Cement Slurry Viscosity Measurement via Pressure Drop
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Solution Overview
Problem
Current cementing processes in well casing operations lack real-time, automated measurement of cement viscosity during the cementing process, relying on pre-laboratory tests which may not accurately represent the properties of the cement slurry due to incomplete mixing or changes over time, leading to potential pumping issues and fluid migration.
Innovation Solution
A method and system for monitoring cement slurry viscosity by directing it through a conduit with pressure sensors to measure pressure losses at different angles, calculating viscosity based on these measurements, and adjusting for temperature and flow rate, allowing for real-time analysis without laboratory samples.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual laboratory measurements are used to test cement properties before cementing operations, then viscosity can be measured, but the measurements may not be representative due to incomplete mixing or changes over time
Solution Approach 1:
The patent replaces manual laboratory viscosity measurement equipment (mechanical viscometers) with an automated in-line measurement system that uses pressure differential sensors to continuously monitor cement slurry viscosity directly in the pumping system, eliminating sampling and manual testing
Solution Approach 2:
The system enables the cement slurry to be measured in its actual pumping environment without requiring removal for laboratory testing. The continuous flow through the conduit with integrated pressure sensors allows the slurry to serve both its pumping function and measurement function simultaneously
2Measurement precision
If samples are taken after mixing cement slurry before pumping, then viscosity can be measured, but the measurements may not be representative due to variation across volume or changes over time
Solution Approach 1:
The system provides continuous viscosity measurement throughout the cementing operation via the conduit with pressure sensors, eliminating intermittent sampling. The measurement occurs continuously as the slurry flows through the system, ensuring no gap between mixing and measurement
Solution Approach 2:
The measurement system is pre-installed in the conduit before cementing begins, allowing immediate measurement as soon as slurry enters the system, eliminating delays associated with post-mixing sampling and laboratory preparation
3Device complexity
If no measurement is performed during cementing operation, then the process is simple, but pumping issues and fluid migration cannot be detected
Solution Approach 1:
The system continuously monitors viscosity via pressure differential measurements in the conduit and provides real-time feedback on cement slurry properties. This feedback enables detection of viscosity changes that could indicate pumping issues or fluid migration risks, allowing corrective action before problems occur
Solution Approach 2:
The patent uses pressure differential measurements as an intermediary parameter to indirectly measure viscosity. Rather than directly measuring viscosity with complex equipment in the high-pressure cementing environment, the system measures pressure drop across a known conduit geometry, which correlates to viscosity, providing a simpler and more reliable measurement approach
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
Enables accurate, real-time monitoring of cement slurry viscosity during the cementing process, reducing the risk of improper pumping and fluid migration, and facilitating immediate action when abnormal properties are detected, ensuring effective cement bonding and well stability.
Implementation Method 1
measuring a first pressure loss along a first portion of the conduit
Data Source
AI summary
A method of measuring the viscosity of cement slurry used for a primary cementing of an oil or gas well includes pumping the cement slurry along a conduit to a cementing location, measuring a first pressure loss along a first, horizontal portion of the conduit and a second pressure loss along a second, vertical portion of the conduit, and calculating a viscosity of the cement slurry based at least in part on the first and second pressure losses and a flow rate of the cement slurry.