Well Pad Construction Using CLSM Backfill and Impact Compaction
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Solution Overview
Problem
Current well pad construction methods for drilling rigs in the oil and gas industry are time-consuming and require significant excavation and backfilling, often taking 10 days and involving extensive transportation and layer-by-layer compaction, which can be inefficient and costly.
Innovation Solution
A well pad construction system utilizing high energy impact compaction (HEIC) and controlled low-strength material (CLSM) for compacting and backfilling, reducing excavation volume by up to 94% and eliminating the need for layer-by-layer compaction and material transportation, with a cellar installed in the excavated area to facilitate drilling operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional layer-by-layer backfilling is used, then the cellar can be held in place, but construction time increases to 10 days and material transportation is required
Solution Approach 1:
The patent replaces the mechanical layer-by-layer backfilling and compaction system with a fluid injection system. A slurry mixture (water, cement, fine aggregates) is pumped through pipes into the excavated area to fill gaps around the cellar, eliminating the need for manual layer-by-layer placement and mechanical compaction equipment.
Solution Approach 2:
The patent employs hydraulic principles by using fluid pressure to inject slurry through pipes into the ground. The slurry is pumped under pressure to flow into the excavated area and fill gaps around the cellar, utilizing fluid dynamics to achieve rapid filling without mechanical compaction.
2Reliability
If conventional layer-by-layer backfilling is used, then the cellar can be held in place, but extensive material transportation is required
Solution Approach 1:
The patent replaces the mechanical transport and placement system with a fluid injection system. Instead of transporting and placing individual layers of backfill material, a slurry mixture is pumped through pipes directly into the excavated area, eliminating the need for extensive material transportation and manual placement.
Solution Approach 2:
The patent changes the physical state of the backfill material from solid particles requiring transportation and layer-by-layer placement to a fluid slurry mixture that can be pumped and injected directly into the ground, significantly reducing material handling and transportation requirements.
3Ease of manufacture
If conventional excavation and backfilling is used, then the construction area can be prepared, but the construction area size remains large (140m x 140m)
Solution Approach 1:
The patent applies local quality by focusing the backfilling process specifically on the gaps between the cellar and the surrounding medium, rather than filling the entire excavation area. The slurry is injected precisely where needed around the cellar structure, reducing the overall construction area footprint while maintaining structural integrity.
4Productivity
If high energy impact compaction is used, then the construction area can be compacted efficiently, but the compactor requires high energy input
Solution Approach 1:
The patent replaces the mechanical high-energy impact compaction system with a fluid injection system. Instead of using heavy compactors that require significant energy input to compact soil layers, the slurry is pumped under pressure to fill gaps around the cellar, achieving compaction and stabilization without extensive mechanical energy input.
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 significantly reduces construction time to 3 days, minimizes material transport, and decreases the required construction area, resulting in cost savings and reduced environmental impact while maintaining engineering properties and site safety.
Implementation Method 1
The compactor is moveable over the construction area. The compactor includes an impact roller for compacting the excavated area prior to excavation.
Implementation Method 2
The backfill equipment is moveable to pour CLSM into a gap between the cellar and surrounding medium in the excavated area for holding the cellar in place.
Implementation Method 3
The impact roller includes a non-cylindrical impact roller with three rounded lobes connected by three joints. Each rounded lobe includes from about 120° to about 180° of a cylinder.
Data Source
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AI summary
A well pad construction system includes a construction area (20), surface compaction equipment (22, 24) to compact the construction area (20), an excavator (34) disposed at the construction area (20) and movable to generate an excavated area (37), a cellar (14) disposed in the excavated area (37), controlled low-strength material (CLSM), and backfill equipment disposed around the excavated area. The backfill equipment (42) is moveable over the construction area (20) to pour CLSM into a gap (18) between the cellar (14) and surrounding medium in the excavated area for holding the cellar (14) in place and providing a firm well pad (10) from which a rig (50) may operate.