Flow Diffuser for Full Cement Coverage in Well Casings
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Solution Overview
Problem
During cementing of a well, the cement slurry fails to fully fill the internal diameter of the casing, especially in highly deviated wells, creating uneven fluid pockets and uncovered openings in the float shoe, which compromises the integrity of the well barrier envelope.
Innovation Solution
A flow diffuser apparatus with a cylindrical housing, hopper, tubing, and bottom plate is used to collect, transport, and diffuse cement slurry along the entire internal diameter of the well casing, ensuring complete evacuation of the shoe track and coverage of the float shoe with cement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cement slurry is pumped through the casing during cementing, then the cement slurry flows through the shoe track in jet streams, but the entire internal diameter of the casing does not flow with cement slurry, creating pockets of uneven fluid
Solution Approach 1:
The patent segments the single jet stream flow into multiple flow paths by introducing a flow diffuser with multiple outlet ports. The diffuser divides the cement slurry flow into several smaller streams that collectively cover the entire internal diameter of the casing, ensuring complete evacuation of the shoe track and eliminating fluid pockets.
Solution Approach 2:
The flow diffuser creates different flow characteristics at different locations within the casing. By positioning outlet ports at specific locations and angles, the patent ensures that cement slurry is delivered to specific zones that require coverage, achieving uniform fluid distribution throughout the shoe track interval.
2Power
If cement slurry flows in jet streams through the shoe track, then pumping efficiency is maintained, but the float shoe openings remain uncovered and integrity is compromised
Solution Approach 1:
The patent transitions from one-dimensional jet stream flow to three-dimensional distributed flow by using a flow diffuser with multiple outlet ports positioned at different locations and angles. This dimensional change allows cement slurry to reach all areas of the shoe track and float shoe openings simultaneously, ensuring complete coverage and integrity.
3Device complexity
If a conventional float collar and shoe configuration is used, then the cementing process is simple, but uneven fluid pockets are created in the shoe track
Solution Approach 1:
The flow diffuser acts as an intermediary device between the cement slurry source and the shoe track. It mediates the flow characteristics by converting concentrated jet streams into distributed flow patterns, ensuring uniform fluid composition throughout the shoe track without requiring complex pumping systems or multiple cementing operations.
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 flow diffuser ensures a complete hydraulic seal in the shoe track, preventing undesirable fluid flow paths and maintaining the well barrier envelope integrity by diffusing cement slurry evenly, thus adhering to regulatory requirements.
Implementation Method 1
a hopper or cone within the cylindrical housing to collect the cement slurry
Implementation Method 2
tubing, including at least one tube, coupled to the hopper or cone within the cylindrical housing to transport the cement slurry from the hopper or cone to at least one exit port
Implementation Method 3
the bottom plate including at least one exit port, e.g. among a network of tubing, shaped to diffuse the cement slurry and arranged on the bottom plate such that the cement slurry flows along the entire internal diameter of the well casing
Data Source
Figure 1
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AI summary
An apparatus (200) for controlling flow of cement slurry in a well casing includes a cylindrical housing (502) and a concrete core (504) surrounded by the cylindrical housing. The apparatus further includes a hopper (506) surrounded by the concrete core to collect the cement slurry and tubing (510), including at least one tube, coupled to the hopper within the cylindrical housing to transport the cement slurry from the hopper to at least one exit port, the at least one tube surrounded by the concrete core. The apparatus further includes a bottom plate (300) coupled to the tubing, the bottom plate including at least one exit port shaped to diffuse the cement slurry and arranged on the bottom plate such that the cement slurry flows along the entire internal diameter of the well casing.