Multi-Process Mixer Manifold for Cement Slurry Isolation
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Solution Overview
Problem
In the oil and gas industry, mixers used for preparing drilling mud and cement slurry often face challenges due to incompatibility of components, leading to poor performance, and require efficient mixing modes to manage time-sensitive cement jobs, where small amounts of mud chemicals can negatively impact cement quality and mixing processes need to handle high solid concentrations and large volumes efficiently.
Innovation Solution
A mixing system with a manifold system and pumps configured to operate in different modes, preventing inert mixing of mud and cement slurries, allowing for 'on-the-fly' and progressive mixing, and including valves and sensors to control flow rates and recirculation for optimal cement and mud production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single mixer is used for both drilling mud and cement slurry preparation, then device complexity is reduced, but the risk of inert mixing increases which negatively impacts cement quality
Solution Approach 1:
The system divides the mixing process into separate functional zones using a manifold system with multiple valves (first valve, second valve, third valve) that segment fluid pathways. This allows the mixer to handle different slurries through isolated flow paths, preventing contamination while using a single mixing chamber.
Solution Approach 2:
The manifold system acts as an intermediary between the single mixer and multiple slurry sources. The valve assembly mediates fluid flow directions, routing cement slurry, drilling mud, and cleaning fluids through the mixer without allowing them to mix, thus preventing inert mixing contamination.
2Productivity
If cement slurry is mixed at high concentration with large volumes, then productivity increases, but the mixing time and time sensitivity constraints become more challenging
Solution Approach 1:
The system performs preliminary actions by pre-positioning valves and pre-routÂing fluids before mixing begins. The manifold system is configured in advance to direct cement slurry, water, and additives through the mixer without contamination, enabling immediate high-volume mixing without time loss for setup or cleaning.
Solution Approach 2:
The valve assembly enables continuous mixing operation by maintaining isolated flow paths for different slurries. The system can continuously process large volumes of cement slurry without interruption for cleaning or reconfiguration, as the manifold system maintains separation throughout the mixing process.
3Ease of operation
If drilling mud chemicals are present in the mixer during cement mixing, then ease of operation is improved, but cement quality deteriorates due to negative impact from mud chemicals
Solution Approach 1:
The manifold system extracts and separates the flow paths of drilling mud and cement slurry using valve control. The first valve, second valve, and third valve work together to extract cement slurry from the mud pathway and deliver it through a dedicated path to the mixer, preventing contamination while maintaining operational convenience.
4Productivity
If the mixer vacuum effect is increased to entrain more cement powder, then productivity increases, but the risk of inert mixing with residual mud increases
Solution Approach 1:
The valve assembly dynamically adjusts flow paths based on operating conditions. The third valve controls the recirculation path and can be positioned to direct high-velocity slurry through the mixer bowl, enhancing the vacuum effect for maximum cement powder entrainment while maintaining isolation from residual mud through dynamic valve positioning.
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 effectively prevents inert mixing, ensures efficient mixing of high-solid cement slurries, and manages large volumes, enhancing the quality and efficiency of both mud and cement production, meeting the demands of time-sensitive cement jobs.
Implementation Method 1
The slurry may also be injected in the bowl of the mixer allowing recirculation into the mixer for a potential increase of the slurry density. Such slurry injection in the mixer also increases the mixer vacuum effect so that more cement powder can be entrained into the mixing process.
Implementation Method 2
Such slurry injection in the mixer also increases the mixer vacuum effect so that more cement powder can be entrained into the mixing process.
Implementation Method 3
In a mud mixer, for instance, drilling mud is prepared by feeding drilling mud to the jet mixer using a centrifugal pump. This creates a suction effect, so that dry chemical dropped into the hopper is drawn into the gooseneck, mixed with liquid ingredients, and then returned to the mud tank.
Data Source
AI summary
A mixing system and method. The mixing system includes a mixer configured to mix a dry component into a fluid to generate a slurry, one or more pumps coupled with the mixer and configured to deliver the fluid thereto, and a manifold system coupled to the mixer and the one or more pumps. The manifold system includes one or more valves configured to direct the slurry from the mixer. The mixing system is operable in a first mixing mode to mix a first type of the slurry, and the mixing system is operable in a second mixing mode to mix a second type of the slurry. The manifold system is configured to prevent inert mixing of the first and second types of the slurry.