Society of Petroleum Engineers

SPE 25546

Practical Horizontal Cementing Today

F.e. Ketti, M.G. Edwards, and R.L. Covington, Halliburton Services
SPE Members

Copyright 1993, Society of Petroleum Engineers, Inc.

This paper was prepared for presentation at the SPE Middle East Oil Technical Conference & Exhibition held in Bahrain, 3-6 April 1993.

This paper was selected for presentation by an SPE Program Committee following review of information contained in an abstract submitted by the author(s). Contents of the paper,
as presented, have not been reviewed by the Society of Petroleum Engineers and are subject to correction by the author(s). The material, as presented, does not necessarily reflect
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ABSTRACT zonal or wellbore segment isolation so necessary to

Horizontal wells present an effective method to maximize
production potential and reduce development costs of
some oil and gas fields. The ability to predict inducEid
fracture direction with reasonable accuracy can allow the
operator to drill in the direction considered' most
profitable. 1 Ideally the well would have extended reach
in the proper direction through a stable, fractured
formation, would not require stimulation, and would not
be subject to the production problems usually
encountered in the life of a field. Since horizontal wells
are drilled in a variety of formations, operators are
experiencing the normal well problems and are finding
stimulation and control methods useful for production
improvement. This paper will examine problems
associated with cementing of horizontal sections and the
recent technology advancements that may be applied to
help assure a competent annular hydraulic seal.
Conventional cemented completions have not been used
extensively in horizontal wells since some operators lack
confidence in the technology that is available. Problems
have been perceived in managing cuttings transport, pipe
centralization, effective mud displacement, cement
free-water control, and effective placement of a cement
seal around the casing. These problems do exist and
corrective techniques are complicated by highly deviated
wellbores, but technology advances have been made to
address horizontal conditions. Proper cementing may
continue to provide an economical hydraulic seal for
effective stimulation and work-over operations.
The use of advanced technology often requires extensive
pre-planning and includes the necessity to properly
communicate the benefits to field operations personnel to
assure the proper implementation of new or different
techniques or materials. Little good will come from the
best ideas without proper follow-through during
application.
THE PROBLEMS
Problems encountered during horizontal well cementing
are similar to those on any cement job, but are
aggravated by factors such as wellbore orientation,
geometry, and gravitational forces. Directional deviation
in the horizontal plane is not viewed as a significant
problem to successful cementing other than where
curvature may interfere with centralization or running of
casing. Deviation in the vertical plane could contribute to
centralization and drag problems as well as leaving high
spots that may trap immobile mud in much the same
manner as washouts. Wellbore geometry is affected by
drill string contact on the low side of the hole which can
lead to an oblong shaped wellbore and thus incorrect hole
volume calculations unless adequate caliper logging is
done. 2 Gravitational forces affect centralization problems
and promote solids settling from the wellbore fluids.

307
 PRACTICAL HORIZONTAL CEMENTING TODAY
Oil-based muds may be the preferred system when
drilling poorly consolidated formations or where there are
compatibility problems between the formations and the
drilling fluids. Borehole stability may also be less
affected through reduced drag or torque stresses when
oil-based systems are used. These muds, though
conducive to effective formation control, are rarely
compatible with cement slurries and often leave the
casing and formation of interest in an oil-wet condition.
This necessitates the use of properly designed spacers,
not only to provide compatibility with the mud and
cement, but also to leave the casing and bore-hole wall
in a water-wet state so that adequate cement bonds to
both may be achieved.
Some brine-based, low solids muds incorporating
formation compatible additives may be appropriate for
some zones. However, to be successful, any fluid used
for drilling must provide effective solids removal, be
readily adjustable to meet a variety of well requirements,
must have consistent density and viscosity, and yet still
be economical.
Optimum drilling mud properties, proper mud
conditioning, and improving displacement practices have
been studied for many years. 3 -7 Other studies considered
mud solids and cuttings settling.3.8 The common
conclusions these studies present are that mud
conditioning, rheology control, centralization, careful hole
cleaning, compatible spacer selection, and flow rates
sufficient to induce turbulence, are each critical to job
success.
Deposition of solids in the wellbore is one of the most
severe problems in horizontal wells. Settling of barite or
drill cuttings causes the mud on the low side of the
annulus to have a higher density than the mud on the top
side. The amount of solids, or channel size, appears to
be a function of the rate of deposition and the rate of
particle erosion by hydrodynamic forces. 3 Even though
smaller particles may remain in suspension, larger
particles may not, and in horizontal systems they
accumulate in the narrowest part of the annulus, which
further diminishes the capability of the mud to remove
them from the well. 9 Mud and settled drill solids which
are not properly removed from the wellbore with the drill
string can be a hindrance in getting casing to bottom in
horizontal wells and these settled solids will be much
more difficult to remove once casing is placed into the
well. The best approach to minimize the settling problem
is a properly designed mud system which is able to
adequately transport solids and drill cuttings from the
well.
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SPE 25546
Solids settling is not limited to the drilling mud, but also
occurs in the cement slurries if proper precautions are not
observed. Proper slurry design is of utmost importance
not only to prevent particle settling, but also to help
insure appropriate rheologies for efficient placement and
mud removal, as well as providing zero free water to help
provide top-side integrity in the annulus. Cement slurries
that have free water and/or settling tendencies can result
in water channels on the top side of a horizontal annulus,
or an area of reduced compressive strength cement
which may not provide the annular seal required for zonal
isolation during stimulation treatments. It is imperative
that well-suspended, zero free water slurries be used in
horizontal cementing applications.
Unstable slurries (those which exhibit tendencies to
settle) caused considerable expense to North Sea
operators when cement solids were found inside the
casing. Wiper plug failure was first blamed for this
problem, but even more durable plugs failed to eliminate
the solids.
Casing centralization is also severely affected by gravity
by allowing the casing to sag between the centralizers.
This not only provides a non-uniform annular geometry
which complicates flow mechanics from a solids removal
standpoint, but also complicates mud removal during
cementing operations. Non-circular cross-section
wellbores have been suggested by Sauer. 2 These
contribute to centralization problems as well as providing
excellent channels for solids deposition. Due to the fear
of increased drag caused by the large number of
centralizers in a horizontal well, many times the number
of centralizers is decreased or centralizers may even be
eliminated. Reluctance to move pipe, either by
reciprocation or rotation, is another major factor
contributing to cementing failures.
Improperly designed spacer systems and cement slurries
can cause cement job failures in otherwise perfectly
planned and executed jobs. Spacer systems must be
compatible with the drilling fluid in order to prevent
forming a highly viscous interface which may promote
mud channeling, must have flow properties conducive to
the removal and suspension of settled solids, and be
stable for extended periods of time at wellbore
temperatures.
Clearly the problems encountered in horizontal well
cementing are critical and present significant chance for
failure to obtain a proper annular seal. The second
portion of this paper will illustrate methods to combat
these obstacles.
SPE 25546 F. KETTLe M. EDWARDS, R. COVINGTON
TECHNOLOGY TODAY
Mud Displacement
Maximum mud displacement with cement slurry is
required for proper zonal isolation, casing support, and
long-term bore hole integrity. Ideally 100% of drilling
mud, filtercake, and settled solids would be removed
from the wellbore to achieve the best possible primary
cement job. The following topics are of utmost
importance in the overall success of any primary cement
job. Once casing is cemented in the wellbore, there is
currently no method by which to accurately measure mud
displacement. Therefore, every effort and precaution
should be taken to obtain the best quality cement job.
Past methods of using acoustic amplitude from CBl logs
to calculate displacement efficiency are now known to be
incorrect and if used for that purpose can lead to
unnecessary expense in attempting to squeeze what
"appears" to be poor mud displacement. lack of
planning and attention to these topics cannot be
overlooked in horizontal wells where many factors
considered important in vertical wells are critical in
horizontal wells.
Mud Conditioning
Proper mud conditioning before cementing any well is
probably the most important factor affecting the success
of the cement job and has been the topic of research and
study for years. Mud properties such as plastic viscosity,
yield point, fluid loss, and gel strength development
should be optimized prior to drilling through areas to be
cemented to prevent excessive filtercake build up and
pockets of highly gelled mud. The mud must be in
optimum condition during the circulation time before
cementing if these pockets of highly gelled and partially
dehydrated mud are to be circulated from the well.
Conditioning the hole with mud in poor condition will do
little to improve mud displacement. Mud conditioning
times prior to cementing should approach or exceed three
hole volumes or until the properties of the mud pumped
into the well equals that of the mud exiting the well. 4 ,6
Mud circulation in combination with pipe movement is
stated by many as a highly recommended procedure. 4 -6
Crook, et al 4 report low-side displacement efficiency
greatly increased with the addition of either reciprocation
or rotation.
309
Eliminating Solids Settling
The elimination of settled solids is critical to a successful
cement job. Controlling or eliminating mud solids or drill
cutting settling can be achieved with careful planning of
mud properties and necessary rig equipment such as de-
silters and centrifuges. Jones6 also reports "the key to
increasing the efficiency of water-based muds has been
the ability to reduce drill solids to levels below 6%."
Yield points as high as 15 to 30 may be necessary to
control the settling of cuttings in horizontal wellbores. 4 •6
Excessive PV/YP values can, however, be detrimental to
mud displacement by causing pockets or areas of highly
gelled or dehydrated mud to be formed. Cement settling
must be prevented to provide uniform compressive
strength and consistent slurry properties throughout the
wellbore. Additives are now available to provide slurry
stability at high temperatures by controlling thermal
thinning properties of the slurry.
Flow Regimes
Most researchers in the industry now agree that turbulent
flow is the most beneficial flow regime for improving
displacement efficiencies. 2 ,6,8 Although many times not
attainable with cement slurries, viscous, weighted
spacers can be designed for turbulent flow even at
elevated densities. low viscosity spacers in turbulence
have been reported to aid in the removal of settled solids
if sufficient volume is used.4 Smith, et al6 report
improved displacement efficiency with increasing annular
velocity up to 155 ft/min.
Spacer Design
Spacer types, properties, and volumes \nust not be
overlooked in importance to the overall cement job
quality. The purpose of the spacer system is to serve as
a mud removal aid and serve as a buffer between the
well fluids and the cement slurry. The spacer must
therefore be compatible with both drilling mud and
cement. Any incompatibilities may cause extremely
viscous fluids to be formed, resulting in fluid channeling
through the viscous mixture and excessive friction
pressure. In wells in which oil based muds have been
used, the added concern of leaving the casing and
formation in a water-wet condition must be addressed.
Many additives and surfactants are now available to
optimize the spacer design to meet the requirements of
an individual well. Drilling mud erodability as defined by
Ravi, et al 10 can be used in properly designing the
 PRACTICAL HORIZONTAL CEMENTING TODAY
properties of the spacer necessary to adequately erode as
much of the highly gelled, partially dehydrated mud and
filtercake as possible. In some spacer tests, neither
water nor viscous flushes increased displacement
efficiency, while others showed pumping large volumes
of thin flushes did improve displacement efficiency. 4.8
Each mud system is unique, and with thorough lab
testing in conjunction with past experience in the area,
spacer designs can be improved.
Density differences between mud, spacers, and cement
slurries must be considered for successful cementing.
According to Wilson and Jan,ll test results show that
optimum displacement efficiency is obtained when the
displacing fluid density is no greater than ± 1.0 Ib/gal
different from the fluid being displaced. Crook, et al 4
prefer to have a spacer density higher than that of the
mud, and a cement density higher than that of the
spacer, with each increment to be 0.5 Ib/gal greater if
possible. Jones5 also suggests "the cementing program
should be designed using (1) a single stage system close
to mud density or (2) two or more cement stages with
graduating density from the mud to the tail cement."
While cementing an extended reach horizontal liner in the
North Sea, one operator pumped greater than normal
volumes of spacer. The designed spacer system included
170 bbl of chemically treated water containing a
surfactant (CTW) and 120 bbl of weighted commercial
blend spacer which can be placed in turbulent flow
(WTFS). However, in this example, flow rates necessary
to provide turbulence with the weighted spacer were not
possible. The spacer sequence, in barrels, was 20 CTW
+ 20 WTFS + 20 CTW + 20 WTFS + 30 CTW + 20
WTFS + 40 CTW + 20 WTFS + 50 CTW + 40 WTFS.
This was followed with a normal density cement slurry
mixed continuously with a mixer equipped with automatic
density control instrumentation. The job was considered
a complete success and was noted as the best cement
job to date in the area for this particular operator.
Contact Time
Spacer volumes are sometimes minimized in an attempt
to control cement jobs costs. In vertical wells, research
has shown that a minimum of 8 to 10 minutes of spacer
contact time at the maximum rate possible should be
planned for. 2 •5 •12 In horizontal wells, contact time may
need to be increased if any settled solids or excessive
eccentricity is expected. Additional spacer volume may
aid in mud removal from the low side of the bore-hole in
eccentric annuli. Spacer designs utilizing alternating
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SPE25546
stages of thin spacer and densified viscous spacer may
also offer improved hole cleaning in eccentric situations
by utilizing the density difference as an aid in removing
mud from the wide and narrow side of the annulus. The
spacer example in the previous paragraph is a good
example of alternating density with increased contact
time in the range of 20 to 30 minutes, which has shown
vast improvement in horizontal cement job success in the
North Sea.
Centralization
Centralization is a major problem in horizontal wells.
Computer programs should be used to ensure that the
stand off in the productive interval exceeds 60% and
approaches 70% if possible. Narrow annular clearance
may require an even greater standoff percentage in order
to provide a sufficient flow path for flow to occur
throughout the entire annulus and to prevent
accumulation of low-side mud solids. 12 Improved solid-
vane centralizers are now available which can be used in
place of bow spring centralizers to help alleviate the
problem of running forces required with large numbers of
bow-spring centralizers. Centralizers are often not
installed by rig personnel due to the fear of increased
drag and sticking problems caused by the centralizers.
Many operators have, however, reported reduced drag
and rotation problems by having the casing adequately
centralized and held away from the borehole wall.
Pipe Movement
Most authors agree that pipe movement, even though
more difficult in horizontal wells, should be attempted
when possible. 2.4.5.8.11.12 Studies have shown that pipe
movement is beneficial not only in helping remove mud
from the low side of the annulus but in removing
deposited drill solids during circulation in combination
with pipe movement. 4 The additional mechanical
agitation helps break up areas of highly gelled mud and
dislodges cuttings trapped in combination with mud
filtercake which may prevent the cuttings from being
removed with fluid circulation alone.
Accessories
If pipe movement is planned, casing scratchers should be
incorporated to aid in removing filtercake or settled
solids. External casing packers have been noted by
SPE 25546 F. KETTL. M. EDWARDS, R. COVINGTON
some6 as improving the success in their given areas.
These ECP's should not be used in place of proper
attention to each area listed above. It should be
considered an additional aid in ensuring that sufficient
zonal isolation is achieved.
Slurry Design
Proper slurry design is critical to the success of a
cementing job. While some deficiencies may be tolerable
in vertical wells, horizontal wells are not forgiving and the
highest quality slurry must be used. Essential parameters
include zero free water at formation temperature and
minimal settling.
The room temperature free water test in API
Specification 1OA14 is not applicable nor is the Operating
Free Fluid test in API Specification 10. 16 After
conditioning at expected well conditions, the slurry is
transferred to a graduated cylinder and allowed to stand
at room conditions where it gradually cools during the
test period. Since slurry properties may change with
cooling, it would seem more realistic to maintain the
slurry at 194 0 F for the remainder of the test, or at well
temperatures if the equipment is available to pressurize
the test. Deviation angle has also been shown to affect
free fluid data,16 and tests should be conducted at 45 0
deviation. It is suggested that a duplicate test be
conducted at the wellbore deviation to assure zero free
fluid. Free fluid may show up not as clear water, but as
a thin portion of cement-colored fluid containing well
dispersed cement fines. This type of slurry should be
rejected or adjusted to eliminate this phenomenon
because the less dense portion at the top may not
provide the strength required for a proper seal, and may
provide a path for well fluid movement. This could also
leave the casing exposed to corrosion from down hole
water contact.
Slurry stability must also be considered an integral part of
the design and various procedures have been devised to
examine slurry settling characteristics. The "BP Method"
uses a cylinder filled with slurry which is then cured
under well conditions until the cement sets. 17 The set
cement sample is then sectioned and a density profile of
the set cement is then determined. Recent laboratory
data indicated a 1.90 S.G. designed slurry containing
cement, dispersant, fluid loss additive, fume silica, and
non-lignin retarder exhibited only 0.016 S,G. density
profile difference using the "BP Method." Other methods
of obtaining pass/fail settling tests are used by others.
The use of a stable slurry eliminated the problem
311
mentioned earlier where cement solids were found to
have settled in the casing during the job. One report5
states requirements of cement yield point exceeding 15
Ib/100 fe to control settling,
Cementing long horizontal intervals often requires a
cement slurry with a low yield point to reduce friction
pressure while pumping, in an effort to avoid exceeding
the equivalent circulation density of the well. Additives
are available to aid in designing slurries in this manner.
Caution should be used when designing thin slurries to
protect against settling or free water.
Proper attention must also be given to standard testing
such as thickening time, compressive strengths, and fluid
loss. It is not uncommon for fluid loss values of less than
30 ml/30 minutes to be used. Numerous gas migration
control additives are now available and should be
incorporated into the slurry design as needed.
Cement Additives
Recent developed slurry additives have widened design
capabilities significantly. Fluid loss additives are now
available for any degree of salinity desired and for very
wide temperature ranges. Some are non-retarding and/or
non-viscosifying, thus allowing fluid loss control not
previously available. Latex systems are now available for
use at temperatures exceeding 375 0 F.
Other additives that have significant application are those
which counteract temperature thinning seen with some
slurries at elevated temperatures. Fume silica or special
heavyweight materials have proven beneficial in providing
slurry stability for horizontal applications. It is now
possible to design heavy weight slurries with reasonable
flow properties and still maintain the weighting material
in suspension. Fume silica and improved surfactants
have increased the design capabilities for low density
and/or foamed cement slurries where these have
application.
Also available are a new range of cement expansion aids
which can be used to help prevent long-term gas
migration and reduce micro-annuli. Other new materials
are useful for delaying gel strength build up after the
slurry is in place, which is beneficial in controlling
short-term gas migration. Non-lignin, non-cellulose
retarder chemicals have been developed to provide more
predictable slurry response and improved control over
thickening time.
 PRACTICAL HORIZONTAL CEMENTING TODAY
Proper slurry design often requires extensive laboratory
examination of the various parameters to arrive at the
desired results. In some cases, it may be extremely
difficult or impossible to meet all the slurry properties
that would be considered ideal. It is imperative that the
maximum possible lead time is provided before any
particular job so that slurries can be optimized.
Instrumentation & Computer Aids
Perhaps the most vital information required for suitable
cement slurry design is an accurate bottomhole
circulating temperature. Downhole temperature recorders
have been designed for easy operation and to provide
accurate data. They are surface programmed for
optimum data gathering by using a personal computer.
The recorder can free-fall downhole, be run on a tool
bundle, or be placed on wireline. Temperatures are
recorded during circulation to obtain BHCT and/or during
static times to record BHST. The recorders are retrieved
by either tripping out the drillpipe or by fishing with a
wireline overshot and the data then recovered with the
computer. 21 This will help eliminate the possibility of
excessive under or over-retardation of the slurry. Many
cement additives are extremely temperature dependent
and incorrect temperature data may lead to cement
slurries failing to perform as designed.
Numerous computer aids are now readily available and
should be incorporated into any job design. Centralizer
programs will give proper spacing required to achieve a
given standoff. Cement job simulators are now very
detailed and can accurately estimate expected surface
pressures, equivalent circulating densities, flow regimes
at given points in the wellbore, and free-fall
characteristics of the job. This tool becomes more
important in designing slurries for long horizontal intervals
to ensure that the ECD is not exceeded.
Improved surface instrumentation and job data gathering
capabilities now provide the capability for thorough job
recording and post job evaluation. This information
allows the identification of specific problem areas such as
channeling or lost circulation which can be addressed
prior to the next job.
Mixing Equipment
Once the slurry has been designed and the computer aids
and job simulations have been completed and accepted
as suitable for the particular well conditions, it then
becomes necessary to run the job. Recent developments
312
SPE 25546
in field mixing capabilities have greatly expanded the
types of slurries than can be mixed while offering
improved slurry consistency.
Design improvements and greater tub capacity on
recirculating type mixers and axial flow mixing systems
(also adaptable to the recirculators now in use) can
readily mix some slurries that were previously only
mixable with batch mixers. This has greatly expanded
the capability to design for well conditions with less
consideration for the type of mixing equipment required.
The axial flow mixers have also shown greatly improved
mixing energy, reduced dust in the mixing tub, and
reduced the amount of air entrained in the slurry.18
Automatic density control units feature improved
instrumentation and computer control of the mixers to
provide the capability to control slurry density to within
0.1 Ib/gal and change from lead slurry densities to tail
slurry densities with very narrow transition intervals.
Miscellaneous Equipment
Cementing heads or plug containers can contribute to
increased job success. Double-plug heads may be
stacked to allow the use of wiper plugs to isolate the
interface between mud-spacer, spacer-cement, and
cement-displacement fluid. When used with remote
actuators, the cementing operation can be conducted
without shut-down times to release plugs. The additional
plugs allow the spacer to remain uncontaminated while
in the casing and therefore provides better displacement
and mud removal in the annulus. 18 Elimination of
shut-down times prior to cementing assists in prevention
of solids deposition or mud gelation under static
conditions. 3 Once hole conditioning is complete, the
transition to pumping spacer and cement should be done
as quickly as possible.
Hydraulically operated multiple stage tools which require
no opening plug are available to assist in effective
cementing operations. This offers obvious advantages
over free-fall opening plug models used in vertical wells.
A hydraulically opened tool used along with an inflatable
packer element was used successfully by one operator. 20
Matson and Bennet suggest hydraulically set liner
hangers which require no surface pipe movement are
preferable to mechanically set hangers. 18 Gust and
MacDonald 12 describe problems and solutions when using
mechanically set hangers for horizontal wells and
conclude that proper centralization of the hanger is
important to ensure the slips set properly. Another
SPE 25546 F. KETTL. M. EDWARDS. R. COVINGTON
conclusion is that liner movement during cementing
improves the quality of the job. A special running tool
allows liner movement, rotation or reciprocation, to help
in running pipe through horizontal sections. This tool is
released either hydraulically or with a backup mechanical
system.
CONCLUSIONS:
1. Successful horizontal cementing is now achieved
throughout the world.
2. Successful cementing of horizontal casing presents
problems that require particular attention during the
design and execution of the cementing process.
Mechanical, chemical, and rheological technology is
available to meet these challenges and do the job
properly.
3. To obtain a good cement job, one needs to consider
all of the mechanical elements discussed in this paper, as
well as the design of the drilling fluid, spacer, and cement
slurry.
4. Laboratory studies of the drilling fluids, spacers, and
cement slurries are imperative. Downhole conditions
must be simulated as accurately as possible. It is
essential that accurate downhole information
(temperature, hole size, etc.) is made available.
5. Field operations must be carried out with the highest
degree of quality and professionalism to help assure that
the job goes according to plan.
6. Computer models are available to aid in the design of
centralizer spacing, job simulation before execution, and
post job analysis. These aids are an essential part of job
planning.
7. Horizontal cementing must be approached as a single
problem where all the contributing factors are identified
and a total horizontal system concept is applied as a
single solution.
ACKNOWLEDGMENTS
The authors would like the thank the management of
Halliburton Services for the permission to present this
paper.
313
I
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 PRACTICAL HORIZONTAL CEMENTING TODAY SPE 25546

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13. Reiley, R.H., Black, J.W., Stagg, T.O., and Walters,

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14. API Specifications for Testing of Materials, API

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