Recirculating Cement Slurry Mixing With Air Entrainment Feedback
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The performance of cement slurry mixing systems in oil or gas wells deteriorates due to variations in dry bulk powder delivery, air entrainment, and inadequate mixing, leading to inconsistent cement slurry properties and potential cavitation, which can weaken cement integrity and result in 'fish eyes' and uneven properties.
Innovation Solution
A mixing system equipped with a recirculation cement mixer, agitator, and sensors to monitor air entrainment and pressure, allowing real-time measurement and adjustment of mixing parameters, such as adding defoaming chemicals or adjusting agitation speed, to maintain optimal mixing conditions and prevent cavitation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a recirculation pump is used to mix and recirculate cement slurry, then mixing efficiency is improved, but cavitation occurs due to variations in dry bulk powder delivery and air entrainment
Solution Approach 1:
The system employs sensors to detect air entrainment and mixing quality in real-time, feeding this information back to the control system. The controller adjusts operational parameters such as pump speed and powder delivery rate based on this feedback, preventing cavitation while maintaining mixing efficiency. This closed-loop control ensures the recirculation pump operates within optimal parameters despite variations in material delivery.
Solution Approach 2:
The system dynamically adjusts operational parameters including recirculation pump speed, powder delivery rate, and water injection rate based on real-time mixing conditions. This dynamic adaptation allows the system to maintain optimal mixing performance while avoiding cavitation conditions that would occur with fixed parameter operation.
2Adaptability or versatility
If dry bulk powder delivery rate varies, then mixing flexibility is improved, but cement slurry consistency deteriorates
Solution Approach 1:
Sensors continuously monitor slurry properties such as density, air content, and mixing homogeneity. The control system uses this feedback to adjust powder delivery rate and water injection rate in real-time, compensating for variations and maintaining consistent slurry quality despite changes in delivery conditions or desired slurry properties.
Solution Approach 2:
The system changes operational parameters (powder delivery rate, water rate, pump speed) dynamically based on real-time measurements of slurry properties. This allows the system to adapt to varying delivery conditions while maintaining consistent slurry quality through continuous parameter adjustment rather than fixed operation.
3Quantity of substance
If air entrainment increases, then slurry volume is improved, but cement integrity weakens due to fish eyes and uneven properties
Solution Approach 1:
Air entrainment sensors detect the presence and quantity of air bubbles in the slurry in real-time. The control system responds by adjusting mixing parameters, increasing defoaming agent injection, or modifying recirculation patterns to eliminate air pockets. This prevents fish eyes and maintains cement integrity while preserving desired slurry volume.
Solution Approach 2:
The system detects air entrainment (a harmful factor) and converts it into a control opportunity. By using air sensors to trigger specific responses such as increased recirculation or defoaming agent injection, the system transforms the presence of air from a quality defect into a controlled parameter that maintains both volume and integrity.
4Manufacturing precision
If mixing parameters are adjusted in real-time, then cement quality control is improved, but system complexity increases
Solution Approach 1:
The system uses automated sensors and controllers to self-regulate mixing parameters based on real-time conditions. The control system automatically adjusts powder delivery, water injection, and recirculation pump speed without requiring constant manual intervention, achieving precise quality control while keeping operational complexity manageable through automation.
Solution Approach 2:
The control system performs multiple functions: monitoring slurry properties, detecting air entrainment, adjusting mixing parameters, and preventing cavitation. This multi-functional approach consolidates what would otherwise require separate systems into a single integrated control platform, managing complexity while achieving comprehensive quality control.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system provides greater control over cement slurry quality and uniformity, reducing the risk of cavitation and ensuring higher integrity of the cement placed in the wellbore by alerting operators to potential mixing issues and enabling timely adjustments.
Implementation Method 1
a recirculation pump fluidly connected to the recirculation tub via a recirculation manifold, wherein the recirculation manifold directs fluid towards the recirculation pump
Implementation Method 2
A sensor is attached to the recirculation discharge manifold, wherein the sensor is configured to measure a property of a fluid in the recirculation discharge manifold
Implementation Method 3
A sensor is attached to the recirculation discharge manifold, wherein the sensor is configured to measure a property of a fluid in the recirculation discharge manifold
Data Source
AI summary
A method and apparatus are disclosed for a mixing system with a recirculation pump and a sensor configured to measure a property of a fluid discharged from the recirculation pump, wherein the sensor may transmit the property to a control system to allow an operator to adjust the mixing system in response to changes in the measurement signal.