~
SPE 30512
First High-Temperature Applications of Anti-Gas Migration Slag Cement and
Settable Oil-Mud Removal Spacers in Deep South Texas Gas Wells
Ronald E. Sweatman, SPE, Halliburton Energy Services, James J. Nahm, SPE, and David A. Loeb, SPE, Shell E & P
Company, and Dean S. Porter, SPE, BJ Services
copyright 1995, Sooiety of Petroleum Engineers Ino.
This paper was prepared for presentation at the SPE Annual Teohnioal Conferenoe & ExhibHion
held in Dallas, U.S.A., 22-25 Ootober, 1995.
This paper was selected for presentation by an SPE Program Committee following review of
information oontalned In an abstraot submitted by the author(s). Contents of the paper, as
presented, have not been reviewed by the Sooiety of Petroleum Engineers and are subjeotto
correction by the author(s). The material, as presented, does not neoessarily refleot any
position of the Sooiety of Petroleum Engineers, its offioers, or members. Papers presented at
SPE meetings are sUbjeot to publioation review by Editorial Committees of the Sooiety of
Petroleum EngineerS, Permission to oopy is restrioted to an abstraot of not more than 300
words. Illustrations may not be copied. The abstraot should oontain oonspiouous acknowledg-
ment of where and by whom the paper Is presented. Write Librarian, SPE, P.O. Box 833836,
Riohardson, TX 75083-3836, U.S.A, fax 01-214-952-9435.
Abstract
Applications of a new slag cement and spacer system have
reduced the chance of gas channels forming in the cement
column during cement hydration in deep, hot south Texas gas
wells. These slag cements were formulated with water and
conventional cement additives to prevent gas migration and to
improve interfacial bonding to oil-wet surfaces. Oil-mud re-
moval spacer fluids (OMRS) were also specially fOlmulated to
remove oily residues and improve water-wetting of the oil-wet
surfaces. These OMRS can also be designed to develop com-
pressive strength when cementing operations have been com-
pleted.
Set slag cement provides a tight gas seal with shear-bond
healing capacity, as demonstrated by recently developed HTHP
shear-bond strength tests. The previously reported phenomenon
of healing or regeneration of slag-mix bonds has been repro-
duced with slag cement. The rapid development of strength at
the top of the long cement column and the improved bonding to
oil-wet surfaces were the two major improvements provided by
the slag cement. OMRS can clean oil-wet surfaces, and then set
once the job has been completed.
Laboratory tests and field evaluations based on cement
bond logs and pressure tests indicated improved bonding and
isolation of the gas zones. Field applications of slag cements and
OMRS fluids have led to greater primary and plug cementing
successes in south Texas gas wells, and well production eco-
nomics have improved accordingly.
References at the end of the paper.
Society of Petroleum Engineers
Introduction
In a continuing effort to improve cementing in south Texas
fields, a new blast furnace "slag cement" (referred to in this
paper as slag cement) system has been developed. This slag
cement may overcome the limitations of current salt-saturated
Class H (SSH) cements used in the field and may offer signifi-
cant improvements in zonal isolation. The slag cement includes
a high-quality blast furnace slag as the hydraulic material
instead of Portland cement. The slag meets ASTM C-989 Grade
120 specifications and will be referred to in this paper as "slag."
The slag cement system, which includes available conventional
cement additives, was jointly developed by Shell and two
service companies. It has been successfully applied in oilwell
cementing operations in south Texas gas fields. The slag ce-
ments are routinely formulated with water, slag, and cement
additives to prevent gas migration, reduce WOC (waiting on
cement) times, and improve interfacial bonding to oil-wet sur-
faces,
A new oil-mud removal spacer (OMRS) fluid system1,2 has
been developed to remove oily residues and improve water-
wetting of the oil-wet surfaces. In addition the OMRS can be
designed to develop compressive strength once cementing op-
erations are completed. Similar non-setting systems were used
in conjunction with the slag cement in the field.
This paper presents laboratory data on the development of
high-temperature, high-density slag cement formulations espe-
cially designed to prevent gas migration in south Texas gas
fields. In addition, the interfacial sealing properties of slag
cement measured in the laboratory with a high-temperature-
high-pressure (HTHP) shear-bond tester are discussed. Field
evidence is also presented, which suggests that specially formu-
lated slag cement controls or minimizes gas migration during
primary and plug cementing and provides a long-term gas seal.
South Texas Cementing Challenges
South Texas gas fields (e.g., Rosita Field in Duval County,
McAllen Ranch in Hidalgo County) have some of the most
challenging cementing conditions anywhere because of the
presence of high-pressure gas and the use of oil muds. Cement-
ing long-string casings and deep drilling and production liners
has long been one of the most challenging aspects of well
643
2 FIRST HIGH-TEMPERATURE APPLICATIONS OF ANTI-GAS MIGRATION SLAG CEMENT AND
SETTABLE OIL-MUD REMOVAL SPACERS IN DEEP SOUTH TEXAS GAS WELLS
Gompletion. Positive and/or negative differential pressure tests
are often used to.evaluate these cement jobs and, in some cases,
results have been poor. Since these wells are subjected to
hydraulic fracturing upon completion, the integrity of the ce-
ment sheath is essential.
These south Texas wells are land locations drilled to an
average depth of about 15,000 ft with bottomhole pressures of
about 13,300 psi and bottomhole temperatures of 350 o P, In
some cases, the bottomhole static temperature (BHST) is as high
as 485°P, Temperature gradients often exceed 2°P per 100 ft
with bottomhole circulating temperatures (BHCT) ranging up to
400 o P. Most of the treatments were performed in wells where
the differences between BHCT and the cooler top-of-cement
.static temperature (TOCST) ranged from 18°P to 185°P.3.5 The
larger differences in these temperatures could be accommo-
dated' through the use of slag cements to achieve acceptable
compressive strengths.
High-pressure gas zones having high potentials for gas
migration further compound the problem of slurry design and
cement placement. In addition, these wells are drilled with high-
density oil-based muds. 3 Traditionally, diesel oil or mineral oil-
based invert oil-mud systems with an intetnal water phase of
high calcium chloride salinity are required for thermal stability
and increased penetration rates with PDC bits.
Applications of Salt-Saturated Class H (SSH)
Cement
Shell has successfully cemented gas wells using low fluid-loss
(less than 50 cc), densifiedSSH cements to control annular gas
migration. 3 Shell's unpublished laboratory data indicate that
SSH cements used in the field have a zero leak rate with the
lowest shrinkage. The addition of silica flour to neat Class H
cement provides a very low leak rate and short sealing time, both
of which are essential for preventing annulargas migration; the
addition of salt reduces volume shrinkage and shortens sealing
time. Organic fluid-loss additives are also beneficial in reducing
leak rate and have a slight retarding effect.
Shell's internal studies show that good sealing properties
are obtained with the densified, low fluid-loss, SSH cement,
because (1) dissolved salt is readily precipitated out as the mix
water is taken up by cement during hydration reactions, and (2)
fine salt· grains plug up pore space or coat cement grains,
resulting in an impermeable cement.
All cement grains are completely covered with salt crystals
and some salt crystals are fused together. Salt can recrystalize
and deform under pressure, yielding an impermeable cement.
The growth of salt crystals can aid in obtaining better hydraulic
bonding and thus reduce fluid communication.
Because they plug pore space, which in turn, results in low
permeability, organic fluid-loss additives can be used to help
prevent gas migration. Laboratory investigations show that SSH
cements are generally less interactive with oil-based muds than
freshwater cements if the two fluids arecommingl~d.
644
SPE 30512
Internal studies also confirmed that the expansion charac-
teristics of SSH cement present another possible reason for
obtaining good sealing properties. Tests with non-saturated
Class H cement containing 5% KCl rather than NaCI resulted in
higher shrinkage values. Set-cement shrinkage has been shown
by others6 to contribute to poor sealing properties.
SSH cements can help operators achieve good cement-to-
formation sealing and bonding because they protect water-
sensitive formations, which are found in many south Texas
wells. These zones may become unconsolidated, bond poorly,
and 'lose strength when exposed to freshwater cements or salt
cements that are not fully saturated.
At this time, the major problem with using a densified SSH
cement is that it is extremely difficult to obtain low fluid loss
(less than 50 cc at 180 0 P) with salt saturation at high-tempera-
ture conditions. 4,5 Most organic fluid-loss additives do not
perform adequately in salt-saturated slurries, especially at el-
evated temperatures. Another problem is obtaining adequate
compressive s~tength at the top of t~e long cement column
where differences between BHCT and cooler TOCST range up
to 185°F, To improve overali cementing in south Texas, an
alternative cement system has been sought. Although the SSH
cement has been successful in Shell operations, an alternative
cement slag/spacer system (OMRS) specification has been
developed and successfully applied in several fields in south
Texas.
Slag Cement Design Criteria
The development ofslag cement for HTHP gas well applications
focused on asearch for improved cement setting and anti-gas
migration properties with better overall economics for the well
than current 88H cement designs. The resulting slag cement
design and properties for typical sotith Texas gas well condi-
tionsare compared to those for SSH cement in Table 1. This slag
cement design changes mainly because of different BHCTs,
TOC8Ts, andBHPsin each well, but the basic types of additives
are retained. In one exception, the hematite was eliminated in the
slag cement design b~cause of a low mud weight of 14.6Ib/gal
compared to an average 006.6 Ib/gal for the other 15 primary
cementing applications. The slag cement-retarder concentration
listed in Table 1 contained a single-component material. Many
of the applications required multiple-component retarder sys-
tems. 80me of the other applications use a combination or
'retarder/dispersant components to obtain desired rheology val-
ues, Initially, many lab tests were performed to complete a
design. However, subsequent designs were finished with about
the same amount of lab work as 88H designs.
The thickening time for the current 88H design must be
within a range of minimum and maximum times. 7 Both slag
cement and SSH slurry thickening times must be designed to
meetot exceed the minimum value. However, some slag cement
designs can have thickening times longer than the current 88H
maximum thickening time without adverse effects on compres-
sive strength development, shown by the values in Tables 1 and
2.
SPE 30512 R. E. SWEATMAN, J. J. NAHM, D. A. LOEB, D. S. PORTER 3

Some high-temperature cement retarders seem to be more cement is placed in the well. Many types ofsolvents and solvent!
effective in slag cement under dynamic slurry conditions and water mixtures were evaluated before suitable organic solvents
less effective under static slurry conditions than the same were found that could clean the OBM from simulated pipe
retarders in SSH cement slurries. The resulting thickening time surfaces within seconds or 2 to 3 minutes. Other design require-
for many slag-cement designs can be more than double the value ments in the formulation ofOMRS 1,2 included a fluid-loss value
for SSH designs and produce set times to 50 psi and 500 psi in of ca. 50 cc/30 min at 180°F and 1,000 psi, a mixable/pumpable
50% or less the time required for SSH designs. rheology, solids suspension stability, and compatibility with oil-
The properties in Table 1meet the following design require- based mud and slag cement. OMRS1,2 also helped improve
ments: bonding of slag cement to pipe as discussed in the following
HTHP Shear-bond Test section.
a minimal thickening time A laboratory "pipe test" was run with conventional weighted
a minimum compressive strength of 200-psi at the top of spacers to evaluate water-wetting and mud-film removal from
cement (TOC) in 12 hours or less the pipe. A laboratory "hole test" was also run to indicate the
a maximum fluid loss of 50 cc/30 min at 180°F and 1,000 amount of mudcake removal from the open hole. These tests are
psi similar to those previously reported in the literature,8,9 but these
zero free water at 180°F tests allowed for development of quantitative procedures and a
pumpable rheologies at 80° and 180°F better flow simulation. Conventional weighted spacer systems
did not perform as well as OMRS in the tests listed in Table 3,
The TOC compressive strengths are tested in a DCA (ultra-
Th.e conventional spacers included an oil-external emulsion
sonic cement analyzer) at TOCST and 3,000 psi. The slurry is
(Spacer A), a water-external emulsion (Spacer B), and a water-
preconditioned in a pressurized consistometer to simulate batch
based polymer-gelled fluid (Spacer C). Although the OMRS
mixing and then ramped to BHCT and BHP to simulate cement
(Table 4) used for the tests was the version weighted with slag,
placement. This exposure to temperature and pressure before
other spacer systems (weighted with hematite or barite instead
transfer into the DCA has helped some SSH designs meet the
of slag) have been used and have given equivalent test results
TOC compressive-strength requirements. Other SSH designs
have required more than 12 hours to obtain the desired 200-psi
with the same OBM and test conditions. ..
Fluid contact times determined in the pipe and hole tests
compressive strength. Slag cement designs have frequently had
were used to calculate the OMRS spacer volumes needed for the
much better results (Table 2). The slag cements' rapid TOC
specific cementing application. These job volumes were similar
compressive-strength development was one of the primary
to the volumes of conventional spacers used previously, i.e., 25
reasons they were selected instead of SSH cement designs. This
bbl ahead of cement for long strings and 20 bbl ahead/5 bbl
property and better downhole bonding properties could be used
behind for liners.
to produce an improved economic value calculation (EVC) for
the well.
Development of High Compressive-Strength Slag
The forecast EVC is based on shorter WOC times, reduced
Cement
remedial cementing squeeze work, and higher production lon-
A typical 17-lb/gal slag cement slurry (Design ST-14, Table 5)
gevity with improved gas zone isolation (no gas leakage). Based
was formulated with slag, hematite, and other conventional
on the forecast EVC for each well, operators will set various
cement additives to give reasonable fluid and set properties.
goals to save rig time. For example, they may set the goal of
Although there are no known thermal strength retrogression
waiting 6 hours rather than 12 to drill out a liner, or if the casing
phenomena lO associated with the hydration of slag, the effects of
will not be drilled out, they may wait 6 hours rather than 12
silica flour on the development ofST-14' s compressive strength
before setting the casing hanger and nipple down the well. The
investigated through the use of DCAs at 330°F. As shown in
trends shown in Table 2 suggest a significant reduction in the 12-
Table 5, ST-16 formulated with 20% silica flour by weight of
hour period for TOC compressive strength.
slag (bwos) shows considerably higher cornpressive strength
Another economic factor being evaluated is the relaxation
than ST-14 formulated without silica flour. The compressive
of the fluid-loss control requirement from 50 cc/30 min to 100
strength of ST-14 more than doubled its value after 20% silica
cc/30 min without sacrificing gas migration control properties.
flour bwos was added. Based on this result and other unpub-
Continuing applications and test data will be used for making
lished data, the most effective amount of silica flour for high-
specific recommendations for EVC improvement for south
temperature slag cement is approximately 20% bwos.
Texas well operations.
Development of Anti-Gas Migration Slag Cement
Development of OMRS Fluids
In 1989, Total CFP formulated a composite slurry consisting of
Because oil-based muds (OBMs) tend to stick to metal and
75% slag and 25% Class G cement with a cationic polymer to
formation surfaces in south Texas wells, OMRS fluids have
improve gas migration control. The slag-Class G composite was
been developed to improve pipe and hole cleaning before
tested with a gas migration test model. Test results indicated that

645
4 FIRST HIGH-TEMPERATURE APPLICATIONS OF ANTI-GAS MIGRATION SLAG CEMENT AND
SETTABLE OIL-MUD REMOVAL SPACERS IN DEEP SOUTH TEXAS GAS WELLS
(1) the higher the slag content, the lower the capillary porosity
(lower permeability) and (2) a reduced capillary porosity de,
creases the. pore size (pore densification) and increases the
pressure losses applied to aninvading gas or fluid. The field trial
of the slag-Class G composite system had been successful in
providing zonal isolation with excellent CBL results in France
and Tunisia, and the addition of slag h~d reduced cement costs. to
In addition, TOTAL CFPcurrently uses a composite slurry of
slag and Type I Portland cement in geothermal wells and across
CO 2 zones in the Far East Asia areas. I I
Previous investigations suggest that if certain anionic or
nonionic surfactantI' are added to slag mix or conventional
Portland cements, they can provide anti-gas migration proper-
ties. 12 •13 Based on Shell's U-tube measurements, the addition ·of
a surfactant to both slag mix and conventional Portland cement
gave zero le'lk rates at a differential pressure of 2,000 psi at
varying temperatures and low slurry-volume shrinkages. The
addition of a very small amount (0.1 gal/sk) of a common
anionic surfactant (e.g., an ethoxylated linear alcohol sulfate) to
a slag-mix sample resulted in a shrinkage to .1.26%. Experimen- ,
tal procedures and drawings for the U-tubetest apparatus are
discussed in Ref. 13. Portland cements containing surfactantI' as
used for anti-gas migration have, shrinkages of about 2,8% and
zero leak rates. 12 Generally, Portland cement slurries not spe-
cially designed for anti-gas migration have a shrinkage of
between 5 and 7% and have very high leak rates in the U-tube
test.
The slag cements under investigation are formulated with a
proven nonionic surfactant based on the results of previous
investigations. The surfactant improves the slag cement's anti-
gas migration properties and increases the water-wettability of
casing and formation surfaces to improve bonding to oil-wet
surfaces. Although the slag cements treated with a surfactant
were not evaluated in this study for specific anti-gas migration
properties, the gross effects of the surfactant on the setting
properties were measured. The effects ofusing an OMRS and a
slag cement to clean ,oily surfaces was also examined. Both
sandstone and black-iron pipe bonding properties were mea-
sured and are reported below.
Table 5 lists three slag-cement formulations showing the
effects of a nonionic surfactant and soda ash on UCA set
properties. Soda ash has been used as an activator for slag mix
as well as slag cement. ST-20 was formulated with 1 gal/bbl of
the surfactant while ST-21 was formulated without the addition
of the surfactant. The surfactant seemed to slightly retard the
UCA set times and slightly reduce the compressive strength. In
ST-22, the amount of soda ash was increased from 1% to 3%
bwos. As expected, the UCA set time was shortened from 5
hours, 25 minutes in ST-21 to 1 hour, 25 minutes in ST-22.
Effects of Oil-based Mud on Cement Strength and
Bonding to Formation
A study was performed to determine how l7.5~)b/gal OBM
would affect the .DCA set properties and compressive strength
646
SPE 30512
of a slag cement formulation. As shown inTable 5, ST-17 is a
17-lblgal base slag cement, ST-18is a contaminated slag cement
with 10% OBM, and ST-19 is also a contaminated slag cement
with 25% OBM. The uncontaminated ST-17 shows fast-setting
behavior and has a crushed compressive strength of 5,290 psi
while the 25% .contaminated ST-19 exhibits slow setting behav-
ior (a UCA set time to 50 psi of 8 hours, 48 minutes to a l,JCA
set time to 500 psi of 20 hours and 46 minutes) and a reduced
compressive strength of 1,540 psi. Slag cement tolerates the.
contamination of 10% of the OBM without many adverse
effects.
The hlboratory bench-top disposable core filtration (DCF)
testapparatus 14 was used to evaluate the shear-bond seal of the
cement created after the initial deposit of an OBM filter cake.
Measurements were made of the shear bonds created between
Berea sandstone cores and a 17-lb/gal slag cement after various
techniques were used to wash off a filter cake previously
deposited by a l7.5-lb/gal OBM. The original OBM filter-cake
deposition and the washes with the OMRS I ,2 slurry and slag-
cement slurries were performed while a filtrate pressure differ-
ential of 100 to 150 psi was maintained on the slurries. The core
was rotated at approximately 125 to 150 rev/min.
Table 6 shows the results offour tests. When OMRS was not
used to remove OBM filter cake, and the cementing was per-
formed with slagcemetlt (without surfactant), a DCP shear-
bond strength of 3 psi was obtained. When the OBM filter cake
was removed by the OMRS 1,2 before slag cement (without
surfactant) was added, a shear bond of 497 psi was obtained.
When the OBM cake was removed by the dMRS before the
sandstone core was cemented with a slag cement containing
surfactant, a higher shear bond of 757 psi was obtained. In the
last example, theOBM filter cake was removed by the slag
cement containing surfactant before the core was cemented. The
clean core was then cemented with the slag cement containing
the surfactant. A much higher shear bond (1,455 psi) was
obtained, demonstrating the benefit of cleaning the formation
face thoroughly.
HTHP Shear-Bond Regeneration Tests. The HTHP shear-
bond tester used in this study is a modified design of the tester
developed by Parcevaux and Sault. 6 The HTHP shear-bond
tester provides shear-bond data at both downhole conditions and
ambient conditions (as normally obtained). A description of the
HTHP shear-bond tester and test procedures, reported in a
previous publication,13 are briefly summarized in Appendix A.
FirstSeries Shear-Bond Test Results. For the first series of
tests, a freshwater slag cement was compared to an SSH. Both
slurries were modified for 280°F conditions. The slurry compo-
sitions and the data collected are shown in Table 7. On the first
tests, the hydraulic pressure VI'. time data were recorded. A
second pair of identical tests were also run with computer
recording. The pressure VI'. time data for the SSH cement is
shown in Fig. 1, while the same comparison fOr freshwater slag
SPE 30512 R. E. SWEATMAN, J. J. NAHM, D. A LOEB, D. S. PORTER
cement in provided in Fig. 2. For example, in Fig. 1, the upper
(initial 8-day) curve shows the pressurization, shear-bond fail-
ure, and subsequent pipe movement at the decreasing skin
friction after the sample had cured for 8 days. The lower (14-day
retest) curve shows the reshearing test after the sample had cured
for an additional 14-day curing period (a total of 22 days in the
shear-bond tester).
Table 8 shows that the SSH cement has a higher initial8-day
shear-bond strength (an average of 155 psi) than the slag cement
(an average of 140 psi). However, the slag cement has a much
greater 14-day retest shear-bond strength (In psi) than the SSH
(100 psi). The SSH shows a shear-bond regeneration of 40 psi
while the slag cement shows a regenerated shear bond of 118 psi.
(In this study, a shear-bond regeneration is defined as the 14-day
retested shear bond minus the initial 8-day skin friction.) The
bond regeneration phenomenon of the SSH may be the result of
the inherent expanding characteristics of the SSH cements. In
our previous study, 13 freshwater Class H cements did not exhibit
bond regeneration characteristics; the slag cement has given
good shear-bond generation in all tests.
The shear-bond tests made at ambient conditions measured
on a hydraulic press gave considerably higher values. The
lengthwise mechanical compression of the pipe section makes
the pipe diameter increase slightly, while the reduced tempera-
ture makes the outer sleeve shrink slightly. These two effects
work together to compress the cement and produce the higher
shear bonds in all three samples. The Class H lower section gave
a shear bond of 451 psi; the slag cement lower section gave a
shear bond of 574 psi.
Second Series Shear-bond Test Results. Another series of
HTHP shear-bond measurements was made with two SSH
cements and one freshwater slag cement. Varying slurry densi-
ties were used for measuring the effects of slurry density and
composition on shear bond. The same approximate amount of
hydraulic material and hematite was used in all three samples.
The 17.7-lb/gal and 17.0-lb/gal SSH slurries were designed with
varied mix-water contents and conventional cement additives.
The 16.4-lb/gal slag cement was also designed with conven·
tional cement additives, but it was not optimized for the best
performance because of constraints (density and solids). Unlike
the SSH cement, the slag cement required a different type of
dispersant/retarder, and contained surfactant and soda ash. The
SSH cements were formulated with 35% silica flour (bwoc)
while the slag cement was designed with 20% (bwos) silica
flour. Slurry compositions and shear-bond test results are listed
in Table 9.
The initial8-day shear-bond tests of Table 8 varied with the
slurry density (17.7,17.0, and l6.4lb/gal), and all three proved
that the higher the slurry density, the higher the initial 8-day
shear-bond strength. A quite different trend is shown with the
14-day retest shear-bond strength. Figures 3, 4 , and 5 show
hydraulic pressure vs. time curves for each of the three samples
measured after they were aged at 280°F and 1,000 psi for 8 days
and then resheared 14 days after the initial shearing tests.
647
5
Each of the three samples gave a high shear-bond regenera-
tion above their 8-day skin friction values. However, even with
these high shear-bond regeneration values, the SSH samples had
the maximum shear bond of the 14-day retests, which were
considerably below the 8-day shear-bond values (-11 % and
-21 %). The slag cement retest gave a 134-psi shear-bond regen-
. eration, but this value (similar to the SSH values) raised the slag
cement's retest to 29% above the initial 8-day shear bond.
Effects of OBM on Cement Bond to Pipe. To continue the
study of cement bonding, tests were conducted with the HTHP
shear-bond tester to measure the effects of an OHM film on the
pipe to be cemented. The pipe surfaces were first immersed in
a washing fluid and then rotated at 120 to 150 rev/min for the
indicated time before they were assembled in the HTHP shear-
bond tester for cementing. The first series oftests involved a 17-
lb/gal slag cement containing a surfactant (Formulation S-20,
Table 5). The results are given in Table 9.
Test A is a reference test that started with clean black-iron
pipe, giving a shear bond at 330°F and 1,000 psi or 374 psi. Test
H, was performed on an OHM-wetted pipe that was rotated in the
slag cement (with surfactant) for 12 minutes before it was
assembled in the HTHP shear-bond tester. Apparently, the
OHM was not completely removed, since the shear bond was
reduced to 297 psi. Test C was also performed on an pipe wetted
with OHM. The pipe was washed for 11 minutes in the OMRS 1,2
and then for 8 minutes in the same slag cement before it was
assembled in the HTHP shear-bond tester. Test C also showed
a reduced shear bond (202 psi), again indicating that the OHM
was not completely removed. While each of these tests indicated
sufficient shear-bond strength to support the pipe, they revealed
that the presence of even a small amount of OBM on a smooth
iron pipe could significantly reduce the shear bond.
All testing to date has shown that slag cement can exhibit
strong shear-bond regeneration. The tests with SSH slurries
(Tables 7,8) exhibit a definite but weaker shear-bond regenera-
tion. All previous tests using freshwater Class H slurries 13
exhibit no shear-bond regeneration. However, all of the initial
shear bonds measured have been more than adequate to support
pipe in the hole.
Field Applications of Slag Cement and OMRS Fluids
Six longstrings and two kickoff plugs were set with slag cement
in the Rosita Field, as well as one drilling liner in the McAllen
Ranch Field. Other very successful applications (five longstrings,
four liners, and three plug jobs) are not reported in this study.
These jobs were in the Monte Christo, Cadre, and McAllen
Ranch Fields. The following three case histories will represent
the types of slag cement systems used and the results that
followed. Only one longstring case history for Hubbard Frost
Gas Unit 5 is discussed. The operations, slurry design, and
results are representative of selected slag cement jobs pumped
to date, and respective test results are supplied in Table 10.
6 FIRST HIGH·TEMPERATURE APPLICATIONSOFANTI·GAS MIGRATION SLAG CEMENT AND
SETTABLE OIL-MUD REMOVAL SPACERS IN DEEP SOUTH TEXAS GAS WELLS
Longstrings (Hubbard Frost Gas Unit ~). The first longstring
job involved 3 1h-in. casing set at 12,315ft inside a 6 Ih-in. hole
a
with a BHST of 330°F and BHCT of 270°F. Slag-,cement
would be circulated from TD to 8,000 ft in a single stage for
1,000 ft inside the 7 Sis-in. intermediate casing previously set at
9,000 ft. The slag cetylent sll;1rry was designed to weigh 17.11bl
gal (Table 10, Welll)and had a thickening time of 4 hours 40
minutes at 270°F. Despite a 40° differential between the BHCT
and the static temperature at TOC (TOCST), the slurry had an
initial 50 psi set.of5 hours, 53 minutes. A 500-psi compressive-
strengthset was achieved in 6 hours, 20 minutes. The 24-hour
strength at 230°F (TOC) w~s 2,260 psi.
Severe lost circulation, with only 50% returns occurred
while the hole was being circulated both before and during the
cementing operation. The floats were checked but did not hold;
therefore, the well had to be shut-in to prl"vent flowback. After
9 hours, the pressure was rekased; no flowback occurred, and
no gas pressure was seen on the annulus~ In an,other producing
well having similar slag-cement strength development, only 5
hours (v~. 12 hours WOC) had elapsed before the pressure was
released and rig-down was begun.
Once the well was nippled down and the drilling rig was
pulled off location, the well was turned over to production
personnel to begin completions operations. A CBL b.ond logrun
16 days later, showed much~improved isolation of the. zones.
Beclluse ofthelost-circulation problem, however, the TOC was
much lowe~ than planned: only 200 [tof cement was above the
gas zone. The first zone of interest was perforated 50 days after
the cementing operation; no signs of cOIVmunication were
evid.ent. A frae job was performed 60 days after the cementing.
Again, no communication up the annulus. Was noticed during or
after the job, and based on the po~t-job analysis, the frac
remained' i~ zone. Four out of the six we)ls have since been
hydraulically fractured, and not one has experienced gas com-
m~nication problems. The slag cement withstood the extreme
hydraulic fracturing pressures in tlwse wells; as much as 10,000
psi was realized during the hydraulic fracturing operation.
Kickoff Plug (LloydNo. 6, Fro~t N~tional BaukN~. 1). In the
past, attempts at setting kickoff plugs in the Rosita Field proved
to be difficult at best. Several attempts were made before a
successful side-track plug was realized. Based .on that prior
experience and the recent promising results seen in the lab
regarding the quick initial and high-end strength cnaracteristics
of slag cement, the decision was made to set a slag cement pl'1g
similar to the sl;lg sYstems used for the longstrings (Table 1D,
Well 8). The first slag.;cement kickoff plug pumped in the Rosita
Field was set at 9,200 ft with;lnopenholefiUof 500 ft. A volume
of 10 bbl of OMRS spacer was used ahead of the slag-cemtrnt
slurry and 5 bbl was pumped behind it. Th~ plllg was balanced
in the 61h~in. hole, and the drillpipe was slowly pulled ;lbove the
plug anef circulated dean. After 12 hours, the plug was tagged
and drilling began. Initially, drilling was "soft," but the drilling
rate gradually slowed, and a successful kickoff eventually
648
SPE 30512
occurred. After the plug was set, no apparent signs of gas
appeared above the plllg as a result of migration.
Drilling Liner (McAllen Ranch NQ.87). This case history
describes some .events and results of slag cement job in the
MyAllen Ranch Field. This well had been drilled to 11 ,538 ft
when it began experiencing several drilling problems before the
slag cement slurry was pumped. Lost returns were a constant
problem and the influx. of gas was creating a well-control
problem. The. well was eventually controlled and the 7 Sis-in.
liner was rlln. Once circulation was established, however, re"
turns were again lost. The slag cement system was mixed and
pumped similar to the systems that" had been used on the
longstrings in the Rosita Fie.1d (Table 10, Well 7). Next, 20 bbl
ofOMRS spacer were run ahead of the slurry and 5 bbl ofOMRS
spacer was run behind. After the job, 50% returns were calcu-
lated, ensuring thatthe liner-top would not be isolated and that
it would eventually have to be squeezed. Although the liner-top
'had to be squeezed, the job was deemed aSuccess because no gas
buildup was realized after the job. The slurry apparently covered
the sands generating the gas and positively isolated them to
prevent gas migration. After the Iiner~top squeeze, the liner.;
shoe was drilled out and tested to an 18.2"lb/gal EMW (equiva-
lent mud weight). Thedrilling operation continued onto its final
objective with the setting of 3 l/~-in.casing and an ending mud
weight of 13.2 Iblgal. The well has since been hydraulically
fractured inthe zones(s) of interest with no evidence of commu-
nication.
Shear-Bond Regeneration
All the initial shear bonds measured are more than adequate to
support the pipe in the hole. Even so, the high-temperature
shear-bond test results may illuminate the slag cement bonding
regeneration or healing process. These shear-bond tests, while
not showing that slag cement is superior to the SSH, do indicate
that a different setting or healing mechanism is occurring. The
equipment and testing procedures have not yet been completely
standardized, but all of the data to date indicate that some such
healing proce~s does occur in the slag cement samples but
occurs to a lesser degree in the salt-saturated Portland cement
samples. The following comments are provided for further
research and discussion in the future.
As reported earlier,13 the current test results with freshwater
slag cement seem to be consistent with the pore densification
theory and may have lead to the improved downhole perfor-
mance of the slag cement which has been experienced in the
south Texas field. The literature indicates that alkali.activated
slag, forms a densified internal gel during the hydration process.
This pore densification leads to a buildup of internal stresses and
seems to be linked to the slag mix or the slag cement's capability
of improving long-term interfacial sealing. The superior
rebpnding 'or healing performance of the slag mix or the slag
cement maybe linked to the development of internal stresses
caused I:)y a densified microstructure and low chemical shrink-
SPE 30512 R. E. SWEATMAN, J. J. NAHM, D. A. LOEB, D. S. PORTER
age during hydration. In general, alkali-activated slag and slag/
Portland cement blends are physically and chemically durable
because of the slag's densified microstructure. Some of the
reported beneficial effects include high mechanical strength,
low permeability, low ionic diffusivity, chemical resistance,
low volume shrinkage, etc. 15 -20
The unique oxide makeup of blast furnace slag may be
related to the improvement of shear bond with time and the
temperature of slag cement mentioned earlier. Portland cement
has a 3: 1 ratio ofCaO to Si02 while slag has approximately a 1: 1
ratio ofCaO to Si02 • Both Portland cement and slag form a CSH
gel upon hydration. The formation of the CSH gel is closely
related to the slag cement's hardening and compressive strength
development. In Portland cement, a limited amount of silica is
available for the formation of the CSH gel. However, in the slag
cement, more silica is available for the formation of the CSH gel.
The hydration reactions of slag may continue with time and
temperature. If the bond between the cement and the shear tube
or casing is broken, rehealing may occur because of additional
available silica in the slag cement. Slag cement has a very low
penneability of approximately 10 nanodarcies. One reason for
such a low permeability is that the hydration reaction continues,
and more CSH gel would reduce the porosity of the slag
cement. 21
Additional evidence suggested that slag cement is different
from Class H cement at the interface of cement and pipe. When
the test samples were dismantled after the HTHP shear-bond
tests, a thin layer of black material was found at the interface
between the smooth iron pipe and the slag cement. This black
material, when scraped from the interface surfaces, was at-
tracted to a magnet. It was present at the smooth surfaces, which
had been (1) sheared at 8 days, (2) allowed to continue curing for
14 days, and (3) then resheared. This material was also present
at the surfaces that were sheared for the first time after 21 days.
The black material has not been found in any of the tests
involving the SSH cement slurries against black-iron pipe. As a
means of detennining if the black deposit may have resulted
from a corrosion reaction of the slag cement with the pipe
surface, slag cement was tested with both smooth black-iron
pipe and with lightly sandblasted 316 stainless steel pipe. The
black material formed, apparently in equal quantities, on both
pipes, indicating that the reaction is not caused by corrosion.
Blast-furnace slag used for slag cement projects normally
contains 0.3 to 1.7% by weight of iron oxide (Fep3) and 0.7 to
1.3% of total sulfur. Although iron in slag is reported as Fep3'
the slag also contains magnetite (Fep4)' Most of the sulfur in
slag is sulfide sulfur in the form of calcium sulfide. Slag cement
becomes dark blue-green as the slag hydrates and hardens. This
color usually appears as the cement sets or hardens and is caused
by a complex reaction of the sulfide sulfur in the slag with other
compounds in the cement. The degree and extent of the colora-
tion depends on (I) the rate of oxidation, (2) the percentage of
total sulfur, (3) curing conditions and (4) the porosity of the
cement surface. 22 Iron hydroxides and ferrous sulfide might
649
7
possibly be formed in slag cement under high-alkalinity, high-
temperature conditions. Gelatinous ferric hydroxide is known to
form when alkalis are added to iron oxides. When iron oxides
react with sulfur compounds, the black compound ferrous
sulfide (FeS) may also be formed. As the data suggest, the
appearance of the black material seems to be linked to the shear-
bond properties because it always forms at the interface. This
unique observation on the formation of black material warrants
further verification and research.
Additional evidence suggests that the slag cement physi-
cally bonded to the stainless steel removable sleeve sections
(Appendix A, Page 9) during the HTHP shear bond tests. The
SSH, however, exhibited little or no bonding. After the pipe
sections were pressed out to measure the shear bond, a band saw
blade was used for making two vertical slots through the cement
down to the stainless sleeve. The sleeve was then rapped with a
hammer to shake out the cement. The SSH broke out cleanly,
exposing the finely threaded inner surface of the removable
sleeve. Slag cement, however broke out with considerable
difficulty and broke partially within the body of the slag cement,
leaving a thin, rough layer of cement covering the internal
surface of the sleeve. The bonding of the slag cement to the steel
may have resulted from the chemical reactions previously
described.
Summary
Although low fluid-loss SSH cements and conventional spacers
for oil-based muds have been used to cement high-pressure,
high-temperature gas wells in several south Texas fields, an
alternative cement system and an improved oil-mud removal
spacer specification was needed. Both the conventional SSH
and the new slag cement seem to show bond regeneration or
healing properties at elevated temperature conditions. How-
ever, the shear-bond properties of slag cement improve with
time and temperature. The bonding performance of slag cement
is also improved with the application of the OMRS. The field
applications of the slag cement and OMRS have substantially
improved cementing results with successful isolation of high-
pressured gas zones in south Texas fields.
Conclusions
Newly applied slag cements are especially suitable for
obtaining shorter WOC times at TOC and faster bonds
where BHCT and TOCST temperature differences are wide
(BHCT - TOCST =40°F to 185°F) and oil-based muds are
used.
OMRS and similarly tested fluids help improve cement
bonding by cleaning oil-wet surfaces. Specifically, OMRS
fluids can be designed to set up. As a result, oily spacer
material is not left in the cement column, which could
weaken the set cement. The new mud removal test results
have better defined the required properties for spacers in
wells with OBM.
8 FIRST HIGH-TEMPERATURE APPLICATIONS OF ANTI-GAS MIGRATION SLAG CEMENT AND
SETTABlE OIL-MUD REMOVAL SPACERS IN DEEP SOUTH TEXAS GAS WEllS
HTHPbond test results indicate that both SSH and slag
cement slurries have excellent shear-bond strengths under
simUlated downhole conditions and that the previously
broken shear bonds seem to regenerate or heal with time.
However, the slag cement has much better-bond regenera-
tion properties than the Class H, and the shear bond of the
slag cement improves with time at elevated temperatures.
Unlike previously studied freshwater Class H cements,
SSH cements used in south Texas show bond regeneration
properties that may be relatyd to the C-S-H crystalline
hydrates and the expanding properties of saturated salt
cement.
The superior rebonding or healing performance of slag
cement may be linked to the development of internal
stresses caused by adensified microstructure and other
mechanisms that are not yet well understood.
Slag cements have maintainedzonalisolation after expo-
sure, to high pressures during hydraulic fracture treatments.
AcknOWledgments
The authors thank Halliburton Energy Services, Shell E & P Co.,
and BJServices management for pennission to publish this
paper. We also thank Bob Romero and Reece Wyant of Shell for
conducting UCA and HTHP shear-bond experiments and edit-
ing the manuscript. We also acknowledge Don Horner, Rene
Cantu, and Carson Parker (Bl), Patty Totten and Rex Hammack
(Halliburton), and Bill Pumphrey, (Western Company) for lab
testing and fonnulation designs.
References
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No. 5,305,831, (1994) . .
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Annual Technical Conference and Exhibition, Washington, D.
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the 1990 IADCISPE Drilling Conference, Houston, Feb. 27-Mar.
2.
5. Brothers, L. E. and Deblanc, F. X. : "New Cement Formulation
Helps Solve Deep Cementing Problems," JPT, 41, No.6, 611-
614.
6. Parcevaux, P. A.and Sault, P. H. ; "Cement Shrinkage and
Elasticity: A New Approach for a Good Zonal Isolation," paper
SPE 13176 presented at the 1984 Annual Technical Conference
and Exhibition, Houston, Sept. 16-19.
7. Gerke, R. R., Simon, 1. M., Logan, 1. L.; and Sabins, F. L.: "A
Study of Bulk Cement Handing and Testing Procedures," paper
SPE 14196 presented at the 1985 SPE Annual Technical Confer-
ence and Exhibition, Las Vegas, Sept. 22-25.
8. Boyington, W. H., Drawe, M.S., Sweatman,R, E., Gill, S. C.:
"Optimized Design, Operations Procedures and Materials Im-
prove Cementing Results in the North Sea," paper SPE 19249
650
SPE 3051:2
presented at· the .1989 Offshore Europe Conference, Aberdeen,
Sept. 5-8..
9. .Holhjem, A, Berck, G. W. and Hoch, R. S.: "Reciprocation of
. Casing \yhile Cementing From a Floating Drilling Unit." paper
EUR364 presented at the 1982 European Petroleum Conference,
London, Oct. 25-28.
10. Fary, J. 1. and Romieu, J. : "Improved Gas Migration Control in
aNew Oil Well Cement," paper SPE 17926 presented at the 1989
SPE Middle East Oil Technical Conference, Manama, Bahrain,
Mar. 11-14.
11. Mueller, D. T., DiLullo, G., Hibbeler, J., and Kelly, P.: "Portland
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pations," paper SPE 30513 presented at the 1995 Annual Techni·
c\ll Conference & Exhibition, Dallas, Oct. 22-25.
12. Cowan, K. M.: "Surfactants: Additives to Improve the Perfor-
ma?ce Properties of Cements," paper SPE 25 \ 81 presented at the
1993 SPE International Symposium on Oilfield Chemistry, New
Orleans, Mar. 2-5.
13. Nahm, 1. J., Romero, R. N.,Javarimardi, K., and Wyant, R. E.:
"Interfacial Sealing Properties of Slag Mix (Mud-to-Cement
Conversion Technology): Laboratory and Field Evaluation,"
paper SPE29407presented at 1995 SPE/IADCDrilling Conf. ,
Amsterdam, Feb. 28 . Mar. 2.
14. Nahm., J. J., Romero, R,~ N., Hale, A. A., Keedy, C. R., Wyant, R.
E., Briggs,.I3. R., Smith, T. R., and Lombardi, M. A.: "Universal
Fluids Improve Cementing," World Oil, November 1994,67-72.
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mingham, Feb. 18-19.
16. Roy, D. M., Kumar, A. and Rhodes, J. P.:"Diffusion of Chlorides
and Cesium Ionsin Portland Cement Pastes and Mortars Contain·
ing Blast Furnace Slag and Fly Ash," International Conference on
.the Use of Fly Ash, SilicaFu01e, Slag, and Natural Pozzo)ans,in
Concrete .(1986) 2, 1423-1444.'
17. Malek, R. LA., RoY, D.' M. and Fang, Y. : "Pore Structure,
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Containing Pastes and Mortars," Materials Research Soc. Proc.'
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Research Society,Symposium, Boston, Nov. 11·18.
19. Feng, Q. L., Lachowski, E. E., Glasser, F. P.: "Densification and
Migration ofIons in Blast Furnace Slag.Portland Cem.ent Pastes,"
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Conversion Byprodu'cts, Boston, (1988) 136,263-272.
20. Feng, Q. L. and Glasser,F. P. : "Microstructure, Mass Transport
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22. American Concrete Institute Com. 226 ACI226.IR-87: "Ground
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SPE 30512 R. E. SWEATMAN, J, J. NAHM, D. A. LOEB, D. S. PORTER 9

Appendix A-HTHP Shear-bond Tester and Test Table 1-Example Slag Cement vs. Salt-Saturated
Procedures 13 Class H Slurry Design/Properties
After the cement slurry has set, the HTHP shear-bond tester (Fig. Example Well Conditions
lA) can be used for measuring the original shear bond and skin BHST at shoe 330°F
or the sliding friction after failure without changes in the BHCT at shoe 270°F
temperature or the pressure. The sheared cement can then TOCST 235°F
remain at the constant HTHP conditions for an additional period Depth at shoe 12,315ft
and be tested again to determine any regenerated bond or OBM weight 17.0Ib/gal
healing within the shear surface. Slurry Designs
The HTHP shear-bond cell is filled with cement slurry and Slag Cement SSH Cement
surrounded by water. The cell is then placed in an oven and Slag API Class H
pressurized, with a space for nitrogen left above the water. After +35% hematite +15% hematite
the required cement curing time, the temperature and pressure
+20% silica flour +35% silica flour
are maintained, and hydraulic oil is pumped into the shear
+0.237 gallsk surfactant +37.2% salt
pressure chamber. This oil lifts the piston and the attached push
+1.25% retarder +0.8% retarder
rod, which apply an upward force on the pipe pull plug. The pipe
+1.0% activator +0.3% set time agent
pull plug lifts the top pipe section. The top pipe section is in
+0.5% fluid-loss control agent +0.7% fluid-loss control agent
tension since its upward movement is restricted by the surround-
+0,15% anti-settling agent +0.1 % anti-settling agent
ing top cement section, which in turn is held down by the shear
+0.2%defoamer +0.2% defoamer
thrust support washer, the top plug, and ultimately, the top cap.
17.1 Ib/gal slurry density 17.6 Ib/gal slurry density
For measuring the shear bond of a sample, a Ruska pump is
used to apply hydraulic pressure though the bottom of the test 1.22 ft%k slurry Yield 1.54 ft%k slurry yield
cell to the shear pressure chamber. The pressure in the Ruska Thicken. Time to 70 Be at 270°F (Min. Req. 2:17, Max. Req. 3:05)

pump builds up to equal the 1,000-psi cell pressure and then 8:02 hr:min 2:20 hr:min
moves the push rod to compress the rubber gaskets, which seat Fluid Loss at 180°F
in the pipe pull plug and apply the shear force to the upper pipe 38cc/30 min 40 cc/30 min
section. After a slow pressure buildup (showing the hydraulic oil Free Water at 180°F
compressibility), the cement sample ultimately shears at or near 0.0% 0.0%
the pipe surface. The pipe then moves at decreasing frictional UCA Compressive Strength at 235°F TOCST
resistance, which is termed "skin friction." (Min. Req. 200 psi in 12 hours)
Current testing involves smooth-surfaced shear pipe sec- 0:53 hr/min = 50 psi 9:40 hr/min = 50 psi
tions made of 1 1/4-in. Schedule-80 black-iron pipe. The cement 1:10 hr/min = 500 psi 10:42 hr/min= 500 psi
shear failure is at the inner pipe interface rather at the removable 2 hr = 1,200 psi 22:32 hr/min =4,447 psi
sleeve interface (2 11s-in.) because of the greater area ofthe outer 8 hr = 1,950 psi
sleeve. The hydraulic pressure minus the cell static pressure 112 hr =2,805 psi
(l ,000 psi) multiplied by 0.215 (the ratio of the piston area to the 451 hr = 3,347 psi
top pipe surface area) provides the shear stress (psi) at the Rheology at 80°F and 180°F
surface of the upper-shear pipe section. The mechanical force Slag Class H
(in pounds) divided by 13.04 (the surface area of the lower pipe 80°F (180°F) 80°F (180°F)
section) provides the shear stress (psi) at the surface of the rev/min 600 817 (292) 669 (372)
lower-shear pipe section. rev/min 300 463 (160) 408 (210)
After the tests on the upper section at temperature and rev/min 200 327 (113) 294 (147)
pressure are completed, the equipment is cooled. It is then rev/min 100 179 (61) 180 (84)
depressurized, and the lower section (shear tube, cement, and rev/min 6 16 (6) 45 (18)
removable sleeve) is removed as a unit. A mechanical force is rev/min 3 12 (4) 39 (15)
then applied to measure the shear bond of the lower undisturbed PV, cp 354 (132) 261 (162)
pipe after the full curing period. 109 (28) 147 (48)
YP, 1b/1 00 ft2

651
10 FIRST HIGH-TEMPERATURE APPLICATIONS OF ANTI-GAS MIGRATION SLAG CEMENT AND SPE 30512
SETTABLE OIL·MUD REMOVAL SPACERS IN DEEP SOUTH TEXAS GAS WELLS

TableS-Performance ofOMRS and.Conventional Spacers:

OBM Removal and ,Cement Wettablllty

Spacer % Mud Removal % Cement Adherence

(14Ib/gal) Pipe Hole (Wettability to Pipe)
spaoer A 66 0 32
Spacer B 0 13 0
Spacer C 0 0 0
OMRS 1,2 96 92 96
Table 2-Thickening Timevs. UCA Set Times (WOC) NOTE: Room temperatureatl~.bbl/min with the foliowing cQntaot
of Various Slag Cements times:
Mud 15 min
TT at UCA Set Times at
BHCT TOCST ilT Spacers 6min
BHCT TOCST (I1r:Min)
("F) ("F) (OF) Cement 5min
(Hr:Min) 50 psi 500 psi
3:48 5:45 6:22 238 212 26
3:30 262 220 42
, 3:20 10:25 11:14 265 215 50
3:18 7:44 8:16 270 235 35
4:40 10:05 11 :39 270 235 35
2:40 5:53 6;20 270 235 35
4:18 1:30 2:13 220 212 .8
4:05 6:12 6:34 385 325 60 Table 4-Example OMRS Design and Properties
4:11 9:15 9:32 420 325 95 Example Design: Slag
3:40 2:34 2:58 224 215 9 +0.75% retarder
4:31 5:35 7:27 222 37 +O.~% fluid·loss control agent "

8:35 8:44 10:13 214 210 4 +Mlx water and solvent chemicals (70:30)
at 14,0 Ib/gal fluid density
,Note: TT : Thickening time to 70 BC Thickening Time: 4:25 hr:ml'ri at 270°F
WOC : Waiting on cement Fluid Loss: 56 cc/30 min at 180°F
UCA : Ultrasonic cement analyzer Atm. Viscosity: 18 ABc initial at 75°F "

TOCST: Top of cement static temperature 11 ABc at 45 min and 180°F

ilT = BHCT • TOCST
Rheology
Data taken only from well applications where BHCT wFls higher
tnan TOCST. Different Slag Cement designs were used to produce rev/min BO°F 180°F
'each line of data. 600 348 108
300 194 53
200 137 35
100 73 16
6 4 2
3 2 1
PV, cp 154 55
YP, Ib/100 ff 40 -2
Compressive Strength
UCAat Hr:Min psi
TOC at 235°F 15:49 50
16:37 500
23:55 1384
167:41 1900
Cubes at
Shoe at 330°F 16:00 1250

652
SPE 30512 R. E. SWEATMAN, J. J. NAHM, D. A. LOEB, D. S. PORTER 11

Table 5-Etfects of Silica Flour, OBM, Surfactant, and Soda Ash on UCA Setting Times
and Compressive Strengths of 17·lb/gal Slag Cement Cured at 330°F/3,OOO psi for 7.65 Days
ST-14 ST-15 ST·16 ST·17 ST·1S ST·19 ST·20 ST·21 ST·22
% Silica flour 0% 10% 20%
% Oil-mud contamination 0% 10% 25%
Slurry Composition, Ib
Slag 87 87 87 87 87 87 87 87 87
Hematite 40.3 34.3 28.3 30.45 30.45 30.45 30.45 30.45 30.45
Silica flour 0 8.7 12.0 16.38 16.38 16.38 16.38 16.38 16.38
Soda ash 0.87 0.87 0.87 0.87 0.87 0.87 0.87 0.87 2.61
Surfactant 2.06 2.06 2.06 2.06 2.06 2.06 2.06 0 2.06
Fluid-loss additive 0.52 0.52 0.52 0.44 0.44 0.44 0.44 0.44 0.44
Anti-settling agent 0.26 0.26 0.26 0.13 0.13 0.13 0.13 0.13 0.13
Cr-lignosulfonate 1.74 1.74 1.74 1.09 1.09 1.09 1.09 1.09 1.09
18-lb/gal oil-mud 0 0 0 0 15 37.5 0 0 0
Mix water, gallsk 5.39 5.06 4.73 5.21 5.21 5.21 5.01 5.27 4.93
UCA Compo Strength, psi
at 7.65 days/330°F nla 5,099 5,988 4,326 ·2,682 683 4,645 5,371 5,278
Crushed camp. str., psi 2,540 4,590 7,230 5,290 4,270 1,540 5,640 5,950 6,240
UCA Set Times
at 50 psi (hr:min) nla nla nla 4:44 9:05 8:48 5:25 4:45 1:21
at 500 psi (hr:min) nla nla nla 5:22 10:06 20:46 5:46 4:54 1:35

Table 6-Effects of Washing with OMRS and Slag Cement on

Shear Bond of Sandstone Core Contaminated
with OBM Film (DCF Test)
Shear Bond
Test Condition to Sandstone
Core, psi
OBM filter cake left on core; cemented with slag
3
cement (no sUrfactant)
OBM cake removed by OMRS; filter cake left on
497
core; cemented with slag cement (no surfactant) .
OBM cake removed byOMRS; OMRS filter cake
left on core; cemented with slag cement 757
(with sUrfactant)
Both OBM and OMRS cakes removed; slag cement
1,455
with surfactant bonded to core
Notes: 17-lb/gal slag cement composition-87lb slag + 30.451b
Hematite +16.38 Ib Si + 2.06 Ib surfactant +0.44 Ib fluid-loss
additive + 0.13 Ib anti-settling agent + 5 gallsk water
OMRS composltlon-14.0 Ib/gal (See Table 4).
DCF cores cured at 200°F at 150 psi for 4 days.

653
12 FIRST HIGH-TEMPERATURE APPLICATIONS OF ANTI-GAS MIGRATION SLAG CEMENT AND SPE 30512
SETTABLE OIL-MUD REMOVAL SPACERS IN DEEP SOUTH TEXAS GAS WELLS

Table 8-17.7 and 17.0 Ib/gal Salt-Saturated Class H Cements

'and 16.4-lb/gal Freshwater Slag-Cement Compositions
an,d HTHP Shear-Bond Test Results
Freshwater
SSH Cement SSH Cement
Slag Cement
(17.7Ib/gal) (17.0Ib/gal)
(16.4Ib/gal)
Table 7- HT and Ambient Shear Bonds of 17-lb/gal Slurry Composition, Ib
Salt-Saturated Class H and Freshwater Slag-Cement Slurries Class H 94 94 0
Measured on HTHP Shear-Bond Tester Slag 0 0 87
Salt-Saturated ,Freshwater Slag Hematite 18 11 15
Class H Cement Silica flour 32.9 32.9 17.4
Slurry 17.05
Ib/bbl Ib Ib/bbl Ib Salt 18.08 0
Composition
Fluid-loss addit. 0.56 0.56 0.52
ClassH 325 (94) 0 0 Retarder 0.19 0.19 0
Slag 0 0 344 (87) Anti-settling
0.24 0.19 0.09
aQent
Hematite 38 (11 ) 120 (30.5)
Defoamer 0.19 0.19 0.17
Silica Flour 113 (32) 69 (17.4) Dispersant!
0 0 0.87
Salt 49 (18.7) 0 .0 retarder
i

Organic Soda ash 0 0 0.52

9.6 (2.8) 6.9 (1.7) Surfactant 0 0 1.78
Additives
Surfactant 0 Water, gal/sk 5.49 5.82 5.08
0 7.0 (1.8)
Shear Bond, psi (280°F/1 ,000 psi)
Soda Ash 0 0 2.1 (0.5)
Initial7-day 339 229 137
Fresh Water 173 (50.2) 168 (168) Repeat, 14-day 301 181 176
Water % Change -11% -21% 29%
Requirement, 6.0 (6.0) 5.1 (5.1) Regenerated" 156 124 134
gal/sk
Lower Section Shear Bond, psi (280°F/1 ,000 psi, 21 days)""
415 475 516
1st 2nd 1st 2nd
Avg. Avg. Avg. Compressive Strength, psi (280°F/1,000 psi, 21 days)t
Test Test Test Test
8,141 7,745 I 2,984
Shear Bond, psi (280°FI1 ,000 psi)
• Regenerated shear bond = 14-day shear bond minus 8-day skin
Initial, 8-day 152 158 155 122 158 140 friction .
•" Sheared at ambient conditions.
Retest, 14-day 109 90 100 191 164 178
t Crushed at ambient conditions.
% Change -28% -43% -36% 57% 4% 28%
Regenerated" 36 44 40 117 118 118
Lower Section Shear Bond, psi Table 9-Effect of Washing Oil-Mud Film from Shear Pipe
Ambient on Shear Bond of 17.lb/gal Slag Cement Cured
442 460 451 560 588 574 at 330°F/1 ,000 ps1l3.5 days
Condition
"Regenerated Shear Bond = 14-day Shear Bond- 8-day Skin Test Condition TestA Test B TestC

OBM film left on shear pipe No Yes Yes

OBM film on shear pipe washed Yes

No No
with OMRS (11 min)
OBM film on shear pipe further
washed with slag cement 18 12 8
(stirring time, min)
Shear bond in Tension, psi
374 297 202
(300°F/1,000 psi)

Note: 17-lb/gal slag cement composition: 87 Ib slag + 30.45 Ib

Hematite +16.38 Ib silica flour + 0.87 Ib soda ash + 2.06 Ib
surfactant + 0.44 Ib fluid-loss additive + 0.13 Ib anti-settling agent +
1.09 Ib thinner.
14.0 Ib/gal OMRS (See Table 4).

654
SPE 30512 R. E. SWEATMAN, J. J. NAHM, D. A. LOEB, D. S. PORTER 13

Table 1O-SIag Cement Properties Used in Various South Texas Gas Wells

Total Slurry Annular Thickening Compo Str. UCA Fluid

Well BHST/BHCT
Depth Weight Coverage of Time 12 Hr/24 Hr Temp. Loss
No. of
ft Ib/gal ft hr:min psi cc/30 min
1 12,315 17.1 4,315 300/270 2:40 2,050/2,260 230 96
2 11,890 17.0 3,590 340/260 3:00 1,800/3,254 260 88
3 12,690 16.6 3,500 335/270 3:18 1,700/2,845 235 98
4 9,600 16.6 2,600 250/230 2:55 1,900/2,590 220 92
5 11,915 16.6 2,815 320/262 3:30 1,580/2,200 220 52
6 12,015 16.6 3,915 320/265 3:20 905/2,320 215 54
7 11,450 17.2 4,175 305/230 3:48 1,440/1,742 212 94
8 9,200 16.6 500 246/175 2:35 n/a 200 n/a
9 7,500 16.5 300 2001160 2:50 2,000/2,750 200 n/a
Note: All slurries in Wells 1 through 9 contained the same types of additives as the slag cement design in Table 1.

2,600 Hydraulic Pressure In HTHP Shear Bond Tester and

Resultant Shear Failure at Cement-Pipe Interface
2,400 Shear Pipe: Smooth Black Iron
'iii Test Conditions: 280"F & 1,000 psi
3 2,200
Initial 8-Day -
~ 2,000 Shear Bond: 158 psi
:::> Skin Friction: 46 psi 14-Day Retest·
~ 1,800 Shear Bond: 90 psi
~ 1,600
Skin Friction: 57 psi
Regenerated Bond: 44 psi
a-
(,) 1,400
:::i
~ 1,200
~ 1,000
:c 800
600
o 2 3 4 5 6
TIME (min.)

Fig. 1-Shear-bond strengths of 17-Ib/gal salt-saturated Class H cement

measured on HTHP shear-bond tester.

2,600 Hydraulic Pressure In HTHP Shear Bond Tester and

Resultant Shear Failure at Cement-Pipe Interface
:m 2 ,400 Shear Pipe: Smocth Black lren
S Test Conditions: 280"F & 1,000 psi
UJ 2,200
0:
:::> 2,000 Initial 8-Day •
C/) Shear Bond: 158 psi
[B 1,800 Skin Friction: 46 psi
0:
a- 1,600
(,)
:::i 1,400 14·Day Retest -
:::>
ci 1,200 Shear Bond: 164 psi
Skin Friction: 108 psi
~ 1,000 Regenerated Bond: 118 psi
:c
800
800 +------,----,--,------,-----,---,------,------,----,------1
o 2 3 456 7 8 9 10
TIME (min.)

Fig. 2-Shear-bond strengths of 17.lb/gal freshwater slag cement measured

on HTHP shear-bond tester.

655
14 FIRST HIGH-TEMPERATURE APPLICATIONS OF ANTI-GAS MIGRATION SLAG CEMENT AND SPE30512
SETTABLE OIL-MUD REMOVAL SPACERS IN DEEP SOUTH TEXAS GAS WELLS

2,600
Initlal8-Day Test-
'iJj2,400, Shear Bond,: 339 psi
.& Skin Friction: 145 psi
LU 2,200
~ 2,000
(f)
13 1,800 14-Day Retest-
ex: Shear Bond: 301 psi
0. 1,600 Skin Friction: 218 psi
(.)
::i 1,400 Regen. Bond: 156 psi
::J
C? 1,200
~ 1,000
:c 800 Test Conditions; 280°F & 1,000 psi
-Reused Smooth Blacl< Iron Pipe
600 ..j(.:...------,---,---...,-,---,-!;=;==r====;====r====";o=;==!J
o 2 3 4 5 6 7 8
TIME (min.)

Fig. 3-Shear-bond regeneration of 17.7-lb/gal salt-saturated Class H

cement measured on HTHP shear-bond tester.

2,600
Initial 8-Day Test - 14-Day Retest -
'iJj2,400 Shear Bond: 181 psi
Co Shear Bond: 229 psi
;2,200 S~ln Friction: 57 psi Skin Friction: 106 psi
ex: 2,000 Regenerated Bond: 124 psi
::J
C/)
13 1,800
ex:
0.. 1,600
o
:J 1,400
::J
C? 1,200
~ 1,000
:c Test Conditions: 280°F & 1,000 psi
Reused Smooth Black Iron Pipe

2 3 4 5 6 7 8
TIME (min,)

Fig. 4-Shear-bon'd regeneration of 17.0~lb/galsalt-saturatedClass H

cement measured on HTHP shear-bond tester.

2,600
'iJj2,400 Initial 8-Day Test - 14-Day Retest -
Co Shear Bond:" 137 psi Shear Bond: 176 psi
;2,200 Skin Friction: 42 psi Skin Friction: 82 psi
Regenerated Bond: 134 psi
~ 2,000
(f)
13 1,800
ex:
0.. 1,600
o
:J 1,400
::J
C? 1,200
~ 1,000
:c 800 Test Conditions: 280°F &1,000 psi
Reused Smooth Black Iron Pipe
600 ¥-------r-----.--------,--~==:;===;:==::::;:::=:::;:;:::::J
o 2 3 4 5 6 7 8
TIME (min,)

Fig. 5-Shear-bond regeneration and improvement of 16.4-lb/gal freshwater

slag cement measured on HTHP shear-bond tester.

656
SPE 30512 R. E. SWEATMAN, J. J. NAHM, D. A. LOEB, D. S. PORTER 15

'fop Cap

'fop Plug

WlIlo,FlIling
Pl'llllSure EqullizElr
& Water Fill Hole
Pipe Pull Plug

- - St\(JIJI'Thrulll
Support Wll$her
Top Rubber
DlaphrlIOm

Top RltIOOllabkt
SI(lOIIO Soollan

TO~~
Top Pipe Soollort

Oenlor RUbbor
Diaphragm

Bottom Aemovabl&
Sleovo Sectlon
Bottom ~menl
Section
Bottom Pipe
s.ction
Low\lrRubbet'
DIaphragm

Support Wll$hor
Piston

Shear p'O$$U(l)
Chamblff

Bottom Plug

., Bottorfl Cap

Fig.1 A-HTHP shear-bond tester.

657