Slow Rate Pumping System for Cementing Operations

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Solution Overview

Problem

Traditional cementing equipment is incapable of performing low-rate pumping operations required for final cement placement in well casing operations, necessitating the use of separate, heavier, and more cumbersome low-rate pumping units, which are not always rated for the same pressure as primary pumps.

Innovation Solution

A slow rate pumping system integrated with primary high-pressure pumping systems, utilizing a diversion line and valves to divert a slow rate flow of displacement fluid, allowing seamless transition from high to low rate pumping without additional equipment, and featuring a control system for managing flow and pressure setpoints.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional cementing equipment is used for high rate pumping, then cementing operation efficiency is improved, but the equipment is incapable of performing low-rate pumping operations required for final cement placement

Engineering Contradiction:

Improvecementing operation efficiencyVSAvoidpumping rate range capability

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The invention makes the pumping system dynamic by enabling it to operate across a wide range of pumping rates (from 1-2000 litres per minute) through electronic control of valve positions. The programmable controller adjusts the divergence valve and return valve positions based on desired flow rate, allowing the same equipment to adapt between high-rate cementing and low-rate final placement operations.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The invention makes the cementing pump system universal by enabling it to perform multiple functions: high-rate cement pumping, high-rate displacement fluid pumping, and low-rate displacement fluid pumping for final cement placement. This eliminates the need for separate low-rate pumping equipment while maintaining all required capabilities.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If a stand-alone low rate pumping unit is used in addition to the cementing unit, then low rate pumping capability is achieved, but device complexity and space requirements increase

Engineering Contradiction:

Improvelow rate pumping capabilityVSAvoidnumber of separate units required

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The invention merges the low-rate pumping capability into the existing cementing pump system by adding a divergence valve, return valve, return line, and programmable controller. This consolidation eliminates the need for a separate stand-alone low-rate pumping unit, reducing overall system complexity and the number of vehicles/equipment required while maintaining both high-rate and low-rate pumping capabilities.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If a stand-alone low rate pumping unit is used, then low rate displacement fluid pumping is achieved, but weight and space requirements increase

Engineering Contradiction:

Improvelow rate displacement fluid pumping capabilityVSAvoidtotal equipment weight

Core Design Contradiction:

Adaptability or versatilityVSWeight of moving object

Solution Approach 1:

The invention combines low-rate displacement fluid pumping capability with the existing cementing pump system, eliminating the need for a separate low-rate pumping unit. This integration significantly reduces the total weight of equipment required, as the same pump, powertrain, and support structures are used for both high-rate and low-rate operations.

Inventive Principle:

Principle #5Merging (Combining)

4Adaptability or versatility

If a stand-alone low rate pumping unit is used, then low rate pumping is achieved, but manpower requirements increase

Engineering Contradiction:

Improvelow rate pumping capabilityVSAvoidmanpower requirements

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The invention consolidates control of both high-rate and low-rate pumping operations into a single programmable controller that manages the cementing pump, divergence valve, and return valve. This unified control system reduces manpower requirements by eliminating the need to operate and coordinate separate low-rate pumping equipment, simplifying the operational workflow.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS11384754B2Method and system of slow rate pumping

Publication Date: 2022.07.12 SANJEL ENERGY SERVICES INC

AI summary

A slow rate pumping system which includes a discharge line to receive a discharge flow of displacement fluid from a high rate pumper, a return line off of the discharge line to receive a return flow of displacement fluid, a slow rate diversion pumping line off of the discharge line for supplying a diversion flow of displacement fluid downhole, a return valve to control the return flow, and a diversion valve to control the downhole flow. A method of supplying a slow rate flow which includes receiving a main pumping flow through a return line at a pumping pressure, producing a differential pressure between the pumping pressure and a downhole pressure matching a differential setpoint, diverting a slow rate flow of fluid from the main flow using a diversion line off the return line prior to the return valve, and maintaining the differential pressure.