Source: http://www.google.nl/patents/US5570743?hl=nl
Timestamp: 2013-05-19 09:25:37
Document Index: 226576466

Matched Legal Cases: ['art 197424', 'art 19765', 'art 198314', 'art 1987', 'art 198925', 'art 1993', 'art 199728', 'art 2001', 'art 200416', 'art 200423', 'art 200524', 'art 200515', 'art 20089', 'art 200820', 'art 2010']

Patent US5570743 - Continuous multi-component slurrying process at oil or gas well - Google PatentenZoeken Afbeeldingen Maps Play YouTube Nieuws Gmail Drive Meer » Geavanceerd zoeken naar patenten | Webgeschiedenis | Inloggen Geavanceerd zoeken naar patenten PatentenA continuous multi-component slurrying process at an oil or gas well comprises flowing at least three separate streams of different essential materials directly into a predetermined mixing unit at the oil or gas well, wherein each of the essential materials is required to obtain a predetermined defining...http://www.google.nl/patents/US5570743?utm_source=gb-gplus-sharePatent US5570743 - Continuous multi-component slurrying process at oil or gas well PublicatienummerUS5570743 APublicatietypeVerlening Aanvraagnummer08/604,697 Publicatiedatum5 nov 1996 Aanvraagdatum21 feb 1996 Prioriteitsdatum3 juni 1993Ook gepubliceerd alsEP0630728A1US5522459 UitvindersRicky L. CovingtonStephen F. CrainKevin D. EdgleyWayne A. HandkeJerry L. LoganPaul O. PadgettDavid W. RitterCalvin L. Stegemoeller Oorspronkelijke patenteigenaarHalliburton Company Classificatie in de VS166/285507/100166/293166/295 Internationale classificatieB28C9/00 Co�peratieve classificatieB28C9/004 Europese classificatieB28C9/00B2ReferentiesPatentcitaties (57)Niet-patentcitaties (22) Verwijzingen naar dit patent (43)Externe linksUSPTO USPTO-toewijzing EspacenetContinuous multi-component slurrying process at oil or gas wellUS 5570743 A Samenvatting A continuous multi-component slurrying process at an oil or gas well comprises flowing at least three separate streams of different essential materials directly into a predetermined mixing unit at the oil or gas well, wherein each of the essential materials is required to obtain a predetermined defining characteristic of the slurry.
What is claimed is: 1. A continuous multi-component slurrying process at an oil or gas well, comprising continuously forming a slurry at the oil or gas well from at least three different ingredients selected to define a selected multi-component slurry, said continuously forming a slurry includes concurrently flowing at least three separate streams, each containing a respective one of the different ingredients, directly into a predetermined mixing unit at the oil or gas well so that premixing of the different ingredients of the respective streams is not required prior to the concurrent flowing of the streams.
2. A process as defined in claim 1, wherein one of the streams includes a hydrating fluid for the slurry, another of the streams includes a cementitious substance for the slurry, and still another of the streams includes a density control agent for the slurry.
3. A process as defined in claim 1, wherein one of the streams includes a dilution fluid for the slurry, another of the streams includes a cementitious substance for the slurry, and still another of the streams includes a drilling fluid for the slurry.
4. A process as defined in claim 1, wherein one of the streams includes a fluid medium for the slurry, another of the streams includes a viscosity control agent for the slurry, and still another of the streams includes a density control agent for the slurry.
5. A process for continuously mixing a multi-component slurry in a mixing system at an oil or gas well, the mixing system including metering and conveying means and a mixing unit, said process comprising concurrently flowing, from respective sources at the oil or gas well, through respective ones of the metering and conveying means of the mixing system, at least three separate streams of different materials directly into the mixing unit of the mixing system, wherein each of the different materials is required for providing a selected one of a cementitious slurry or a drilling fluid and wherein at least one of the materials is from the group consisting of a cementitious substance, a density control agent and a viscosity control agent.
6. In a process for making a slurry at an oil or gas well using a system providing for first and second streams flowed into a mixing unit of the system, wherein the first stream includes a stream of a first material and the second stream includes a stream of premixed substances including at least second and third materials different from each other and from the first material, the improvement comprising providing for at least three concurrent, separate, continuous, properly proportioned flow streams directly into the mixing unit, including performing the following steps concurrently: flowing the first material directly into the mixing unit; flowing an at least partially unpremixed stream directly into the mixing unit, wherein the at least partially unpremixed stream includes at least one, and only one, of the second and third materials; and flowing the other of the second and third materials directly into the mixing unit.
7. A process for continuously mixing a settable mud at an oil or gas well, comprising: (a) flowing a dilution fluid directly into a mixing unit at the oil or gas well; (b) flowing a drilling fluid directly into the mixing unit; (c) flowing a cementitious substance directly into the mixing unit; and (d) mixing the dilution fluid, the drilling fluid and the cementitious substance in the mixing unit.
8. A process as defined in claim 7, wherein: said process further comprises before said steps (a), (b), (c) and (d): flowing a fluid medium into the mixing unit; flowing a viscosity control agent into the mixing unit; flowing a density control agent into the mixing unit; mixing the fluid medium, the viscosity control agent and the density control agent in the mixing unit into a drilling fluid to be pumped into the well; pumping the drilling fluid of the preceding step into the well; and returning at least a portion of the pumped drilling fluid from the well and flowing the returned portion into a storage facility; and said step (b) includes using at least a portion of the drilling fluid from the storage facility.
9. A process as defined in claim 8, wherein using at least a portion of the drilling fluid from the storage facility includes conditioning at least a portion of the drilling fluid from the storage facility without substantially increasing the volume of the conditioned portion, and pumping the conditioned portion into the mixing unit.
10. A continuous multi-component slurrying process at an oil or gas well, comprising continuously flowing at least four streams of differing compositions into an inlet mixer and through the inlet mixer into an averaging tub to define a mixture in the tub, wherein the at least four streams of differing compositions include at least one stream having an essential dry material, at least one stream having an essential liquid material, at least one stream having another essential material, and at least one stream including a portion of the mixture recirculated from the tub through the inlet mixer.
11. A process as defined in claim 10, further comprising continuously flowing an additive into the portion of the mixture recirculated from the tub through the inlet mixer.
12. A process as defined in claim 10, wherein the inlet mixer includes at least one axial flow mixer.
13. A continuous multi-component cementitious slurrying process at an oil or gas well, comprising: continuously flowing into an inlet mixer a first stream including a fluid; continuously flowing into the inlet mixer a second stream including a dry cementitious substance; continuously flowing into the inlet mixer a third stream including another material; continuously adding into at least one of the first, second and third streams at least one additive; and continuously mixing the first, second and third streams in the inlet mixer without stopping the flow of the streams through the inlet mixer and flowing the mixed streams into a tub and further mixing the mixed streams in the tub into a cementitious slurry.
14. A process as defined in claim 13, wherein the inlet mixer includes at least one axial flow mixer.
15. A process as defined in claim 13, further comprising continuously flowing from the tub into the inlet mixer a fourth stream including a portion of the cementitious slurry.
16. A process as defined in claim 15, further comprising continuously flowing a further additive into the portion of the cementitious slurry flowing from the tub into the inlet mixer.
17. A process as defined in claim 16, wherein the inlet mixer includes at least one axial flow mixer.
18. A continuous multi-component cementitious slurrying process at an oil or gas well, comprising: pumping water into an axial flow mixer having an outlet communicating with a tub; flowing a dry material into the axial flow mixer; pumping a mixture into the axial flow mixer, including pumping an additive into a flowing fluid for defining at least part of the mixture; and mixing the water, dry material and mixture in the axial flow mixer and continuing to mix the water, dry material and mixture in the tub to define a cementitious slurry.
19. A process as defined in claim 18, further comprising pumping a portion of the cementitious slurry from the tub into the axial flow mixer for mixing therein with the water, dry material and mixture.
This is a continuation of application Ser. No. 08/074,051 filed on Jun. 3, 1993, now U.S. Pat. No. 5,522,459.
As shown in FIG.2, the four streams of differing compositions are continuously flowed into the inlet mixer 2 (specifically a Halliburton Services axial flow mixer modified to receive all four inlet streams) and through the inlet mixer 2 into the averaging tub 4 to define a mixture (i.e., the slurry) in the tub 4. This inlet flow occurs without stopping the flow of the streams through the inlet mixer 2. One stream has the dry material 6a (e.g., cement or slag is flowed by the metering and conveying means 14a into the axial flow mixer 2). Another stream has the fluid 10a (e.g., water is pumped into the axial flow mixer 2 under control of a pump 22 and a metering valve 24 of the metering and conveying means 18a which also includes a flow meter 26). Still another stream has another essential material (in FIG. 2, this stream includes a mixture of the second essential fluid 10b, such as drilling fluid, and two liquid additives 12a, 12b, such as a dispersant and an activator; the additives are pumped by respective metering pumps 27, 29 of the metering and conveying means 20a, 20b, respectively, into the fluid 10b that is pumped by a pump 28 through a flow meter 30 and a control valve 32 defining the metering and conveying means 8b; this mixture is pumped into the axial flow mixer 2). These streams are mixed in the axial flow mixer 2. Continued mixing of these streams occurs in a known manner in the tub 4.
The system that was tested specifically comprised an SKD4 cementing skid with an 8 barrel mix tub 4 and Halliburton Services automatic density control with the following additional equipment: drilling fluid pump 28--Deming 5M centrifugal; drilling fluid control valve 32--pneumatically actuated 3--inch butterfly valve; drilling fluid line connection in the mixer 2 and an alternate connection in the primary mix tub 4; the two liquid additive pumps 27, 29; hydraulic power pack for driving the pumps; and two liquid additive tanks.
TABLE 1______________________________________SLURRY FORMULATION______________________________________Materials required for onebarrel of dilute mud:Bulk Material   300     lb.Caustic Soda    5       lb.Soda Ash        15      lb.Spersene        2.5     lb.One barrel of mixedslurry required:Original Drilling Fluid           16.0    gal.Water           11.5    gal.Bulk Material   229.2   lb.50% Caustic Solution           0.6     gal.25% Soda Ash Solution           4.4     gal.Spersene        1.9     lb.For a 5 bbl/min mix rate:Original Drilling Fluid           80.2    gal/min, 1.9  bbl/minWater           57.3    gal/min, 1.4  bbl/minBulk Material   1,145.8 lb/min,  13.5 sks/min50% Caustic Solution           3.0     gal/min25% Soda Ash/   22.7    gal/min   Spersene Solution______________________________________
TABLE 2__________________________________________________________________________Laboratory Test Results              Compressive        Thickening              Strength.sup.2                     Initial    Plastic                                     Yield   Density        Time.sup.1              UCA, 24 hr                     Set  Fluid Loss                                Viscosity                                     Point   (ppg)        (hrs:min)              (psi)  (hrs:min)                          (cc/30 min)                                (cp) (lb/100 ft.sup.2)__________________________________________________________________________PILOT TESTS   14.4 4:33  1870   3:24 183   29   9RUN #1FIRST   14.27        4:08  1175   2:14 190   29   18MIDDLE  14.86        2:58  1605   3:11 153   49   18FINAL   14.87        2:35  1440   3:00 164   40   23RUN #2FIRST   13.75        4:20                    19   18MIDDLE  13.40                        20   17FINAL   13.40                        18   21RUN #3FIRST   14.78        3:03  1568   1:59 160   32   26MIDDLE  14.45        3:32  1041   1:55 150   29   20FINAL   14.40        2:37  800    1:48 148   28   24__________________________________________________________________________ .sup.1 Thickening times using API Spec 10 Schedule 5 g @ 125 .sup.2 UCA Compressive Strength @ 200
From the foregoing, the present invention can be implemented using a prior type of system that provides for first and second streams flowed into a mixing unit of the system, wherein the first stream includes a stream of a first essential material and the second stream includes a stream of premixed substances including at least second and third essential materials (e.g., a blended premix of cement and fly ash for a cement slurry, or a dosed premix of drilling fluid and barite and/or bentonite for a drilling fluid, or a premixed drilling fluid and water for a settable mud). For the present invention, this system is adapted to accommodate three or more inlet flows of essential materials rather than just two. In this context the present invention encompasses the improvement of providing for at least three continuous, properly proportioned flow streams directly into the mixing unit of the system. Providing for this includes: flowing the first essential material directly into the mixing unit; flowing an at least partially unpremixed stream directly into the mixing unit, wherein the at least partially unpremixed stream includes at least one, and only one, of the second and third essential materials; and flowing the other of the second and third essential materials directly into the mixing unit.
In the automatic state of operation wherein continuous mixing is automatically obtained, the supervisor controller 46 calculates from the active slurry recipe and a selected downhole flow rate a mass flow rate setpoint for each essential dry material and a mass flow rate setpoint for each essential fluid. Mass flow rate setpoints are preferably used in the performance of the control method as opposed to volumetric flow rate set points because of the possibility of bulk density changes in the dry material. Broader aspects of the control method do, however, encompass volumetric or other types of control parameters. In a flow mode where a fixed flow of material is desired, the desired flow is provided. In a ratio mode where the material is to be added relative to an overall slurry flow rate factor, an equation for computing an essential material mass flow rate setpoint is:
essential material mass flow rate setpoint=(measured or calculated mass flow rate of slurry) where the measured mass flow rate of slurry is a sensed parameter, the calculated mass flow rate of slurry=(the preentered expected slurry flow rate) the preentered value for the respective essential material, and the correction factor is 1 or determined by multiplying subsequently described tub level and density control factors. The measured, or actual, mass flow rate of slurry may be used, for example, when the slurry is to be pumped as fast as possible under a preset pumping pressure setpoint. The calculated mass flow rate is used when a specific flow rate of slurry is desired.
From the foregoing, the automatic control method comprises: continuously flowing a plurality of substances into a mixer, and controlling the flowing of the plurality of substances in response to respective predetermined flow setpoints for each of the plurality of substances. These substances include at least an essential dry material and an essential liquid material; however, as previously explained as to the overall process there is at least a third essential material, for which there is a respective material controller 48 as represented in FIGS. 8A and 8B by the (. . . ).
Upon receiving a valid concentration setpoint from the supervisor controller 46, a dry/liquid additive controller 50 uses this setpoint along with the parent flow information to calculate a mass flow rate setpoint for the respective dry/liquid additive. An equation for doing this is: additive mass flow rate setpoint=(parent mass flow rate) flow rate setpoint of the dry/liquid additive is calculated, the respective dry/liquid additive controller 50 provides and adjusts an output control signal to the respective dry/liquid additive metering system 16 or 20 of the FIG. 1 system in the process of matching the measured actual mass flow rate to the desired mass flow rate setpoint. The measured mass flow rate is obtained from the respective metering and conveying means 16 or 20, specific examples of which are given above. More generally, the measured mass flow rate can be an actual measured signal from a mass flow rate device or a calculated mass flow rate from a volumetric measuring device or a calculated mass flow rate from a volumetric metering device. There is a respective additive controller 50 for each additive 8, 12 and its associated metering and conveying means 16, 20.
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