Reverse Cementing Shoe with LCM Filter Cake for Completion Detection

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Solution Overview

Problem

Current methods for determining when to stop the flow of cement during reverse cementing operations in well drilling lack precision, leading to potential inefficiencies and the need for additional cementing processes.

Innovation Solution

The implementation of a reverse cementing system that uses lost circulation material to form a filter cake on a screen, creating a pressure spike detectable by sensors, which signals the completion of cement placement in the annulus between the casing and the borehole.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If logging tools and tagged fluids are used to monitor cement entry, then measurement precision is improved, but device complexity increases

Engineering Contradiction:

Improvecement entry detection accuracyVSAvoidmonitoring system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent uses inexpensive, disposable materials such as lost circulation material (LCM) and standard drilling fluids instead of expensive logging tools or tagged fluids. The LCM is intentionally lost to form the filter cake, providing a low-cost, single-use detection mechanism that eliminates the need for complex monitoring equipment.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent replaces mechanical/electronic monitoring systems (logging tools, sensors, tagged fluids) with a passive mechanical indicator system. The completion of cement placement is indicated by natural pressure changes and flow patterns that occur when the filter cake forms, eliminating the need for active electronic detection devices.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of operation

If cement flow is stopped based on calculated volume, then ease of operation is improved, but manufacturing precision deteriorates

Engineering Contradiction:

Improvecement flow control simplicityVSAvoidcement placement accuracy

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The patent implements a feedback mechanism where operators monitor real-time pressure and flow rate changes during cement pumping. When specific pressure spikes or flow reductions occur, indicating filter cake formation, the operator receives immediate feedback to stop cement injection, ensuring precise placement without relying solely on pre-calculated volumes.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system uses the cementing process itself to provide placement indication. The formation of the filter cake naturally creates pressure changes and flow pattern alterations that self-indicate when the shoe is plugged, eliminating the need for external monitoring systems while maintaining precision.

Inventive Principle:

Principle #25Self-service

3Productivity

If reverse cementing is performed without filter cake formation, then productivity is improved, but reliability deteriorates

Engineering Contradiction:

Improvecementing operation speedVSAvoidcement placement reliability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent performs preliminary action by intentionally allowing lost circulation material to be carried into the formation ahead of the cement front. This pre-forms the filter cake before the main cement body arrives, ensuring reliable shoe plugging and preventing premature cement loss, thereby guaranteeing successful cement placement while maintaining operational efficiency.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The lost circulation material acts as an intermediary between the cement and the formation. It forms a filter cake that mediates the interaction, allowing the cement to reliably plug the shoe without directly contacting and being lost into the formation, thus ensuring both reliability and productivity.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 method accurately indicates the completion of cement placement, preventing unnecessary cement flow and reducing the need for secondary cementing operations by utilizing a pressure spike detection mechanism.

Implementation Method 1

lost circulation material to form a filter cake on a screen

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Implementation Method 2

creating a pressure spike detectable by sensors

Methodology Applied

Scientific EffectPressure detection:

Data Source

PatentUS11466520B2Systems and methods for indicating completion of a reverse cementing operation

Publication Date: 2022.10.11 HALLIBURTON ENERGY SERVICES INC

AI summary

A shoe for use with a casing string in a borehole. The shoe may include a first screen positioned within a bore of the shoe or of the casing string near the shoe. The first screen may include orifices sized to prevent the passage of lost circulation material or a material with properties similar to the lost circulation material from outside the shoe through the first screen.