HALLIBURTON

Primary Cementing Best Practices

The considerations reviewed in this summary are based on sound Cementing Best Practices that are known to enhance the probability of success when they are followed. Primary cement job failures are predominately due to a breakdown in the "displacement process." This typically results in poor zonal isolation manifested by channeling or nonuniform displacement of the annular fluid(s) by the cementing fluid(s). These guidelines, when applied in conjunction with the Halliburton OptiCem job design program to optimize displacement parameters, will enhance the displacement process and improve the probability of successful primary cementing. 1) Flow Rate: Three flow regimes that a non-Newtonian fluid (such as cement) may exist as are Turbulent, Laminar, and Plug Flow. When reduced to its simplest terms, maximum displacement efficiency is achieved when the maximum available energy is transferred to the annulus and applied to the fluids to be mobilized. Therefore, regardless of the flow regime, high-energy displacement rates are most effective for ensuring good displacement. Turbulent flow conditions are usually more desirable, but frequently cannot be achieved or are not always required. When turbulent flow is not a viable option for a situation, use the highest pump rate that is feasible for the wellbore conditions. The best results are obtained when (1) the spacer and/or cement is pumped in such a way as to deliver maximum energy to the annulus, (2) the spacer or flush is appropriately designed to remove the drilling fluid, (3) and a competent cement is used. The OptiCem job design program can be used to determine the optimum pump rates under the given conditions of geometry, fluid properties, and eccentricity to obtain the best displacement and while maintaining safe ECD's. 2) Conditioning the Drilling Fluid: The condition of the drilling fluid is one of the most important variables in achieving good displacement during a cement job. A fluid that has excellent properties for drilling may be inappropriate for cementing purposes. Regaining and maintaining good mobility is the key. An easily displaced drilling fluid will have low, non progressive gel strengths and low fluid loss. Pockets of gelled fluid, which commonly exist following the drilling of a well bore, make displacement difficult. These volumes of gelled fluid must be broken up and mobilized. To condition the drilling fluid in preparation for a cement job, perform the following: a. Determine the volume of the circulatable hole and evaluate the percentage of the hole that is being circulated. Good fluid returns at the surface do not reliably indicate the mobility of fluid in the annular space. For best results, use a fluid caliper to determine downhole fluid mobility. b. When making the last bit trip, and especially when the casing is on bottom, the mud must be prepared for the cement job. Circulate, treat, and condition the drilling fluid to help break its gel structure, remove gas, and lower the low-gravity solids content. This will decrease the viscosity and increase the mobility of the mud. Continue until equilibrium is achieved.

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HALLIBURTON c. NEVER allow the drilling fluid to set static for extended periods, especially at elevated temperatures. Even when the drilling fluid is well conditioned (mud properties in equals mud properties at the outlet), continue circulating the drilling fluid until the cementing program begins. d. Modify the flow properties of the drilling fluid to optimize drilling fluid mobility and removal of drill cuttings. Yield Point (YP) and Gel Strengths should be maintained as low as possible without causing settling and barite sag downhole. Mud weight and temperature dictate allowable plastic viscosity (PV) and yield point (YP) values. As such, these variables must be evaluated on a case-by-case basis given prevailing circumstances. e. Measure gel strengths at 10 seconds, 10 minutes, 30 minutes, and 4 hours to examine the gel strength profile of the drilling fluid. In addition, an HTHP gel strength test should be run at some point in the design and planning stages. When conditioning just prior to the job, verification readings taken at 10 seconds, 10 minutes, and 30 minutes are typically sufficient. An optimum drilling fluid will have flat, non-progressive gel strengths such that the 10 minute is less than twice the 10 second (Example: gel strength values of 8, 12 and 14). f. Decreasing the filtrate loss into a permeable zone enhances the creation of a thin filter cake. A high fluid loss creates a thick, highly gelled mud layer immediately adjacent to the formation wall that is difficult to mobilize without mechanical or chemical intervention. The fluid loss of the mud should be minimized prior to running casing and cementing. In deviated wellbores, a higher-viscosity drilling fluid may be required to help prevent solids from settling on the low side of the wellbore. The presence of large drill cuttings may also necessitate higher viscosity fluids. The higher-viscosity fluid needs to be optimized based on wellbore conditions and inclination. Regardless of the final fluid properties, it is critical to communicate this information to the cementing engineer so that any necessary adjustments to the cementing program can be made. 3) Spacers and Flushes: Spacers and flushes are effective displacement aids because they separate unlike fluids such as cement and drilling fluid, and enhance the removal of gelled mud allowing a better cement bond. Spacers can be designed to serve various needs. For example, weighted spacers can help with well control, and reactive spacers can provide increased mud-removal benefits. Compatibility of the drilling fluid/spacer interface as well as the compatibility of the spacer/cement slurry is of prime importance. Application of the compatibility procedures as outlined in the API SPEC RP10B, 22nd Edition, December 1997 is highly recommended. Parameters governing the effectiveness of a spacer include flow rate, volume, contact time, and fluid properties. To achieve maximum mud displacement, adhere to the following guidelines: a. Pump the spacer fluid at an optimized rate based on OptiCem. b. Provide a contact time and volume of spacer that will provide optimum amount of mud removal. Typically 8 to 10 minutes contact time or 1000 feet of annular space are adequate. Rev. 06-14-00 RRF, JFH CEMENTING

HALLIBURTON c. Make sure that the viscosity, yield point, and density of the spacer and the following cement slurry provide for adequate solids support and has the required rheological profiles as recommended by the errodibility calculations in OptiCem. d. When an oil-based or synthetic-based drilling fluid is used, ensure that the spacer package is formulated to thoroughly water-wet the surface of the pipe and the formation, ensuring a strong bond between the cement, the pipe, and the formation. The use of Halliburton's newly developed apparent wettability testing technique that has been endorsed by the API is highly recommended for customizing the spacer/surfactant package to ensure water wetting. Flushes are used for thinning and dispersing drilling fluid particles. They go into turbulence at low rates, helping to clean drilling fluid from the annulus. However, flushes generally have a density that is less than the drilling fluid and may not provide proper well control. Running the spacer or the cement slurry at a higher density can compensate for the lack of density. While jobs are frequently pumped with only a flush ahead of the cement, spacers are usually recommended to ensure greatest displacement efficiency. The chemistry of specific reactive flushes are also intended to react with and mobilize muds with certain chemical components. While water-based muds composed primarily of bentonite and associated dispersants are best attacked with MudFlush or SuperFlush, muds containing PHPA or other polymers are best attacked with PHPA PreFlush. When used, preflushes for nonaqueous muds are usually composed of a volume of base oil that may or may not contain solvents or surfactants. 4) Pipe Centralization: Centralizing the casing with mechanical centralizers across the intervals to be isolated helps optimize drilling fluid displacement. In poorly centralized casing, cement will bypass the drilling fluid by following the path of least resistance; as a result, the cement travels down the wide side of the annulus, leaving drilling fluid in the narrow side. Good pipe standoff insures a uniform flow pattern around the casing and helps equalize the force that the flowing cement exerts around the casing, increasing drilling fluid removal. In a deviated wellbore, standoff is even more critical to prevent a solids bed from accumulating on the low-side of the annulus. Generally the industry strives for about 70% standoff. However, the preferred standoff should be developed from computer modeling and will vary with well conditions. When adequate centralization cannot be achieved, use the eccentricity option in OptiCem to help compensate as much as possible with other parameters such as rate and fluid rheologies. Centralizers and other mechanical cementing aids as are commonly used in the industry may also provide inline flow disturbances, changing the flow pattern of the fluids. This can promote better mud removal for short distances in the annulus.

5) Pipe Movement: Pipe movement is one of the most effective methods of transferring energy downhole. Pipe rotation or reciprocation before and during cementing helps break up gelled, stationary pockets of drilling fluid and loosens cuttings trapped in the gelled drilling fluid. Pipe movement allows high displacement efficiency at lower pump rates because it helps to keep the drilling fluid flowing. If the pipe is poorly centralized, pipe Rev. 06-14-00 RRF, JFH CEMENTING

HALLIBURTON movement can compensate by changing the flow path through the annulus and allowing the slurry to circulate completely around the casing. The industry does not specify a minimum requirement for pipe movement, however it is acknowledged the even a small amount of movement will enhance the displacement process. In some instances, pipe movement is not recommended. For example, when equivalent circulating density and fracture pressure are very similar, or shallow gas or water influx is at a critical potential, moving the pipe can induce surge and swab pressures that could promote pipe sticking, and induce flows or formation failures. The use of mechanical devices, such as some types of liner hangers, may also prevent casing movement. All of these factors must be considered when designing the displacement program. Use of hydraulics simulators with surge and swab capability such as Baroid's DFG-Win is advised in these situations. 6) Hole Size: Best mud displacement under optimum rates is achieved when annular tolerances are approximately 1.5 to 2 inches. Centralization of very small annuli is very difficult, and pipe movement and displacement rates may be severely restricted. Very large annuli may require extreme displacement rates to generate enough flow energy to remove the drilling fluid and cuttings. Combined small and large intervals resulting from the use of bi-centered bits below small casings can be very challenging. Very careful hydraulics modeling is required in such cases. 7) Gas Flow: Although gas flow may not be apparent at surface, it may occur between zones, damaging the cement job and eventually lead to casing pressure at the surface. The OptiCem program can be utilized as a tool to determine the gas flow potential (GFP) on any primary cement job. The Halliburton GFP calculation, when combined with local engineering experience, is the premier industry solution to gas flow problems through unset cement. 8) Wiper Plugs: Top & bottom wiper plugs are recommended on every primary cementing job unless prohibited by mechanical or other special restrictions. The bottom plug serves to minimize contamination of the cement as it is pumped, in some cases it may be prudent to use multiple bottom plugs to separate mud/spacer and spacer/cement interfaces. The top plug is used to prevent any contamination of the cement slurry by the displacement fluid and minimize the chances of leaving a cement sheath inside the casing. The top plug also gives a positive indication that the cement has been displaced. 9) Rat Hole: When applicable, a weighted, viscous pill in the rat hole prevents cement from swapping with lighter weight mud during the cement job or when displacement stops. 10) Shoe Joint: A shoe joint is recommended on all primary casing/liner jobs. The length of the shoe joint will vary. The absolute minimum length is one joint of pipe. If conditions exist, such as not running a bottom plug, two joints of pipe is a minimum requirement.

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