Pressurized Foam Generator for Accurate Cement Bubble Distribution
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Solution Overview
Problem
Laboratory-generated foamed cement does not accurately represent field-generated foamed cement, leading to less than optimum foam-cement designs due to differences in gas bubble size distribution and stability, which affects the mechanical properties and well integrity in oil and gas wells.
Innovation Solution
A pressurized laboratory foam-cement test system that mimics field conditions by using a source of pressurized gas, a cement reservoir cell, and a foam generator configured similarly to field equipment, allowing for the production of foamed cement at wellhead pressures and bubble distributions similar to those in the field.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional laboratory mixing methods are used to generate foamed cement, then the laboratory testing process is simple and quick, but the gas bubble size distribution and stability do not match field conditions
Solution Approach 1:
The patent applies parameter changes by adjusting pressure, temperature, and mixing speed parameters to replicate field conditions in the laboratory. The system varies these parameters to produce foamed cement with gas bubble size distribution and stability that match actual well site conditions, resolving the contradiction between simple lab testing and accurate field representation.
Solution Approach 2:
The patent creates a copying mechanism by developing a laboratory system that replicates field equipment operations. The foam generation apparatus copies the pressure differential, mixing dynamics, and gas injection methods used at well sites, enabling lab-generated foamed cement to accurately represent field conditions while maintaining testing efficiency.
2Reliability
If field equipment is replicated in the laboratory, then foamed cement properties match field conditions, but the device complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the complex field equipment into separate functional modules: a foam generation section, a mixing section, and a testing section. This modular approach replicates field conditions while keeping the laboratory system manageable and easier to operate than the full field equipment.
Solution Approach 2:
The patent introduces an intermediary foam generation apparatus that bridges the gap between simple lab mixers and complex field equipment. This intermediary device replicates the essential foam generation mechanics of field equipment while operating at scaled-down, laboratory-appropriate complexity levels.
3Ease of manufacture
If atmospheric pressure mixing is used in the laboratory, then the testing process is straightforward, but the foam stability and mechanical properties differ from field performance
Solution Approach 1:
The patent applies dynamics by implementing variable pressure and temperature conditions in the laboratory system. The apparatus dynamically adjusts these parameters to match field conditions, enabling the foam to achieve stable bubble size distribution and mechanical properties representative of actual well site performance while maintaining laboratory testing feasibility.
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
This system produces foamed cement with gas bubble size and distribution characteristics that match field conditions, enabling more reliable laboratory testing and improved well integrity by ensuring foam stability and mechanical properties representative of actual field performance.
Implementation Method 1
a source of pressurized gas... introduce a gas into a foam generator... at a pressure equal to the capture pressure
Implementation Method 2
displace the cement slurry from the cement reservoir cell into the foam generator... such that the cement slurry and gas mix to form a foamed cement
Implementation Method 3
The cement reservoir cell is configured to pressurize a cement slurry contained within the cement reservoir cell to a capture pressure... the cement reservoir cell is pressurized to a pressure equal to the capture pressure
Data Source
AI summary
Systems and methods related to preparing foamed cement for laboratory analysis are provided. A prepared cement slurry is placed in a cement reservoir cell configured to pressurize the cement slurry contained within the cement reservoir cell to a capture pressure. After pressurization, the cement slurry and a compressed gas are introduced into a foam generator. Foamed cement generated in the foam generator is introduced from the tee into a foam capture cell where it can cure prior to analysis.