SOP Cement Program

STANDARD OPERATIONAL PROCEDURE
ONSHORE DRILLING IDENTIFICATION CODE : -

CHAPTER 18 CEMENT PROGRAM REVISION : 0
18. Cement Program

18.1. General
1. Cement is used in the drilling operation to:
a. Protect and support the casing,
b. Prevent the movement of fluid through the annular space outside the casing,
c. Stop the movement of fluid into vugular or fractured formations, and
d. Close an abandoned portion of the well.
A cement slurry is placed in the well by mixing powdered cement and water at the
surface and pumping it by hydraulic displacement to the desired location. Thus, the
hardened, or reacted, cement slurry becomes "set" cement, a rigid solid that exhibits
favorable strength characteristics.
2. This Standard Operational Procedure applies within Pertamina and may also be a
reference to a subsidiary of Pertamina. Scope of this work is as follows:
a. Preliminary information
b. Slurry design
c. Spacer design
d. Hydraulic calculation
e. Cement placement technique
f. Downhole equipment
g. Surface equipment
h. Operating program
3. Definition:
a. Consistometer is a device with rotating paddles, used to check the pumpability and
set time of cement slurries.
b. Chiksan Swivel Joints are metal are metal pipe fittings with integral ball-bearing
swivels. These rugged fittings come in 3/8- to 12-inch sizes and can handle cold
working pressures up to 20,000 psi.
c. Klampons is tubing protectors that used by the Rig operators while handling
Tubulars between the rack and the rig floor.
d. Slurry is a thin sloppy mud or cement or, in extended use, any fluid mixture of a
pulverized solid with a liquid (usually water), often used as a convenient way of
handling solids in bulk.
e. Additive is material added to a cement slurry to modify or enhance some desired
property
f. Spacer is Fluid containing insoluble weighting materials that is used to separate
drilling fluids and cementing slurries.
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4. Standard operating procedures have limitations and some points that must be obeyed.
The following points are:
a. Cementing program in this SOP used for conventional drilling. For other case (i.e.
HPHT drilling, Deep Water Drilling) have own SOP.
b. Specification for Cements and Materials for Well Cementing base on API SPEC 10A.
5. Reference:
a. Saudi Aramco-Drilling Manual
b. Dehadrun Drilling Operation Practice Manual
c. Eni Drilling SOP
18.2. Cement Types, Specifications, & Additives

18.2.1. Cement Types
Class G (HSR)* cement is used exclusively operations as the basic oilwell cement.
This cement can be blended with many additives to cover a wide range of well
conditions. The five normal slurry compositions are as follows:
a. All the above figures refer to a 94 lb sack.
b. Slurry weights listed above are absolute weights. Weight of cement measured
from the cement tub in a non-pressurized mud balance may be as much as 15
pcf lighter due to entrapped air.
c. Modifications of the basic slurries will be specified by Drilling Engineering.
Table 18. 1 High Sulfate Resistant Cement
Cement Slurry Weight Slurry Yield Water Requirement

(PCF) (FT3/SK) (GAL/SK)
Class G Neat 118 1.15 5.03
Class G +35% Silica Flour 118 1.52 6.28
Class G + 1.5% Bentonite 101 1.69 8.96
(Prehydrated), 6.6 Lbs.
Gel/bbl Of Mix Water
Class G +35% Silica Sand 125 1.35 5.01
Class G +35% Silica Sand + 125 1.40 5.25
5% Expanding Additive
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18.2.2. Specifications
API Specification 10A “Specification for Cement and Materials for Well Cementing”
is used for the approval of the purchasing of class G (HSR) cement.
API Recommended Practice 10B is used for the basic test procedures for the physical
testing of cement slurries. Many instruments in the cement lab are not listed in API
RP 10B. Procedures for testing cements are located in the labs procedures manual.
18.2.3. Performance of Cement Slurry

Data given for the effectiveness of any additives is only valid for the cement, water
and additives used for the test. Different cement brands, and even different
production runs of the same brand of cement, react differently to the various
additives. When there is any doubt, have the actual job cement, water and cement
additives tested. Most cement additives from the various service companies are
completely compatible with each other. Testing is always recommended if additives
from different service companies are being used.
Almost all of Schlumberger/Dowell's products are completely compatible with
Halliburton’s and BJ’s products and vice versa. Before making any substitutions,
consult with the Cement Lab, Drilling Engineering or the Service Company. Many
additives have more than one function. For example, a dispersant (friction reducer)
can be added to a slurry design to help make the mixing easier for a class G cement
slurry that is mixed at a density greater than 118 pcf. The physical effects of adding
the dispersant will be reduced the rheology, and lengthen the thickening times. Lists
of the more common cement functions and additives are included in the following
pages.
18.2.4. Additive Functions:

a. Retarders
The function of retarders is to increase the thickening time (pumping time) of
the cement slurry being pumped. Lignosulfonates and their derivatives make up
the majority of the cement retarders for use in low and medium temperatures.
(80 0F – 220 0F) Higher temperature retarders are composed of Polyhydroxy
Organic Acids and sugar derivatives. It has been observed that combinations of
low and high temperature retarders are effective in extending thickening times
for high temperature applications. High temperature retarders should never be
used in cements with BHCT lower than 180 0F, unless confirmed by lab tests.
b. Fluid Loss Additives
The function of fluid loss additives is to reduce the water loss from the cement
slurry. This class of cement chemicals and gas migration additives are generally
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the most expensive part of the cementing invoice. If high fluid loss occurs the
following can happen:
 Premature dehydration of slurry, which can cause annulus plugging and
incomplete placement of slurry.
 Changes in slurry flow properties (rheology) and increased slurry density.
 Damage to production zones by cement filtrate
Most fluid loss additives also retard the thickening time. On the 4 ½” and 7”
liner jobs for vertical Arab D wells, no retarder is used. Adequate retardation is
produced from the synergetic effects combining the fluid loss additive with the
dispersants.
c. Dispersants (Friction Reducers)
The functions of dispersants are: A) to thin the slurry in order to reduce the
turbulent flow rate or enable easy mixing of slurry B) to densify cement slurry
(increase the solid-to-liquid ratio). C) to aid in fluid loss control.
Over dispersing the cement slurry can cause high free fluid and density settling
in the cement column. This must be avoided at all times and especially when
cementing deviated or horizontal section of the well. Pumping slurry that is not
up to the designed weight (density) can easily settle after placement.
Pressurized mud balances must be used to confirm correct cement density.
Pumping cements that are heavier than the planned density doesn’t cause
settling problems.
However, the thickening times are generally shorter.
d. Accelerators
The function of accelerators is to reduce the thickening time and decrease the
(WOC) time. Calcium Chloride is the most common accelerator used. Calcium
Chloride does not increase the final strength of cement and may perhaps lower
the final compressive strength a little. Most fluid loss additives do not work well
with Calcium Chloride in the cement slurry. Sodium Silicate is recommended if
low fluid loss is required with fluid loss control in most cases. Special mixing is
required for sodium silicate slurries 1) if accelerator is used then the accelerator
must be added first. 2) if a retarder is to be used then the Sodium Silicate should
be added first and the retarder must be added last.
e. Non-Foamers
The function of non-foamer (defoamers) in cement slurry is to release trapped
air in the slurry as it is being mixed. Entrapped air cause viscosity increases,
which make the cement slurry more difficult to mix. Entrapped air also makes
the density of the slurry more difficult to measure. Special non-foamer are used
for Latex cement slurries. The addition of excess non-foamer may stabilize foam.
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Bentonite cement slurries usually require twice as much non-foamer than

conventional cements. Latex cements may require as much as five times more
non-foamer than conventional cement slurries.
f. Strength Retrogression Preventers
The function of silica flour and silica sand in cement is to prevent strength
retrogression of the set cement. Exposure temperatures of 250 0F to 300 0F
require 25% silica flour or silica sand by weight of cement. When cement is
exposed to temperatures from 300 0F to 450 0F, 35% silica flour or silica sand is
required. At temperatures above 450 0F only silica flour should used. Service
companies recommend 35% silica at temperatures over 235 0F. This
recommendation is conservative with built in safety factors for improper
blending ratios of cement-silica flour and inaccurate temperature data.
g. Strength Retrogression Preventers
The function of silica flour and silica sand in cement is to prevent strength
retrogression of the set cement. Exposure temperatures of 250 0F to 300 0F
require 25% silica flour or silica sand by weight of cement. When cement is
exposed to temperatures from 300 0F to 450 0F, 35% silica flour or silica sand is
required. At temperatures above 450 0F only silica flour should used. Service
companies recommend 35% silica at temperatures over 235 0F. This
recommendation is conservative with built in safety factors for improper
blending ratios of cement-silica flour and inaccurate temperature data. be
blended in the mix water, and 2) it is spherical which makes the gel strengths
much lower, thus reducing the viscosity.
h. Gas Migration Additives
The function of Gas migration additives is to help prevent fluids (gasses &
Liquids) from migrating to the surface during the loss of hydrostatic pressure
that occurs prior to the setting of cement. The most popular additive is Liquid
Latex. Latex provides low fluid loss to the slurry and lower initial permeability to
the set cement. Expanding additives are often included in the slurry design to
reverse any shrinkage that occurs during the setting of cement.
Special mixing instruction for latex systems: add the stabilizer to the water after
the bactericide but prior to any other cement additives.
i. Extenders
The function of the extenders is 1) to decrease the slurry density or 2) to
increase the slurry yield decreasing the total cost. Pre-hydrated Bentonite is the
best example of cost saving of a neat cement slurry. However, if low fluid loss is
required, the cement can become more expensive as the increased water in the
system requires more chemicals to prevent it from escaping from the slurry.
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Sodium Silicates have also been used to lower the density of cement but are
more expensive than pre-hydrated Bentonite. Foam cement and Micro spheres
have been utilized with limited success.
j. Expanding Additives
The function of expanding additives is to increase the bonding strength of the
set cement. After cement goes through hydration reaction, the cement shrinks.
Expanding additives primarily MgO and CaO or combinations of the two are dry
blended in cement to take the set cement out of shrinkage and provide up to
2.5% expansion. This expansion may take up to two weeks to reach completion.
Salt (NaCl) is not recommended as an expansion additive in cement due to the
higher permeability that high concentrations of salt in cement produce. On the
other hand MgO and CaO are not as water soluble as NaCl and provide a lower
permeability once the cement has set.
k. Bactericide
The function of the Bactericide (biocide) is to kill significant quantities of
bacteria in the cement mixing fluid to prevent chemical degradation of cement
additives. Bacteria reproduce exponentially and if not controlled will reduce the
cement additives to an ineffective level.
18.3. Slurry Desain

18.3.1. Factors That Influence Cement Slurry Design
Lab tests are run prior to pumping cement in a well. Collecting accurate data prior to
designing the cement ensures a good cement design. The following factors will
effect the cement slurry design:
 Well depth
 Well temperature
 Mud column pressure
 Viscosity and water content of cement slurry
 Strength of cement require to support the pipe
 Quality of available mixing water
 Type of mud & density
 Slurry density
 Cement shrinkage
 Permeability of set cement
 Fluid loss requirements
 Resistance to corrosive fluids
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18.3.2. Limitations of Thickening Time Test Data

The thickening time test is a dynamic test. While the cement slurry is being tested,
measurements are being made of the consistency (viscosity) under downhole
circulating conditions. The thickening time test does not give information on how
the cement slurry performs under down hole static conditions. The thickening time
test does not give useful information on the following:
 The setting profile of the cement after the plug is bumped.
 The compressive strength of the cement.
 How the fluid loss to the formation affects the cement slurry.
 How long the cement will be pumpable during a shutdown. This is different for
each cement slurry and the particular well conditions.
To determine theses parameters, tests that simulate the slurry’s environment under
static/dynamic conditions must be performed.
Figure 18. 1 Shown above is a typical thickening time curve for Class
G cement + 1% CaCl2 @ 118 pcf, a BHCT of 100 0F. When the
consistency reaches 100 Bc the thickening time is terminated.
18.3.3. Fluid Loss Tests

Cement is like drilling mud in some aspects, as it is a suspension of solids. Chemical
reactions occur on the surface of the solid particles of cement after water has been
added. The rate that a cement slurry loses water through a high permeability zone
under pressure is called fluid loss or filtration rate.
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The water that is lost from the slurry does not give the cementing properties that
were originally designed.
When water is lost from the cement slurry, the slurry property’s change:
 Viscosity increases which increases friction or pump pressures. – High loss of
water will result in a highly viscous cement slurry which is unpumpable.
 Thickening time decreases
 Higher solids to liquid ratio – cement bridges may form in areas of narrow
clearances
The water that is lost from the cement slurry will have higher compressive
strengths. High fluid loss cement slurries can be used when squeezing high injection
rate leaks or perforations.
Two types of tests are preformed for cement slurries. 1) HT/HP Fluid loss test and 2)
Stirred fluid loss test. The permeable medium for both tests is a 325 mesh screen.
a. HT/HP Fluid Loss Tests (BHCT<190 0F)
The cement slurry is condition at bottom-hole circulating temperature
(maximum 190 0F) under atmospheric pressures. The cement is then
transferred to the fluid loss cell and tested at the bottom-hole circulating
temperature and 1000 psi. The filtrate collected is used to calculate the fluid
loss.
b. Stirred HT/HP Fluid Loss Tests (BHCT>190 0F)
The cement slurry is condition in the test apparatus at bottom-hole circulating
temperature and 1100 psi. The cell is then rotated 180 degrees and the test
cement slurry falls on to the 325 mesh screen. Back pressure (100 psi) is
maintained through out the testing period. The filtrate collected is used to
calculate the fluid loss. Cements tested with the Stirred fluid loss cell generally
give higher fluid loss values as compared to the same cements tested on the
HT/HP fluid loss cell.
18.3.4. WOC Time

The industry accepts a compressive strength of 500 psi for drilling out the casing
shoe. This is also true for testing and drilling out the top of the liner. On
conventional wells, where the top of the liner is shallow and the cement density is
low the 500 psi compressive strength may take up to 10 hours to develop. On deep
gas wells with long liners, up to 30 hours may be required for the cement to develop
500 psi compressive strength.
a. Ultrasonic Cement Analyzer (UCA Test)
The UCA is a non-destructive test that gives sonic (compressive) strength data as
a function of time. This test is usually run for 24 hours. The test is run for longer
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periods of time depending on the setting profile of the cement. The most
important use of the data from the UCA is WOC (waiting on cement) time. It
should be noted that this test uses uncontaminated cement slurry unless
otherwise specified. Mud contamination in cement slurries can either shorten or
lengthen the initial set of the cement. Mud contamination also reduces the final
compressive strength.
Figure 18. 2 Shown above is the compressive strength of

a 7” liner jobs for a Khuff gas well
b. Static Gel Strength Analyzer (SGSA Test)

The SGSA/UCA is a non-destructive test that gives static gel strength & sonic
(compressive) strength data as a function of time. The most important use of
the data from the SGSA are 1) the time that the cement slurry begins to gel
(zero gel) and the time that the slurry reaches a gel strength of 1200 lb/100 ft2
(maximum gel) and 2) sonic strength which WOC (waiting on cement) time is
determined. Hydrostatic pressure from the cement slurry is being lost at the
Zero Gel point. At the maximum gel point the cement is so thick that fluids
(including gases) can not pass through the cement column. For gas and fluid
migration control, the shorter the time between zero gel and maximum gel the
better the chance for preventing migration of downhole fluids through annulus
to surface. Some literature states that gel strength of 500 lb/100 ft2 is the point
that gas leakage can be contained. It should also be noted that this test uses
uncontaminated cement slurry unless otherwise specified.
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Figure 18. 3 This Static gel strength data is for a 150 pcf
cement used to cement across abnormal pressure
18.3.5. Pressurized Mud Balance & Densitometers

A pressurized fluid density balance is used to monitor the density of cement slurry
that is mixed in the field. Non-pressurized fluid density balances (mud balance)
should be avoided as errors of up to 15 pcf can occur due to entrapped air in the
cement slurry. The pressurized density balance greatly reduces the volume of
trapped in the slurry. High density cement slurries that are mixed with latex
additives tend to trap more air than conventional cements.
A pressurized fluid density balance should be used to calibrate any densitometers
on the cementing units. Calibration should be made at two densities. It is
recommended to calibrate the densitometer at the cement density and either the
spacer or mud density. Once the calibration is complete, it should not be re-
adjusted before or during the cement job unless confirmed by the pressurized
density balance. The densitometers should be placed on the pressure side of pumps
to guaranty accurate density measurements.
18.3.6. Free Fluid Test (free water)

If excess water is added to the cement beyond the requirement for fluidity or
chemical reaction the solid particles separate from the slurry leaving the lighter
excess water on top. This excess fluid is called free fluid. Neat class G cement mixed
at 118 pcf should have a maximum free fluid of 1.4% according to API Spec 10A,
Specification for Cements and Materials for Well Cementing, 22nd Edition, January
1995.
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18.3.7. Rheology Test

Measuring the rheological properties of a cement slurry provide information of the
cement slurry’s flow properties and settling tendency. The Fann model 35 rotational
viscometer is the most widely used instrument used for determination of
rheological properties for well cements. The rheological model is first determined
from the Fann readings. Two models are considered for cement slurries (Power Law
and Bingham Plastic). Turbulent flow is more easily achieved if n’ (power law)
approaches 1 and YP (Bingham Plastic) approaches 0 or negative. Density settling is
possible if n’ >1.0 or if YP<1.
18.3.8. Mud-Spacer-Cement Compatibility Test

Rheology data of cement, spacer and mud are used as guidelines to determine if the
fluids are compatible. Rheology of the mixtures of various concentrations of
cement-spacer, spacer-mud and cement-spacer-mud are taken to evaluate the
effect of mixing of the three fluids. Sever gelling is noted when the rheology
readings of the mixtures is much higher than the three initial readings of the
cement, spacer and mud. Highly compatible fluids are determined when the Fann
readings of the mixtures of the fluids fall in between the readings of the base fluids.
Example of mud compatibility test is shown below.
18.3.9. Gas Migration Additives

Every service company has cement additives that helps reduce or eliminate gas
migration during the setting of cement. Service companies also have cement
additives that expand after the cement has set. Most additives that are supposed to
prevent gas migration as the slurry sets produce cement slurry that has low fluid
loss. Common additives to prevent gas migration during the setting of cement are D-
600 (Dowell), Latex 2000 (Halliburton) and B-86L (BJ). All of these latex additives
require the addition of stabilizer D-135, Stabilizer 434B and LS-1 respectively.
Studies show that these polymers and latex additives fill the porosity of the cement
matrix giving the cement very low permeability during the transition from slurry to
solid.
Expanding additives (Microbond-HT, B-82 and EC-2) all expand after the cement has
set. This expansion is dependent on the exposure temperature of the cement. The
maximum linear expansion with 5% (by weight of cement) of these additives is
around 2.5%. It is possible for gas leaking up the annulus, after the cement job, to
stop some time later (up to one month) due to late expansion of set cement, which
contains these additives. Cements without expanding additives normally shrink after
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the hydration reaction is complete. Expanding additives and latex additives have
been successfully used in cementing the abnormally pressured Jilh formation. More
recently expanding additives have been used to cement the Arab-D open hole
sections of deep gas wells. These wells have abnormal pressure due to their
location, which is usually near to water injectors.
18.3.10. Cementing: Pre-Job Considerations for Slurry Design

The following will aid in planning a successful cement job.
 What is the depth? MD, TVD?
 What is the BHST?
 What is the BHCT?
 Has correction been made for Horizontal section of the well with respect to
BHCT?
 What is the required density? (LOC or Abnormal Pressure Zones)
 What is the estimated job time?
 What is the chemical composition of the mix water? Ca+2,Mg+2,Clvalues?
 What is the chemical composition of the drilling fluid’s filtrate? Ca+2,Mg+2,Cl-
values?
 Has bactericide been added to the mix water?
 Is there a potential for annular flow of gas or liquid as the cement sets?
 Are there any special or unusual well conditions that must be considered?
18.3.11. Pre-Job Meeting

Before every cement job, the Foreman will hold a pre-cement meeting to assure
that the objectives are understood, assignments made and possible problems and
solutions are discussed. Those involved in the meeting will be the Drilling Engineer,
Contract Toolpusher, Foreman, Cementer(s) and the Driller. The liner hanger
representative will be on location for liner jobs. The Engineer is available for cement
slurry design, volume calculations and recommended pressures for bumping the
plugs. He will also discuss the mixing, displacing, and thickening times. All three
parties, Engineer, Foreman, and Cementer will individually calculate and compare
the slurry and displacement volumes.
Assignments will be made as to who will:
 Monitor the cement slurry weight.
 Pump water and mud to the pump trucks or cementing unit.
 Insert plugs. (Foreman & Cementer)
 Check displacement volumes.
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 Catch samples. It doesn't do much good to catch a dry sample of cement unless
a container of mixing water is caught at the same time.
All signals for communications will be reviewed. The pressure recorder on the
cementing unit, the 5 or 6 pen drilling recorder and the radioactive Densiometer (if
used) should all be inspected prior to the job to insure that they are working
properly.
The Foreman must not have any duties that will tie him down to any one operation.
He must be free to supervise the overall operation and be able to go to any trouble
that may occur.
To avoid any potential problems in communications onshore, the pump truck should
be located so that visibility is good between the driller's console and the pump
truck. The best way to accomplish this is by placing the pump truck at the end of the
catwalk.
18.4. Lab Testing of Cement

18.4.1. Types of Tests
The cement lab routinely performs the following test on all field cement jobs.
 Thickening Time (pumping time)
 Fluid Loss (only if the slurry contains fluid loss additives)
 Free fluid (free water, vertical or 45 degrees)
 Rheology (determine turbulent flow rate)
 Sonic Strength (compressive strength)
 Slurry Density (pressurized density balance)
 The cement lab can perform the following special test at the request of
 Drilling Operations or Drilling Engineering:
 Static Gel Strength
 Settling (density settling)
 Expansion (both linear & radial)
 Cement-Spacer-Mud compatibility
 Gas Migration Potential
 Cement ROP (Kick-off/Sidetrack Plugs)
18.4.2. When To Send Samples For Testing

 Forman or Engineer suspects a problem with cement, cement additives
 or mix water.
 Service company lab not functioning
 BHST > 2200F
 Khuff wells: K2 wells, 13 3/8” casing and deeper,
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 K1 wells, 9 5/8” casings and deeper

 All CTU Cement Jobs
 Abnormal well conditions that may adversely affect the cement job.
 Remote locations *
*For remote locations, cement and rig water should be sent to Oil Company and
Service Company labs at least three days before the cement job.
18.4.3. Initial Pilot Testing

This test is performed on lab cement, raw water (rig water if in stock) and lab
additives. The most recent batch of cement from the factory is used to perform
these tests. The standard tests are carried out. The most important function of
performing this test is to save lab and rig time. Lab tests are performed to
determine the retarder and fluid loss additive concentrations to meet the thickening
time and fluid loss requirements. Pilot tests are not always performed prior to the
writing of the program. Database searches are usually a good starting point in the
design of the cement slurry.
18.4.4. Pilot Testing prior To Mixing

Samples of rig cement blend and rig water are collected and tested for the critical
physical properties. This test is used to compare test results from the Aramco oilwell
cement lab with the Service company’s lab. When comparing the thickening time
results of both labs the following rule should apply: The thickening time results that
have the highest concentration of retarder for the shortest acceptable thickening
time is the cement formulation that should be mixed in the field. This applies only if
all other tests like fluid loss, compressive strength development, etc. are within the
requirements set by Drilling Engineering. These requirements are usually listed on
the drilling program.
18.4.5. Field Sample Confirmation Testing

Samples of cement blend and mixing fluid (water plus cement additives) are sent in
by the Service Company to both Saudi Aramco and service company oilwell cement
labs. The results are usually faxed to the rig as soon as the thickening time is
finished. The compressive strength data is usually sent the next day.
18.5. Mixing Cement

The most important cement slurry property that can be measure in the field is slurry density.
All lab tests are performed at the designed slurry density. Variation in slurry density in the
field will produce cement slurry that may be unpredictable with respect to thickening time,
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fluid loss, rheology, free fluid, settling, static gel strength and compressive strength. The
pressurized density balance is the best device readily available to field personnel to measure
cement density. Batch mixing is the most effective way to ensure accurate slurry density.
18.5.1. Mix Water Quality
The water used as pre-blended cement mix water should be reasonably fresh. If the
water is too hard (high Calcium & Magnesium concentration) then alternative sources
of water should be located. If the proposed water is high in Chloride then alternative
sources of water should be located. If no acceptable water can be found send a
sample of the proposed water to the cement lab and a softening treatment can be
recommended in most cases. Softening treatments usually include adding Soda Ash
and or Caustic causing a heavy white precipitate to settle to the bottom of the tank.
The clear water should be skimmed off the top after the precipitate has settled to the
bottom of the tank. Sometimes there are exceptions to this rule and they should be
clearly defined in the drilling program. Biocide should be added to all mix waters that
contain retarders, friction reducers or fluid loss additives. If any mix water is
questionable then verify that such water is acceptable with the Drilling
Superintendent / Engineer / Oil well cement lab prior to blending chemicals.
18.5.2. Type of Chemicals and Quantity to Be Blended

The type of chemicals and quantity to be blended in the mix water will be specified in
the drilling program or separate cementing procedure (supplement to the program)
based on lab data. Mix those chemicals in the water on location. This allows an "on
site" check of the water quality and type and quantity of chemicals blended. The
Drilling Foreman is personally responsible for confirming that the proper types and
amounts of chemicals and water are utilized in preparing the "mix water” blend.
18.5.3. Mix Water Blending and Storage System

Mix water must at all times be completely isolated from any source of contamination.
The fluid handling system used to blend and pump the cement mix water should be
completely isolated from all other fluid systems. A common manifold for the pre-flush,
mix water, wash water and mud systems is not acceptable. It is acceptable to utilize a
manifold for other fluids than cement mix water; i.e., pre-flush, wash water and mud.
An individual fluid handling system of tanks and lines to the cementing unit is
necessary for the mix water system. This will usually involve rigging up special lines
and tanks. Rig up as necessary to achieve the above.
18.5.4. Cement Job Quality
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The preparation work prior to performing a complicated cement job is crucial to the
success of the cement job. Batch Mix cement when possible. This gives you a positive
check of the total batch of cement slurry before it goes downhole. On large jobs
(where you can't batch mix), mix and pump a small amount to the desert before
pumping cement downhole. This short 'pump test' will exercise the pump system and
prove that the system can blend cement slurry with the fluid properties and weight
desired. On large critical jobs, where one particular service company does not have
the sufficient batch mixing capacity, employ the use of other service company batch
mixers. It is recommended that only one Service Company pump the cement job. The
Foreman should completely satisfy any question he might have regarding the
mechanical reliability of the equipment, cementing technique to be used, mix water
blend and mix water system reliability, ell conditions, etc. before mixing cement. Don't
hesitate to discuss any question with the Drilling Superintendent and eliminate as
many problem areas as possible.
18.5.5. Pre-mixing additives

The tanks that the mixing fluid will be stored should be clean. Lines filling the tank
should be flushed if used for purposes other than transporting water. Liquid
Bactericide (biocide) should be poured on the bottom of the tank prior to filling the
tank. Most resident bacteria colonies will be on the tank bottom. Bacteria thrive on
cement chemicals like retarders, fluid loss additives and dispersants. Fill the tank with
water. Mixing water should be cool. If Wasia water is used, it must be allowed to cool
in open tanks for at least 24 hours. Past experience has indicated that many 'flash
sets' were the direct result of using a Hot, saline water. The calcium & chloride
content of the mixing water should be checked prior to mixing. Temperature, calcium
and chloride content of the mix water should be recorded. Biocides generally have
short half-lives. Additional biocide should be a ded every eight hour during the hotter
months (April through October). During the cooler months (November through
March) add biocide every 12 hours. Check with the Service Company or the Aramco
cement lab for proper order of addition of cement chemicals prior to pre-mixing
additives to the water.
18.5.6. Sampling and Sample sizes

a. Sample Containers
All sample containers should be clean and free of moisture. The sample containers
for dry cement should be air tight. The sample containers for water and the mixing
fluid should be leak proof. Saudi Aramco Material Stock number (25-008-865)
One-gallon wide mouth plastic bottles are good for both dry cement and mix fluid.
Page | 16
b. Dry Cement Sampling

For sampling dry cement either of two methods are acceptable. 1) First Aerate the
cement for five to ten minutes, then open the hatch on the bulk storage unit and
sample the cement blend approximately one foot (12”) below the top level. 2)
Pressurize the bulk storage unit, then blow out a volume of cement that would
represent the volume left in the line, then catch the required sample of dry
cement.
c. Sampling of Mix Fluid
After all the cement additives have been mixed in the water, continue to circulate
the fluid for thirty minutes. At this point sample the fluid from the top of the tank.
Do not sample from a valve. If any fisheyes (dry additive that have gelled due to
improper hydration) are floating on the top, do not include them in the sample.
d. Sample Size of Lab Testing
For pilot testing purposes, each lab should receive a minimum of two gallons of
water from the same source that will be used for cementing. The minimum dry
cement sample size for lab testing is one gallon for each laboratory and each
stage. For a three stage cement job, where all three stages are requested to be
tested, the samples should be distributed as follows: Three dry cement samples
would go to the Saudi Aramco Cement lab and the other three would go to the
Service Company lab.
The minimum mix water sample size is one gallon. This is approximately twice the
amount required to mix with one gallon of cement. Additional water is required
because adjustments may be needed to lengthen the thickening time of the field
mixed sample. Usually, the labs will have some leftover cement blend from the
pilot tests performed prior to mixing. The lab will only resort to using that sample
as a last resort.
e. Sample Labeling
All samples should be labeled as follows:
 Well Name & No.
 Rig Name & No.
 Date
 Job Description & Stage
 Description of Sample
 Include all the additives that are mixed in the water or blended in the cement.
 Name of Lab (Saudi Aramco or Service Co.)
18.6. Check List for Cementation Job

18.6.1. Before Casing running
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a. Tally the casing and total depth such that the casing can be landed within 1.5 m (5
ft.) of the bottom (floor).
b. Caliper log should be recorded to know the hole size at various depths and for the
calculation of cement slurry volume to be pumped to achieve desired cement rise.
c. Well is properly conditioned so that it is free from lost circulation, tight pull,
caving and activity prior to pulling out for casing lowering.
18.6.2. During Casing Running In

a. Check the prepared casing running and fill up schedule.
b. Control lowering speed to prevent fracturing/loss circulation.
c. Control torque make up on casing threads.
d. Use differential type of floating equipment in potential mud loss wells.
e. To see that float shoe is checked and placed on first joint of casing to guide casing
into well and minimising derrick strain.
f. To check float collar and should be placed on one/two/three joints above casing
shoe depending upon well depth.
g. To ensure float shoe and float collars used are of same type.
h. Type of floating equipment, conventional or differential. If differential type is
used, the tripping ball is checked.
18.6.3. Mechnical Aids

a. To check the following for centralizers :
 Total number of centralisers used.
 Ensure use of stop rings to place the centralizers.
 Ensure the stop rings are not welded on casings.
 Ensure centralizer spacing done with computer programme.
 60 Mts. below and above the zone and the interval of the zone should be
properly centralized.
 Total cement column is centralized.
b. Ensure use of scratchers against permeable formation to remove filter cake
c. Ensure use of swirlers in washout sections.
18.6.4. Circulation Prior to Cementation

a. Condition hole with good surface conditioned mud at a maximum possible rate
within the limitation of fracture gradient for 1.5 to 2 cycles (minimum).
b. Circulation rate and pressure.
c. Mud was conditioned to lowest possible Pv & Yp as the system permits without
dropping solids.
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d. Mud parameters during final circulation:

 Specific gravity.
 Pv
 Gel
 Viscosity
 water loss
e. Casing reciprocation during circulation was done.
f. Cementation started only after the mud is free from any gas bubbles /pockets/
cuttings and at least 90% of the hole mud is being circulated.
18.6.5. Cementing Head

a. Whether single or double plug container cementing head is used.
b. Cementing head should be checked for any leakage during cementing operation
and proper function of plug release indicator.
c. Stopper pin is checked for its easy movement.
d. Top and bottom plugs are placed in proper sequence viz. Bottom hollow plug is
loaded first and then top solid plug.
18.6.6. Cementing Equipment

a. The cementing units, bunkers/silos are thoroughly checked to avoid any break
down during the operations.
b. The discharge of cementing unit is checked physically for their capacity in
accordance with the liner size.
c. Tanks of cementing units are thoroughly cleaned.
d. Cementing head and all connection lines are pressure tested to 1.5 times the
maximum pressure to be encountered during cementing.
e. Check and calibrate the pressure gauges.
18.6.7. Blending of Cement Additives

a. A minimum of two transfers of cement and additives is a must, when dry blending
is recommended.
b. Correct weights (dosage) of powdered additives are mixed.
c. Conduct test of each blended cement sample.
d. If wet mixing is done, the correct percentage of additive is thoroughly mixed with
the mixing water.
18.6.8. Preflush / Spacer
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a. Check whether sufficient volume of Spacer/Preflush to be displaced ahead of

cement slurry in turbulent flow with minimum 10 minutes contact time or equal
to 150-200 mts. of annulus height, is prepared.
b. Check compatibility of preflush/spacer, drilling mud and cement slurry at room
temperature and BHCT.
18.6.9. Cement Slurry Design

a. Determine maximum permissible down hole cement slurry density to prevent
fracturing or induced losses. The density of cement slurry should be at least 1 ppg
(preferable 2-3 ppg) heavier than the drilling mud.
b. Correct bottom hole circulating temperature and pressures should be used to
design the slurry.
c. Thickening time:
 Is there a safety factor for placement taken into consideration?
 Has it been laboratory tested with drill site technical water under simulated
conditions?
d. Viscosity (Consistency) of cement slurry is low enough for the required
displacement rate to achieve turbulence.
e. Fluid loss control is adequate as per well requirement.
f. Free water is controlled as per well requirement.
g. Comprehensive strength of cement is determined after 24 hrs and 48 hrs at BHST.
h. Silica Flour 35% is used with ‘G’ class cement at temperature above 110°C.
18.6.10. Slurry Mixing and Pumping

a. Sufficient mixing water is available for the volume of cement to be mixed and
enough liquid or solid additives are present at site.
b. Mixing pump pressure should be tested for required discharge.
c. Batch mixer/ recirculating mixer/ precision slurry mixer is used for preparing
homogenous slurry.
d. Mud balance or other density measuring device is calibrated with fresh water
before actual cement job.
e. The SG of cement slurry is continuously monitored during cementation job.
f. The SG of cement slurry is maintained as close as the lab design with variation of ±
0.2 ppg.
g. Quantity of cement used and slurry volume pumped is as per plan.
h. Continuous monitoring of mud returns during cement slurry pumping.
18.6.11. During Displacement
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a. Displacement volume is calculated as per casing string actually being run in the
well.
b. Displacement is to be done by :
 Rig pumps
 Cementing units.
c. Number of strokes were calculated with 100%, 98% or 95% rig pump efficiency.
d. The discharge of the rig pump is checked physically as well as theoretically.
e. The SPM of pump was calculated to achieve desired flow regime during
displacement.
f. Casing was reciprocated/ rotated during cementing operation.
g. Cycle of reciprocation ——————m/mins.
h. If rotated, the speed of rotation—————RPM.
i. Displace top plug out of cementing head with minimum down time.
j. Last 200 strokes are pumped at slower speed to bump the plug.
k. Check function of NRVs.
l. Pressure applied to be calculated in case of NRV failure.
m. If well was kept under pressure, necessary directions to be conveyed to shift in-
charge for monitoring of pressure during WOC.
n. Casing left open during WOC if NRV holds after plug hitting.
o. Continuous monitoring of mud returns during displacement.
18.6.12. Operational Considerations

a. Necessary instructions to be passed to the cementing officials before starting the
job.
b. The cementing unit pumps are loaded prior to starting the cementation job.
c. Extra bunker / silo loaded with cement is kept as standby
d. Necessary arrangement for applying back pressure (if it is to be given) has been
made.
e. Anchoring / rig up of cementing units has been properly made.
f. Supply of water to the cementing unit has been checked.
g. Safety precaution has been taken prior to commencing of actual cementing
operation.
h. WOC time specified is sufficient.
18.6.13. Monitoring
a. Data comparisons with calculated predictions and post analysis of the job.
b. Calculate material balance for mix water, cement and cement additives and
compare with volume of each slurry pumped.
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c. Prepare a summary of the completed job.
18.6.14. Evaluation
a. Quality of CBL/VDL: Excellent / Satisfactory / Poor.
b. CBL/VDL was taken after 48 hrs. / 60 hrs.
c. Whether CBL/VDL is recorded under pressurized conditions.
d. CBL/VDL taken before or after hermatical test.
e. Interpretation of CBL/VDL in terms of Bond Index.
18.7.Primary Cementing
18.7.1. Cement slurry mixing and pumping
a. Pressurize bulk units to 15-25psi just prior to starting mixing slurry.
b. Start the pumping operation to break circulation to ensure that the casing shoe is
open and check the mud return.
c. Do not premix the cement additives in the water more than 5-6 hours before the
cementing job. Before premixing additives in water, better to wait until the final
circulation is started after casing lowering to the target depth. Verify metering
device if liquid additives are pre mixed in water, continue to agitate chemical
water thoroughly until the job is complete.
d. The mix water for cement should be measured through displacement tank
because it helps to calculate easily how much quantity of cement has been
pumped in the event of unplanned shutdown. When liquid cement additives are
mixed in displacement tanks, measurement of mixed water is absolutely
necessary as tanks are alternately filled and emptied.
e. Control slurry density with pressurized mud cup balance. Check calibration of
densometer as well as mud cup balance with fresh water to ensure the reliability
of density readings.
f. Use top and bottom cement rubber plugs. Inspect plugs before loading. Turn
bottom plug upside down and inspect hollow core and rubber diaphragm. Do not
puncture diaphragm of bottom plug prior to loading. Bottom hollow plug is loaded
first and then Top solid plug is loaded. Check order of plug loading.
g. A bottom plug is not recommended with large amounts of lost circulation material
in the slurry or with badly rusted or scaled casing, as such material may collect on
the ruptured diaphragm and bridge the casing.
h. Displace top plug out of cementing head without shutting down operations. Do
not open cementing head to drop top plug and better to use a two plug container,
as it will allow the well to suck in air and cause honey combing of cement around
the shoe joints.
Page | 22
i. Use pre-flush or spacer volume equal to 150-200 m annular height, Pump pre-
flush or spacer ahead of bottom plug. Better use two bottom plugs, one ahead of
pre-flush and one ahead of cement slurry. Be sure to conduct compatibility test
with pre-flush, mud and cement slurry.
j. To ensure good control of slurry density and other properties, batch mix all
cement slurries, if possible. Alternatively use continuous mixing devices like
Precision Slurry Mixer (PSM) or
k. Recirculating Cement Mixer (RCM).
l. Do not try to get the last few quantity of cement out of the cement bunker or
surge tank. This will cause reduction in slurry density and will result in poor slurry
at shoe joint and outside bottom joints. Maintain constant density of the last 10-
12bbls. (2cu.m) slurry pumped which is very critical.
18.7.2. Displacement Technique

18.7.2.1. Single Or First Stage
1. Line up to the rig pumps. Break circulation slowly. When it has been
determined that full returns have been established, gradually increase the
pump rate and circulate total hole volume. Record the pressures at the
various flow rates. At the end of circulation, record the pressure with
estimated displacement rate.
2. During circulation monitor pit levels, bottoms-up mud properties and

eventual shows.
3. After bottom circulation, line up the cement head to the cementing

manifold.
4. Check the cementing lines and connect the cementing manifold to the rig
mud pumps. All lines of the cementing manifold shall be flushed with water
and pressure tested to 5,000psi prior to cementing.
5. The Mud Engineer shall record initial pit levels. He shall be present at the
mud pits during the whole cementing and displacement operations
reporting any loss on returns, pertinent facts and data.
6. Pump the spacer. Unless the effective mud density required to control
formation pressure dictates otherwise, all cement jobs shall be flushed with
a water spacer. The spacer volume shall be equivalent to, circa three
Page | 23
minutes of contact time. The use of other particular spacers, related to mud
weight and system in use, will be specified, in the drilling program (contact
time, compatibility with cement slurry, etc.).
7. In all cementing operations, a top and bottom plug shall be utilized unless
otherwise specified in the Cementing Program, 30" and 20" casing will be
cemented through an inner string.
8. The use of non rotating PDC drillable plugs are recommended to enable
further drilling phases.
9. In advance to the cementing job, the water and cement shall be checked to
ascertain that the chemical characteristics are the same as the samples used
in the pilot tests.
10. Mix the cement to the required slurry weight and have the weight checked
regularly. A pressurized mud balance is recommended in order to reduce
any air entering the system to a negligible volume. The use of this tool
provides advantages:
 A fluid density value that is virtually the same as that under actual
downhole conditions.
 The correct water/cement ratio. It must be noted that changing the
W/C ratio, means the amount of additives in the slurry also change.
11. When mixing cement, samples of slurry shall be collected in numbered

containers, taken at the start, middle and end of each type of slurry. Also
take water, mixing water samples and one sample of dry cement from each
tank used.
12. For the slurry recipe follow the Cementing Program.
13. Leave the mixing tube full of the required weight slurry at the conclusion of
mixing to avoid the possibility of pumping diluted cement or possibly water
into the casing before the top plug is released.
14. Flush the cement from the lines prior to releasing the top plug.
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15. The Cementing Operator shall personally release the top plug and the
Company Drilling and Completion Supervisor shall personally witness the
process.
16. Switch over to the rig pumps. The cement pumping unit shall be ready,
waiting to take over in case of any malfunction or in the event pressure
becomes excessive for the rig.
17. Displace the cement with mud at the maximum permissible rate and surface
pressure, unless otherwise stated in the Cementing Program.
18. Slow the pumps, if there is a loss of returns during the displacement, to
regain circulation.
19. If returns cannot be regained, continue to displace the cement at the lowest
permissible rate (unless otherwise advised) record the returns.
20. Stop displacement only in the event the pressure exceeds 70% of the casing
burst pressure or 5,000psi, whichever is least.
21. Reduce the flow rate at the end of operation to avoid any sudden pressure
surge when bumping the plug.
22. Bump the plug, pressure up to conduct the casing pressure test. Release the
pressure gradually as soon as possible to avoid the micro annulus effect.
23. The bumping pressure values are always given in the Drilling Program.
24. Should the plug not bump, never over displace more than half the shoe
truck volume (between collar and shoe).
25. Check for back flow to ascertain if the float equipment is holding.
26. If the float equipment fails, shut-in the well by closing standpipe manifold a
period at least long enough for thickening. Monitor the pressure gauge so
that required pressure can be maintained by bleeding excessive pressure
periodically.
Page | 25
27. In this case, the pressure remaining must not exceed the observed
differential pressure between the mud and cement.
28. The displacement procedure for 30" CP and 20" surface casing is as follows:
 The displacement volume should be approximately 1 bbl less than the
theoretical volume.
 Check for returns. If the floating equipment is holding back pressure,
pick up the stinger, circulate and retrieve inner string. If floating
equipment is not holding the back pressure, pump the volume bleed
back plus 1 bbl, fill up the annulus (required), hold the pressure on the
inner string and wait on cement.
 Keep the annulus under control to be sure that seals are holding the
pressure.
 At the end of this surface casing cementing job, carefully wash the
annulus between the CP and the surface casing to at least 5m below the
seabed, in order to allow well abandoning operations making the
seabed free from any obstructions.
29. Record all mixing, displacing and bumping operations on a pressure

recorder.
30. Consider the option of reciprocating the casing during and after the
cementing job to maximize the bonding performance.
Page | 26
Figure 18. 4 Typical One Step cement Job
Page | 27
18.7.2.2. Dual/ Second Stage Cementing

1. The appropriate position of the stage tool in the casing string is always given
in the Drilling Programme.
2. Drop the bomb (opening plug) immediately after the first stage cement job
according with floating equipment. Record the opening time.
Note: In relation to the drift angle of a directional well, mud density and mud
rheological properties, heavier bombs may be selected.
3. Open the stage collar. Follow the manufacturer's procedure for the stage
tool opening pressure and approximate bomb landing time. If difficulty is
experienced in opening the stage collar occurs, re-check the pumping circuit
and relevant valves before a final decision is made to reduce the tension on
DV sleeves by slacking-off weight of the hook.
4. With the stage collar opened, start circulation with a low pump rate,
keeping the mud level under control. Increase the pump rate only when it is
certain that no cuttings or cement contamination will cause bridges and
compromise the circulation due to fracturing below the stage collar.
Circulate a volume equal to the total open hole capacity from the stage tool
to surface, checking the eventual excess cement slurry returns.
5. During circulation and after bottom's up, record the pressures at each
different flow rates. The bottoms up must be analyzed with a gas detector, if
the are gas-cut keep circulating until normal again. If necessary, wait on
cement for the first stage cement slurry.
6. Prepare for the second stage cement job as per the Cementing Programme.
7. Perform the second stage operation as soon as the cement setting time of
the first stage is complete (at least twice the thickening time). A Lab only
test is recommended.
8. Arrange the by-pass manifold at the rig floor with double lines (pumping
and reversing-out).
9. Keep the casing in tension with the slip elevator as required by casing
hanging calculations (Refer to the Drilling Programme).
Page | 28
10. Prepare the wellhead (with partially made up bolts) and BOP lifting system
to quickly hang the casing string after the second stage cement job.
11. With the mud well balanced, insert the closing plug into the cementing
head. Check the stop pin, indicating flag and the circulation manifold.
12. Pump the first cushion and pump the cement slurry.
13. Launch the closing plug and verify its release.
14. Displace the slurry with a pump rate in accordance with the Cementing
Programme and previous circulation tests. Make sure that the hydraulics of
annulus are correctly considered to avoid fracturing (if a stage tool-packer is
not provided).
15. Configure the surface mud system to recover the excess cement slurry,
spacer, contaminated mud.
16. Close the stage collar with the pressure advised by the manufacturer's
instructions. After pressure testing, gradually bleed off the pressure.
17. Wash through all the inlets in the wellhead and BOP stack with water.
Page | 29
Figure 18. 5 Two Stage Cement Job
18.7.3. Waiting-On-Cement
1. Sufficient WOC time must be observed for the cement to develop adequate
strength before operations are resumed. For a period of hours after the plug is
bumped, the cement is rigid but has very little strength, and any damage
sustained by the cement sheath during this period does not “reheal”.
2. The required period of WOC time varies depending on the cement and down hole
condition of temperature and pressure.
3. Cement used to cement an intermediate casing string should have compressive

strength of at least 500 psi before drilling is resumed.
Page | 30
4. Completion interval cement should have compressive strength of at least 2000 psi
before the well is perforated.
18.7.4. Cement Job Monitoring

1. Use a cementing monitoring van to collect data and to enable job supervisor to
observe entire operation.
2. Compare data with calculated predictions and carry out post analysis of the job.
3. Calculate material balance for mix water, cement and cement additives and
compare with volume of each slurry pumped.
4. Prepare a summary of the completed job.
18.7.5. Job Evaluation/ Post Job Analysis

1. Evaluation of cement job is very crucial to determine the success of a cement job
for its objectives. A complete post job analysis comparing field job parameters
with actual results is the best way to reasonably understand what happened in
down hole and accordingly necessary corrective measures for future operation
may be applied.
2. Caliper, CBL-VDL, CET or USIT logs can provide accurate and useful information to
evaluate post job success or failure. However, production results are the actual
proof of the acceptable quality of cementation.
3. The general rule is that the cement bond log should not be run until 48 hrs. after
the cementation in order to achieve the true cement bond reading. This again is
highly dependent on the cement type and additives used in the slurry and bottom
hole conditions.
4. Field results show that more than 90% of wells exhibit a micro-annulus on a
primary cement job. Always record CBL-VDL under 700-1000psi pressure to
eliminate micro-annulus effect.
5. The bond index method is most commonly used for interpretation of amplitude
curve in CBLVDL towards achievement of zonal isolation. This method is
essentially a graphical solution, which allows determination of amplitude value
corresponding to a particular bond index.
Page | 31
6. One of the guidelines followed by international operators for deciding on

requirement of remedial jobs based on the bond index method given below.
18.8. Specialized Primary Cementing Operation

18.8.1. Stab in Cementing
Stab in cementing is done when large size of casing necessitates high displacement
volume in conventional cementing or combined strings do not allow the use of
conventional plug. This cementing is carried out with drill pipe with a stabbing unit
attached to its bottom end. The drill pipe with stab in unit (stringer) is stabbed into
the stab-in cementing collar or shoe and then cementation is carried out.
1. Run in the casing in place with a stab-in float shoe/collar and set in the casing slips
suspending the string off bottom.
2. With the casing set, fix the stringer equipped with a centralizer at the end of drill
pipe string and run in the assembly until it is approximately 3 ft (1 m) above the
float shoe/collar. When running in, the pipes are filled with the same fluid as the
one placed in the well.
3. Establish circulation with the drilling fluid and see the returns coming from the
annulus between the drill pipe and the casing.
4. Stop circulation and lower drill pipe so as to enabling the stinger to stab into and
seal in the stab-in float shoe/collar in the casing. As much as possible, the stringer
is engaged only once into the collar or shoe. Test the surface lines and hermeticity
of the inner string.
5. Again establish circulation and observed for returns flowing between the
conductor pipe and the casing.
6. Mixed cement and pumped through the drill pipe and up the annulus until it
reaches the surface. As soon as mud contamination is no longer evident in the
cement returns, mixing can be stopped and the drill pipe volume displaced.
Continuously monitor the weight on string during displacement to ensure proper
engagement of stringer all the time
7. If lost circulation is noticed before the cement reaches the surface, mixing should
be stopped and the cement displaced, avoiding the pumping of large quantities of
cement into the fractured zone. Care must be taken to avoid collapsing the casing
Page | 32
because of excessive differential pressure between the outer annulus and the drill
pipe/casing annular space.
18.8.2. Liner Cementation

A liner is a standard casing string which does not extend all the way to the surface up
to the well mouth, but it is hung from inside the previous casing, generally keeping an
overlap of 50 to 100 m.
18.8.2.1. Critical points for liner cementation
1. Slurry Design: While designing the cement slurry for liner cementation job,
the following slurry parameters should be carefully considered.
 Thickening Time: It is usually designed to include the time taken for
reversing out the excess slurry above the liner hanger top. However the
wells where high pressure gas is being isolated behind the liner,
relatively short thickening and setting time are required to reduce
chances of gas penetrating the unset cement.
 Slurry Density: High density low water ratio cement is used to prevent
water separation and entry of fluid into the well bore, but the combined
density and displacement pressure must remain below the fracture
pressure of the weakest zone.
 Fluid Loss Control: Fluid loss of the slurry should remain less than 100
ml/30mins so as to avoid building up of cement filter cake and to reduce
chances of annulus bridging due to small annular channels.
2. A four arm caliper should be run prior to the liner operation to ascertain the
hole size for calculation of cement slurry volume which is very critical for
liner cementation.
3. No lost circulation material should be used in liner cementation to avoid

plugging of float equipment or the narrow annulus. If loss control material is
added in mud to combat loss, then after lowering of liner the well should be
circulated with fresh mud free from LCM (Lost Circulation Material).
4. Centralizing the liner in the hole is very critical, because annular clearance
are so small that the liner must be kept clear of borehole wall for effective
cement placement. This is particularly true in case of deviated wells. Bow
spring centralizers may be used in the open hole if there is sufficient annular
clearance. Rigid centralizers are used in the casing/liner lap region, and also
in the open hole in cases of very narrow annular clearance. Centralizers or
Page | 33
positive standoff devices also reduce the likely hood of differential pressure
sticking of the liner in the open hole.
5. The length of the liner overlap can be as little as 50ft for a drilling liner or as
much as 500 ft for a production liner.
6. In deviated wells rotating type liner is recommended to facilitate mud

removal and placement of cement slurry at the lower side of the hole.
7. Use combination dart in case of combination string is used for lowering

liner.
8. Preferably use liner hanger with integral packer or with top seal in case of
loss prone areas to avoid hanger top squeeze job.
9. The small clearance also makes it difficult to run liners. Swab/ surge
pressure can be extremely severe and running speed should be slow to
avoid pressure that could break down formations to cause lost circulation. It
is frequently necessary to restrict running speed to one stand of drill pipe
every 2 – 3 min.
10. Circulation should be carried out before setting the liner to clean the mud
system of any cutting or debris. Cutting will come during circulation and at
the restricted area of liner hanger it may accumulates causing the rise in
pressure.
11. The plug arrangement for liner cementing eliminates the opportunities to
run a bottom plug a head of the cement. Normally a spacer fluid which is
compatible with mud and cement is pump between mud and cement to
provide a buffer to avoid serious contamination.
12. The amount of cement excess for liner cementing must be carefully
calculated by taking into accounts the well conditions and displacement
efficiency. Displacement efficiency is a key variable in determining cement
slurry volumes as it is not uncommon to have 60% to 80% displacement
efficiency in liner cementing. Excess volume increase the likelihood for good
cement placement but it is also increases the possibility of operating
problems.
Page | 34
13. The volume of cement used on most deep liners is usually rather small.
Since slurry design parameters are critical for liner cementation batch
mixing should be done to promote uniformity.
14. Slow down displacement when the pump down plug (dart) approaches the
liner wiper plug in order to observe the first pressure surge (about 300psi)
corresponding to the shearing of the pins.
15. Release the liner setting tool after completion of displacement and if packer
type liner hanger is used then set the packer.
16. Pull the setting tool free from the liner and reverse out any excess cement
above the liner top. If no packer is incorporated into the liner hanger then
reverse out keeping excess cement over the top of the liner so that 8 to 10
joints of the intermediate casing will contain cement to be drilled out after
setting.
17. Reverse circulation places an extra pressure on the annulus and this
additional pressure should be pre-calculated and controlled where
necessary to avoid formation break down. A liner packer keeps reverse
circulation pressure off the formation.
18. In long liners, there may be a considerable temperature differential

between the bottom and top of the liner. The cement may take very long
time to set at the top and as such drilling of cement must be done after the
cement develop the minimum compressive strength at the top of liner also.
18.8.2.2. Testing of liner top

A leaking liner top can become a serious and expensive problem during future
drilling operations, or during the production life of the well. Therefore, testing
the top of a liner after it has been cemented is absolutely essential to the
success of the well completion. There are two methods that may be used to test
the pressure integrity of a cemented liner top.
1. Hydrostatic testing
Testing the liner top with applied pressure can be done with or without a
packer; however, in either case, burst limitation of the intermediate casing
must be considered. In case of a drilling liner, pressure applied to the liner
top should be equal to or greater than the hydrostatic pressure at the liner
Page | 35
top when the maximum anticipated mud weight has been attained in
subsequent drilling operations. To complete the testing of the pressure
integrity of a liner top, the fracture gradient of the zone at the shoe of the
intermediate casing must also be considered. Until the testing pressure is
high enough to be above the fracturing pressure of the zone, the cement
job on the liner top has not been tested.
2. Differential testing
A Negative pressure test should be run on liner tops because of the
possibility of mud solids plugging up a small channel or the existence of
“honeycombed” cement or micro-annulus. These type environment often
cannot be pumped into and give a false sense of security. A negative
pressure test should be equal to any differential pressure that the well may
encounter later in drilling or completion. Differential testing of a liner top
requires the use of a packer normally set at 100 to 300 ft above the top of
the liner. This testing is accomplished by lowering the pressure above the
liner to a point lower than
The highest pore pressure behind the liner. This may even require partial
evacuation of the fluid from the drill pipe by adding nitrogen or some
combination of nitrogen and fluid to lighten the column. Differential
pressure testing requires close scrutiny of the collapse rating of the liner
itself.
18.9. Secondary Cementation

18.9.1. Plug Cementation
A cement plug of a specified length when placed across a selected interval in an open
hole or a cased hole, is called “Plug cementing”. The most commonly used technique
for plug placement is known as “Balanced Plug Method”. Plug failures can be
prevented by following the standard best practices as detailed below.
 Select gauge section of a hole. Consult a caliper log for selecting a location to set a
plug And determining the temperature of the formation where the plug is to be
set.
 Circulate long enough to condition the well so as to ensure that the entire mud
system is uniformly weighted.
 Check the mud system carefully for loss of returns, fluid gain or gas entry. Any
movement of the plug after it is placed may cause the cement not to set.
 A cement plug is best set in a competent hard rock. Shale should be avoided as
they are
Page | 36
 Often caved and out of gauge.

 However, if the kicking off is the objectives, the plug should not be set in a
excessively hard formation. Ideally, the plug should extend from a soft shale down
to a hard formation. Logs and drilling rate record should be consulted when
selecting a location to set a plug for kickoff.
 Slurry design
 Viscous slurries with high gel strength and low density are needed for lost
circulation plugs, to restrict flow into voids or fractures.
 High compressive strength is mandatory in whipstock plug to have a sharp
contrast between the plug and the formation hardness. Use densified cement
slurry that will tolerate considerable mud contamination. Addition of sand or
weighting materials will not improve the compressive strength of lower water
content slurry.
 Carefully calculate cement, water and displacement volumes and always plan to
use more than enough cement (1.5 to 2 times the calculated volume) to
compensate for contamination effect so as to get the desired plug length.
 Batch mix the cement slurry to ensure uniform slurry density.
 Pump preflush that is compatible with drilling fluid. Preflush volume should be
sufficient to cover an annular height of 500 to 800ft and the after flush volume
should cover the same height in the tubing string as that of the preflush.
 For open hole cement plugs in gas wells, use a weighted spacer 1 to 2ppg heavier
than the mud. Using water as preflush can cause reduction of hydrostatic head,
resulting in gas migration through the cement.
 Whenever possible preflush/spacer should be pumped in turbulent flow
conditions.
 Try to rotate or reciprocate drill pipe slowly till the completion of displacement.
 Under displace the plug by 200-300 liters to avoid any back flow.
 Pull out the drill pipe/tubing slowly (30-50 ft/min) out of the cement to minimize
contamination.
 Reverse wash twice the drill string volume to wash excess slurry out of the hole.
 Ample WOC time to be allocated (12 to 24 hours) for a plug job. A common
practice is to allow for longer WOC time since well temperature for a cement plug
job is difficult to know accurately.
 Always test the cement plug by tagging top of cement with Bit and apply required
weight for “Hardness” test.
 While placing a cement plug for kick-off special measures as depicted below are
required to be followed for success at first attempt
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 Use either a mechanical or chemical method to provide some static barrier

below the intended bottom of the plug
 When a high viscous pill is used for achieving a static barrier below the
cement column, then the length of the pill should be equal to the cement plug
length and funnel viscosity of the pill should exceeds 150 sec. Also the pill
density should be greater than the mud weight and 10 sec gel strength of the
pill should be above 50 lbs/100 sq.ft.
 Use a “Divertor tool” for placement of cement to achieve uniform placement
of cement slurry all around the wellbore and to prevent contamination due to
downward movement.
 Typically 2 7/8 tubing should be used as tail pipe to minimize contamination
during pulling out as it will create less disturbances of the cement plug when
the pipe is being pulled. The length of tail pipe should be 1.5 - 2 times the plug
length.
 At least provide 48 hrs. W.O.C for attaining sufficient hardness/ strength for
sidetrack plug.
18.9.2. Squeeze Cementing

Squeeze cementing is defined as the process of forcing cement slurry, under pressure,
through holes or splits in the casing/well bore annular space and then allowing it to
dehydrate by further application of pressure. Squeeze cementing is necessary for
many reasons but probably the more important use is to segregate hydrocarbon
producing zones from those formations producing other fluids. The key element of a
squeeze cementing job is that of placement of cement at the desired point or points
necessary to accomplish the purpose.
A basic fundamental of squeeze cementing is that regardless of the technique used

during a squeeze job, the cement slurry (a suspension of solids) is subject to a
differential pressure against a filter of permeable rock. The resulting physical
phenomena are filtration, filter-cake deposition and, in some cases, fracturing of the
formation. The slurry, subject to a differential pressure, loses part of its water to the
porous medium, and a cake of partially dehydrated cement is formed. As the filter
cake builds, the pump in pressure increase until a squeeze pressure less than
fracturing pressure is attained. A good guide for a squeeze pressure is 500-1000 psi
above the pump in pressure with no flow back in 3 to 5 minutes.
18.9.2.1. Injectivity Test Prior To Squeezing
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Prior to placement of cement slurry, conduct injectivity test against the squeeze
interval to determine if and at what rate below the fracture gradient fluid can
be placed against the formation. A rate sufficient to allow adequate time for
cement placement must be reached before actually mixing the cement. When
the fracture gradient must be exceeded to obtain sufficient rate for cement
placement, it should be done without excess.
A minimum of ten barrels volumes should be used when obtaining an injection
rate. Deep perforations require more volume than shallow ones because of the
additional hole volumes. Consider spotting a clear fluid such as water across the
perforations when obtaining an injection rate.
The injection test is performed for several reasons:
 To ensure that the perforations are open and ready to accept fluids.
 To obtain an estimate of the proper cement slurry injection rate.
 To estimate the pressure at which the squeeze job will be performed, and
 To estimate the amount of slurry to be used.
If suitable injection rate could not be established at the desired injection
pressure, it may be necessary to use acid to clean up the perforations, channel
etc. Hydrochloric and hydrofluoric acids are commonly used. While taking
injectivity test, raise the pressure very slowly up to the point of injection
without fracturing the exposed formation.
18.9.2.2. Design of Cement Slurry for Squeeze Job

The properties of cement slurry must be tailored according to the characteristics
of the formation to be squeezed, and the technique to be used. Squeeze slurry
should be designed to have the following general attributes:
 Low viscosity: to allow the slurry to penetrate the small voids
 Low gel strength: a gelling system restricts slurry movement
 No free water
 Appropriate fluid loss control.
Following factors may be considered in designing the cement slurry for any
squeeze operation:
1. Fluid Loss Control
Fluid loss and filter cake growth rate vary directly i.e. higher the fluid loss,
faster will be the filter cake build up. As such, while designing the slurry,
fluid loss must be tailored to the formation type and the permeability so as
to achieve a uniform cake build up against the squeeze interval.
The generally accepted API fluid loss rates are listed below:
 Extremely low permeability formation - 200 ml/30min
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 Low permeability formation - 100 to 200ml/30min

 High permeability formation (>100md) - 35 to 100 ml/30min
2. Thickening Time
The temperatures encountered in squeezing can be higher than those of
primary jobs, because fluid circulation before the job is usually less. For this
reason, special API testing schedules exist for squeeze cement slurry design
and must be followed to prevent premature setting. The added stringency in
the API testing schedules for squeeze cementing simulates the actual
temperature the slurry is subjected to when hold near bottom for extended
periods.
Thickening time must be sufficient to assure slurry placement and reversing
out of the excess. For running squeeze method, requirement of thickening
time should be less. Whereas for a hesitation squeeze method, higher
pumping time must be designed so that cement slurry remains in fluid stage
till squeeze pressure is achieved.
3. Compressive Strength
High compressive strength although desirable but is not a primary concern
for squeeze slurry design as a partially dehydrated cement cake of any
normal cement slurry will develop sufficient compressive strength.
18.9.2.3. Slurry Volume

The optimum amount of cement is the volume required to seal the void. The
volume of slurry needed is generally inversely proportional to the injection
pressure and directly proportional to the injection rate. The appropriate volume
of cement slurry depends upon the length of the interval to be cemented, and
the placement technique to be used. A low-pressure squeeze requires only
enough slurry to build a certain filter cake in each perforation tunnel. In many
cases less than a barrel is sufficient. However, for job convenience and because
of problems in placing the cement into the correct place to provide a seal, a 5-
15bbl batch is normally prepared. A high-pressure squeeze, in which the
formation is fractured, requires a higher volume of slurry.
The following may be considered when determining the volume of cement to
use.
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 The volume should not exceed the capacity of the running string.
 Two sacks of cement should be used per foot of perforated intervals
restricted to minimum of 50-sacks.
 The minimum volume should be 100 sacks if an injection rate of 2bbl/min
can be achieved after breakdown: otherwise it should be 50 sacks.
 The volume should not be so great as to form a column that cannot be
reversed out.
 The volume of the void to be filled behind the cement or in the zone plus
the volume to be left in casing but not less than 50 sacks.
18.9.2.4. Squeeze Pressure

Squeeze pressure is the pressure at the injection point. In most cases, if the
cement can be placed at the proper point, a successful squeeze can be obtained
with 500 to 1000 psi standing pressure above the injection pressure. The
pressure should be hold for 10 to 15 minutes with no flow back. Low-pressure
squeeze is recommended where possible. A safety factor of about 300 psi below
formation fracturing pressure is reasonable for low pressure squeezing.
After a squeeze is obtained, the pressure should be bled off and the volume of
fluid measured. The squeeze should then be repressured and the volume
measured again. If the volumes are equal, this indicates that the squeeze has
held and the volume of fluid pumped compensated for tubular expansion.
18.9.2.5. Slurry Preparation

When preparing the slurry, the use of a recirculating mixer or batch mixer is
strongly recommended, because it ensures that the properties of the slurry
pumped in the well are as close as possible to those of the slurry designed in the
laboratory. On most squeeze jobs, the amount of slurry involved is quite small,
but the requirements of its quality are quite high, therefore special care must be
taken in preparing it.
18.9.2.6. Evaluation of Squeeze Job

Pressure testing is the most common means of evaluating the success of the
operation. Both positive and negative test should be used. A squeeze job may
appear successful when pressure is applied to the well bore but may fail to hold
back the pressure from the zone into the casing.
The universally recognized technique for confirming whether the cement in
place will hold the formation fluids under producing conditions consist of
applying a negative differential pressure on the face of the plugged perforations.
Page | 41
Positive pressure test

After the W.O.C time, test the cement by applying required surface pressure for
checking integrity of the perforation squeezed. The pressure applied at the face
of the perforation is predetermined at the job design stage. It may be the
reservoir pressure or pressure equal to future working pressure in the well from
fracturing or acidizing treatments but should not exceed the formation
fracturing pressure.
Negative pressure test
A negative test or differential pressure testing of the well bore may be obtained
either by swabbing and lowering the fluid level or by displacing work over fluid
with some lighter fluid. Negative pressure test should be conducted using
pressure no greater than the expected maximum drawdown in the well when it
is put into production.
When the objective of the squeeze is to repair a primary cement job, the normal
cement log (CBL/VDL) should be run to evaluate the effectiveness of the repair
by comparing pre-squeeze and post squeeze logs.
18.9.2.7. Misconception in Squeeze Cementing

 The cement slurry penetrates the pores of the rock
Only the mix-water and dissolved substances penetrate the pores, while the
solids accumulate at the formation face and form the filter cake. It would
require a permeability higher than 100 darcy for the cement grains to
penetrate a sandstone matrix. The only way for slurry to penetrate a
formation is through fractures and large holes.
 High pressure is needed to obtain a good squeeze
If the formation fracturing pressure is exceeded, control of the placement of
the slurry is lost, and the slurry enters unwanted areas. Pressure is of no
help to place the slurry in all the desired location. Once created, a fracture
may extend across various zones, and open unwanted channels of
communications between previously isolated zones.
 Plugged perforation
It is rare to find all perforations open and producing. Perforations will
usually have some degree of mud fill up, depending on the completion,
fluid. Mud filter cake is capable of withstanding high pressure differentials
especially in the direction from the well bore to the formation and the high
pressures may create a fracture before accepting cement filtrate. Many
squeeze failure may be attributed to subsequent clean up of a previously
Page | 42
plugged perforation which did not accept the cement slurry during the
squeeze job.
18.9.2.8. Squeeze Cementing Procedure

18.9.2.8.1. Low Pressure Squeeze Cementing
1. Consult a CBL / VDL log prior to squeeze job.
2. Decide the point of perforation and perforate against a permeable
formation at least 6 to 8 Shots (Gun Perforation) per foot for achieving
better intake.
3. Carry out injectivity test in water. If injectivity is found to be poor, acid
job may be required to improve injectivity.
4. For low pressure squeeze cementing, follow all the standards as given
for a normal cement plug job so as to spot the slurry against the
perforated interval.
5. Then pull out drill string sufficiently above the cement top.
6. Close BOP and apply pressure through drill string to squeeze cement.
7. Squeeze calculated volume of slurry and close the well under pressure
for 4 hrs.
18.9.2.8.2. Block Squeeze Cementing

1. For block squeeze perforate 2 sets of perforation i.e. above and below
the cement retainer.
2. If the poor bondage is continuous for a longer section, decide to carry
out block squeeze using a cement retainer.
3. Establish circulation through cement retainer behind casing with water
or cleaned fluid to ensure good clean up of the channels.
4. Maintain the down hole treating pressure below the formation fracture
pressure when carrying out injectivity test or establishing circulation
behind casing.
5. Calculate slurry volume keeping into consideration the annular volume
and slurry required below cement retainer.
6. Use spacers ahead and behind cement slurry for a minimum length of
50 to 75m to avoid contamination.
7. While displacement monitor free falling /U tubing of cement slurry by
controlling through choke. Displace cement up to the tip of cement
retainer so as to keep the cement inside the string and engage tubing
string to retainer, and squeeze to circulate out cement between the two
perforations.
Page | 43
8. Disengage the string from retainer and balance the plug. Pull out the
string above the top of perforations, reverse wash and squeeze cement
in the upper perforation (optional) and keep the well under final
squeeze pressure.
18.9.2.8.3. Water /Gas Shut Off Squeeze

1. For elimination of water intrusion or reduction of gas oil ratio this
squeeze cementing is carried out to seal all the perforations and then
re-perforate a selected interval.
2. All procedures that of low pressure squeeze cementing are to be
followed for placement of cement slurry against the perforated interval.
3. In case of good injectivity, squeeze calculated volume of slurry into the
perforations leaving a cement plug inside the casing. Squeezing to be
done by hesitation method, so that final squeeze pressure is achieved.
4. In case of no injectivity, squeeze cement slurry at the maximum
permissible squeezing pressure and close the well under squeeze
pressure for 4 hours.
18.10. Cementing Safety Guidelines

This cementing guideline is intended to standardize cementing procedures and safety aspects
with a view to improve planning, execution and evaluation areas related to cementing
services and to reduce occurrences of accidents.
The cementing of oil well is an important and highly critical operation which is accomplished
in a relatively short period of time. Utmost care should be taken to follow established safety
regulations to avoid any untoward accident during cementation. Following are some
distinctive features /areas of safety concern associated with cementing operations.
a. Simultaneous presence of a large crew of different disciplines makes coordination
extremely essential.
b. Several liquid chemicals and cementing additives used in cementation can cause safety
hazards which needs proper precautions while handling.
c. High pressure and air pressure involved in cementing job execution.
d. Simultaneous running of all equipment creating high level of noise pollution.
e. Special attention is required when cementation is being carried out in night time.
18.10.1. Pre-Departure Checks of Mobile Cementing Equipment

1. Oil level, HSD level, Radiator water level, Steering hydraulic oil level, battery
connections, tyre pressure etc. are to be checked.
Page | 44
2. After initial warm up of engine, check engine oil pressure, water temperature,
air pressure, brake application, auto electrical light indications etc.
3. Fire extinguisher, spark arrestor in engine’s exhaust pipes and a first-aid kit
should be there in all cementing vehicles.
4. Accessories like high pressure lines, valves, swivels, jet mixers, rubber hoses etc.
should be clamped and fastened to avoid any loss and third party injury while
plying the cementing vehicle on road.
5. While lifting the cab of cementing vehicle for chassis engine check-up/ repair, no
person should be allowed to stand underneath the charging pump till the cabin
is locked and properly clamped in position.
18.10.2. Safety During on Land Cementation

1. Onshore cementing operator should be well conversant with traffic signals, road
safety rules and regulations to minimize road accident.
2. One should never attempt to perform work or drive a vehicle when he is

impaired by alcohol or drugs.
3. While reversing a cementing vehicle, one should be certain that the sides and
backing area is clear. One should not reverse a vehicle at the facility or on the
work location without a guide.
4. One should use the prescribed personal protective safety kits like overhaul,
hardhats, safety glasses, hard-toed shoes, hand gloves etc. Wearing of rings,
bracelets or neck chains should be avoided while on oil field duty and in repair/
maintenance garage.
5. A pre-job planning meeting should be held to ensure proper job layout and
placement of cementing equipment following all safety procedures.
6. Mobile cementing equipment positioning should be planned for quick removal

from the work area in case of an emergency. All vehicles should be placed with
cabin facing away from the well and wooden wedge support should be placed
behind wheels to minimize vibrations and movement of line while pumping
operation.
Page | 45
7. Place cementing pump / bunkers / mobile silos at least 1.5 - 2 m apart from
other cementing vehicles and at least 25 m distance from the well head.
8. Park all vehicles which are not required for the job to safe areas from the well
head so as not to block the well site exits.
9. In hooking of high pressure lines from cementing units, avoid crossing of two
discharge lines. Lines should not be run under cementing trucks. Ensure proper
anchoring of high pressure lines to prevent accident in case of line failure.
10. Use sufficient number of chicksans to provide more flexibility to discharge lines
for reducing vibrations during cementing operations.
11. Do not suspend discharge lines from cementing head without safety chains.
Inclined or vertical discharge lines should be tied off to prevent them from being
dragged.
12. Use only high pressure fittings and approved steel pipes which are in good
condition and thoroughly inspected.
13. Cementing heads, manifolds, valves and plugs should be inspected, cleaned and
lubricated prior to hooking up. Always clean an oil line connection before
making up cementing lines.
14. The cementing operational in-charge must supervise line hook up work and
thoroughly inspect prior to testing lines.
15. Care should be taken to avoid damage to the threaded pin end and stopper of
cementing head during handling and tightening to the casing. Cementing head
must be secured to the links by safety chains.
16. Thread protectors must be used on all exposed male threads of circulating subs
or cementing heads to avoid thread damage.
17. Only steel lines should be used for releasing pressure and checking back flow
from the wells.
Page | 46
18. In electrical rigs, all cementing equipment should be earthed to the derrick
structure to avoid any electrical shock accident. Electrical powered cementing
skid unit should also be earthed properly.
19. Cementing head, safety valves and high pressure lines of cementing units should
be checked for operation at stipulated pressure to ensure operational safety
and NDT should be carried out at an interval of 3 years.
18.10.3. Pumping Job
1. All valves in discharge lines shall be checked properly to see that they are open
before orders are given to start pumping.
2. No pumping should take place while any personnel is working on, above or
below floor level.
3. Flammable or combustible fluids are not to be placed in open displacement

tanks on cementing equipment.
4. Acid pumping with cementing units should be avoided, if possible. In case it

cannot be avoided, make extra sure that all the valves, caps, lines etc. are fitted
correctly and also the least number of people should be present in the vicinity.
After the job, the cementing unit and the lines should be washed thoroughly so
as to remove any traces of acid.
5. When pumping into any system :

 Be sure that you have an accurate pressure gauge.
 Be alert for closed valves also.
 Start slowly with little throttle to confirm that system is open.
6. A pressure-chart to record pumping pressure continuously should be made

available for all cementing jobs. Pressure chart should be supplemented with
pumping sequence volume, time and rate.
7. Surface pumping pressure should not exceed the lowest pressure rating of the
union and / or whatever connections used such as chicksans, valves, cross-over
etc.
Page | 47
8. When transferring or venting material through an open ended hose, a “T” shall
be affixed to the end of the hose to prevent the hose from whipping around.
The end of the hose should be secured tightly to a stationary object.
9. Cement bunker or mobile cement silo loaded with cement should be kept on
jacks at drill site when parked.
10. During slurry, mixing, chemical preparations, adequate precautions must be

taken to avoid chemical / additive contact with skin, eyes and clothing. Fumes of
defoamer should not be inhaled while using. When handling cement additives,
appropriate safety goggles, respirators, dust or vapor masks, face shield, rubber
gloves, shoes and hearing protection should be worn.
11. Fluid loss, retarder and dispersant, additives for cement do not contain
hazardous ingredients.
12. Primary routes of their entry in human body is by skin contact, eye contact,
inhalation and ingestion. Material safety data sheet should be made available at
work-center while handling cement additives. Review method and hazard of
handling, transferring and chemical mixing as well as proper mixing sequence.
13. Proper illumination with adequate flame proof lighting arrangements should be
provided in the operational area especially at slurry mixing point and additive
mixing system to ensure safe and effective job coordination during night time.
18.10.4. Rig Down

1. Before dismantling the line, pressure must be released to zero. Pressurized line
should not be hammered. Tightening or loosening of connections under
pressure is strictly prohibited.
2. After pumping has been completed, all pumps, lines and hoses will be flushed
before rigging down. All valves and caps on all piping of each unit shall be
opened or removed to allow complete drainage of any fluid in the units piping.
Piping choked with cement slurry may damage cementing equipment and lead
to major breakdown.
3. The air pressure in pneumatic bulk silo / mobile cement silo should be relieved
before the vehicles are moved off to location.
Page | 48
4. Transportation of chicksans, high pressure lines, valves, swivels, hoses with end
connections from rig floor to ground should be done by winch line only.
Throwing down these equipment from derrick floor must be prohibited.
18.10.5. Safety in Cement Bulk Handling Plant

1. All cement silos and other pressurized vessels should be emptied and pressure
tested at the specific rating. Safety valves and pressure gauges attached to each
vessel should be checked for proper functioning.
2. If any leakage is observed during pressure testing of silos, it should be rectified
immediately on top priority.
3. Valves in pipe lines should also be checked for proper isolation.
4. Proper functioning of air dryer should be ensured to get rid of moisture in the
air line to silos with a view to prevent cement lump in the system and provide
consistent dry cement supply for slurry mixing.
5. The discharge of air, dust and cement from vent line should be directed away
from the operational area and preferably in a water pit to avoid air pollution.
6. Personnel concerned with bulk handling plant operation must use all personal
protective safety equipment including helmet, goggles, dust mask, ear
protection etc.
18.11. Cementing Equipment

18.11.1. Downhole equipment
1. Floating Equipment
This equipment consist of shoe and float collar. Guide shoe is equipment
installed at the end of the casing so that the casing does not get caught during
unloaded. Guide shoe is equipped with a back pressure retaining called float
shoe.
Page | 49
Figure 18.6 Various Float-Shoe and Float Collar To Prevent

Reverse Flow
2. Wiper Plug
Wiper plug is a plug that is used to clean the walls of the casing of the drilling
mud. This plug is divided into two, the top plug and bottom plug. Bottom plug
serves to encourage the mud in the casing while the top plug is used to urge
the cement column in the casing so that the cement can be to spot the
location of cementing.
Figure 18.7 Wiper Plug to insulate the mixing of

Cement and Mud
3. Scratchers
Page | 50
Scratchers is cleaning equipment wellbore wall of mud cake so that cement can be
attached directly to the wall and avoid channeling formation (hole between cement
and formation channel). There are several kinds to use this tool, by twisting
(rotating) or by pulling down (reciprocating).
Figure 18..8 Scratcher for Cleaning Wall of hole Wells

4. Centralizer
Centralizer is a tool to put the casing exactly in the middle of the wellbore in order
to obtain the same distance between the wall with the wall of the wellbore casing.
Installation of this tool on the casing is usually by means of welded (welding). The
placement of the casing in the wellbore as much as possible is located in the middle
to avoid channeling.
Figure 18.9 Centralizer to make casing in Middle
Page | 51
5. Landing collar
Serves to insulate and capture the liner wiper plug, preventing it from rising back to
the top of the hole, to insulate the pressure from below and to prevent it from
spinning out while drilling (drill-out).
Figure 18.10 Landing Collar

6. Packer Bore Receptacle
Commonly called Bore Receptacle polished which is a thick-walled tube with an
inner diameter of teeth and the inside is smooth which is usually coated with TFE to
prevent the attachment of cement or other materials, thereby reducing friction and
corrosion.
Figure 18.11 Packer Bore Receptackle
Page | 52
7. Pack-off Bushing
Usually inserted between the setting tool and liner hanger as the top of the
insulation between the liner setting tool. Pack-off bushing there is drillable and
retrievable. Drillable type must be drilled back to the bit or mill. Retrievable
commonly used in the drilling, can be part of the setting tool and taken back to the
time setting of the tool is moved from the liner, which saves time drilling out.
Figure 18.12 Pack-off Bushing
8. Pump Down Plug Dropping Head Dan Cementing Manifold

Anchored at the top of the drill pipe. Manifold is used to assist in the mud and
cement pumping time into the drill pipe and hold down pump to pump down plug
behind the cement plug is released. (Figure 18-8)
Page | 53
Figure 18.13 Pump Down Plug Dropping Head
9. Liner Swivel
Is a tool used for the liner stuck in the open hole or in the hole where the hanger is
not straight barrel spinning difficult. By using this tool rotates liner will not, just the
liner hanger and setting tool are rotating. (Figure 18-11)
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Figure 18.14 Liner Swivel
18.11.2. Surface equipment
1. Mixer
This tool, in principle, is to bring the slurry of cement and water with very high
speed (jet system) through a venturi flow causing turbulence which makes the
mixing process to be perfect.
Figure 18.15 Jet-Mixer For Mixing Cement and Cement Water Being
Suspension
2. Cement Pump
Page | 55
Cement pump used for pumping a cement slurry down the well. Commonly
used pumps are double-acting piston pumps duplex or triplex single acting
plunger pump. Plunger pump is commonly used as the exit rate is more
uniform slurry with considerable pressure. Sometimes pumping the
recirculating mixer put together in a single place that is easily moveable. This
is referred to as a mobile cementing equipment.
Figure 18.16 Plunger Pump Can It was found In Cementing
3. Plug Containers
Plug container as the top and bottom cementing plug placed above and below
the cement slurry.
Figure 18.17 Cementing Head To Store Before Cement Wiper Plug Removable
4. Casing Cementing Head
Page | 56
This tool serves as a media liaison between the pipe cementing of casing and
pump cement into a place to put the plug (top and bottom plug). With the
casing cementing head is then mud can be circulated by the insistence of the
bottom plug to the bottom of the casing and the cement slurry loaded on it
before pendesakan by top plug begins.
Figure 18.18 Cementing Head / Head Plug Conditioner For Saving

Cement Wiper Plug Before Removable
18.7.
Page | 57

SOP Cement Program

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SOP Cement Program

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STANDARD OPERATIONAL PROCEDURE

ONSHORE DRILLING IDENTIFICATION CODE : -

18. Cement Program

18.2. Cement Types, Specifications, & Additives

Table 18. 1 High Sulfate Resistant Cement

Cement Slurry Weight Slurry Yield Water Requirement

18.2.3. Performance of Cement Slurry

18.2.4. Additive Functions:

Bentonite cement slurries usually require twice as much non-foamer than

18.3. Slurry Desain

18.3.2. Limitations of Thickening Time Test Data

18.3.3. Fluid Loss Tests

18.3.4. WOC Time

Figure 18. 2 Shown above is the compressive strength of

b. Static Gel Strength Analyzer (SGSA Test)

18.3.5. Pressurized Mud Balance & Densitometers

18.3.6. Free Fluid Test (free water)

18.3.7. Rheology Test

18.3.8. Mud-Spacer-Cement Compatibility Test

18.3.9. Gas Migration Additives

18.3.10. Cementing: Pre-Job Considerations for Slurry Design

18.3.11. Pre-Job Meeting

18.4. Lab Testing of Cement

18.4.2. When To Send Samples For Testing

 K1 wells, 9 5/8” casings and deeper

18.4.3. Initial Pilot Testing

18.4.4. Pilot Testing prior To Mixing

18.4.5. Field Sample Confirmation Testing

18.5. Mixing Cement

18.5.2. Type of Chemicals and Quantity to Be Blended

18.5.3. Mix Water Blending and Storage System

18.5.4. Cement Job Quality

18.5.5. Pre-mixing additives

18.5.6. Sampling and Sample sizes

b. Dry Cement Sampling

18.6. Check List for Cementation Job

18.6.2. During Casing Running In

18.6.3. Mechnical Aids

18.6.4. Circulation Prior to Cementation

d. Mud parameters during final circulation:

18.6.5. Cementing Head

18.6.6. Cementing Equipment

18.6.7. Blending of Cement Additives

18.6.8. Preflush / Spacer

a. Check whether sufficient volume of Spacer/Preflush to be displaced ahead of

18.6.9. Cement Slurry Design

18.6.10. Slurry Mixing and Pumping

18.6.11. During Displacement

18.6.12. Operational Considerations

c. Prepare a summary of the completed job.

18.7.2. Displacement Technique

2. During circulation monitor pit levels, bottoms-up mud properties and

3. After bottom circulation, line up the cement head to the cementing

11. When mixing cement, samples of slurry shall be collected in numbered

12. For the slurry recipe follow the Cementing Program.

29. Record all mixing, displacing and bumping operations on a pressure

Figure 18. 4 Typical One Step cement Job

18.7.2.2. Dual/ Second Stage Cementing

13. Launch the closing plug and verify its release.

Figure 18. 5 Two Stage Cement Job

3. Cement used to cement an intermediate casing string should have compressive

18.7.4. Cement Job Monitoring

4. Prepare a summary of the completed job.

18.7.5. Job Evaluation/ Post Job Analysis