BJ Services recently set a world record for cementing the longest solid expandable tubular liner for an operator in the Gulf of Mexico. The 6,935-ft (pre-expansion length) 7 5/8-in. liner was set and successfully cemented with a shoe depth below 20,000 ft (6000 m). BJ used a specially formulated XtremeSet™ cement slurry system to overcome challenges with isolating the deep wellbore section, including bottomhole static temperatures of 368°F (187°C).

"We are pleased with the performance of our high-pressure/high-temperature cementing technology in this unprecedented operation," said John St. Clergy, Product Line Technology Manager for Cementing, BJ Services. "It provides further validation that properly designed cementing systems and good cementing practices enable the continued exploration and development of deeper, more remote reservoirs around the world."

Overcoming Challenges

To effectively seal the annulus in the operation, BJ Services formulated the XtremeSet slurry to remain fluid for more than 15 hours downhole, permitting the expansion of the liner. BJ cementing specialists conducted extensive laboratory testing and simulation modeling to determine the proper circulating temperature for the application and precise additive package. The custom XtremeSet slurry formulation weighted 18.7 ppg (2.24 g/cc) against a mud weight of 17.9 ppg (2.14 g/cc). The system performed as designed, yielding good density control, minimal fluid loss and zero free water. After drillout and a successful leakoff test to 19 ppg (2.28 g/cc) equivalent mud weight, the operator commenced drilling with no need for remedial operations.

Set for Life™ Family of Advanced Cementing Systems

XtremeSet slurries are part of BJ Services' Set for Life family of cementing systems, each designed to solve a challenging well condition, including hydrogen sulfide infiltration, shallow water flow, gas migration, high bottomhole temperatures and more. The systems can be combined to achieve multiple desired slurry characteristics such as flexible, lightweight and CO2-resistant compositions for operators involved in critical applications. Other Set for Life systems include the DeepSet™ deepwater system, DuraSet™ high tensile strength system, EnviroSet™ environmentally compliant system, LeanSet™ ultralow-density system and PermaSet™ corrosion-resistant system.