
1.6 CROSS-REFERENCES ............................................................................................. 10
1.7 SUMMARY OF MAIN CHANGES .............................................................................. 10
1.8 COMMENTS ON THIS MANUAL ............................................................................... 10
1.9 EXCEPTIONS TO GO-LIVE ....................................................................................... 10
2 SUBSURFACE DOCUMENTS SUMMARY ........................................................................ 11
3 SHALL[WELLS] STATEMENTS SUMMARY ..................................................................... 12
4 REQUIREMENTS COMMON TO ALL CEMENT JOBS ..................................................... 13
5 CEMENT JOB CONSIDERATIONS .................................................................................... 14
5.1 CEMENT AS A BARRIER .......................................................................................... 14
5.2 CEMENT VOLUME .................................................................................................... 15
5.3 SPACER VOLUME ..................................................................................................... 15
5.4 CASING HARDWARE ................................................................................................ 16
5.5 LAB TESTING ............................................................................................................ 17
5.6 STRESS MODELING ................................................................................................. 17
6 CEMENTING BASIS OF DESIGN CRITERIA ..................................................................... 18
6.1 REQUIREMENTS OF A CEMENTING BASIS OF DESIGN ...................................... 18
7 TEMPERATURE SIMULATION........................................................................................... 20
7.1 TEMPERATURE SIMULATION FOR CEMENT DESIGN ......................................... 20
8 PIPE CENTRALIZATION..................................................................................................... 22
8.1 REQUIREMENTS FOR PIPE CENTRALIZATION/STANDOFF ................................ 22
9 MECHANICAL SEPARATION BETWEEN FLUIDS ........................................................... 23
9.1 REQUIREMENTS OF MECHANICAL SEPARATION................................................ 23
10 CEMENT LABORATORY TESTING GUIDELINES ............................................................ 24
10.1 GUIDELINES SUMMARY .......................................................................................... 24
10.2 RECOMMENDED SLURRY TESTS .......................................................................... 24
10.3 TESTING ROLES AND RESPONSIBILITIES ............................................................ 27
10.4 TEMPERATURE SIMULATION ................................................................................. 28
10.5 REPRESENTATIVE SAMPLING GUIDELINES......................................................... 28
10.6 PILOT TESTING ......................................................................................................... 30
10.7 FIELD-BLEND TESTING............................................................................................ 30
10.8 SLURRY PREPARATION .......................................................................................... 31
10.9 SLURRY MIXABILITY ................................................................................................ 31
10.10 SLURRY DENSITY .................................................................................................... 32
10.11 COMPRESSIVE STRENGTH .................................................................................... 32
10.12 THICKENING TIME .................................................................................................... 32
10.13 THICKENING TIME SENSITIVITY TESTING ............................................................ 34
10.14 FLUID LOSS ............................................................................................................... 35
10.15 RHEOLOGY AND GEL STRENGTH ......................................................................... 36
10.16 SLURRY STABILITY .................................................................................................. 36
10.17 FREE FLUID ............................................................................................................... 36
10.18 STATIC GEL STRENGTH – TRANSITION TIME ...................................................... 36
10.19 FLUIDS COMPATIBILITY .......................................................................................... 37
10.20 WETTABILITY ............................................................................................................ 38
10.21 DEEPWATER CEMENT TESTING ............................................................................ 38
10.22 HPHT CEMENT TESTING ......................................................................................... 39
10.23 WATER ANALYSIS .................................................................................................... 39


10.24 GUIDELINES FOR HANDLING OF POZZOLAN FLY ASH MICROSPHERES
DURING LAB TESTING ............................................................................................. 39
10.25 QA/QC OF BLENDED MICROSPHERE SLURRY DESIGNS ................................... 40
10.26 OTHER JOB-SPECIFIC TESTING TO BE PERFORMED ON AN AS-NEEDED
BASIS ......................................................................................................................... 42
11 GUIDELINES FOR THE DRY MIXING OF CEMENT BLENDS .......................................... 43
11.1 PLANT PRE-CHECKS ............................................................................................... 43
11.2 GENERAL BLENDING PROCEDURES .................................................................... 43
11.3 TRANSPORT TO THE RIG ........................................................................................ 44
11.4 STORAGE OF BLENDS............................................................................................. 44
12 WELLBORE CONDITIONING AND PIPE MOVEMENT ..................................................... 45
12.1 MUD CONDITIONING AND PIPE MOVEMENT ........................................................ 45
12.2 DISCUSSION ON WELLBORE CONDITIONING AND PIPE MOVEMENT .............. 45
13 JOB DATA COLLECTION AND ARCHIVE ........................................................................ 47
13.1 REQUIREMENTS OF DATA COLLECTION AND ARCHIVE .................................... 47
14 CEMENT PLUGS ................................................................................................................. 48
14.1 GUIDELINES FOR TESTING AND PLACEMENT OF CEMENT PLUGS ................. 48
14.2 ADDITIONAL GUIDELINES FOR SIDETRACK CEMENT PLUGS ........................... 49
15 OFFSHORE RISERLESS CEMENTING ............................................................................. 51
15.1 PROJECT PLANNING FOR OFFSHORE RISERLESS CEMENTING...................... 51
15.2 CEMENT JOB PLANNING FOR OFFSHORE RISERLESS CEMENTING ............... 51
15.3 PREPARATION AND EXECUTION OF OFFSHORE RISERLESS CEMENT
JOBS .......................................................................................................................... 52
16 FOAM CEMENTING ............................................................................................................ 53
16.1 FOAM CEMENTING DEFINITIONS ........................................................................... 53
16.2 MINIMUM REQUIREMENTS FOR FOAM CEMENTING........................................... 53
17 DESIGN AND TESTING GUIDELINES FOR HIGH-TEMPERATURE CEMENTING ......... 55
17.1 TEMPERATURE SIMULATION IN HIGH-TEMPERATURE WELLS ......................... 55
17.2 ADDITIONAL DESIGN REQUIREMENTS TO CONSIDER FOR HIGH-
TEMPERATURE WELLS ........................................................................................... 55
17.3 FLUIDS STABILITY TESTING IN HIGH-TEMPERATURE WELL APPLICATIONS.. 56
17.4 HIGH-TEMPERATURE SPECIFIC ADDITIVES ........................................................ 56
17.5 USE OF SIMULATION SOFTWARE IN HIGH-TEMPERATURE WELL
APPLICATIONS ......................................................................................................... 57
17.6 FLOAT EQUIPMENT FOR HIGH-TEMPERATURE APPLICATIONS ....................... 58
17.7 KEY FACTORS IN THE EXECUTION OF A HIGH-TEMPERATURE CEMENT
JOB ............................................................................................................................. 58
17.8 SETTING CEMENT PLUGS IN HIGH-TEMPERATURE ENVIRONMENTS ............. 59
18 EXTREME (HIGH AND LOW) DENSITY SLURRIES ......................................................... 60
18.1 REQUIREMENTS FOR ALL EXTREME DENSITY SLURRIES ................................ 60
18.2 REQUIREMENTS FOR EXTREME HEAVYWEIGHT SLURRIES............................. 60
18.3 REQUIREMENTS FOR EXTREME LIGHTWEIGHT SLURRIES .............................. 61
19 FLOAT EQUIPMENT AND CASING ATTACHMENTS ...................................................... 62
19.1 MINIMUM REQUIREMENTS FOR FLOAT EQUIPMENT.......................................... 62
19.2 MINIMUM REQUIREMENTS FOR CENTRALIZERS AND CASING
ATTACHMENTS ......................................................................................................... 62
20 MINIMUM LABORATORY EQUIPMENT REQUIREMENT ................................................ 63
20.1 LABORATORY EQUIPMENT REQUIREMENT TABLE ............................................ 63
21 DEEPWATER SLURRY VERIFICATION TESTING GUIDELINES .................................... 65
21.1 RECOMMENDED JOBS FOR VERIFICATION ......................................................... 65
21.2 RECOMMENDED TESTS TO BE PERFORMED DURING VERIFICATION ............ 65
22 CONFIRMATION TESTING OF CEMENT DUMP BAILER KITS ....................................... 67


22.1 REQUIREMENTS FOR CONFIRMATION TESTING ................................................ 67
23 RP – USING THE CEMENTING FEASIBILITY ASSESSMENT TOOL .............................. 68
23.1 CEMENTING FEASIBILITY ASSESSMENT TOOL ................................................... 68
24 CEMENT BOND LOGGING GUIDELINES ......................................................................... 70
24.1 PLANNING AND EXECUTION................................................................................... 70
24.2 DEFINITION OF SUFFICIENT BOND: ...................................................................... 71
25 RP – CEMENTING THROUGH COIL TUBING ................................................................... 73
25.1 SLURRY TESTING PROCEDURES .......................................................................... 73
25.2 SLURRY DESIGN ...................................................................................................... 74
25.3 SPACER DESIGN ...................................................................................................... 74
25.4 PLUG SPOTTING PROCEDURES ............................................................................ 75
26 REFERENCES ..................................................................................................................... 76


1 INTRODUCTION
1.1 Scope
This manual details the requirements for cementing wells associated with the oil and gas
industry. This manual also lists requirements regarding the relationship between Global
Wells Manuals, line of business (LoB) Wells Manuals, Subsurface Manuals, Shell Design
and Engineering Practice (DEP)1 manuals, and external industry standards.
This manual is part of the Global Wells Manuals and not applicable retroactively.
1.2 Distribution, Intended Use, and Regulatory Considerations

This document is classified as restricted. Access is allowed to Shell personnel, associate
companies and contractors working on Shell projects who have signed a confidentiality
agreement with Shell. Authorised access to any Global Wells Publication does not
constitute authorisation for access to other documents, data, or information to which the
Global Wells Publication may refer.
This Global Wells Manual is intended to have key sections integrated within the Global
Well Delivery Process (GWDP). A cementing feasibility assessment shall be done in the
IDENTIFY AND ASSESS phase of the project to determine ahead of time if there are any
major issues that could challenge the successful outcome of any of the potential
cementing operations. Such issues would initiate discussions with the Well Engineering
(WE) staff on potential changes to the well plan and/or cementing proposal. If the
changes required were considered significant, then the discussions would be raised to
the higher TA level, potentially becoming part of the project’s technology plan.
During the SELECT phase, the cementing feasibility assessment will be rerun and
reviewed by the Cementing Focal Point Production Chemist (PC) or Cementing Subject
Matter Expert (SME) or TA as defined in the DCAF to determine whether there are any
additional well planning changes from the first review that could affect the cementing
process. The cementing proposal and pilot lab testing will follow the requirements in this
manual and will be done during the DEFINE phase by the Service Contractor. Review of
the final cementing proposal and lab tests will be done by the Well Engineer (WE),
Production Technologist (PT) accountable for well integrity (WI), Cementing Focal Point,
and Service Contractor under the EXECUTE phase prior to performing the cement job.
This Global Wells Manual is intended for use by all involved in well construction and
workover operations when cementing activities are planned and executed.
When implementing Global Wells Manuals, a Management of Change (MOC) process
shall be utilised when appropriate at LoB level to ensure manual compliance.
If LoB or local regulations exist, and contain requirements that are more stringent than the
relevant Global Wells Manual, the regulatory requirements shall be followed.
1.3 Requirements Statements

SHALL[WELLS] (uppercase): These statements designate a requirement intended to
reduce or eliminate the occurrence of a process safety risk ranked as Risk Assessment
Matrix (RAM) red or yellow 5A/5B in Figure 1. To deviate, approval is required from the
Technical Authority (TA)1 [as per the Discipline Controls and Assurance Framework
(DCAF)] and endorsement from a Qualified Technical Professional as deemed qualified
by the TA. Deviations shall be risk-assessed and logged in the appropriate system as
designated in the Management of Change and Deviation Manual2. A process safety risk is
a hazard that can give rise to major accidents involving the release of potentially
hazardous materials, release of energy, or both. The deviation approval is time-
constrained per Table 1 and shall not exceed 12 months prior to additional approval
requirements.


Figure 1 – Risk Assessment Matrix
Shall: The word “shall” (lowercase) indicates a mandatory requirement that is ranked
other than process safety risk RAM red or yellow 5A/5B defined above. TA2 approval is
required for deviation against a “shall” requirement. A Qualified Technical Professional,
as deemed qualified by the TA, can be requested at the discretion of the TA2. The
deviation approval is time constrained per Table 1 and shall not exceed 12 months prior
to additional approval requirements.
Should: The word “should” indicates a preferred solution/option with no mandatory
requirement.
Table 1 – Time-Based Summary for Deviation Requests
Deviation Approver of Approval of Approval of

Original Request Extension at Year Extension at Year
1 2
SHALL[WELLS] TA1 TA0 TA0*
shall TA2 TA1 TA0
* Endorsement of the VP Wells Discipline required.
1.4 Definitions
The following key terms are used within this manual:
General Terms Definition
Company The Company is the party that initiates the project and ultimately
pays for it. The Company may also include an agent or consultant
authorised to act for, and on behalf of, the Company.
Contractor A general term for an individual or firm that has entered into a legal
contract to provide services to Company. In delivering the services,
contractor and Company agree that the work scope will be
performed using contractor’s own management system(s) and/or
industry standards that are materially equivalent to those of
Company, or that will be brought in line through interface or
bridging documents.
For the purpose of this publication, this term does not apply to
individuals that are on direct hire (e.g., contract staff, consultants,
etc., that represent Company and are managed as Company staff).


Custodian Person within the discipline appointed by the VP Wells Discipline to
be responsible for the contents, upkeep, and approval of a specific
Global Wells Publication. The Custodian is normally the PTE on the
contents of the document. The Custodian also acts as the focal
point for questions relating to the content via the online feedback
tool.
Deviation Deviation is any non-compliance with a SHALL[WELLS] or shall
requirement statement. Not meeting either of these requirement
statements requires the appropriate level of approval as per
Table 1.
Discipline The DLT is comprised of the LoB Discipline Leads and the
Leadership functional VPs at a global level and is led by the VP Wells
Team (DLT) Discipline.
Exceptions to List of requirements and date on which these specific requirements
Go-Live Date within the Global Wells Manual become mandatory, where the go-
live date differs from the overall Wells Manual go-live date.
Go-Live Date Date on which Global Wells Manual’s requirements become
mandatory and, if not followed, require a deviation.
Last Revision The date of the last revision of the publication. This will start as the
date the publication is released and will be updated with every
subsequent version release.
Line of Thematic LoB in Wells organisation, which includes Operated,
Business (LoB) Unconventionals, Integrated Gas, Deepwater, Arctic and Joint
Ventures/Non-Operated Ventures (JV/NOV).
LoB Discipline Individuals who lead their discipline community at a LoB level and
Leads set the local standards using the global standard as a minimum,
adding local requirements when required or desired.
Manual Global Wells Manual developed with input from the LoB(s) and
approved by the DLT. It establishes requirements, guidelines, and
good practices for Wells global activities.
Owner Document owner who is ultimately responsible for the approval and
release of a specific Global Wells publication. In all instances, this
is the VP Wells Discipline.
Guide Global Wells Guide developed with input from the LoB(s) and
approved by the DLT. The Guide supplements the Wells Manual in
most cases with informational/educational material to help
understand its concepts and requirements.
Principal Globally recognised technical experts with deep technical
Technical knowledge and significant influence on the business in their specific
Expert (PTE) field. PTEs primary role is to provide global technical consultancy
support in their specific fields and lead a Common Interest Network
(CIN) comprised of subject matter experts (SMEs) from each LoB.
Subject Matter Locally recognised technical experts with deep technical knowledge
Expert (SME) and significant influence on the business in their specific field.
SMEs primary role is to provide LoB technical consultancy support
in their specific fields and participate in the CIN comprised of SMEs
from each LoB.
Valid To The date to which the publication is valid. This will be a minimum of
three years from every major revision to ensure that the manual
content is validated and updated on a regular basis.
Specific Terms Definition
Cementing The Cementing Focal Point is a designated person [Wells Engineer
Focal Point (WE or CWI)] that has been assigned, by the Wells TA1, to be


responsible for review of the cementing design and job execution
program. In some operating units this may be a Cementing SME, if
available.
Cementing The Cementing SME is a subject matter expert designated by the
SME Global Wells PTE Cementing Operations. Cementing SMEs may
have remit be based in the local operation, thematic line of
business or in a global role
Electrical A test to measure the emulsion stability of oil-based and synthetic-
Stability based muds (OBM/SBM).
Field Blend Samples of bulk cement blend from location and or rig.
First Sack The first barrel of cement pumped down the pipe.
Last Sack The last barrel of cement pumped down the pipe
Pilot Test Cement testing using non job-specific samples.
1.5 Acronyms
The following acronyms are used within this manual:
ALARP MWD
As Low As Reasonably Practicable Measurement-While-Drilling
API OBM
American Petroleum Institute Oil-Based Mud
BHCT OD
Bottom-Hole Circulating Outside Diameter
Temperature
BHP PBR
Bottom-Hole Pressure Polished Bore Receptacle
BHST PC
Bottom-Hole Static Temperature Production Chemist
BOD PE&D
Basis of Design Geosciences, Petroleum Engineer and
Development
bwoc POOH
By weight of cement Pull Out of Hole
CT PP
Coiled Tubing Pore Pressure
DCAF PS
Discipline Controls and Assurance Process Safety
Framework
DEM PT/PC
Design and Engineering Manual Production Technologist/Production
Chemist
DEP RP
Design and Engineering Practice Recommended Practice
ECD SAGD


Equivalent Circulating Density Steam-Assisted Gravity Drainage
FG SBM
Fracture Gradient Synthetic-Based Mud
FIT SG
Formation Integrity Test Specific Gravity
GDH SME
Global Discipline Head Subject Matter Expert
HPHT TAP
High Pressure High Temperature Trapped Annular Pressure
HSSE TD
Health, Safety, Security, and Total Depth
Environment
HT TOC
High Temperature Top of Cement
ID WBM
Internal Diameter Water-Based Mud
ISO WFS
International Standards Well Functional Specification
Organization
LOT WI
Leak-Off Test Well Integrity
WOC
Wait on Cement
1.6 Cross-References
If the Global Wells Publication contains cross-references to other parts of the same
Global Wells Publication, the referenced section number shall be included in parentheses
( ). A cross-reference to a section of an appendix indicates the appendix number and the
section number.
1.7 Summary of Main Changes

This manual is an update of and replaces EP 94-1100 which was issued in 1994.
Changes in cementing technologies and industry practices warranted the construction of
this new manual.
1.8 Comments on this Manual

Trapped Annular Pressure (TAP) is not addressed in this document. Review of the
3
Casing and Tubing Design Manual (CTDM) is recommended since this subject is
discussed in detail in that document. Review of the cement job objectives and risks
should be done by the Wells Engineer (WE) in conjunction with the PT, PC, Cementing
SME/Focal Point and relevant Service Contractor with regard to the required Top of
Cement (TOC) and the affect that the TOC has on TAP.
1.9 Exceptions to Go-Live

PC and Contractor Laboratories requirements - 24 months from release date.


2 SUBSURFACE DOCUMENTS SUMMARY
The Geosciences, Petroleum Engineer and Development (PE&D) staff will be developing
standards to improve PS of the technical work done in the function as it relates to subsurface.
These standards are not issued yet but have been included below as a reference since they will
have relevance to the Cementing Manual in the future.
• Top-Seal Integrity Assessment For Primary Recovery, Waterflood, EOR, and CO2 Storage
Operations
• Formation pore pressure, fracture gradient (PP/FG), and borehole stability prediction for
exploration, appraisal, and development wells, well entries, and abandonments
• Subsidence prediction
• Shallow hazards prediction


3 SHALL[WELLS] STATEMENTS SUMMARY
The responsibility for deviation of this section shall be as per Wells and/or PC/PT DCAF with
endorsement by relevant PTE(s) (Cementing Operations, Well Fluids, Well Integrity) in
accordance with the deviation process described in the Preface.
1. Each critical job SHALL[WELLS] have documented technical oversight of the engineering
design and laboratory verification by designated SMEs for cementing operations from both
WE and PC.
• Critical jobs shall be identified in the Well Functional Specification (WFS) by the PT
TA with support from the Wells TA. Examples of critical jobs include, but are not
limited to, cementing across a zone deemed to have flow potential, cementing
through coiled tubing (CT), and cementing expandable tubulars.
• Technical oversight is defined by the appropriate Wells and PC technical authorities.
Examples of technical oversight includes, but is not limited to, performing pre-project
review, cement feasibility assessment, pilot testing review, pre-job cementing
program review, and blend test verification review and capturing lessons learned for
future job design improvements.
• TA is defined in the Wells Engineering (WE) and PC DCAF.
PS Risk 5B based on the National Commission report on the BP Deepwater Horizon Oil
Spill, indicating the blowout was the product of a series of missteps and lack of oversight by
the operator and service contractors.
2. For each cement operation where the cement is intended as a barrier to prevent potential
flow and provide formation isolation, a RAM assessment SHALL[WELLS] be made to
identify key assumptions and risks that could threaten achieving the cementing objectives.
The assessment will be performed by the Well Engineer (WE).
PS Risk 5B based on the National Commission report on the BP Deepwater Horizon Oil
Spill of April 2010, indicating that there is no evidence to suggest that the engineering team
conducted a formal analysis of the combined impact of a number of risk factors on the
prospects of a successful cement job.


4 REQUIREMENTS COMMON TO ALL CEMENT JOBS
The responsibility for deviation of this section shall be as per Wells and/or PC DCAF in
The below list of shall statements is not inclusive, but rather represent those shall statements
that are common to all types of cement jobs.
1. Specific cementing requirements, including evaluation logging, shall be specified in the
WFS.
2. All cement lab testing shall be performed based on a well-specific bottom-hole circulating
temperature (BHCT) model.
3. Lab testing shall be performed with representative samples of the cement, water, and
additives that will be used on the job.
4. The local law and regulations in force in each country at the time an activity is carried out
shall always prevail if they are more stringent than the Shell requirements.
5. Each job shall have clearly defined cementing objectives with agreed acceptance criteria of
those objectives between company and service contractor.
6. A cementing feasibility assessment shall be done in the IDENTIFY AND ASSESS phase of
the GWDP for each project to determine ahead of time whether there are any major issues
that could challenge the successful outcome of any of the potential cementing operations.
7. The drilling program shall include a wellbore circulating and mud conditioning procedure
prior to cementing operations.
8. All cement slurries shall have a mechanical separator ahead and behind (wiper plug/wiper
dart/wiper ball). Separation is not required between cement slurries.
9. Computer simulations software shall be used to validate design against cement job
objectives.
10. All casing and liner cement jobs shall be designed to give a positive differential pressure at
the end of the job as the top plug lands.
11. Compatibility of all fluid interfaces shall be tested and verified on all critical cement jobs.
12. Centralizers shall be run according to engineering software output to meet cement job
design objectives.
13. Planned TOC shall be a minimum of 500 ft (152 m) above potential flow zone or as stated
by local regulatory requirements, whichever is greater.
14. All shallow aquifers shall be isolated by cement.


5 CEMENT JOB CONSIDERATIONS
The responsibility for deviation of this section shall be as per the Wells and/or PT DCAF in
This section outlines the basic minimum requirements for many types of cement job designs
and is not intended to replace engineering due diligence. Situations may exist in which the
minimum requirements will not satisfy what is required based on engineering analysis and
available specific information.
a) Cementing requirements shall be specified in the WFS. The WI requirements, including
critical cementing jobs, are specified by the PT TA with support from the Wells TA in the
WFS. This covers the life cycle aspects of production and injection operations and WI
management.
b) The WFS shall include specific requirements for isolation of all reservoirs (hydrocarbon
bearing or not) penetrated by the wellbore. The WFS shall be signed off by the PT TA.
Applicable local laws and regulations in force in each country at the time an activity is carried
out shall prevail if they are more stringent than the Shell requirements. Deviation from these
minimum requirements shall be reviewed with the Cementing Focal Point, Wells Engineering
and Production Technology TA2. Approval of the deviation will be as per DCAF
5.1 Cement as a Barrier

Cement can be defined as a barrier only if the integrity of the cement has been verified.
Verification shall not rely on only one method but consist of a combination of methods.
The suite of methods may be different for each application. There are two types of
cement barrier elements: cement plug and cement in the annulus.
Methods for cement plug verification can consist of, but are not limited to:
• Tagging and weight test of the plug
• Positive and negative pressure testing if inside casing
Methods for cement in the annulus verification can consist of, but are not limited to:
• No drop in cement height when casing is cemented back to surface
• Pressure testing of the cement if the TOC is inside the casing-by-casing annulus
• Successful shoe integrity test
• Wireline logging can be used in conjunction with the other methods above in the
verification process. See Section (24) of this document for further discussion on the
guidelines for cement bond logging based on the Cement Bond Logging Planning,
4
Execution, Evaluation, and Audit Trail Assurance Guideline document.
When considering the above methods of verification, note that it is important to factor in
the job execution and if it was executed as per plan including quality control. For annular
cement jobs, the cement volume and pressure differential at the completion of the cement
job should also be factored in the evaluation of the cement’s integrity.
Wireline logging data is often used to find the TOC behind casing to determine if the well
objectives were met and regulatory requirements satisfied. Log evaluation of the cement
sheath to determine the quality and isolation around the circumference of the casing from
the casing outer surface to the wall of the openhole, still falls short as a definitive
verification method. However, recent technological advances show promise for future
applications of wireline logging as a verification method for cement sheath integrity and
isolation.
As with the physical methods outlined above, the approach to using logging/electronic
data to assist with barrier verification in combination with the physical methods mentioned
above will also lie in a suite approach combining the best of the different technologies. A
full discussion on the application of logging data as a tool to help with the verification
5
process is included in the API TR 10TR1 .


The lack of annular pressure buildup is not considered indicative of annular seal
verification, as the pressure may be noticed after a period of time.
Detailed discussions on the subject of cement as a barrier and pointers to its verification
can be found in Well Abandonment Manual and Guidelines6 as well as industry
documents API RP 967 and API Standard 65 Part 2 Second Ed8.
5.2 Cement Volume

• Local regulatory requirements will take precedence if more stringent than Shell
requirements. Volume shall be sufficient for a minimum of 500 ft (152 m) above the
potential flow zone based on actual caliper log data. In the event that caliper log data
are not available, an annular excess, based on best available offset well information
or local/field experience, shall be used.
• The guidelines for the length of the shoe track for casing and liner cement jobs are
stated below, based on the number of wiper plugs used and the type of job.
Recommended shoe track volume/length should not be less than:
- If one each wiper plug (top only) is used, the shoe track length should be equal
to the volume of 1/32 in (0.79 mm) mud film on the inner wall of all tubulars plus
100 ft (30 m) of pipe capacity. An example of a film calculation is below.
Mud film volume = Length x ((𝐼𝐼𝐼𝐼 2 - (𝐼𝐼𝐼𝐼 − 0.03125)2 ) x 0.0009714)
Example: 8000 ft (2438.4 m) of 7 in (17.78 cm) casing with 6.5 in (16.51 cm) ID
8000 x ((6.52 - (6.5 − 0.03125)2 ) x 0.0009714) = 3.34 bbls of potential film on the
ID of the casing.
Assuming this film volume will substantially contaminate the shoe slurry, twice
this volume should be considered a minimum shoe track volume. This
recommendation can be amended based on local experience.
- If two each wiper plugs (top and bottom) are used, the shoe track length should
be equal to:
• 120 ft (36 m) for casing sizes equal to 9 5/8 in (244.48 mm) and smaller
• 80 ft (24 m) for casing sizes greater than 9 5/8 in (244.48 mm)
- For inner string stab-in cement jobs, the shoe track length should be equal to 40
ft (12 m).
- For inner string cement jobs where it is not stabbed in, the end of inner string
should be 200–250 ft (60–76 m) above the top float. TOC at the end of
displacement should be 100 ft (30 m) above the top float.
5.3 Spacer Volume

The volume of spacer should be between 800 to 1000 ft (244 to 304 m) of annular casing
by open hole fill or a volume equal to 8 to 10 minutes of contact time at the job pump rate,
whichever is greater. An example of spacer volume based on contact time would be 10
min x 6 bpm = 60 bbls of spacer.
• The spacer design is critical to the cement job success. Rheological properties of the
spacer should be optimized for effective mud displacement and rheological hierarchy
using the service contractor simulation software for primary and remedial cement
jobs.
Mechanical separation of the spacer and cement shall be used to avoid contamination of
the spacer while travelling down the tubulars.
In many instances, an acceptable practice is large volumes of lead or “scavenger” slurry
used as a surrogate spacer, assuming such practice is not ill-advised due to mud/cement
incompatibility.


5.4 Casing Hardware
Casing hardware is an integral part of cementing. The following hardware types should
be considered based on the job type:
• Wiper plugs/darts/mechanical separators
- Liner cement job – top and bottom wiper plugs with releasing darts
- Casing cement job – top and bottom wiper plugs
- Tieback cement job – top and bottom wiper plugs
- Inner string cement job – two wiper balls or drill pipe wiper darts to provide
mechanical separation of the cement slurry. Use catcher sub to catch the wiper
balls or wiper darts.
- Cement kick-off plug – two wiper balls or drill pipe wiper darts to provide
- Standard cement plug – two wiper balls or drill pipe wiper darts to provide
• Some jobs where multiple cement plugs are set may not use a catcher sub
for the wiper balls/darts due to the limited capacity of the subs.
• Use of foam wiper balls does not require a catcher sub.
NOTE If circumstances dictate that minimum requirements cannot be met for casing
and liner jobs, a deviation to the requirement will be implemented and a
sufficient shoe track length shall be used to offset the risk of a wet shoe from
the mud film on the ID of the pipe.
• Float shoe/collar:
- Liner cement job – minimum two float valves shall be used when the string is set
across a hydrocarbon zone.
- Casing cement job – minimum two float valves shall be used when the string is
set across a hydrocarbon zone.
- Tieback cement job – landing collar, baffle plate, or float valve with a weep hole
so as to prevent a hydraulic lock when lowering the tieback string into the
polished bore receptacle (PBR).
9
- All float equipment shall meet or exceed API Standard RP 10F .
• Centralizers:
- If a potential flow zone is present – minimum standoff should be 70% to a point
500 ft (152 m) above the top of the potential flow zone
- If no potential flow zone is present–minimum standoff should be 70% to a point
500 ft (152 m) above the shoe
- Expandable casings – mold on casing centralizers to a point 100 ft (30 m) above
the shoe
- All centralizers shall meet or exceed API Standard RP10D10.
- Type and placement shall be determined by the results from the Service
Contractor’s standoff/running software and available centralizer inventory Service
Contractor software can provide cement displacement simulations based on
standoff (Schlumberger–Wellclean™, Halliburton–iCem™ and Displace3D™, BJ–
CemFACTS™, Weatherford - CEMPRO™). These simulations should be used
to determine whether adequate displacement efficiency is achieved at the
calculated standoff.


NOTE For special conditions and circumstances such as highly deviated wells,
horizontal wells, and casing string with tight dimensional tolerances, please
contact Shell Cement and Drilling Fluids SMEs.
5.5 Lab Testing

See Section (10) for Cement Testing Guidelines.
5.6 Stress Modeling

A stress analysis to design the cement sheath for long-term integrity shall be performed
on wells that are expected to undergo extreme or repeated thermal and/or pressure
changes. Examples include wells for steam flood, Steam-Assisted Gravity Drainage
(SAGD), gas storage, certain deepwater wells, High Pressure High Temperature (HPHT)
wells, and any well that is subjected to cyclic pressure and temperature conditions. Wells
that will be subjected to severe loads due to events such as production-induced
subsidence are also candidates. Stress Modeling is a time and resource-intensive
process that shall be completed prior to project startup. Although some cementing
contractors can perform this service to various levels of competency, the Shell Cement
SME should be engaged for all wells requiring stress modeling. Shell has the internal
expertise to perform this modeling entirely or to work with the Service Contractor to
validate its work for the asset.
Service Contractor software available for stress modeling includes CemStress™ from
Schlumberger and WellLife™ from Halliburton.
The results of the stress modeling should be used to determine appropriate set cement
mechanical properties needed for survivability of the cement sheath during the life of well
events.


6 CEMENTING BASIS OF DESIGN CRITERIA
The responsibility for deviation of this section shall be as per Wells DCAF in accordance with
the deviation process described in the Preface.
The purpose of this section is to clearly define the minimum requirements for the cementing
Basis of Design (BOD) provided by the Service Contractor. A BOD shall be written for all
primary casing and liner cement jobs. Although not required a BOD is recommended for
remedial plug and squeeze cement jobs. Providing a thorough, well-written document that
defines the objectives and presents the proposed cement designs and simulations is critical to a
successful job. The requirements stated in this document represent the absolute minimum and
shall be adhered to. BOD shall be updated prior to the cement job to reflect any operational
changes and location materials/fluids lab test results.
6.1 Requirements of a Cementing Basis of Design

At a minimum, the BOD shall include:
• Signoff and revision table
• Cementing requirements as stated in the WFS document
• A brief discussion (summary) of the key inputs used for slurry designs and simulation
calculations. This would include fluid properties used, temperatures used, pumping
rates, calculated TOC, and centralizer specifications data.
• Primary objectives and measures of success for the job. These objectives shall be
clearly defined with agreed acceptance criteria between the company and Service
Contractor. Examples of this would be:
- Requirements from the WFS
- What is the required TOC planned in the cementing program and why?
- Acceptable Formation Integrity Test (FIT) with no shoe squeeze
- Maintain well control.
- Achieve goal zero; no accidents or incidents.
• Recommended mud property requirements for a successful cement job based on
discussions with the mud service provider, PC/Well Fluids Focal Point, and Shell
drilling team. This may involve changing out the mud system from the one used to
drill the section.
• Time to circulate the well and the rate to circulate at prior to the cement job
• Recommended Practices (RPs) for success based on the lessons learned on like
jobs in the area and or industry findings
• Potential risks if the planned job deviates from the best practices. For these risks,
assessment of consequence shall be carried out and Health, Safety, Security, and
Environment (HSSE) as Low As Reasonably Practicable (ALARP)
mitigation/contingencies detailed.
• Job information to include casing and openhole data as well as detailed spacer and
slurry designs, mixing instructions, and calculations of fluid volumes including excess
- Recommended spacer and cement slurry properties with ranges of acceptance
- Any specific lab testing guidelines
- Planned TOC shall be a minimum of 500 ft (152 m) above potential flow zone or
as stated by local regulatory requirements, whichever is greater.
- Shallow aquifers shall be isolated by cement.
• Detailed breakdown of the pumping schedule and estimated job placement times for
all slurries, including general job procedures such as rig up and necessary rig
activities


• Simulation software shall be used to validate design against cement job objectives.
Output and plots to include:
- Final fluids position plot
- Estimated differential pressure at the end of the job as the top plug lands. All
casing and liner cement jobs shall be designed to have a positive differential
pressure as the top plug lands.
- Equivalent Circulating Density (ECD) at the previous shoe
- ECD at the current shoe or end of workstring or point of interest
- Maximum ECD plot verses depth of the entire openhole section
- Erodibility/Fluids Displacement Efficiency/Fluids Interface Modeling graphs for the
entire openhole section for predicted top of good cement
- Calculated centralizer standoff across the area where the centralizers are placed
- Temperature simulation plots for BHCT and Wait on Cement (WOC)
temperatures
- Rheological Hierarchy graph based on pump rates for pumped fluids
- Anticipated differential pressure at the end of the job
• Preliminary lab reports. See Recommended Slurry Tests in Section (10.2).
• Detailed specifications of surface mixing and pumping equipment as well as
downhole float equipment and service tools
• Estimated costs and volumes for materials and services. Materials costs should
include excess.


7 TEMPERATURE SIMULATION
Typically, the most critical parameter used to design a cement slurry for placement in a wellbore
is temperature. The amount of retarder or accelerator used in the design can only be
determined by running thickening time tests using the correct temperature profile for that
specific job. During well execution, simulations shall be continually updated with all new
information as it becomes available because this may alter the final slurry design.
7.1 Temperature Simulation for Cement Design

• The Wells Engineer (WE) shall provide the Service Contractor with the geothermal
gradient and lithology information as soon as possible to allow design/simulation.
These data shall be based on information from the Geologist responsible for the
project. Actual logged Bottom-Hole Static Temperature (BHST) together with offset
well data should be used when available.
• For deepwater applications, the Wells Engineer (WE) shall provide the Service
Contractor with the seawater temperature gradient information and current profile.
• The Service Contractor is not responsible for predicting/determining the geothermal
gradient or actual BHST.
• The Service Contractor shall be responsible for using the gradient data to accurately
simulate BHCT and use the simulated temperature profile in slurry design.
• The Service Contractor should have access to software designed to simulate the
thermodynamics of fluid circulation in the wellbore.
Examples of software platforms:
TM
- Wellcat (Landmark)
- CemCADETM (Schlumberger)
- iCemTM (Halliburton)
- CemFACTSTM (Baker Hughes)
- CEMPROTM (Weatherford)
• BHST shall not be taken from measurement-while-drilling (MWD) data without the
Cementing SME’s approval and guidance. MWD temperature data can be higher due
to additional heat at the BHA caused by mechanical energy during the drilling
process. Actual logged BHST should be used when available.
• Temperature simulation should replace all other BHCT determination methods (e.g.,
API calculations, Service Contractor spreadsheets) where feasible, unless proven
success exists using local or field-specific correlations.
- The Temperature vs. Time profile generated by the temperature simulation
software should be used as the temperature schedule for thickening time tests.
Only the “First Sack” plot shall be used.
- The WOC profile generated by the temperature simulation software should be
used as the temperature recovery schedule for compressive strength and
ultrasonic cement analyzer testing. The “Last Sack” plot should be used for
testing cement slurries around the shoe. The “First Sack” plot can be used when
the compressive strengths at the TOC are required.
NOTE
- The term “First Sack” is used in temperature simulation software to indicate
the first sack of cement mixed and pumped down the tubing.
- The term “Last Sack” is used in temperature simulation software to indicate
the last sack of cement mixed just before going to displacement.


- Additional information on API temperature calculations can be found in API
Technical Report 10TR311.
• Temperature simulation shall be run on all wells that fall under the following
classification:
- Any job with BHST > 300 °F (148 °C)
- Any deepwater well
- Deviated wellbores with a horizontal step-out of more than 1,000 ft (304 m)
- Wellbores that have nonlinear geothermal gradients such as those involving
massive salt zones
- All production casing and liner jobs
- Extreme environments or non-typical operations such as coiled tubing,
expandable liners, steam flood injection wells, geothermal wells
• For BHCT calculated using API calculations or Service Contractor spreadsheets, the
ramp time to temperature for thickening time tests should be equal to the cement job
placement time. It is always important to use sound engineering judgment to
determine BHCT for thickening time tests.
• For standard compressive strength and ultrasonic cement analyzer testing, when a
temperature simulation is not run, the recovery time from BHCT to BHST should be a
minimum of 18 hours. This recovery time is conservative and has been used
successfully to determine WOC times.
• The Service Contractor shall include the temperature simulation chart(s) in the
cementing basis of design and attached with the cement design lab report(s) for
review by the Wells Engineer (WE).
• In addition to determining the estimated BHCT during the job, the simulation software
should be used to calculate the thermal production profile of the well from Total
Depth (TD) back to surface if the bottom-hole production temperature is expected to
be over 230 °F (110 °C). This profile represents the temperatures in the casing
strings above TD when the well is on production. These data can be used to
determine whether silica flour is needed in the shallower casing and liner strings to
avoid strength retrogression of the set cement when temperatures exceed 230 °F
(110 °C) during production.
• If the well is an injector well, the thermal injection profile can be estimated using the
simulation software. This profile can be used in stress modeling to determine the
effect of the reduction in temperatures from injection on the cement sheath.


8 PIPE CENTRALIZATION
This section defines the minimum standards for the standoff or eccentricity of pipe in a wellbore
during a primary cement job. This document may apply to any situation where displacement of
a fluid is affected by centralization, including, but not limited to, placement of balanced plugs.
These guidelines are not specific to any one Service Contractor or operating area. These
guidelines are provided to aid the engineer in understanding the importance of mechanical
standoff of a casing to the outcome of a cementing job. Deviation from these minimum
requirements shall include alternative methods such as additional spacer/cement volumes and
pipe manipulation to ensure zonal isolation.
8.1 Requirements for Pipe Centralization/Standoff

Shell requires that all liner and casing jobs consider the following issues for centralizer
placement:
• A minimum value of 70% standoff should be applied from TD up to and across the
zone of interest. The engineering software simulation by the pumping Service
Contractor will indicate if deviation from this value is recommended. Figure 2 below
illustrates standoff.
• Standoff calculations should include the directional survey and caliper log or best
estimate of hole size.
• The contractor(s) shall provide Shell with a simulation report with recommended
centralizer type, placement, running force calculations, standoff at the centralizer and
between centralizers.
- The contractor’s simulation software should take into account joint lengths for
calculations and installation.
- The recommended contractor software is CemCADE (Schlumberger), iCem
(Halliburton), CemFACTS (Baker Hughes) and CEMPRO (Weatherford).
• If the centralizer component supplier is different from that of the pumping service
company, the centralizer component provider should supply the pumping service
company with all necessary technical information of said components so that the
displacement simulator can account for standoff.
Figure 2 – Illustration of Standoff

NOTE Eccentricity = 100% standoff


9 MECHANICAL SEPARATION BETWEEN FLUIDS
The purpose of this section is to clearly define the minimum standards for the mechanical
separation (e.g., wiper plugs and darts) between fluids when being pumped down a tubular
such as casing or drillpipe.
9.1 Requirements of Mechanical Separation

The following shall be adhered to:
• Top and bottom wiper plug and/or dart directly ahead of and behind the cement slurry
• Plug/dart set correctly sized for the tubulars, including tapered strings
• All rubber components compatible with the fluids in the wellbore and at maximum
BHST
• Plugs to be compatible with the float collar or landing collar
Wiper equipment requirements specific to the Service Contractor shall be outlined in the
contract. At a minimum, the requirements shall include:
• Part numbers and certification documents
• Verifiable documentation that the personnel on location are qualified to operate it
• Documentation on operating limits and requirements of each piece of equipment
General guidelines:
• Double-plug containers are preferred to prevent pumping interruptions and minimize
HSSE risk on the rig floor.
• Positive pump-down plug containers are preferred over gravity-release.
• The cement pumping line should be closed while dropping the top and bottom plugs
to ensure that no fluid is sucked down the tubular if the well is on vacuum.
• For smaller-sized production strings [7 in (17.78 cm) or less] putting cement on top of
the top plug during displacement should not be done. This is because the cement on
top of the plug may need to be drilled out before completing the well. Drilling out of
the cement could cause unwanted wear on the inside of the casing.


10 CEMENT LABORATORY TESTING GUIDELINES
The responsibility for deviation of this section shall be as per PC DCAF in accordance with the
deviation process described in the Preface.
This section outlines the basic minimum requirements for Service Contractor and Shell
laboratory cement testing and is not intended to replace engineering due diligence.
10.1 Guidelines Summary

The extent of pre-job testing should be commensurate with the severity of well
conditions, operational complexity, operating environment, and cost environment. The
higher the risks, the more stringent the pre-job lab testing.
The intent of these testing guidelines is to allow considerable flexibility as to the extent of
testing and test conditions; however, there are some specific requirements:
• No cement slurry shall be pumped on any Shell well that has not been previously
pilot tested.
• All cement jobs shall be field-blend (location-blend or rig-blend) tested prior to the job
using location cement, water, and additives. The Service Contractor shall provide a
quality-controlled thickening time test chart and compressive strength test chart for
the final slurry design(s).
• If both pilot and field materials are tested, both sets of test charts shall be submitted
to the Wells Engineer (WE) for review. If the test data are acceptable, then the results
of the final field materials should be given to the location site to avoid confusion.
• The Service Contractor, engineer, or technical advisor assigned to the well shall be
responsible for providing test parameters to the Service Contractor’s laboratory,
including test temperature and pressure, time to temperature, thickening time
window, etc.
• All cement lab testing shall be performed based upon a well-specific BHCT model.
Verification testing at the Shell laboratory may be required for critical jobs.
• A temperature simulation shall be performed at a minimum as per the job types in
Section (7). The temperature results shall be used for cement testing at simulated
conditions.
The type and quantity of testing required for each job is at Shell's discretion. See Section
(10.2) for a guideline of tests required.
10.2 Recommended Slurry Tests

API/ISO RPs and standards provide detailed procedures for dry-cement sampling, slurry
preparation, equipment specifications, etc. However, these documents stipulate that,
when reasonably possible, cement tests should be performed under simulated well
conditions. Use API standard testing procedures only if other suitable information is
unavailable.
API testing procedures and specifications for cement and materials for well cementing is
12 13 14 15
provided in documents API 10A , API 10B-2 , API 10B-3 , API 10B-4 and
16
API 10B-6 .
Use sound engineering judgment to determine cement test parameters. The Service
Contractor shall provide the recommended testing parameters for review and approval by
the Wells Engineer (WE) and PC/Cementing Focal Point. Cement tests shall be
performed based on anticipated well conditions and the anticipated cement job sequence
(mud pre-conditioning, pump rates, volumes, etc.). If the well conditions and/or the job
parameters change, the Wells Engineer (WE) should be consulted as to the possible
ramifications and the need to retest.
For a variety of reasons it may be necessary to test the same slurry design under
anticipated placement conditions and contingency or “what if?” conditions. Sensitivity
tests may be required if, for example, the BHCT is uncertain.


Retesting due to significant changes in well conditions and job procedures shall be
approved by the Wells Engineer (WE).
Examples of significant changes include:
• Severe losses necessitating a change of pump rate
• Change in BHCT +/-10 °F (+/-5 °C)
• More than 20% change in slurry volume and/or significant change in placement time
• Well has taken an influx
• Change to planned displacement fluid (i.e., due to losses during section)
• Change of hole size or angle/geometry (+/-10°)
• Complete changes to slurry designs
• Mud weight is increased by more than 0.5 ppg (0.06 SG)
• A change in mud type
On the job, if actual well conditions and/or placement procedures differ from those used
for testing, the Service Contractors shall provide the Wells Engineer (WE) their opinion
as to the viability of the planned cement job design before the job commences. This may
lead to additional confirmation testing as required.
Table 2 is only a guideline. Special cases may require more testing or less. The
cement job objectives shall be discussed with the Service Contractor to determine if
additional or less testing is needed.


Table 2 – Recommended Testing Based on Job Type
Multi-
Interme- Produc- Riser- Expan- CT
Surface Prod. Kick-off Plug to stage
diate Liner 1 tion less dable Tieback Cement
Casing Liner Plug Abandon Cement
Casing Casing Casing Liner Job
Job
Test
See
Thickening Time ✔ ✔ ✔ ✔ ✔ ✔ ✔
note 11
Modified
Thickening Time See See See See See
(see note note 5 note 5 note 6 note 11 note 7
below)
Ultrasonic
Cement
See See See
Analyzer ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔
note 3 note 3 note 11
Compressive
Strength
See
Fluid Loss ✔ ✔ ✔ ✔ ✔ ✔
note 11
Tail See
Free Fluid ✔ ✔ ✔ ✔ ✔ ✔ ✔
Only note 11
Rheology at
80°F (27°C) See
and BHCT ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔
note 11
(see note 8 )
See
Settling Test ✔ ✔ ✔ ✔ ✔ ✔ ✔
note 11
Static Gel
Strength See
✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ note 4
Transition Time and 11
(see note 4)
Pressurized
See
Mud Balance of ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔
note 11
slurry density
Compressive
Strength
Contamination ✔ ✔ ✔ ✔ ✔ ✔
Testing
(see note 9 )
Thickening
Time Sensitivity See
Testing ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ note 10 ✔
and 11
(see note 10 )
Slurry Mixability ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔
Rheological
compatibility ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔
(see note 1)
Wettability
testing (see ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔
note 2)
Note 1). Rheological compatibility of mud/spacer/cement should be tested on all casing and liner strings when
weighted spacers are used. See Section (10.19) below.
Note 2). Wettability should be tested on all casing and liner strings when non-aqueous-based drilling muds are
used. See Section (10.20) below.
Note 3). For liner jobs with annular cement fill greater than 2,000 ft (607 m) total (true) vertical depth,
compressive strength tests shall be performed at the predicted conditions of both the top and bottom of
the liner. Additional contamination testing with wellbore fluids can be done to evaluate the impact of
contamination on compressive strengths and strength development.
Note 4). Static gel strength – transition time should be checked on all cement slurries placed across potential
flow zones. See Section (10.18) below.
Note 5). Modified thickening time tests for liner strings where the cement slurry could come above the liner
hanger. Perform a thickening time test with a stirring-motor stoppage period that simulates the post
slurry-placement (liner setting) procedure. Perform the stoppage test in addition to the conventional
thickening time test. This is done once the slurry reaches BHCT. See Section (10.12) below.
Note 6). Modified thickening time tests for expandable liners includes multiple stop/start sequences where the
slurry cup paddle is stopped and started again. The number of start/stops is determined by the number
of expansion sequences. See Section (10.12) below.
Note 7). Modified thickening time tests for CT cement jobs includes testing the slurry at BHST conditions. This is
due to the fact that little circulation will be done before the job to cool the hole down. See
Section (10.12) below.


Note 8). Test rheological properties at ambient conditions and at BHCT or 190 ºF (88 °C); whichever is lower.
To improve simulation accuracy for critical jobs, test rheological properties at three different
temperatures—typically ambient, intermediate, and BHCT. See Section (10.15) below.
Note 9). Compressive strength contamination testing should be performed with 10% mud contamination. For
liner applications where the cement is placed in the lap, this should be tested at the TOL static temp.
See Section (10.11) below.
Note 10). Thickening time sensitivity testing should be performed on all slurries when the BHCT is greater than
250 °F (121 °C). See Section (10.13) below.
Note 11). Multi-stage cement jobs are similar to traditional casing cement jobs except the job is divided into
multiple jobs. The first job may be similar to a production casing and the second similar to an
Intermediate of surface casing job. Slurry design, testing, and procedures for a multi-stage cement job
should be reviewed with a Cementing SME during the planning of the job.
10.3 Testing Roles and Responsibilities

Shell shall provide accurate and detailed well information to the Service Contractor within
24 hours of receiving the request. Shell and the cement Service Contractor should agree
on what tests to perform, test conditions, and range of acceptable results.
The Service Contractor engineer or technical advisor assigned to the well shall provide
test parameters to its laboratory. Test parameters should include, but are not limited to:
• Slurry density
• Basic slurry components (e.g., cement type, water source, silica, salt, fluid loss, etc.)
• BHST/BHCT
• Final bottom-hole pressure (for thickening time test and ultrasonic cement analyzer)
• Time to temperature/pressure (for thickening time test and ultrasonic cement
analyzer)
• Thickening time window
• Fluid loss range
In some regions, Shell has a laboratory that can perform verification testing and pilot
testing for the operating company. Tests to be done and the specifics of those tests shall
be overseen by the local PC/Cementing Focal Point and/or Cementing SME.
Laboratory personnel (Shell and Service Contractor) should not determine test
parameters without interaction with the engineering team.
Laboratory personnel (Shell and Service Contractor) shall be responsible for accurately
and completely reporting test results to the Shell representative. The lab report should
include comments related to any testing abnormalities such as slurry gelation, settling,
excess foaming, incompatibility, and modified testing procedures. Thickening time tests
should be terminated promptly once the slurry has set and the test cup removed
immediately for visual inspection of the cement slurry inside. Comments about the visual
appearance of the set slurry inside the thickening time test cup shall be reported on the
lab report.
Accuracy of these reports is important because the data is used in the execution of the
cement jobs.


10.4 Temperature Simulation
Temperature simulation software should be used to determine the BHCT for all cement
jobs and shall be performed on the following categories:
As per Section (7):
• Any job with BHST > 300 °F (148 °C)
• Any deepwater well
• Any well with a horizontal component of it trajectory over 1,000 ft (304 m)
• Wellbore with nonlinear geothermal gradients such as massive salt zones
• All production casing and production liner jobs
• Extreme environments or non-typical operations such as coiled tubing
It is always important to use sound engineering judgment to determine BHCT for
thickening time tests.
In addition to determining the estimated BHCT during the job, the simulation software
should be used to calculate the thermal production profile of the well from TD back to
surface if the bottom-hole production temperature is expected to be over 230 °F
(110 °C). This profile represents the temperatures in the casing string above TD when
the well is on production. These data can be used to determine whether silica flour is
needed in the shallower casing and liner strings to avoid strength retrogression of the set
cement when temperatures exceed 230 °F (110 °C) during production.
If the well is an injector well, the thermal injection profile can be estimated using the
simulation software. This profile can be used in stress modeling to determine the effects
of the reduction in temperatures from injection on the cement sheath.
See Section (7) for more details on temperature simulation.
10.5 Representative Sampling Guidelines

• Samples collected from a contractor facility:
- Additives shall be requested by the Service Contractor in writing/e-mail to its
facility. Avoid verbal orders.
- Updates to Shell from the contractor regarding the status of the samples during
this process shall be required. At a minimum, an e-mail and/or phone notification
shall be required when the samples are shipped.
- Prior to collecting liquid additive samples, the contractor shall circulate or stir
liquid materials in the parent container. Bubble hoses shall not be used; only
mechanical agitation or circulation is acceptable.
- Dry additive samples shall be collected from containers/packaging that are not
damp or damaged. Samples taken from damaged containers may be
contaminated and lead to inaccurate test results.
- Dry bulk cement samples shall be collected from the transfer line using an in-line
sampling device.
• Automatic in-line sampler
• Delta “Y” sampling point
- Samples shall have the following information labeled on the container:
• Additive name
• Collection date
• Where was it collected
• Leak-Off Test (LOT) number/manufactured date
• Shipping destination and any detailed instructions


- All samples must have accompanying MSDS data sheets as required by local
regulation and shipping company.
- Additives shall be shipped to the contractor’s lab, where they will be logged into
inventory and assigned sample identity numbers. Samples shall then be split
before shipping to Shell’s lab. Shell will advise how much must be shipped.
- Splitting of samples shall be done as follows:
• Container shall be rolled/stirred/mixed well before splitting.
• For dry material splitting, using a V-blender is preferred. See Figure 3 below.
Figure 3 – V-Blender
• Splitting shall be from the same container so that the Service Contractor and
Shell have equivalent samples representative of what is on location.
- All samples shipped to the Shell lab shall have the following labels and
documents:
• Additive name
• Collection date
• Collection point
• LOT number/manufactured date
• All samples sent to a Shell facility shall have accompanying MSDS data
sheets.
• Lab inventory sample ID number that was used in the contractor’s lab testing
procedures
- Contractor shall notify Shell when the samples are being sent.
- Shell shall notify contractor when the sample is received.
• Samples collected from well-site:
- Additives shall be requested by the Service Contractor in writing/e-mail to its
well-site representative. Avoid verbal orders.
- Updates to Shell from the contractor regarding the status of the samples during
this process shall be required. At a minimum, an e-mail and/or phone notification
shall be required when the samples are shipped.
- Prior to collecting additive samples, the contractor shall circulate or stir liquid
materials in the parent container before collection. Bubble hoses shall not be
used; only mechanical agitation or circulation are acceptable.
- Dry additive samples shall be collected from containers/packaging that are not
damp or damaged.


- Dry bulk cement samples shall be collected from the transfer line using an in-line
sampling device.
• Automatic in-line sampler
• Delta “Y” sampling point
- Samples shall have the following information labeled on the container:
• Additive name
• Collection date
- All samples sent to a Shell facility shall have accompanying MSDS data sheets.
No exceptions.
- Additives shall be shipped to the contractor’s lab, where they shall be logged
into inventory and assigned sample ID numbers. Samples shall then be split
before shipping to Shell’s lab. Shell shall advise how much must be shipped.
- Splitting of samples shall be done as follows:
• Container shall be rolled/stirred/mixed well before splitting.
• For dry material, splitting using a V-blender is preferred. See Figure 3 above.
• Splitting shall be from the same container so that the Service Contractor and
Shell have equivalent samples representative of what is on location.
- All samples shipped to the Shell lab shall have the following labels and
documents:
• Additive name
• Collection date
• All samples sent to a Shell facility shall have accompanying MSDS data
sheets. No exceptions.
• Lab inventory sample ID number that was used in the contractor’s lab testing
procedures.
- Contractor shall notify Shell when the samples are being sent.
- Shell shall notify contractor when the sample is received.
10.6 Pilot Testing

The Service Contractor shall provide pilot test results in a timely manner. No cement
slurry design shall be pumped on any Shell well that has not been previously pilot tested.
Pilot test results shall be used as the basis of the design for comparison with field-blend
tests.
Whenever reasonably possible, the same material LOT numbers for the cement job shall
be used for pilot testing; otherwise, lab samples of cement and additives shall be used.
Cement and additive LOT numbers shall be reported on the test report.
10.7 Field-Blend Testing

Field-blend testing is defined as lab testing using samples from the field/rig/location that
have been dry blended. This can also include liquid samples from the field/rig/location
that will be used on the job.


The Service Contractor shall provide field-blend (location-blend or rig-blend) test results
in a timely manner. All critical cement jobs shall have field-blend testing prior to the job.
Deviation from this will follow the DCAF process.
For land jobs, a 50-sack field-blend test or test a composite sample of the entire job shall
be performed; whichever method is approved locally by the Shell Cementing TA or SME.
Cement and additive LOT numbers shall be reported on the test report.
For offshore jobs, field-blend tests shall be performed using rig samples of dry cement
(blended or neat), additives samples taken from the materials on the rig, and rig water
(fresh or seawater).
10.8 Slurry Preparation

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Cement slurries shall be prepared according to API RP 10B-2/ISO 10426-2 mixing
procedures. Any deviation from the API mixing procedures on the lab report shall be
reported. An example is the preparation of high solids to water ratio slurries.
All tests shall be performed with room-temperature mix water unless field conditions
dictate otherwise. The use of non-ambient temperature mix water shall be reported on
the lab report.
Lab testing shall be performed with representative samples of the cement, water, and
additives that will be used on the job.
Mixing fluid preparation in the laboratory should mimic fluid preparation in the field (and
vice versa). Document the detailed mixing procedure and order of chemicals used on the
lab report.
10.9 Slurry Mixability

Determining the mixability of a slurry can only be done by mixing the slurry in a warring
blender as per API RP 10B-2/ISO 10426-2 Section 5.3.4 and observing how the dry
materials wet with the mixing fluids and the vortex of the slurry in the blender jar.
Below is an example of a scale that can be used for grading mixability. The scale is a
guide and can vary slightly based on Service Contractor and technician’s observation.
• A mixability of “5” means that the dry material mixes with the mixing fluid in less than
15 seconds with a good visible vortex in the blender.
• A mixability of “4” means that the dry material mixes with the mixing fluids in 15–30
seconds with a good visible vortex in the blender.
• A mixability of “3” means that the dry material mixes with the mixing fluids in 30
seconds to 1 minute with a small viable vortex in the blender. Stopping during the
blending may be required to allow trapped air to be released, which can improve
mixing. This level of mixability may indicate that batch-mixing the slurry may be
required in the field.
• A mixability of “2” means that it was difficult for the dry materials to mix with the
mixing fluids and took a longer time (> 1 minute) for the material to wet and form a
vortex in the blender. Typically little to no vortex is seen.
• A mixability of “1” means that the dry materials took a very long time (significantly
longer than 1 minute) to mix with no vortex.
• A mixability of “0” means that the dry materials are not able to wet when in contact
with the mixing fluid no matter how much time is applied.
Typically, a mixability of “2” and less is not accepted, and the slurry should be
redesigned. Deviation from this shall be reviewed by the Well Engineer (WE) and
Cementing SME. A mixability of “3” is acceptable, but field personnel should be advised
that a slower mixing rate may be needed during the job. Mixability ratings of “4” and
above can be mixed on location at standard mixing rates.


10.10 Slurry Density
It is important that all slurries prepared using field blends have the density measured
using a pressurized fluid balance. This is a simple means to quickly gauge whether the
field-blend slurry falls within the calculated design specifications for density. Pressurized
fluid balance densities that do not meet the calculated design density indicate potential
QA/QC issues with the blended cement. Report the measured slurry density and the
calculated design density on the lab report.
Some specialized blends with high concentrations of lightweight additives will require
Specific Gravity (SG) tests (pycnometer) of the dry blend. The SG of the rig blend should
be compared to the lab blend to determine if there are potential bulk-blending quality-
control issues. Consult the Shell Cementing TA/SME when these types of slurries are
used.
10.11 Compressive Strength

Reference API RP 10B-2/ISO 10426-213 shall be used for both the destructive (crush)
and non-destructive (sonic) compressive strength testing specifications and procedures.
Table 2 in Clause 7 of the API/ISO document for testing schedule parameters should not
be used. Instead the estimated Bottom-Hole Pressure (BHP) and Temperature Recovery
schedule from the temperature simulation software should be used.
The recommended method for compressive strength testing should be with an ultrasonic
cement analyzer. The cement samples shall be cured based on anticipated downhole
conditions (temperature and pressure), job sequence, and temperature recovery. The
temperature ramp and test pressure shall be reported on the laboratory test report.
For liner jobs with annular cement fill greater than 2,000 ft (607 m) total (true) vertical
depth, compressive strength tests shall be performed at the predicted conditions of both
the top and bottom of the liner. Additional contamination testing with wellbore fluids
should be done to evaluate the impact of contamination on compressive strengths and
strength development. Typical contamination ratios are 10% and 20% by volume of
cement slurry. The cement slurry shall be conditioned in the consistometer as
appropriate based on downhole conditions and placement sequence.
The Service Contractor should provide an electronic copy (PDF format preferred) of the
ultrasonic cement analyzer compressive strength test chart. The ultrasonic cement
analyzer test chart should include individual traces for transit time, temperature, and
compressive strength. The pressure trace should be included if the device capabilities
allow. The ultrasonic cement analyzer chart should include a unique project number,
cement slurry composition, test pressure, and test date.
10.12 Thickening Time

Thickening time tests shall be performed based on anticipated well conditions and the
anticipated job sequence using a consistometer. Standard API/ISO test schedules
should be modified to emulate the anticipated job conditions. Surface mixing time and
field conditions for jobs that are batch mixed shall be accounted for. Batch-mix time
(surface retention time) shall be reported separately from total thickening time.
If insufficient information is available to model the anticipated well conditions, the most
appropriate API RP 10B-2/ISO 10426-2 standard test schedule shall be used. Test
parameters, no matter which test schedule is used, shall be reported.
The time to the arbitrary Bearden Unit (Bc) of consistency such as 40 or 70 Bc shall
appear on all lab reports. The Point of Departure and/or heat of hydration shall also
be reported on the lab report. Heat of hydration is defined as when the cell temperature
and the wall temperature cross on the HPHT consistometer test chart. Heat of hydration
can be an important reference point when it occurs before the viscosity increases and
point of departure. It identifies when the slurry is chemically beginning to start the setting
process and should be considered the maximum pump time. In some instances, the heat
of hydration may not be seen due to the type of slurry and/or the testing equipment. For


Shell slurry designs, the point of departure is generally considered to be the maximum
time that slurry can be pumped. The point of departure is defined as the point on the
viscosity curve where the slope of the line makes a significant increase from a constant
state. See Figure 4 below.
Figure 4 – Example of Consistometer Thickening Time Chart

NOTE The maximum estimated job placement time is equal to the calculated job
placement time plus the safety factor.
NOTE The maximum estimated job placement time should be equal to or less than the
point of departure.
Safety factors are typically 0.3–0.5 times the estimated placement time. Another indicator
that the maximum job placement time has been reached is when the cement slurry
temperature and chamber temperature intersect, indicating that the cement is releasing
heat of hydration. The chart showing the Bc, slurry temperature, chamber temperature,
and pressure shall be provided to assess the complete dynamic behavior of the slurry.
The thickening time test chart should include a unique project number, cement slurry
composition, and test date.
10.12.1 Modified Pump Time Test Schedule
For some types of jobs, a modified pump time test schedule is required to reflect
the actual pump schedule of the job. Some of the modifications to API test
schedules to take into account are:
- Batch mixing: If the slurry is to be batch mixed, the slurry shall be pre-
conditioned at the expected surface temperature for the estimated time
required to mix the cement. Approximately 60 minutes is sufficient for typical
jobs, and 30 minutes is sufficient for small liner, plugs, and squeeze volumes
(although longer times may be used if applicable). Depending on local lab
practices, the pre-conditioning period may or may not be included in the
slurry thickening time. This distinction shall be clearly indicated in the lab
report with either annotations on the chart or in the “Comments” section
(preferably both).
- Time-to-temperature (heat-up rate): The time required for the leading edge of
the cement to reach TD should be calculated based on the following
equation (assuming top and bottom wiper plugs are used to separate the
fluids):


DisplacementVol.(bbls )
Time to Temperature:
EstimatedPumpRate(bpm)
Time-to-temperature is the time required to heat the slurry from ambient
conditions to the BHCT. This time shall be reported on the lab report. The heat-
up rate can also be determined from the temperature simulator software looking
at the “First Sack” time versus temperature plot.
- Liner jobs: For all liner jobs where the cement slurry will come above the liner
hanger, thickening time test shall be performed with a stirring-motor
stoppage period that simulates the post slurry-placement (liner setting)
procedure. Typical stoppage time is 30–60 minutes but should be based on
the estimated time to set the liner hanger. In calculating the slurry pumping
time requirement, the time to circulate out any excess cement on top of the
liner shall be taken into account.
- CT job: The thickening time test shall be performed at the BHST.
- Multi-stage cement job: For cement jobs where there are two stages, the
slurry design for the first stage should be tested with a shutdown period
during the thickening time test to account for the estimated time that it takes
to drop the opening plug to open the stage tool. The stage tool manufacturer
shall be consulted for the plug dropping time in the displacement fluid. The
time required to circulate out any excess cement above the stage tool shall
be taken into account in the slurry pumping time requirement. Compatibility
testing of the displacement fluid with the cement slurry shall be done to
ensure that when the stage tool is open and the displacement fluid comes
into contact with the cement, there is no viscous interface. If the displacement
fluid is incompatible, a cement compatible spacer shall be designed and
incorporated in the displace train. Recommended amount of spacer volume
should be equal to 300 ft (91 m) above and below the stage tool.
Thickening time chart(s) showing these modified test schedules shall be included
in the lab reports as well as a description of the testing schedule in the lab report
comments section.
10.13 Thickening Time Sensitivity Testing

The sensitivity of the cement slurries response to temperature and retarder concentration
changes should be considered. Sensitivity testing is typically done for cement jobs that
are performed at the lower and upper temperature ranges of a retarder. Variations in
cement slurry density, water content, or other additives may also affect retarder
performance.
All sensitivity testing results shall be reviewed and approved by a Cementing SME.
Table 3 below should be used to document the cement slurries’ response to changes in
retarder concentrations versus variations in the BHCT.
Table 3 – Slurry Sensitivity to Retarder and Temperature Variations
Designed Retarder
-10% Retarder +10% Retarder
Concentration
BHCT – 20 °F (-10 °C)
BHCT
BHCT + 20 °F (10 °C)
10.13.1 Sensitivity to Retarder Concentration

For retarder sensitivity testing, use concentrations of +/-10% for the design
retarder concentration.
Acceptable slurry designs should be those that generate:


- Thickening time > Maximum estimated job placement time with 10% less
retarder
- Thickening time < 1.5 × base slurry thickening time with 10% more retarder
- Thickening times that decrease with less retarder and increase with more
retarder
Slurries that do not meet these guidelines should be redesigned.
10.13.2 Sensitivity to BHCT
To account for the uncertainty of predicting the actual BHCT, the thickening time
should be repeated at +20 °F (10 °C) above and -20 °F (-10 °C) below the
predicted BHCT.
Acceptable slurry designs should be those that generate:
- Thickening time > Maximum estimated job placement time with BHCT + 20°F
(10°C) temperature
- Thickening time < 1.5 × base slurry thickening time at BHCT -20 °F (-10 °C)
- Thickening times that decrease with more temperature and increase with less
temperature
NOTE On rare occasions, there are combinations of cement and additives and
well conditions that do not exhibit this and shall be reviewed by the
Cementing SME to determine if the slurry design can be used.
Slurries that do not meet these guidelines should be redesigned.
10.14 Fluid Loss

Fluid-loss testing could be performed on any slurry but is typically only performed on
slurries that have fit-for-purpose fluid loss additives, slurries placed across permeable
zones, slurries used for loss circulation, and slurries that are pumped through tight
clearances. Fluid-loss tests shall be performed and reported according to
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API RP 10B-2/ISO 10426-2 . A stirring fluid-loss cell may be preferred for some slurries
and/or additives. Typically a static fluid-loss cell shall suffice below 190 °F (88 °C).
Above
190 °F (88 °C), the slurry should either be preconditioned in an HPHT consistometer to
BHCT before testing in a static fluid-loss cell or tested in a stirring fluid-loss cell. A stirring
fluid-loss cell allows the slurry to be stirred and conditioned at the BHCT before the static
fluid loss is measured.
General guidelines for fluid-loss values based on job types are below. These are only
guidelines and actual design values should be recommended by the Service Contractor
and reviewed by the Wells Engineer (WE) and PC/Cementing Focal Point. Local
requirements and past experiences should be referenced when determining fluid-loss
requirement.
• Surface casing and liner strings: not applicable for non-flow-potential applications
• Potential stray gas, surface casing vent flow: < 50 cc
• Intermediate casing and liner strings: 150–200 cc
• Production casing and liner strings: < 150 cc
• Casing and liner strings where there is a flow potential: < 50 cc
• Lost circulation: little-to-no control
• Shoe squeeze: 150–250 cc
• Perforation squeeze: job-specific, but could be as low as 50 cc and as high as
150 cc


10.15 Rheology and Gel Strength
A rotational viscometer shall be used to determine rheological properties and gel
strengths according to API RP 10B-2/ISO 10426-213. Rheological properties for each fluid
used on the job (flush, spacer, cement slurry, and mud) shall be determined.
Rheological measurements at five (minimum) rotational speeds (3, 6, 100, 200, and
300 rpm) shall be required. Additional readings at 10, 20, 30, and 60 rpm are
recommended and used in the Service Contractor’s simulations software to improve
accuracy.
Rheological properties at ambient conditions and at BHCT shall be tested, or at 190 °F
(88 °C), whichever is lower. To improve simulation accuracy for critical jobs, rheological
properties shall be tested at three different temperatures—typically ambient,
intermediate, and BHCT.
Pressurized or atmospheric conditioning shall be used for slurries tested below 190 °F
(88 °C). For pressurized conditioning, the appropriate heat-up test schedule for the well
conditions shall be followed. A heated sample cup shall be used as (when) specified by
API RP 10B-2/ISO 10426-2.
Pressurized conditioning shall be used for slurries with BHCT above 190 °F (88 °C). The
appropriate heat-up test schedule shall be followed for the well conditions. Rheologies at
190 °F (88 °C) shall be tested using a heated sample cup as when specified by
API RP 10B-2/ISO 10426-2.
10.16 Slurry Stability

The API RP 10B-2/ISO 10426-2 sedimentation test method shall be used to determine
the static post-placement stability for slurries in the following categories:
• Slurries that incorporate weighting agents, low density microspheres, bubbles, or
beads
• Slurries set across a potential flow zone, including all production casing and
production liner jobs
The API specifications do not advise what is the acceptable density difference from top to
bottom for the results of a sedimentation test. Typically it is recommended not to have
more than a 0.5 ppg density difference from top to bottom.
10.17 Free Fluid

Free fluid tests shall be performed according to API RP 10B-2/ISO 10426-2. For wells
deviated 15 ° or less, vertical or deviated tests should be performed. For wells deviated
greater than 15 °, free fluids tests at 45 ° should be performed. The angle of the test
shall be reported. Optionally, the test can be performed at the desired wellbore angle and
temperature, if the lab is so equipped.
A pressurized or atmospheric consistometer shall be used for conditioning of slurries with
BHCT below 190 °F (88 °C). For pressurized conditioning, the appropriate heat-up test
schedule for the well conditions shall be followed.
A pressurized consistometer shall be used for conditioning of slurries with BHCT above
190 °F (88 °C). The appropriate heat-up test schedule for the well conditions shall be
followed.
10.18 Static Gel Strength – Transition Time

Transition time testing should be done for all liners and production casing and any other
string where high potential for gas/fluid influx after cementing exists. Transition time is
defined as the time it takes for the static gel strength to build from critical static gel
2
strength to 500 lbs/100 ft . Transition time can also be called critical gel strength period.
The calculation for the critical static gel strength shall be performed as detailed in
API RP 10B-6/ISO 10426-6200816. The critical static gel strength will vary from job-to-job
based on the geometry of the wellbore, pore pressure, depth of the zone, density, and


height of the fluids. The test shall be done under pressure and temperature conditions at
the depth of the potential flow zone using an HPHT paddle-type static gel strength tester.
Transition time for a slurry across a potential flow zone should be minimized and not
exceed 45 minutes. See API RP 10B-6/ISO 10426-62008 for additional details on static
gel strength of cement formulations.
10.19 Fluids Compatibility

Compatibility of all fluid interfaces shall be tested and verified on all critical cement jobs.
In addition to all critical cement jobs, the compatibility should be checked in the following
circumstances:
• When the mud system changes
• When the mud weight is increased more than 2.0 ppg (0.24 SG) after a compatibility
test is done
• At least one compatibility test should be done per well independent of any testing for
critical cement jobs.
For OBM/SBM applications, checking the compatibility of the fluids and wettability of the
spacer should be done simultaneously because the surfactant loading in the spacer will
affect the mud/spacer compatibility testing.
The process for checking fluids compatibility is Shell-specific and listed below in three
steps:
•
13
The cement slurry shall be prepared in accordance to API RP 10B-2/ISO 10426-2 .
Spacers shall be prepared in accordance to service company procedures. All
preconditioning of fluids shall be started at 80 °F (27 °C) and ramped up to the BHCT
or 190 °F (88 °C), whichever is less using an atmospheric consistometer. This
should typically take 20 to 35 minutes, depending on the BHCT. A preheated
atmospheric consistometer shall not be used. Once at BHCT, the slurry shall be
conditioned for 20 minutes. For BHCT greater than 190 °F (88 °C), the PC/Cementing
Focal Point and/or Cementing SME shall be consulted to determine if conditioning is
to be conducted using an HPHT consistometer.
- For OBM/SBM, samples of mud should be taken as close to completion of
drilling the hole section and tested for compatibility as soon as possible. Samples
that are left static for too long and/or taken too far in advance may not reflect
what is in the hole. The sample should be taken from the return line before the
shakers. Sample should be filtered through the screen on the marsh funnel to
remove large drilling solids. It is important to take a sample of mud that has been
sheared during drilling and circulation. A mud report should be sent with the mud
sample. After arrival in the lab and before the sample is taken for testing, the
container should be stirred well. Prior to testing, the mud sample should be
preconditioned in an atmospheric consistometer and the electrical stability
checked at the temperature noted on the mud report [usually 120 °F (49 °C)].
Compare the mud sample electrical stability to that on the mud report. If the
sample’s electrical stability value is <30% of that reported, then the sample
should be placed in a waring blender and sheared for 60 sec at 10,000 rpm. This
can be repeated as needed to add additional shear to the fluid which should
strengthen the emulsion and increase the electrical stability of the mud. If the
sample’s electrical stability value is significantly higher (>50%), the sample may
not reflect what is in the wellbore. If this is the case, contact the mud company
service representative and PC/Cementing Focal Point or Cementing SME.
Conducting compatibility tests with a mud sample that has a higher electrical
stability than the actual mud in the hole can lead to inaccurate surfactant loadings
in the spacer design process. Inaccurate surfactant loadings could lead to poor
compatibility and instability at the mud and spacer interface. Check rheologies at
the same temperature that is reported on the mud report. If the sample rheologies


are significantly higher or lower, consult the mud company and PC/Cementing
Focal Point or Cementing SME.
- For water-based mud (WBM), stir the field mud sample to ensure uniformity in the
sample container. Check rheologies at the same temperature that is reported on
the mud report. If the sample rheologies are significantly higher or lower, consult
the mud company and PC/Cementing Focal Point or Cementing SME. A new
sample may need to be obtained.
• At a minimum, combinations of mud/spacer and spacer/cement shall be tested at
BHCT or 190 °F (88 °C) whichever is less. Report rheometer dial readings (3, 6, 10,
20, 30, 60, 100, 200, and 300 rpm) for combinations of compatibilities that were
tested. At a minimum, fluid ratios of 100/0, 25/75, 50/50, 75/25 and 0/100 shall be
run for all compatibility tests. Determine which of the three sets has the highest
likelihood of incompatibility (see guidelines below) and test compatibility at 10%
volume change on each side. For example, if the 25/75 mud/spacer test has the
highest rheology or other indicator of potential incompatibility, test at ratios of 15/85
and 35/65.
• Fluid combinations that show incompatibility can cause increased downhole ECDs,
resulting in losses and potential lower TOC. The spacer shall be redesigned if a fluid
combination has a potential incompatibility. The spacer redesign can include
adjustments to surfactant levels for OBM applications and changes to the rheological
properties for both OBM/WBM applications.
• Both rheological properties and visual observations are important when determining if
a fluid is compatible.
Guidelines that should be considered while checking the compatibility of fluids are:
• As a guideline, a spacer is compatible with a drilling fluid:
- For OBM/SBM, if there is no phase (oil/water) separation of the mud/spacer
mixture and no settling of solids in the testing cup at all testing ratios.
- For WBM/OBM/SBM, if there is no gelation of the mud when contaminated by
spacer at all testing ratios. Results of the rheological tests at the ratios stated
above should not be significantly higher than the highest values of the base
uncontaminated fluids
- For WBM/OBM/SBM, if there is no loss of solids suspension of mud/spacer
mixture.
• As a guideline, a spacer is compatible with a cement:
- If there is no acceleration of the cement with 5% and 25% contamination of
spacer
- If there is no gelation of the cement when contaminated by spacer at all testing
ratios. Results of the rheological tests at the ratios stated above should not be
significantly higher than the highest values of the base uncontaminated fluids.
- If there is no loss of solids suspension of spacer/cement mixture
10.20 Wettability
As stated above, for OBM/SBM applications, checking the compatibility of the fluids and
wettability of the spacer shall be done simultaneously due to the fact that the surfactant
loading in the spacer will affect the mud/spacer compatibility testing.
The wettability of all spacers for non-aqueous fluid interfaces shall be determined as
13
recommended by API RP 10B-2/ISO 10426-2 .
10.21 Deepwater Cement Testing

Unless otherwise instructed, testing for slurries used in deepwater should follow
procedures outlined in API RP 6517 and API RP 10B-3/ISO 10426-2, keeping in mind the
testing guidelines in this section.


10.22 HPHT Cement Testing
See Section (17) for design and testing guidelines for high-temperature applications.
10.23 Water Analysis

Standard water analysis shall be required any time a new source of cement mix water is
accessed for cement testing and/or an actual job (e.g., moving to a new location with a
new water supply well). This applies to fresh water, seawater, and surface water supplies.
At a minimum, the standard test shall include:
• SG
• pH
• Chloride, calcium, and magnesium concentration
Other contaminates in the water like oil and grease, iron, solids, bacteria, H2S, and algae
can have significant effects on the cement testing process and should be noted if seen
when the sample is taken.
General guideline limits for chemicals found in the water are:
• Magnesium <300 mg/l
• Calcium <500 mg/l
• Barium <300 mg/l
• Iron (+3) <300 mg/l
• Sulfate (SO4) <200 mg/l
• Total of Sodium + Potassium <5000 mg/l
• Chloride <7000 mg/l
• Carbonate <1000 mg/l
• Dissolved organics <200 mg/l
• pH 6 to 8
• No hydrocarbons in the water
Quantities found over these amounts can affect how cement performs with the water.
Pilot testing should be performed to determine the effect of mixing water on the cement.
In some instances, fresh water should be used.
The dissolved organics can be determined by doing a test for total organic carbon. Total
organic carbon testing has been recognized as an analytical technique to measure water
quality. Total organic carbon in source waters comes from decaying natural organic
matter. This decaying organic matter is more likely to be found in water that comes from
surface locations like lakes, ponds, and rivers. Organic matter can affect cement slurry
properties, so it is recommended to test all new sources of surface water and to
periodically test the sources during a project.
10.24 Guidelines for Handling of Pozzolan Fly Ash Microspheres during Lab Testing
There are two types of hollow microspheres used as lightweight additives and extenders
in cement slurries. The two types of hollow microspheres used as lightweight additives
and extenders in cement slurries are:
• Artificial ceramic microspheres
• Pozzolan microspheres that are a naturally occurring byproduct of coal-fired power
plants
Note that both the artificial ceramic spheres and the pozzolan spheres come in various
pressure ratings that should be reviewed before a product is selected for a specific job.
Ceramic microspheres have no special lab-handling procedures. There are specific
handling procedures that shall be followed for slurries containing pozzolan microspheres
when mixing these slurries during lab testing to avoid breakage of the spheres in the
mixing blender. These procedures are covered below, including pressurization of the


slurry to account for breakage due to elevated pressures downhole. The slurry should be
conditioned at the anticipated downhole pressures because breakage of the spheres will
affect the slurry properties.
The following procedures shall be followed:
• Weigh up microspheres separately.
• Mix cement slurry (without the microspheres) using the blender following normal
procedures.
• Add the microspheres by hand to the base slurry, stirring in using a spatula or low-
shear mixer such as a Hobbart bender. Do not use a high-speed mixer.
• Check the slurries’ density using pressurized mud scale. This will be the surface
mixing density.
• Check the rheology. This will be the surface mixing rheology.
Pour the slurry into a plastic bag, removing as much air as possible. Pressurize the slurry
in an appropriate vessel such as a curing chamber or consistometer to the maximum
anticipated downhole pressure, including ECD effects. Hold pressure for 5 minutes, then
release pressure, and remove slurry. Check density and rheology(s) and reassess for
applicability to the well since these are the downhole properties. Reassessment using
computer simulation software is important since properties such as density and rheology
will change as the slurry is pressurized downhole. The pressure-conditioned slurry can
now be used for all other testing including thickening time, free water, compressive
strength, transition time, settling, etc. For compressive strength testing of a microsphere
slurry, both the ultrasonic cement analyzer compressive strength and the crush
compressive strengths should be tested. This is because large numbers of microspheres
in the slurry can affect the quality of the results of an ultrasonic cement analyzer test.
10.25 QA/QC of Blended Microsphere Slurry Designs

Dry-blended microsphere slurries typically have 5–60% by weight of cement (bwoc) of
microspheres in them. The amount of these microspheres in the design has a severe
impact on the properties of the slurry, which is why the blends need to be QA/QC.
There are two methods for checking the amount of microspheres in blended cement. The
two methods are:
• Float test in Section (10.25.1)
• Slurry density test in Section (10.25.2)
Float test for all weights of slurries using microspheres should be performed. The float
test is the most accurate of the two tests because it directly measures the amount of
beads in the cement blend. The slurry density test measures the density of the slurry that
includes cement, microspheres, and water. Accuracy of the blended microspheres
concentration is critical because variations in the amount of spheres has a significant
effect on the water requirement of the blend and mixability. Figure 5 below illustrates the
amount of water that a slurry requires at varying amounts of bead concentrations.
Changes in the bead and water requirements become more significant at lower densities.
Trying to mix a blend that does not have the correct amount of beads can be disastrous
to the success of the job.
All results of these tests shall be documented and presented to the Wells Engineer (WE)
and Cementing SME for approval before the blend is used on the job.


Figure 5 – Density vs. Bead Concentration and Water Requirement
10.25.1 Blended Microsphere Float Test
The purpose of this test is to assess the amount of microspheres in a blended
sample of cement from the rig/location/bulk facility. There are two parts of this
test. The first part is to prepare a lab blend with the correct amount of
microspheres and conduct the below test procedure. The amount of floating
microspheres measured for the lab blend shall be the baseline to compare to the
float test on the blended sample. The second part of this test process is to check
the rig blend or location blend or bulk facility blend using the procedure below.
Typically this test is done at the bulk plant before the blend is shipped. It is
important to check the blend and if needed modify the blend while it is at the bulk
plant. It can also be done on location if the testing equipment is available.
The float test procedure shall include the following:
- Use a clean, 100-ml graduated cylinder.
- Add 20 cc saturated saltwater to the graduated cylinder.
- Add 20 cc of a prepared lab blend with the microspheres to the graduated
cylinder.
- Disperse blend in the saturated saltwater (shake, swirl).
- Wash down the inside of the graduated cylinder using saturated saltwater
until the total volume in the cylinder is 60 cc.
- Allow the microspheres to float and solids to settle.
- Record the amount of microspheres (number of cc’s) that are floating. If this
is the result for the lab blend, this shall be the baseline used to measure the
quality of the rig blend or location blend or bulk facility blend.
- Repeat the above steps on the rig blend or location blend or bulk facility
blend samples.
- Compare the results from the rig blend or location blend or bulk facility blend
samples to the results from the lab blend.
- The rig blend or location blend or bulk facility blends shall be within +/-10%
of the lab blend. If not, the test(s) shall be repeated. If the repeated test(s) is
the same, a new blend sample shall be taken and QA/QC’d. If the new
sample does not meet these criteria, the blend is not acceptable, and the
Wells Engineer (WE) should be notified.
- Results of this test shall be reported to the Wells Engineer (WE) for approval
before the blend is used on the job.
10.25.2 Blended Microsphere Slurry Density Test
The purpose of this test is to mix the rig/location/bulk facility blend with the lab
calculated amount of water and measure the density of the fluid. If there is an


incorrect amount of microspheres in the blend, the density of the slurry will not
match the lab-calculated design weight.
Typically this test is done at the bulk plant before the blend is shipped. It is
important to check the blend and if needed modify the blend while it is at the bulk
plant. It can also be done on location if the testing equipment is available.
The slurry density test procedure shall include the following:
- Use a clean waring blender jar.
- The Service Contractor lab will calculate how much blend and water is
needed for the designed slurry density.
- Measure the appropriate amount of grams of blend as per the lab
calculations.
- Measure the appropriate amount of grams of water as per the lab
calculations.
- Mix the blend into the water in the warring blender jar by hand. After mixing
by hand, use the warring blender at a very low speed for 10 seconds to make
sure the slurry is thoroughly homogeneous.
- Weigh the slurry in a pressurized mud scale and compare to the calculated
density from the lab.
- The slurry made from the rig blend or location blend or bulk facility blend
shall be between +/-0.2 ppg of the design density before being approved to
be used on the job. Any results out of this range shall require fresh samples
taken and repeated. The Wells Engineer (WE) and Cementing Focal Point
shall be notified. If the repeated test yields the same results, the blend shall
be transferred between two tanks and a new sample taken and the process
repeated.
- Approval to send the blend to location shall be made by the Wells Engineer
(WE) with consultation of the Cementing Focal Point.
10.26 Other Job-Specific Testing to be Performed on an As-Needed Basis

• Set-cement permeability
• Thickening time sensitivity tests based on (slurry density variations and mix water
requirement variations
• Thickening time tests to determine the effects of contamination
• Mechanical properties testing
• Dynamic HPHT settling


11 GUIDELINES FOR THE DRY MIXING OF CEMENT BLENDS
These general guidelines apply to all cement blends required in cementing operations. Every
cement plant and each of the Service Contractors shall have their own standard procedure for
dry blending cement materials. Prior to the startup of a project and periodically during execution
of the project, the Wells Engineer (WE) and Cementing Focal Point should review the Service
Contractor blending processes. For complex dry blends with lightweight microspheres or
heavyweight additives, the Wells Engineer (WE) should review the Service Contractors
blending procedures with the Cementing SME.
11.1 Plant Pre-Checks

Prior to the startup of any project, a bulk plant audit shall be conducted by a Cementing
SME or Cementing Focal Point or the Well Engineer (WE). Additional periodic audits
should be done based on the Service Contractors’ quality management system or at
least every 2 years. Spot-check audits should be required during the project if blend
quality is suspected. Contact Shell WTC Cementing SME staff for an example of a bulk
plant audit document if the Service Contractor does not have one.
During the audit, the experience and competence level of the bulk plant staff shall be
assessed.
Any past audits and findings should be reviewed, as well as any service quality issues
identified in the past and how they were addressed and closed out.
11.2 General Blending Procedures

• A well-defined and agreed written procedure specific to the bulk plant, and in some
cases specific to the dry blend, shall be developed.
• Batch numbers and volumes of additives and the silo numbers with contents shall be
recorded.
• All calculations related to the additives and volumes to be blended shall be checked
and agreed to.
• A blend volume shall always equal one transport tank load. Batch blends shall not
be split.
• Cement shall always be added first to the scale tank.
• Any sack additives shall be carefully pre-weighed and staged before starting the
batch.
• Industry experience is that the sandwich approach works best (i.e., 1/3 cement then
1/2 of the additives, followed by 1/3 of cement and the other 1/2 of the additives, and
then the last 1/3 of the cement).
• A minimum of four pneumatic transfers between tanks shall be required to
homogenize the blend, which is then transferred to the transport tank (and counts as
a fifth transfer). Some blends may require more transfers.
• Samples shall be taken during this last transfer using one of the following. See
Section (10.5) for handling of representative samples.
- Automatic in-line sampler
- Delta “Y” sampling point
• The load-out papers shall be checked and signed off by all witnessing parties.
Weight tickets shall accompany the service company field ticket to location and be
used for reconciling returned materials and the final invoice.


11.3 Transport to the Rig
Separation may occur upon long-term storage (e.g., in case of job delays) and during
transit to the rig site. Samples shall be taken during the transfer of the blend to the rig
tanks. A sample from the beginning, middle, and end is usually requested from each tank
as it offloads. See Section (10.5) for the handling of representative samples.
11.4 Storage of Blends

Caution should be used if additional periodic aeration and or transfer between tanks is
done because this may actually be detrimental due to the risk of the blended additives
segregating out and the introduction of moisture. Any transfers should be done with
appropriate sampling and testing to confirm stability.
NOTE In offshore applications, some blends may have separation issues due to rig
movements and operations that cause the blends to move in the storage tanks.


12 WELLBORE CONDITIONING AND PIPE MOVEMENT
The purpose of this section is to define the minimum requirements for wellbore conditioning and
pipe movement. Conditioning the mud and wellbore prior to cementing operations as well as
movement of the pipe have been shown to improve the success of the cement job and zonal
isolation. The basic premise of these recommendations is to apply energy to gelled mud in the
wellbore in an effort to mobilize the mud. Drilling programs shall include a wellbore circulating
and conditioning procedure prior to cementing.
12.1 Mud Conditioning and Pipe Movement

Prior to cementing operations, the mud in the hole and active system shall be
conditioned in preparation for cementing activities. If there are no losses or gains, mud
properties going in and coming out should be stable and consistent before commencing
the cement job.
It is widely recognized that mud properties used during drilling are not always the
optimum properties needed for good displacement efficiency and a successful cement
job. The Service Contractor, drilling fluids contractor, and Wells Engineer (WE) shall work
closely to determine the best mud properties at downhole conditions for the cement job
without jeopardizing hole stability and cuttings suspension.
For deepwater well applications where a riser is present, stop periodically while running in
the hole with pipe to break circulation moving the wellbore fluids. This will help reduce the
gels of the system reducing the ECD spikes when the pipe reaches TD and the pumps
are put on line before the cement job.
With the pipe on bottom prior to the cement jobs, pump at least two bottoms up if losses
are not severe. If losses are severe, pump at least 1.5 times the openhole by pipe volume
before the cement job.
When feasible, rotate and reciprocate the pipe during wellbore conditioning and
cementing operations to break up gelled pockets of drilling fluids, loosen cuttings beds
and improve the displacement efficiency of the mud. Do not reciprocate the casing
hanger assembly across a subsurface BOP stack.
When well conditions do not allow rotating, reciprocate 10 to 20 ft (3 to 6 m) before and
during cement operations. Some pipe movement is more beneficial than no movement at
all. Do not reciprocate the casing hanger assembly across a subsurface BOP stack.
Fluid rates during conditioning shall depend on wellbore conditions and should be
pumped at the maximum rate possible. Studies have shown that higher rates are more
efficient at preparing the wellbore for cementing operations.
Additional casing attachments like casing scratchers can be added to the pipe to improve
wellbore conditioning.
Prior to setting all balanced cement plugs, condition the plug setting area by washing
while reciprocating and rotating the workstring. This will aid in breaking up any gels. See
Section (12) for detailed procedures.
12.2 Discussion on Wellbore Conditioning and Pipe Movement

Rotating and reciprocating casing before and during the cementing operation breaks up
gelled pockets of drilling fluid, loosens the cuttings bed, and enables high displacement
efficiency. When the ECD and the fracture pressures are similar, pipe movement may not
be possible, and other program design parameters may need adjustment to compensate
for the lack of movement. Do not reciprocate if there is shallow gas or potential water
flows. However, if pipe movement is essential, the casing grade and type of threads shall
be selected to withstand the loads.


Conditioning the mud prior to cementing ensures that the fluid in the wellbore is
homogeneous and has the desired rheological characteristics, particularly low gel
strength, as well as low fluid loss to avoid thick mud cakes. Mud conditioning is done by
circulation of the drilling fluid until properties in and out are consistent. This will also
contribute to cleaning of the annulus and “mobilizing” gelled mud.
Pipe rotation has been shown to enhance cuttings transport, especially in deviated and
horizontal boreholes and well paths. Hole cleaning is, therefore, improved with pipe
rotation. Studies have observed that the critical fluid velocity required to remove the
cuttings bed is decreased when the pipe is rotated. Liner rotation has been shown to
reduce liner remedial squeeze cementing and improve the primary cementing of liners.
Rotation speeds of 3–10 rpm are satisfactory but the torque rating of the casing will
determine the maximum speed.
Pipe reciprocation, when used, has been shown to improve cementing operations. Liners
in particular have gained the benefits of reciprocation because rotation is usually
restricted. Reciprocation should be started slowly with a very short stroke and built up to
approximately 25 ft (8 m) in 2-minute cycles. The reciprocation should be maintained
from the time the casing reaches setting depth until the top plug is landed. If required by
the wellbore condition or the well fluids, break circulation before the casing reaches
bottom. In such cases the casing should be pulled upward before starting circulation at a
slow rate.
Wellbore pressure surge/swabbing occur as pipe is moved in mud-filled boreholes. A
positive pressure peak is produced as the casing is moving at maximum velocity.
Negative peaks can be observed as the casing is lifted from the slips and as the brakes
are applied to stop pipe movement. Casing/liner running speeds are modeled beforehand
to avoid inducing losses and swabbing.


13 JOB DATA COLLECTION AND ARCHIVE
This section defines the minimum requirements for job execution data collection and archiving.
Cement job data is critical to understanding the performance of the job compared to design. It is
the responsibility of Shell to ensure the Service Contractor understands the minimum
requirements and is in compliance. It is the responsibility of the Service Contractor to ensure all
sensors are calibrated and that the data are collected and reported to relevant Shell staff in a
timely manner.
13.1 Requirements of Data Collection and Archive

The following electronic data shall be provided to Shell Wells Supervisor and the Wells
Engineer (WE or CWI) for all cementing operations:
• Pump pressure at surface
• Slurry density measurements at surface before the fluid is pumped downhole
• Job rates and volumes
• Mixing fluid rates and volumes
The following electronic data shall also be provided to Shell Wells Supervisor and the
Wells Engineer (WE) and / or Wells Engineer (CWI) as appropriate for the job:
• Mixing density (when mixing on the fly)
• Liquid additive rates and volumes, annotated with end-of-job inventory
• Nitrogen pressure, rate, and volume (both liquid volume from stroke counter and
turbine meter)
• Liquid-to-solid ratio on ultra-lightweight [less than 12 lb/gal (1.44 SG)] slurries that are
not batch-mixed
• Mixing centrifugal pump pressure
The following procedures shall be followed at all times:
• Evidence of sensor (pressure, density, rate) calibration will be provided for all jobs.
• All jobs will show the pumping iron pressure test data. Testing will be conducted on
all pumping iron up to the cement head.
• Pressure data will be recorded at all times when the cement pump is live to the well.
• Data will be recorded at 2-second intervals at a minimum.
• All data will be provided as charts (printed or electronic image) and in ASCII format
converted to a field-consistent unit system compatible with Microsoft EXCEL.
• All charts, whether printed or in electronic image format, will have the axis scaled to
be commensurate with the job data.
• Data files will be properly annotated to clearly show job events—testing, stage
changes, shutdowns, and accompanying explanations. If simultaneous events occur
(e.g., cement unit is washing up while rig is displacing) and the data are recorded in
the same file, this shall be shown to prevent confusion.
• All cement job data will be archived on Shell servers after completion of the well by
the Wells Engineer (WE).
• The Service Contractor will archive all data and make all data available as needed for
a minimum of 5 years.
When applicable, the contractor will provide real-time job data to the mud logging
company for monitoring of the well and integration into the rigs kick detection system.


14 CEMENT PLUGS
Cement plugs are often given the least amount of detail other than rig time considerations and
hence statistically lead to a higher ratio of job failures. This section defines the minimum
requirements for setting plugs in any well.
The Well Abandonment Manual and Guidelines should be referenced when planning an
abandonment program since this section does not cover Shell’s RPs for well abandonment in
detail. Cement plug length and placement technique shall be dictated by the Wells Engineer
(WE or CWI) or as per regulatory requirements. The more stringent requirement will prevail.
Cement plugs that have been weight tested and/or pressure tested should be considered a
physical barrier in the well abandonment process.
14.1 Guidelines for Testing and Placement of Cement Plugs

• All plug slurries shall be lab tested at minimum to the recommended slurry tests
given in Section (10) of this document.
- Temperature used for testing shall be determined as per Section (7) of this
document.
- Testing schedules should be based on the actual pump schedule and pipe
retrieval schedule.
- Compressive strength contamination testing should be performed based on
Table 2 in Section (10) of this document if the cement plug will be pressure tested
or weight tested.
- Spacers and washes shall be used to minimize cement contamination.
• Cement shall be isolated in the workstring by means of mechanical separation. See
Section (9) of this document.
• Spacer volume ahead should follow Section (5.3) with the appropriate volume behind
based on the job parameters.
• Rheological hierarchy of the mud/spacer/cement is important. This will help on the
displacement efficiency and removal of wellbore fluids ahead of the cement.
• The density of the cement plug will be job-specific based on the wellbore conditions
and job objectives. Selection of the density should be made between the Wells
Engineer (WE & CWI) and Service Contractor. Typically plug densities are between
14.5–16.4 ppg (1.74–1.96 SG).
• The Service Contractor should provide software simulation to determine the
recommended:
- Pull-out-of-hole speed
- Volume to under-displace
- Placement of mechanical separators
- Rotation and reciprocation schedule
- WOC time
NOTE This simulation shall be based on the most recent and accurate information
available, and every effort should be made to follow the recommendations
given. If it is not physically possible to use these recommendations, the drilling
team must apply alternative methods, document the situation, and communicate
it to the Service Contractor and Cementing SME to expedite the development of
new methods or technology.
• The workstring should consist of a stinger and diverter sub. The size and length of
the stinger is dependent on actual situation, and it may be the case that the stinger


size is the same as the workstring. The stinger shall be sized to allow efficient mud
displacement and minimize fluid disturbance while pulling out of the hole.
• The cement plug setting area should be conditioned while running in the hole with
the workstring. Conditioning will include rotation and reciprocation while pumping at a
high rate. This will help break any pockets of gelled mud and cuttings.
• Pipe rotation and reciprocation shall be used while pumping the cement and spacer
down the workstring. As the spacer and cement exit the end of the workstring and
come up the annulus, only pipe rotation shall be used.
• All plugs shall be placed on top of a supporting base to minimize downhole slurry
movement prior to cement setting. There are three types of bases:
- A viscous weighted pill, minimum of 100 ft (30 m) in length, with a density of 0.5
ppg (0.06 SG) over the cement weight
- Chemically reactive pill-like sodium silicate with a minimum length of 100 ft (30 m)
- Mechanical base such as a bridge plug or cement basket
• Displacement rates during the job should be kept as high as possible without
exceeding the openhole fracture gradient. This will aid in displacement of the wellbore
fluids by the spacer and cement as they come up the annulus. Spacer volumes
should be adjusted to provided adequate contact time based on the estimated
displacement rate. Contact time details are specified in Section (5.3).
• Wiper balls and an indicating catcher sub should be used. The use of an indicating
catcher sub provides pressure indication at surface when the wiper ball arrives at the
sub. This indication can be used to confirm displacement volumes for placement of
cement plugs and spacer fluids downhole. Consult the cement services provider for
details on this subject and what is available.
• If operations do not allow for the use of wiper balls, wiper plugs or wiper darts during
the cement plug job, a wiper ball, wiper plug or dart should be pumped after the job
before pulling out of the hole to clean the ID of the workstring. Residual cement left
on the ID of the workstring could be detrimental to future operations that use the
same workstring tubular.
• The WOC time should be based on the pre-job testing of the slurry at BHST on an
ultrasonic cement analyzer. Typically the time to 500 psi (3447.3 kPa) compressive
strength is adequate for tagging cement. If the cement plug does not take weight, it is
recommended to WOC in 4 hours increments up to a maximum of 12 hours additional
WOC time. This is only a guideline, and the actual WOC time should be determined
by the Wells Engineer (WE & CWI) and Service Contractor.
14.2 Additional Guidelines for Sidetrack Cement Plugs

As discussed above, placement practices are crucial to the success of a kickoff plug.
Generally, a sidetrack plug should be 700 to 1000 ft (213 to 304 m) in length and
designed for a slurry density of 17 to 17.5 ppg (2.0 to 2.1 SG) with no weighting material,
using only a dispersant and retarder. This is assuming the mud weight is less than 17.0
ppg (2.0 SG). A lower density design can be used when the sidetrack formation is not
very hard. However, a higher density slurry with a higher cement to fluids ratio should be
used because the compressive strength of the set cement will be higher compared to a
lower density slurry.
Higher cement compressive strengths along with effective placement practices are key
factors in the success of sidetracking. All sidetrack cement slurries shall have a
compressive strength test done for reference on the amount of WOC time needed. An
ultrasonic cement analyzer test, see Figure 6 below, is typically the test of choice
because it is nondestructive and provides a strength development plot. For situations
where the mud weights are above 17.5 ppg (2.1 SG), a slurry design using weighting
material may be designed, but the Cement SME shall be involved.


Figure 6 – Example of Ultrasonic Cement Analyzer Chart


15 OFFSHORE RISERLESS CEMENTING
The purpose of this section is to define the minimum requirements for cementing a casing or
liner string in offshore operations when there is no marine riser present and there is a potential
flow hazard. This document is not intended to replace API RP-6517, API RP 65 Part-2, May
201018, but is instead a guide that the Shell drilling staff can refer to during the planning and
execution phase. All personnel should review and understand API RP-65 in its entirety.
15.1 Project Planning for Offshore Riserless Cementing

All efforts shall be made to identify potential shallow flow hazards from seismic and offset
well data.
Detailed information to Service Contractor cementing staff about the potential flow
hazards including depths shall be provided. Offset data should be used to better identify
the potential severity of the flow.
A detailed estimate of the openhole pore pressure and fracture gradient shall be provided
to the Service Contractor cementing staff.
Foam on riserless cement jobs should be used when equipment and materials are
available as well as the experienced personnel to design and execute the job.
When foam services are not available, lightweight non-foam extended slurry shall be
used.
Due to the complexity of foam and non-foam lightweight slurries, the Cementing SME
should always be consulted when planning these jobs.
15.2 Cement Job Planning for Offshore Riserless Cementing

The cementing Service Contractor shall provide detailed simulation for offshore riserless
cement jobs showing estimated ECD and hydrostatic values for the entire openhole.
These should be compared to the expected pore pressures and fracture gradients.
If a potential flow hazard is expected, a foam cement slurry design should be used. The
base non-foam lightweight slurry shall be tested for static gel strength development in
addition to the standard tests. A static gel strength transition time of 45 minutes or less
should be used for slurries placed across the potential flow hazard zone.
TOC shall be a minimum of 500 ft (152 m) above potential flow zone or as stated by local
regulatory requirements, whichever is greater.
Pump and dump mud spotted across flow zones should have fluid loss control and low
progressive gels. API RP-65, API RP 65 Part-2, May 2010 recommend a fluid loss less
2
than 15 cc and API gel strengths less than < 25 lb/100 ft .
Spacer rheology design profile should be adequate for efficiency displacement of the
mud before the cement. For improved cleaning, a nitrified spacer should be considered.
Centralizers should be run on the casing at a minimum of one centralizer every third joint
for vertical holes. Service Contractor shall run standoff software for any deviated hole
sections. Centralizers not only help center the casing but also add turbulence to the fluid
stream for better hole cleaning.
On foam cement jobs, the cement left on the inside of the casing and 50 ft (15 m) above
the shoe on the outside of the casing should be non-foam base slurry.
For inner-string cement jobs, a diverter should be run on the end of the drill pipe. The
end of the drill pipe/diverter should be placed 200 to 250 ft (61 to 76 m) above the shoe.
Cement shall be displaced 100 to 150 ft (30 to 46 m) above the casing shoe. For shorter
casing lengths, this may be reduced.


15.3 Preparation and Execution of Offshore Riserless Cement Jobs
The following should be performed for riserless cement jobs:
• Monitor for potential flow hazards while drilling the hole section. Be prepared to pump
weighted fluids or adjust the mud weight if needed to control any potential flows.
• Pumping a caliper sweep at TD before Pull Out of Hole (POOH) can be used to
determine how much of a washout is expected in the openhole. Typical openhole
excess volumes range from 150 to 200%.
• Minimize the time from TD of the hole section to running the casing.
• Prior to cementing, it is recommended that 1.5 times the openhole annular volume be
pumped to condition the mud and prepare the well for spacer and cement.
• Job monitoring is crucial to the success and quality of the job. All parameters of the
job have to be monitored by the onsite team. Parameters will include pumping
pressure, downhole base fluid density, mixing tub density, nitrogen rate, nitrogen
pressure, and nitrogen temperature.
• Pumping rates during mixing of cement and displacement are critical to the success
of the job and must be kept as high as possible. Generally, cement mixing and
pumping will be in the range of 5 to 6 bpm with the displacement at 10 to 12 bpm.
• Any rat hole below the casing shoe should have a fluid mud weight greater than or
equal to the base cement density.
• When possible, foamed cement should be pumped until verified returns at the
seafloor before switching to non-nitrified tail cement.


16 FOAM CEMENTING
The purpose of this section is to define the minimum requirements for foam cementing a casing
or liner. This document is not intended to replace API 10B-415, but to complement it and as a
guide with bullet points that the Shell WE staff can refer to during the planning and execution
phase. All personnel should review and understand API RP-6517, API RP 65 Part-2, May
201018, and API 10B-4 in its entirety.
The Cementing SME shall be contacted for assistance in the preparations and design of a
foam cement job.
16.1 Foam Cementing Definitions

• Foam cement: stable dispersion of an inert gas in a base cement slurry
• Foam quality: ratio of the volume of gas to the volume of base cement slurry
• Surface foam density: density of the foamed cement at the cementing head
• Downhole foam density: final in place foamed cement density
• Automated process control system: computerized system designed to control
nitrogen rate based on liquid cement rate, temperature, and pressure
• Constant foam density: method of job design and procedure in which surface nitrogen
rate is varied to achieve a constant final in place foam density from the TOC to the
bottom
• Constant nitrogen rate: method of job design and procedure in which surface nitrogen
rate is held constant so that the in place foam density will vary from TOC to the
bottom
16.2 Minimum Requirements for Foam Cementing

• All temporary pipe associated with pumping nitrogen and nitrified fluids shall conform
to current version of the Shell Global Standard for Temporary Pipework19.
• All foam cement jobs shall be performed using automated process control system.
• An HSSE risk assessment shall be performed for all foam cementing operations. The
risk assessment should address safety, health, and environmental risks as well as
design and operational risks. The risks shall be mapped against the Shell RAM
Assessment Matrix. Details of the RAM can be found under the HSSE & SP Control
Framework on Shell’s internal website.
Examples of risks to be included in the assessment are:
- High pressure pumping of energized fluid
- Additional temporary pipe installation
- Additional equipment and personnel on location
- Heavy lifts of equipment for offshore applications
- Mechanical failure of nitrogen pumping unit
- Cryogenic fluid spill
- Accurate nitrogen rate control
- Slurry contamination
- Surface handling of nitrogen returns
- Well control due to nitrogen breakout
• Service Contractor engineering software with compressible fluid simulating capability
shall be used in the design and placement of foamed cement.


• All nitrogen-pumping equipment shall have emergency kill switches on the unit and
remotely on the automated process control computer.
• Service Contractor shall have 100% redundancy of nitrogen-pumping equipment.

- Nitrogen-pumping unit
- Surfactant/stabilizer injection skid
- Turbine gas flow meter, temperature and pressure sensors
- Additional nitrogen tanks
• All nitrogen pumping equipment sent to location shall be in good working order with
up-to-date maintenance documentation. Documentation shall be presented to the
Wells Supervisor before rig up.
• All high-pressure pumping iron and transfer hoses shall have current pressure test
and inspection certification in accordance with Shell Global Standard for Temporary
19
Pipework . Documentation shall be presented to the Wells Supervisor before rig up.
• All foam cement slurries shall be tested in accordance with API 10B-4/ISO 10426-
415. Additional Shell-specific foam cement tests may apply. Please contact the PTE
Cementing Operations assistance. Surface rheologies of the base slurry should be
tested with and without the surfactants and or stabilizers.
• There shall be a nitrogen spill plan in place.


17 DESIGN AND TESTING GUIDELINES FOR HIGH-TEMPERATURE CEMENTING
The purpose of this section is to discuss the additional focus and requirements needed when
cementing a high-temperature well. A well is considered high temperature when the maximum
BHST is greater than 300 °F (149 °C). Many of the design aspects critical to the success of a
high-temperature cement job are the same for a low temperature cement job and, therefore, are
not repeated here. However, specific requirements and special testing will be recommended as
appropriate.
Portland cement is an excellent material for isolation and structure support in oil wells up to
230 °F (110 °C) BHST using standard additives. With the addition of specific additives, the
temperature range of Portland cement can be extended to 600 °F (315 °C).
Traditionally, high-temperature cementing has been defined as both high-temperature and high-
pressure. More and more drilling is being conducted in areas where there is reservoir depletion,
or alternative recovery methods like steam flood are being used so the high-pressure part of the
equation is not as prevalent a factor as before.
17.1 Temperature Simulation in High-Temperature Wells

This section is in addition to the information in Section (7) with regard to temperature
simulation.
Estimating the BHCT of a high-temperature well can be challenging and starts with
having an accurate BHST. The best data on BHST is a logging tool run after the well has
been static for more than 24 hours. Another good source of BHST is offset shut-in
production logs. Sometimes the BHST can exceed the higher boundaries of the tool, but
the readings from the tool before it fails or at a shallower depth can be used to determine
the geothermal gradient. As stated in Section (7.1), temperature simulation shall be run
on all jobs where the BHST is greater than 300 °F (148 °C). A list of contractor software
platforms is given in Section (7.1). Results of the software simulation should be
compared with BHA temperature readings as well as flowline out temperatures. This is
done as a reference to catch any potential input errors in the simulation software.
Simulation software should also be used to predict the temperature recovery schedule
after the slurry is in place. This recovery schedule should be used for compressive
strength testing.
The Cementing SME shall be contacted for assistance in temperature simulation of a
high-temperature well.
17.2 Additional Design Requirements to Consider for High-Temperature Wells

High-temperature applications can be demanding on the cement sheath(s). Additional
slurry design requirements such as improved mechanical properties, gas migration
control, and protection of the casing from corrosion should be considered.
For producing wells with a high bottom-hole flowing temperature, the cement sheaths of
all of the casing string can be affected by the higher temperatures during production of
the well. Temperature changes in excess of 150 °F (66 °C) can impart a significant
amount of stress on the cement sheath. For this reason, all casing strings should be
evaluated for any need for strength retrogression prevention additives and mechanical
property requirements.
The Service Contractor should use software (CemStress™ from Schlumberger and
WellLife™ from Halliburton) to predict the required mechanical properties of the slurry for
the demanding conditions of a high-temperature well.
Gas migration control should be evaluated using the Service Contractor’s standard
17
cementing simulation software or by hand using the formula provided in API RP 65 .


The Cementing SME should be contacted for assistance in evaluating the slurries’
design needs for a high-temperature application.
17.3 Fluids Stability Testing in High-Temperature Well Applications

Cementing in high BHCT conditions can challenge the stability of spacers and cement
slurries. Pilot testing of both fluids shall incorporate stability/settling tests.
For spacers, testing should be performed in an HTHP rheometer. Alternatively, checking
the stability should be done with the same ON/OFF settling test in a HPHT consistometer
as is done with the cement slurry. This test consists of conditioning the slurry at BHP and
BHCT in an HPHT consistometer. While still in the HPHT consistometer at BHP and
BHCT, the fluid will be subjected to three 10-minute static periods. Any severe spikes in
the consistency reading after a restart can indicate stability issues. After the last startup,
the HPHT consistometer is cooled down quickly, and the slurry cup is removed to inspect
the fluid inside for settling. The fluid shall be observed, and if a large quantity of solids is
on the bottom of the slurry cup, instability is highly likely, and adjustments to the spacer
design shall be made.
Since most polymer-based viscosifiers lose effectiveness at around 300 °F (150 °C), the
addition of clays to the spacer system should be necessary. For spacers with a large
amount of weighting agent [spacer weights >17.0 ppg (2.0 SG)], the particle size
distribution should be managed. It is very important to work closely with the Service
Contractor on the design of their spacers and confirm that they have engaged their
technology group with regard to the best stability chemicals for its systems.
For cement slurry testing, the recommended way of checking the post-placement stability
is to use the slurry sedimentation testing method outlined in API RP 10B-2/
13
ISO 10426-2 . This test consists of conditioning the slurry at BHP and BHCT in an HPHT
consistometer, then pouring the slurry into a cylinder mold for curing at BHST. After
curing, the mold is removed. and the density of the set slurry is compared from top,
middle, and bottom and reported. There are no published pass/fail requirements of this
test, but typically a cement that has a density difference greater than 0.5 ppg (0.06 SG)
from top to bottom shall be redesigned to improve the stability of the slurry.
The Cementing SME shall be contacted for assistance in evaluating the stability of high-
temperature spacers and slurry designs.
17.4 High-Temperature Specific Additives

The Service Contractor and Cementing SME should always be contacted when planning
a high-temperature cement job so that the correct additives and combinations can be
advised. Comprehensive pilot testing shall be required.
For high-temperature applications, silica shall be added to stop strength retrogression of
the slurry when the BHST is greater than 230 °F (110 °C). Selecting the correct amount
of silica for these applications shall be critical. Standard concentrations used in lower
temperature wells shall not apply for higher temperature wells.
Types of silica that can be used are:
• Standard silica: an example is natural sand. For oil well cementing applications, this
product can come in different particle sizes. Sizes vary but are typically coarse, fine,
and microfine. Using various sizes in a high-temperature slurry design can help with
slurry stability.
• Amorphous silica: silicon dioxide and a byproduct of the smelting process in silicon
and ferrosilicon plants. It is sub-micron in size and cannot be used solely as a
strength retrogression additive.
Standard silica shall be used for strength retrogression prevention. Amorphous silica can
be used at lower concentrations in conjunction with standard silica for special applications
and slurry stability.


Typical total silica concentrations based on BHST:
• 230 °F (110 °C) to 300 °F (150 °C): 35 to 40% bwoc silica
• 300 °F (150 °C) to 400 °F (204 °C): 40% bwoc silica
• 400 °F (204 °C) to 450 °F (232 °C): 50% bwoc silica
• For static temperatures over 450 °F (232 °C), a total silica content > 60% bwoc shall
be required. The Cementing SME shall be contacted with regard to the specific
amount required and additional long-term curing tests may need to be performed.
Cured cement should be tested for compressive strength, permeability, and free
available silica to determine if the correct amount of silica is designed into the blend.
All major Service Contractors have developed additives for high-temperature applications.
Typically these additives are used in the temperature ranges from 250 °F (121 °C) to
500 °F (260 °C). The Service Contractor shall be contacted for specific temperature
ranges for their additives.
Additives include but are not limited to:
• Retarders
• Fluid-loss additives
• Suspension additives
• Heavyweight additives
• Some standard additives may also be rated for high-temperature usage.
Weighting material composed of manganese oxide should not be used for BHST >
400 °F (204 °C). Tests have shown that at elevated temperatures, the cured cement
develops a new phase in the microstructure that could be detrimental to the integrity of
the set cement. The Cementing SME shall be contacted before using this additive on
high-temperature applications.
17.5 Use of Simulation Software in High-Temperature Well Applications

This section is in addition to the information in Section (6) with regard to cement job basis
of design.
The behavior of fluids and the forces that they exert during the cement job need to be
understood. The results of the software simulations are only as good as the accuracy of
the input data. When dealing with high-temperature wells, the accuracy of the input data
is questionable since most of the fluids are tested for rheological properties at 190 °F
(88 °C). When possible, the rheologies of the fluids (mud, spacer, and cement) should
be checked using a high-pressure, high-temperature rheometer. Higher temperatures and
pressures can also affect the effective downhole mud weight of non-aqueous fluids. The
Service Contractor providing the mud shall be contacted to determine the effective
downhole mud weight and use that in the simulation software.
The Cementing SME shall be contacted for assistance in evaluating the simulation
software inputs and outputs from a Service Contractor.


17.6 Float Equipment for High-Temperature Applications
This section is in addition to the information in Section (19) with regard to float equipment.
For temperatures above 400 °F (204 °C) BHST, special float equipment should be
required. Typically, float equipment designed for these higher temperatures is made from
metals like aluminum so that they maintain pressure integrity. Drillout procedures for
aluminum float valves are very specific; the Service Provider shall be contacted for these
details. This type of float equipment is a special order and will typically require longer lead
times compared to standard float equipment.
Compatibility with the wellbore fluids and temperatures shall be considered when it
comes to selection of wiper plugs to be used in high-temperature applications. These
types of plugs may also be a special order and typically have an aluminum core for
strength and drillability.
Like all specialized casing attachments, the manufacturer shall be contacted to discuss
the job requirements and wellbore conditions to ensure the correct equipment is ordered
and used. The Cementing SME should be contacted for assistance in the selection of
float equipment and casing attachments for high-temperature application.
17.7 Key Factors in the Execution of a High-Temperature Cement Job

These factors shall be addressed when executing a high-temperature cement job:
• QA/QC of the blending process shall be implemented as outlined in Section (11).
High-temperature blends can have many additives, requiring a tight control on the
bulk-blending and handling process.
• All cementing materials to be used on a high-temperature cement job shall come
from isolated batches that are assigned to the job and were used for pilot and field-
blend testing.
• Some jobs will require some or all additives to be prehydrated in the mixing water.
Blending procedures for the additives in the water and the order of additives shall be
the same as those used in laboratory testing.
• QA/QC of the spacer on location shall be implemented. An incorrectly mixed spacer
could lead to an inadequate fluid downhole and poor displacement efficiency.
• Spacers and slurries that will be placed above a liner top and running tool shall be
checked for stability. This is also recommended for cement plugs that will be spotted
and the workstring removed. Fluid instability can lead to stuck pipe and running tools.
• Slurries used in high-temperature applications shall be batch mixed if the volume
allows. A slurry with all high-temperature retarders and stability additives
homogeneously mixed and checked for the correct density is beneficial to a
successful job.
• Chemicals added to the mix water shall be added in the same order as they are
added in the lab. High-temperature retarders and stability additives may have
sensitivity issues if mixed in the wrong order.
• The need for standby pumping equipment shall be assessed in case the primary unit
becomes disabled or the pumping pressure exceeds the horse power rating of a
single unit.
• Maximum pumping pressures shall be reviewed. All surface pumping lines shall be
tested and certified, including the plug container.


17.8 Setting Cement Plugs in High-Temperature Environments
This section is in addition to the information in Section (14) with regard to
recommendations for cement plugs:
• Because of the higher temperatures, a supporting base (mechanical or chemical)
may not be feasible, so additional cement plugs should be considered to build up the
TOC to the required depth.
• For cement plugs greater than 1.000 ft (304 m) in length, sacrificial tubing with a
tubing release sub should be considered. This reduces the concerns with pulling out
of the cement plug and fluids contamination.
• Placement of the cement plug is critical, but due to higher temperatures, indicating
wiper balls and catcher subs may not be applicable. An accurate calculation of the
workstring volume should be made to help ensure accurate placement of the cement
slurry.
• The same issues discussed in Section (17.3) above shall apply with regard to spacer
and slurry stability when setting cement plugs in High Temperature (HT)
environments.


18 EXTREME (HIGH AND LOW) DENSITY SLURRIES
This section defines the minimum requirements for design and application of extreme density
(high and low) slurries, regardless of job type. Although an extreme density slurry is generally
classified as below 11 ppg (1.32 SG) and above 18 ppg (2.16 SG), extreme density slurry can
be any slurry designed to be mixed with a low mixing fluid content (high solids-to-fluid ratio).
Extreme density slurries are very complex and should be considered for only specialized
applications. Because of the complexity of design, blending, and execution, these slurries
should be considered only after traditional standard slurries are deemed inappropriate.
A detailed breakdown of the components of all slurries provided and pumped downhole shall
be given to Shell for review and approval before the cement job. This is very important when it
comes to extreme high- and low-density slurries that may have complicated dry blends.
18.1 Requirements for all Extreme Density Slurries

Due to the complexity of these slurries, a Cementing SME shall be consulted for design
review and testing. As per Section (11.1), the Service Contractor’s bulk plant facilities and
blending procedures shall be audited prior to project start up and periodically during the
project by Shell. The local Service Contractor representative should have the slurry and
job design peer reviewed by internal technical experts, including confirmation lab testing
by their research or regional technology lab. The slurry should also be verified by a Shell
laboratory or approved third-party lab.
3
Batch-mix whenever logistics will allow. Slurry volumes less than 100 bbls (15.9 m ) or
those being used for high flow-potential applications should always be batch mixed.
Final lab tests shall be done using samples caught at the last bulk transfer as close to
on-location delivery as possible. If the retarder is to be dry-blended, the sample shall
include the retarder.
Less mixing fluid in the slurry means that the API fluid-loss value shall be lower than
normal to prevent premature bridging across permeable formations. Less than
100 ml/30 min API fluid loss is considered a general rule; less than 50 ml/30 min if the
annular gap width is less than 0.5 in (1.27 cm). This guideline may be relaxed based only
on local experience with the slurry being used.
Extreme density slurries have much less tolerance to contamination by fluids that may
normally result in only marginal incompatibility issues. Rheological and thickening time
compatibility testing with any fluid that may come into contact with the cement slurry shall
be performed.
18.2 Requirements for Extreme Heavyweight Slurries

Large percentages of silica and weighting materials are typically used. Correct bulk
equipment maintenance and blending and sampling practices shall be used. The Service
Contractor shall review its blending and sampling practices and ensure these meet
Shell’s requirements in Section (11) of this document.
Particle sizes of the base weighting materials and silicas should be varied whenever
possible to improve slurry stability, mixability, and viscosity.
Slurry stability tests shall be done in addition to the traditional free water test. Maximum
density difference from top to bottom will not exceed 0.5 ppg (0.06 SG).
Because most extreme heavyweight slurries are mixed with minimum mixing fluid, there
is much less tolerance than a normal slurry to density and/or mixing water variations. The
design and confirmation testing should include reasonable sensitivity testing [e.g.,
thickening time testing at +/-0.2 ppg (0.02 SG) density variation and retarder sensitivity
testing as outlined in Section (10.13.1)].


18.3 Requirements for Extreme Lightweight Slurries
Dry blends with low SG solids should be transferred via the bottom transfer lines
whenever possible to reduce the risk of blend separation. Do not load the tanks from the
top.
See Section (10.25) for the QA/QC of the blended microsphere.
Batch mixing should be done if possible. When batch mixing is not possible and because
density is not a reliable means of quality control when the slurry density is this close to
the density of the mixing fluid, a volumetric or liquid-to-solids ratio mixing system should
be used.
Be aware that slurries containing hollow microspheres must be designed so as not to
break or crush against maximum pressure, including ECD during placement. The
microsphere product chosen shall be appropriate for the maximum anticipated wellbore
pressures.
There are two types of microspheres: manmade glass microspheres and pozzolan
microspheres, which are a naturally-occurring byproduct of coal-fired power plants.
There are no special handling procedures for artificial microspheres, but there are special
handling procedures for naturally-occurring pozzolan microspheres when mixing these
slurries during lab testing to avoid breakage of the spheres in the mixing blender.
The lab procedure that shall be followed is:
• Weigh microspheres separately.
• Mix cement slurry (without the microspheres) using the blender, following normal
procedures.
• Add microspheres by hand to the base slurry, stirring in using a spatula or low-shear
mixer such as a Hobbart. Do not use a high-speed mixer.
• Check the slurry's density using a pressurized mud scale. This will be the surface
mixing density.
• Check the rheology. This will be the surface mixing rheology.
• Pour the slurry into a plastic bag, removing as much air as possible. Pressurize the
slurry in an appropriate vessel such as a curing chamber or consistometer to the
maximum anticipated downhole pressure, including ECD effects. Hold pressure for 5
minutes; then release pressure and remove slurry. Check density and rheology;
reassess for applicability to the well. These will be the final in-place parameters. The
pressure-conditioned slurry can now be used for all other testing—thickening time,
free water, compressive strength, transition time, and settling. Note that ultrasonic
compressive strength testing should be verified by destructive testing because
microspheres can affect the ultrasonic signals during the test.
The blend should not be aerated after it has been placed in the tank. This can cause the
lightweight materials to segregate upward.
Because most extreme lightweight slurries are mixed with minimum mixing fluid, there is
much less tolerance than a normal slurry to density and/or mixing water variations. The
design and confirmation testing should include reasonable sensitivity testing [(e.g.,
thickening time testing at +/-0.2 ppg (0.02 SG), density variation, and retarder sensitivity
testing as outlined in Section (10.13.1)].


19 FLOAT EQUIPMENT AND CASING ATTACHMENTS
The purpose of this section is to define the minimum requirements for float equipment and
casing attachments. These items are as critical as the cement slurries and must be reviewed
and vetted before being placed in the casing string.
19.1 Minimum Requirements for Float Equipment

• All float equipment shall meet API Spec. 10F/ISO 10427-3: 20039.
• All casing and liner jobs placed across a hydrocarbon-bearing formation shall have a
minimum of two float valves in the string.
• If pre-job planning dictates that pumping rates are expected to exceed 10 bpm for a
long period of time (>12 hours), the service company supplier should be contacted
about providing higher flow capacity float equipment.
• Float equipment ratings vary for each manufacturer. Prior to tendering, ordering, and
running float equipment, the float equipment shall be verified as designed for the
application.
• Prior to running any float equipment, compatibility with other devices in the casing
workstring shall be reviewed. Some float equipment is activated using wiper darts
and or by releasing balls.
• All float equipment should be thread-locked to the casing to avoid back-off problems
during drillout.
19.2 Minimum Requirements for Centralizers and Casing Attachments

There are three basic types of centralizers:
• Bow spring: These have flexible springs that compress and expand based on the hole
size. See manufacturer’s technical data sheet for details.
• Semi-rigid: These have semi-rigid springs that have some flexibility and a maximum
outside diameter (OD) less than the bow-spring model. (Examples are TANDEM
RISE™ centralizers) See manufacturer’s technical data sheet for details.
• Rigid: These have a fixed OD. (Examples are SPIRAGLIDER™, SPIRAL RIGID™,
LoTORQ™ and RIGID™ centralizers). See manufacturer’s technical data sheets for
details.
All bow-spring centralizers shall meet or exceed API Spec. 10 D/ISO 10427-110.
The service company provider should provide the following information to Shell on all
bow-spring centralizers:
• Restoration force
• Starting force
• Running force
A computer-generated prediction of the estimated standoff should be provided by the
centralizer supplier. Standoff should be estimated at the centralizer position and the
midpoint between centralizers.
Prior to running any casing attachments, the Wells Engineer (WE) shall confirm that the
proposed casing attachments are dimensionally compatible with the wellbore and
openhole configuration.
The use of non-standard casing attachments such as specialized centralizers, stop
collars, and expandable/swellable packers should be reviewed with the Cementing SME
prior to deployment.


For applications where there is suspected to be thick filter cake on the openhole wall,
casing scratchers should be considered. Before running any casing, the application with
the service company provider should be reviewed.
20 MINIMUM LABORATORY EQUIPMENT REQUIREMENT
The purpose of this section is to define the minimum laboratory equipment that shall be
available to service Shell requirements at any time. All equipment shall be able to meet the
calibration and testing requirements as detailed in API and/or ISO or manufacturer
specifications. It is expected that all equipment will meet HSSE requirements and have
certifications to demonstrate compliance. It is expected that the laboratory will perform
calibrations, maintain all testing and calibration records, have calibration equipment, or have
access to third-party calibration services. The lab will also maintain all spare parts on-site,
within the scope of normal wear and maintenance needs. Additional equipment requirements
(e.g., foamed cementing, deepwater) are specific to the scope of work, level of activity, and any
additional needs of the operating company.
20.1 Laboratory Equipment Requirement Table

The information in Table 4 below is only an estimate. Actual conditions may require additional
equipment.
Table 4 – Minimum Laboratory Equipment Requirement
Regional or R&D
Item Field Lab
Support Lab
API constant-speed slurry mixer 2 1
5 blade stacked blender for foam slurry preparation. See API 10B-
As needed As needed
4 section 5.2.2 for details.
Atmospheric viscometer – 6-speed minimum 2 1
Viscometer components – R1, B1, B2 and B5 1 R1/B1
Heated viscometer cup 2 1
Pressurized mud balance 2 1
Heated water bath 1 1
Refrigerated water bath As needed As needed
Atmospheric consistometer – up to 190 °F (87.7 °C) 2 1
Static fluid loss cells – 190 °F (87.7 °C) and 1,000 psi (6,894.7
2 1
kPa)
Stirring fluid loss cell – 400 °F (204.4 °C) and 1,000 psi (6,894.7
1 1
kPa)
Nondestructive (ultrasonic) compressive strength tester – 400 °F
4 2
(204.4 °C) and 10,000 psi (68,947.5 kPa)
Destructive compressive strength tester 1 1
Curing molds – 2 × 2-in (5.08 x 5.08 cm) cubes, 1 in (5.08 cm) ×
As needed As needed
1-in (2.54 cm) cylinders
Curing chamber – 400 °F (204.4 °C) and 3,000 psi (20,684.2 kPa) 2 1
Cement consistometer–400 °F (204.4 °C) and 20,000 psi
2 2
(13,7895 kPa)
Cement consistometer–600 °F (315.5 °C) and 40,000 psi
As needed As needed
(27,5790 kPa)
HTHP paddle-type static gel strength tester–400 °F (204.4 °C)/20
1 As needed
kpsi
Apparatus for measuring hydration volume changes 1 N/A
Pycnometer 1 As needed
Apparatus to test air and water permeability Available N/A
Apparatus for measuring Brazilian tensile strength Available N/A
Apparatus for measuring shear bond Available N/A
Apparatus for measuring slurry stability (settling) 1 1
Apparatus for visually measuring slurry stability (free water and
settling) at any angle 1 1
Apparatus for evaluating water-wetting capability 1 As needed
Apparatus for mechanical property testing under triaxial load
Available N/A
conditions
Basic water test kit (chlorides, calcium) 1 1
pH meter 1 1
Analytical support – XRD, XRF, SEM Available N/A


This list is not exhaustive and only shows the major components based on normal
cement testing. It is understood that some components will have multiple uses, and some
major pieces of equipment will have multiple test cells (e.g., double-cell static fluid loss
rack counts as two cells). “Apparatus” implies sufficient components to cure multiple
samples or run multiple tests at once, depending on scope of work and activity level. The
column labeled “Regional or R&D Support Lab” is shown for informational purposes only
to show that most service companies have additional support to call on when needed.
On-site lab testing may be required in certain circumstances such as remote locations
and unique job situations. This issue should be addressed before project startup to allow
the contractor time to procure any equipment and personnel and address on-location
logistics (footprint, utilities, or HSSE).


21 DEEPWATER SLURRY VERIFICATION TESTING GUIDELINES
The Shell Deepwater cementing slurry verification process should consist of two levels,
referred to as Slurry Design Verification and Rig Slurry Verification.
• Slurry Design Verification is defined as verification testing done on the pilot slurry design.
• Rig Slurry Verification is defined as verification testing done on a rig blend slurry design.
Decisions as to whether to test a particular slurry shall depend on the type of job and the
circumstances and shall be mutually agreed on by the Wells Engineer (WE) and Cementing
Focal Point/PC and the Service Contractor.
21.1 Recommended Jobs for Verification

The following types of deepwater cement jobs shall be verified:
• Riserless conditions with shallow water flow potential
• Foamed cement
• Lightweight specialty blends (e.g., those containing hollow microspheres)
• Production liners/casings
• Jobs involving new chemicals, materials, or processes or technology that is new to an
operating area
• Batch-set operations may be handled differently. After the initial Rig Slurry
Verification testing has taken place, additional verifications may be done at the
discretion of the Wells Engineer (WE) and Cementing Focal Point/PC, such as in
case of significant changes (e.g., well conditions, cement grind number, retarder LOT
number). Shell will also reserve the right to randomly perform spot-check verification
or witness thereof slurries during batch-set operations at any time.
21.2 Recommended Tests to be Performed during Verification

Verification testing should be carried out by physical testing in a Shell laboratory or
witnessed in a Service Contractor laboratory by a qualified Shell representative in that
LoB or operating company. This shall be in accordance with Section (10) and (21) of this
document. The specific tests performed during the verification process shall also depend
on the job type and the requirements of the slurry.
The minimum tests that shall be performed are:
• Slurry thickening time
• Rheologies at 80 °F (27 °C) and BHCT [may be as low as 29 °F (-1.6 °C) for
riserless jobs]
• Free fluid and stability
• Ultrasonic cement analyzer compressive strength
• Additional tests like fluid loss, compatibility, spacer evaluation, and other specialized
tests may be performed as needed.
Below is a brief outline of what to expect for each verification process:
• Designed slurry verification process:
- The Service Contractor shall prepare the cement job design and perform the
slurry(s) lab testing.
- The design shall be approved by the Service Contractor, Wells Engineer (WE),
and Cementing Focal Point/PC.
- The Service Contractor shall send samples to the Shell lab for verification testing
as per the sampling guidelines in Section (10.5).


- Shell shall perform verification testing. Where no Shell lab exists, then
verification testing should be done in the contractor’s lab and witnessed by a
Shell representative.
- Verification testing results shall be reviewed. The Shell representative shall be
advised if the test results are acceptable or if additional testing is required.
- A copy of the verification test results recommendations shall be provided to the
Wells Engineer (WE).
• Rig slurry verification process:
- The Service Contractor shall obtain samples from the rig as per sampling
guidelines in Section (10.5).
- After the samples arrive in the contractor’s lab, they shall be split as per sampling
guidelines in Section (10.5) and sent to Shell’s laboratory for verification testing.
- Shell shall perform verification testing. Where no Shell lab exists, then
verification testing should be done in the contractor’s lab and witnessed by a
Shell representative.
- Verification testing results shall be reviewed. The Shell representative shall be
advised if the test results are acceptable or if additional testing is required.
- A copy of the verification test results recommendations shall be provided to the
Wells Engineer (WE).


22 CONFIRMATION TESTING OF CEMENT DUMP BAILER KITS
The purpose of this section is to define the minimum requirements for confirmation testing of
cement dump bailer kits. Because dump bailer jobs are not as frequent as common cement
jobs, these jobs are often not tested before the job, and the quality control on the kits may not
be sufficient or applied and/or the kits may have been on the shelf for some time. Testing the
kits can be beneficial to avoid misruns of the dump bailer.
22.1 Requirements for Confirmation Testing

• The Cementing SME shall be consulted before having the cement dump bailer kit
tested.
• Most kits have the complete dry blend in a bucket with separate retarder packs. The
material in the bucket shall be homogenized well before lab samples are taken from
the bucket.
• The maximum temperature and depth where the cement will be dumped shall be
determined. Add 15 °F (8 °C) to that temperature to account for friction while the
dump bailer is run in the hole.
• The technical data sheet shall be reviewed to determine the number of retarder
packs to be used for the estimated temperature.
• Conditioning of the slurry and static gel strength testing shall be conducted on a
rotational paddle type of gel strength testing machine.
- The slurry should be conditioned to BHST in 80 min and held at temperature for
10 min. Paddle rotation will be held to 1 rpm only to maintain heat transfer
throughout the slurry in the test cup.
- The static gel strength mode of the test should be conducted for 30 minutes
before the test is stopped and the slurry quickly cooled down for visual inspection.
•
2
A slurry with a static gel strength greater than 500 lbs/ft may have difficulty exiting
the dump bailer.
• A visual inspection of the slurry after the test should be done to determine if any of
the slurry has set and if settling and severe gelation is observed.


23 RP – USING THE CEMENTING FEASIBILITY ASSESSMENT TOOL
This section gives a general outline of the Cementing Feasibility Assessment tool and how it
should be used to identify potential shortfalls in the cementing processes of a proposed project
and/or cementing program. The Cementing Feasibility Assessment tool shall be used in the
early stages of the Global Well Delivery Process to determine ahead of time if there are any
major issues that could challenge the successful outcome of any potential cementing
operations. The Cementing Feasibility Assessment tool is currently an Excel spreadsheet
available from the Cementing PTE.
23.1 Cementing Feasibility Assessment Tool

The feasibility assessment of a proposed cementing program is developed from the
answers to a series of questions in an Excel spreadsheet. These questions range from
basic information about the well and its location to more specific ones about the proposed
job itself. The answers to the questions are scored and then plotted on an X–Y plot, as
indicated in Figure 7 below.
The X-axis defines the well criticality (type of well, well location, cost), and the Y-axis
defines the cementing program compliance to regulatory requirements and this manual.
The color bands green/yellow/red indicate the degree of criticality and compliance, with
green being high on compliance and low on criticality and red ranging from being very low
on compliance to high on criticality.
Figure 7 – Cement Feasibility Assessment

Depending on the outcome of the initial assessment, it may be necessary to rework the
program by changing some input parameters and/or involving additional staff, such as the
Cement SME, for more technical input to deliver a cementing program carrying an assessment
that is more compliant and can improve the successful outcome of the job.
The plot also identifies the TA Level required to approve the agreed cementing program.


In a worst-case scenario, if the proposed design is so far out of compliance or considered
beyond current technology and capabilities such that the risks involved are not only on the
proposed cement job but may have an impact on the well/project itself, a higher authority, VP
Wells (TA0), may be required to assist with the resolution.


24 CEMENT BOND LOGGING GUIDELINES
The responsibility for deviation of this section shall be as per Wells and PT DCAF as described
in the Preface.
This section will define minimum requirements for cement bond logging. Detailed guidelines
broken down by roles and responsibilities, HSSE, logging tool overview, job planning, pre-job
communication, job execution and data QC, and Evaluation and Techlog Workflow are in the
Shell petrophysical document titled Cement Bond Logging, Planning, Executions and Audit Trail
Guideline. In addition to the Shell document, the API Technical Reference 10TR15 is a good
guide to cement sheath evaluation.
The following requirements shall be followed with regard to cement bond log requirements,
planning, and execution:
The WFS prepared by the PT shall be provided to the Wells Engineer (WE), including any
requirements regarding cement evaluation logging for critical cement jobs or where a cement
evaluation log is mandatory under local law.
Real-time wellbore conditions, variations to the drilling program, and questionable cement job
execution could mandate a cement evaluation log when previously not specified in the WFS.
The Wells Engineer (WE) shall work with the Petrophysicist to specify the cement evaluation
logging program before the casing workstring is run and cemented. The Petrophysicist shall
lead the planning, QC, and evaluation of the bond log. The Petrophysicist shall work with the
Wells Engineer (WE), PT, PC, Cementing SME/Focal Point, and relevant contractors to
determine the strategy for evaluating the quality of the cement bond.
The results of the cement evaluation log, openhole logs, daily drilling records, and cement job
execution details shall be used in combination to determine the presence or absence of bond.
The Wells Engineer (WE) shall work with the Petrophysicist, PT, PC, Cementing SME/Focal
Point, and relevant contractors to determine if remedial action is required during the well
construction process. After Action Reviews (AARs) should be performed and lessons learned
from cement job execution should be documented for implementation on future cement jobs.
Note that cement evaluation logging is not without risk to the wellbore, and these risks shall be
taken into account on a string-by-string basis in the decision on whether to run a cement
evaluation log. In addition, there still exist inherent uncertainties in cement bond evaluation.
24.1 Planning and Execution

Before any cement evaluation log can be successfully run and evaluated, the following
steps shall be taken:
• Identify the roles and responsibilities of the Wells, PT/PC, and Petrophysics staff for
the planning, execution, and evaluation of the log.
• Contact Service Contractor for logging tools availability and the limitations of the
tools.
• Planning for the logging job to include:
- The objective
- Tool selection
- The need for a lubricator for a pressurized logging pass to evaluate potential
micro annulus
- Development of a detailed logging program with assigned responsible parties
- Review of the set cement properties including transit time data from the ultrasonic
cement analyzer compressive strength tests
- Review of the operational details of the cement job, including estimated TOC


- Wellbore data
• Fluid inside the casing
• Casing dimensions and depths
- Any openhole logging data
• Execution and data QC of the logging job:
- Tools shall be run as per the toolstring diagram.
- Check log header to confirm input data is correct.
• Casing specs
• Type of mud and mud weight
• Type of cement and weight
• Estimated cement compressive strength based on the time that the cement
has been in place
- At the beginning of the job, confirm that the plots have the correct presentation
and scales.
- Confirm that gamma ray, casing collar locator, and line tension are being
recorded and plotted.
- The repeat section of the log should match the main log.
- Additional information on logging with CBL-VDL, SBT, USIT, IBC, and CAST
tools can be found in the Shell Petrophysical Cement Bond Logging, Planning,
Executions and Audit Trail Assurance Guidelines document.
• Evaluation of the bond log:
- See the Shell Petrophysical document titled Cement Bond Logging, Planning,
Executions, and Audit Trail Assurance Guidelines for detailed information on
interpretation of the log results.
24.2 Definition of sufficient bond:

From the Shell Petrophysical Cement Bond Logging, Planning, Executions and Audit Trail
Assurance Guidelines: Acoustic cement evaluation logs do not measure hydraulic seal.
Consequently, the quantification of cement evaluation log data is problematic. A cement
evaluation log will show the presence or absence of bond (or something in between), but
on its own, these data cannot be translated into zonal isolation statements.
Some criteria used in the industry to define good bond are detailed below, but each
individual case must be looked at carefully. Always use cement evaluation log data in
conjunction with all other available data such as openhole log data and cement job
execution data (e.g., losses during the job, pump pressures as the top plug lands, mixing
densities during the job).
- The observed cement bond log response agrees with the modeled response
(compressive strength of cement; free pipe reading)
- No (or weak) casing arrivals are seen on the waveforms
- Strong formation arrivals are seen on the waveforms
- Bond index >0.8 over a specified interval (see Note on Bond Index below)
- Absence of channels
- TOC theoretical vs. logged agree
NOTE Well abandonment criteria are specified in the Well Abandonment Manual and
Guidelines. These require at least 100 ft (30 m) of good cement as isolation
criterion for abandonment of a porous zone.


NOTE For sonic logs, a continuous bond index can be computed. The bond index is
not a quantitative measure of cement sheath quality. It is the percentage of
measured signal in relation to the difference between the theoretical value for
perfectly cemented pipe and the theoretical value for free pipe. It does not
represent the circumferential percentage of the annulus that is filled with
cement. The bond index should only be interpreted in context with all other
data. The use of a bond index of 0.8 as a cutoff threshold value and crossplots
of "thickness of interval with good bond" vs. "casing thickness" are not suited to
make statements on zonal isolation. The cutoff and the crossplots are based on
data developed from a study on a limited number of wells, so zonal isolation
statements should not be made based on cement bond logs alone.


25 RP – CEMENTING THROUGH COIL TUBING
The responsibility for deviation of this section shall be as per Wells DCAF as described in the
Preface.
The purpose of this section is to define minimum requirements for the design and testing of
cement slurries and spacers to be pumped through CT. All cement jobs involving CT shall be
reviewed by the Shell Cementing SME.
25.1 Slurry Testing Procedures

Testing procedures in API RP 10B-213 shall be followed except where defined differently
in this document.
• All cement slurry lab tests shall be performed using isolated samples of cement,
additives, and water that will be used on the CT cement job.
• Slurry preparation in the lab for all tests shall follow the standard API RP 10B-2
procedures in Section (5.3.4) of that document unless defined differently in this
document. Deviation from this shall be reviewed with the Cementing SME for
approval.
- For weighted >17.0 ppg (2.0 SG) batch mixed Latex slurries that have a
weighting additive (e.g., hematite) in the design, the Shell Cementing SME
shall be contacted for advice on lab testing procedures. Shell in the North
Sea has experienced reductions in the thickening time of weighted Latex
slurries that have been prepared in batch-mixing environments. To
accommodate this effect, modified slurry testing procedures have been
20
adopted. Reference UIE Cementing Operations Manual details.
• When conducting the HPHT consistometer thickening time testing, the following
modifications to the testing procedures shall apply:
- The BHCT used for all testing shall be the same as the BHST unless thermal
modeling in Wellcat indicates otherwise. Job conditions such as CT diameter,
pump rate, well depth, footage of coil remaining on the reel, and hole
inclination will all have significant effects on the thermal modeling.
- If the slurry is batch mixed, the estimated time in the batch mixer and surface
temperature should be included in the thickening time test schedule. Typical
batch-mixing times range from 30 to 45 minutes. This would be added to the
beginning of the testing schedule with the pressure at zero psi.
- For the thickening time testing schedule, the initial pressure at the start of the
pressure ramp shall be the pressure predicted by the pumping simulator. A
typical value is 4,000 psi (27,579 kPa). This is because the cement will see
friction pressure immediately from the start of pumping the job as it enters the
CT spool.
- The final pressure at the end of the pressure ramp shall be equal to the
hydrostatic of the fluid above the cement plus the hydrostatic of the cement
column. Any additional pressures for squeezing operations shall be added as
appropriate.
- Time to BHCT and final pressure will be equal to the time that it takes the first
barrel of the slurry to reach the end of the CT. This is typically 20 to 40
minutes, which is much faster than a conventional cement job.
- All slurries shall be designed for a thickening time between 5 to 6 hours or 3
hours over job placement time, whichever is longer. The job placement time
is defined as the time it takes from the start of mixing the cement until the
cement has been displaced out of the CT and the end of CT is above the
estimated TOC. Additional time should be added for any squeeze
procedures as appropriate.
- During the thickening time test after the slurry has reached a stable
temperature and pressure, a 30-minute shutdown shall be done. For this
shutdown the stirring of the slurry in the HPHT consistometer will be stopped


for 30 minutes while the temperature and pressure are maintained. The
viscosity of the slurry after the stirring is resumed shall not be greater than
(+15%) of the viscosity before the shutdown. Slurries that do not meet these
criteria shall be redesigned and retested. The thickening time chart shall be
submitted with the lab report.
• When conducting compressive strength testing, the following modifications to the
testing procedures shall apply.
- Because the BHCT is very close if not equal to the BHST for CT cement jobs,
the slurry shall be conditioned at BHST before being placed on an ultrasonic
cement analyzer.
25.2 Slurry Design

Cement slurry designs used on CT applications are usually very similar to slurries
designed for liner applications. They have low rheologies and no settling with some
degree of fluid loss control. The following guidelines shall apply for slurries pumped
through CT:
• Discuss what slurries the service company has used on past CT cement jobs
successfully as well as the pumping rates and pressures with the service company
engineer. These designs will be a good starting point and reference because the
accuracy of job simulation software for estimating pumping pressures on CT
applications is questionable.
• The slurry shall be designed with the required amount of retarder to pass a 30-
minute shutdown during the thickening time test and meet the pump time
requirements.
• The slurry shall be tested for static stability using the API Sedimentation test. Stability
of the slurry is very important to avoid settling in the CT while being pumped or during
a shutdown. A slurry that has less than a 0.5 ppg (0.06 SG) density difference test
result from top to bottom is considered acceptable. Slurries that do not meet this
requirement shall be redesigned and retested.
• Slurry rheologies are very important and shall be tested. The objective is to have a
thin slurry that is also stable and has no settling issues. Designing such a slurry may
take a number of lab design iterations. For reference and comparison, consultation
with the service company engineer on the properties of past designs successfully
used on CT jobs is recommended.
• For some applications to achieve the job objectives, fluids loss control is required.
The Shell Cementing SME and service company engineer should be consulted to
determine the amount of fluid loss control required. In most cases, fluid loss control
additives will be used in the slurry design for stability control.
25.3 Spacer Design

• All spacer lab tests shall be performed using isolated samples of spacer, additives,
water, and mud that will be used on the CT cement job.
• The spacer should be designed to have lower rheologies but enough viscosity to
support any weighting material in the design and provide stability when contaminated
with wellbore fluids or cement. Spacer stability at expected temperatures is important
to avoid plugging of the CT.
• The design of the spacer ahead of and behind the slurry is very important.
Compatibility of the spacer with the wellbore fluids and cement is crucial.
Incompatible fluids can result in very high friction pressures that may lead to a job
termination.
- Compatibility testing shall follow Section (10.19) of this document, with the
exception that the rheologies of each fluid ratio tested should not be greater
than either of the two base fluids.


- Stability of each fluid ratio tested is very important. Observation of any solids
settling during compatibility testing is not acceptable and requires redesign of
the spacer.
25.4 Plug Spotting Procedures

Placement of cement plugs using CT is different from the traditional balanced plug
method. Cement plugs should be spotting using the pump-and-pull method outlined
below. This is only a guideline; and prior to any cementing operation through CT, the
Shell Cementing SME and service company engineer shall be consulted to determine the
best procedure to meet the job objectives.
Pump-and-Pull Method:
1. Run in the hole with the CT to the bottom of where the cement plug is required.
2. Mix and pump the cement slurry with the annulus open.
3. After the slurry has reached the end of the CT, allow 1 bbl (0.16 m3) of cement to turn
the corner and come up the annulus before starting to move the CT.
4. Synchronize the pickup speed of the CT and the fluids pumping rate so that the end
of the CT stays below the TOC.
5. The last barrel of cement should exit the CT as the end of the CT reaches the
required TOC.
6. Pick up 100 ft (30 m) above the TOC and circulate 1.5 coil tubing volumes while
reciprocating +/- 20 ft (6 m). A foam wiper ball may be used during this step to wipe
the ID of the CT.
7. Pick up another 1,000 ft (304 m). Close the annulus and WOC while periodically
reciprocating the CT +/- 20 ft (6 m). If WOC is not required, pull out of the hole with
CT.


26 REFERENCES
In this manual, reference is made to the following publications:
NOTE Unless specifically designated by date, the latest edition of each publication should
be used, together with any amendments/supplements/revisions thereto.
NOTE Standards external to wells including DEPs and most industry standards are available
to Shell users on the Shell Wide Web (SWW) at http://sww.shell.com/standards.
Shell Standards Document Number
1 Index to DEP Publications and Standard Specifications DEP 00.00.05.05-Gen.

2 Management of Change and Deviation Manual WS 38.80.31.11-Gen.
3 Casing and Tubing Design Manual WS 39.01.20.12-Gen.
4 Shell Petrophysical document titled Cement Bond Logging, SR.12.11130
Planning, Executions, and Audit Trail Assurance Guidelines
6 Well Abandonment Manual WS 38.80.31.35-Gen.
19 Shell Global Standard for Temporary Pipework EP 2006-5393 Rev. 4, Feb
2010
20 Shell UIE Cementing Operations Manual and Standards Rev. 1, April 2010
Industry Standards Document Number
5 Technical Report on Cement Sheath Evaluation API Technical Report

10TR1, Second Edition
7 Deepwater Well Design Considerations API RP 96, FEB 2011
8 Isolating Potential Flow Zones During Well Construction API Standard 65 Part 2
Second Edition
9 Recommended Practice for Performance Testing of Cementing API RF 10F/ISO 10427-
Float Equipment 3:2003
10 Specification for Bow-Spring Casing Centralizers API 10D/ISO 10427-1-
2001
11 Technical Report on Temperatures for API Cement Operating API Technical Report
Thickening Time Tests 10TR3, First Edition
12 Specification for Cements and Materials for Well Cementing API 10A/ISO 10426-1-
2001
13 Recommended Practice for Testing Well Cements API RP 10B-2/ISO 10426-
2:2003
14 Recommended Practice on Testing of Deepwater Well Cement API RP 10B-3/ISO 10426-
Formulations 3:2003
15 Recommended Practice on Preparation and Testing of Foamed API RP 10B-4/ISO 10426-
Cement Slurries at Atmospheric Pressure 4: 2003
16 Recommended Practice on Determining the Static Gel Strength API RP 10B-6/ISO 10426-
of Cement Formulations 6:2008
17 Cementing Shallow Water Flow Zones in Deepwater Wells API RP 65, SEPT 2002
18 Isolating Potential Flow Zones During Well Construction API RP 65 PART-2, MAY
2010


The standards listed below pertain to this Global Wells Manual but are not referenced within it.
Shell EP Asia Pacific (EPA) and Brunei Shell Petroleum (BSP) Rev. 2.2, March 2010
Wells Standards
High Temperature High Pressure Well Cementing Manual SIEP 99-5848
Design and Testing Guidelines for HPHT Cementing Version 1, June 2010
Well Cementing, published by Schlumberger Second Edition



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Custodian PTE Cementing

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1.2 Distribution, Intended Use, and Regulatory Considerations

1.3 Requirements Statements

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Deviation Approver of Approval of Approval of

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1.7 Summary of Main Changes

1.8 Comments on this Manual

1.9 Exceptions to Go-Live

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5.1 Cement as a Barrier

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5.2 Cement Volume

5.3 Spacer Volume

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5.5 Lab Testing

5.6 Stress Modeling

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6.1 Requirements of a Cementing Basis of Design

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7.1 Temperature Simulation for Cement Design

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8.1 Requirements for Pipe Centralization/Standoff

Figure 2 – Illustration of Standoff

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9.1 Requirements of Mechanical Separation

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