Flow Diffuser for Cement Slurry Distribution in Well Casings

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Solution Overview

Problem

During well cementing, the cement slurry does not flow evenly through the shoe track, leading to uneven fluid distribution and uncovered openings in the float shoe, which reduces the integrity of the well barrier and allows fluid to flow when pressure is applied, especially in highly deviated wells.

Innovation Solution

A flow diffuser apparatus with a cylindrical housing, hopper, and tubing system that collects and transports cement slurry through multiple tubes to a bottom plate with angled exit ports, ensuring the cement slurry flows along the entire internal diameter of the well casing, filling the shoe track and covering all openings with cement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If cement slurry is pumped through the shoe track using conventional methods, then the cementing operation can be performed, but the cement slurry does not flow evenly through the shoe track, creating pockets of uneven fluid and leaving uncovered openings in the float shoe

Engineering Contradiction:

Improveuniformity of cement slurry flow distributionVSAvoidintegrity of well barrier

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The invention divides the single cement slurry stream into multiple separate streams by introducing a flow diffuser with multiple exit ports. This segments the flow path, allowing cement slurry to be distributed across multiple locations in the shoe track simultaneously, ensuring complete evacuation and uniform coverage of all openings in the float shoe.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The flow diffuser creates different flow conditions at different locations within the shoe track. By positioning exit ports at specific locations and angles, the invention ensures that cement slurry is delivered precisely where needed to evacuate pockets of uneven fluid and cover all openings, creating locally optimized flow distribution throughout the annulus.

Inventive Principle:

Principle #3Local quality

2Productivity

If the cement slurry flows in jet streams through the shoe track, then the pumping operation can proceed, but the cross sectional area of flowing fluid is much less than the casing internal diameter, preventing complete evacuation of the shoe track

Engineering Contradiction:

Improveefficiency of shoe track evacuationVSAvoidcompleteness of fluid distribution

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The invention transitions the flow from a single-dimensional jet stream to a multi-dimensional distributed flow pattern. The flow diffuser with multiple exit ports arranged at different angles and positions projects cement slurry in multiple directions simultaneously, filling the entire cross-sectional area of the casing and ensuring complete evacuation of the shoe track.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Reliability

If conventional float collar and float shoe components are used, then the basic cementing function is provided, but undesirable flow paths are created between the casing and annulus, reducing well barrier integrity

Engineering Contradiction:

Improvewell barrier integrityVSAvoidundesirable flow paths and fluid leakage

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The invention converts the potentially harmful jet stream flow pattern into a beneficial distributed flow pattern. By using the flow diffuser to break up concentrated cement slurry jets into multiple smaller streams, the system eliminates the creation of undesirable flow paths and pockets of uneven fluid, transforming a flow distribution problem into a solution that ensures complete and uniform evacuation of the shoe track.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 complete evacuation of the shoe track with cement, eliminating undesirable flow paths and pockets of uneven fluid, thereby enhancing the well barrier integrity and preventing fluid leakage under pressure.

Implementation Method 1

a bottom plate 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

Methodology Applied

Scientific EffectFlow diffusion: Diffusion

Data Source

PatentUS12173582B2Flow diffuser

Publication Date: 2024.12.24 VELIKX LLC

AI summary

An apparatus for controlling flow of cement slurry in a well casing includes a cylindrical housing and a hopper within the cylindrical housing to collect the cement slurry. The apparatus further includes tubing, 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 apparatus further includes a bottom plate 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.