CN1256500C - 流体混合系统 - Google Patents

流体混合系统 Download PDF

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CN1256500C
CN1256500C CNB018217672A CN01821767A CN1256500C CN 1256500 C CN1256500 C CN 1256500C CN B018217672 A CNB018217672 A CN B018217672A CN 01821767 A CN01821767 A CN 01821767A CN 1256500 C CN1256500 C CN 1256500C
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CN1484730A (zh
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乔尔·朗杜
皮埃尔·维格诺克斯
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Sofitech NV
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Abstract

本发明涉及一种用于连续混合井内流体(诸如水泥)的方法，所述方法包括：当混合时使用水泥泥浆中的固体分量以便于确定加入到泥浆中的固体和液体成份的比率。用于混合的系统包括：包括流量计的液体物质(水)供给装置；固体物质(水泥)供给装置；混合器，所述混合器接收所述液体物质和固体物质，并且包括用于将所述物质从混合器中传输到输送系统的输出部分；用于测量混合器中物质的量的装置；以及输出部分中的流量计；其中，来自于流量计和用于测量混合器中物质的量的装置的测量结果用于控制加入到混合器中的固体物质和/或液体物质的量。

Description

流体混合系统
技术领域
本发明涉及一种用于混合包含固体和液体物质的流体(诸如水泥)的系统。更具体地说，本发明提供了一种用于的钻井、完井、或井孔增注(诸如油井或天然气井)的水泥或者其他流体的连续混合的系统。
背景技术
当已经钻出井(诸如油井或天然气井)时，为了使所述井稳定或防止各开采层之间流体连通或阻断不需要的流体开采(诸如水)，通常希望各种开采层相互隔离或与所述井本身隔离。通常通过在所述井中安置套管并在所述套管的外部与井壁(地层)之间的环状空间中充满水泥而实现所述隔离。通常通过将水泥泥浆向下泵入到所述套管以使得所述泥浆从井底出来并溢到所述套管外部以便于充满所述环状空间而使得水泥布置于环状空间中。虽然可在泵入到所述井中之前预先将水泥批量混合，但是人们更希望恰好在泵入到所述井中之前有效地连续混合地面的水泥泥浆。我们已经发现这可更好地控制水泥特性以及更有效地使用材料。
上述操作中所使用的水泥泥浆包括干燥物质和液体物质的混合物。液相通常是水，因此该液相易于得到并且便宜。当加入水并混合时，固体物质限定泥浆和水泥特性，因此泥浆中固体物质的量是很重要的。由于液相是恒定的，因此通常通过测定泥浆的密度并通过控制所加入的固体物质的量将所述泥浆的密度保持在期望的水平来监控所加入的固体物质的量。图1示出了现有技术混合系统的示意图。在图1的系统中，从供给装置10中通过泵12将混合水泵入到混合器14中，所述混合器14将其供给到混合桶16中。供给装置10包括：一对排液箱11、11′，每个排液箱11、11′都具有与阀13相连接的独立出口，而阀13为泵12进料。通常用两种方法确定供水量：
1.安装于泵12的轴上的接近开关计算每一转的脉冲数。每次脉冲对应于一个排液容积。该方法易受泵效率的影响。
2.通过计算向井下泵送液体的排液箱(tanks pumped down-hole)的数量来测定排液容器。该测定方法易受液面读数、从一个箱到另一箱的切换以及箱精确容量等方面的人为误差的影响。所计算的箱数量方面的误差更是可能具有多个后果(过度排液可导致湿鞋(wet shoe)，排液不足可导致无压力泵送或者水泥遗留在套管中)。
固体物质从振荡罐18中被输送到混合器14中或直接从水泥贮仓中经由流量控制阀20被输送到混合器14中，并被送入装有混合水的混合桶16中。通过再循环管22和泵24将混合桶16中的内容物再循环到混合器14中。再循环管22还包括密度计26，所述密度计26提供对混合桶16中泥浆的密度测量。设有出口28以便于将泥浆从混合桶16中送到用于将其泵送到所述井中的其他泵(未示出)中。通过加入固体物质因此使得泥浆保持在期望泵送的指定水平上而将混合桶16中的密度控制为密度计26所提供的密度，从而实现泥浆混合物的控制。所述密度计26通常为非放射性的装置(诸如科里奥利计量表)。
虽然本系统适用于使用其密度远高于水的物质构成的泥浆，但是它不适用于使用低密度固体物质构成的泥浆，尤其是在固体的密度接近于水的密度的情况下。在这样的情况下，密度测量不足以灵敏到可将所加入的固体物质的量控制到必需的精确度。
发明内容
本发明试图提供一种混合系统，所述系统避免了上述密度测量方面的问题。
概括地讲，本发明包括：在流体被混合的情况下使用对流体中固体分量的测量，以便于确定加入到泥浆中的固体和液体的成分比率。
本发明具体适用于钻孔水泥泥浆的混合，在这种情况中，将固体分量确定为(泥浆容积-水容积)/泥浆容积。另一种表示法(但是相关参数为孔隙度)为水容积/泥浆容积(孔隙度+固体分量＝1)。
本发明所涉及的用于混合水泥的系统包括：液体(水)供给装置，包含用于测量所供应的液体量的装置；固体物质供给装置；混合器，所述混合器接收所述液体和固体物质，并且所述混合器包含用于从混合器中将所述物质输送到输送系统的输出口；用于测量混合器中物质的量的装置；以及输出口中的流量计；来自于流量计以及用于测量混合器中物质的量的装置的测量结果可用来控制加入到混合器中的固体物质的量。
所述流量计可为质量流量计或容积式流量计。任何适用形式的计量表都可使用，例如科里奥利计量表或电磁式仪表。
混合器通常包括箱或桶，其中用于测量混合器中物质的量的装置可为液面传感器。尽管也可使用声学或漂浮装置，但是所述液面传感器最好是时域反射仪或雷达型装置。最好以这样的布置安装这样一种用于阻尼罐内液面中的短暂波动的装置，例如有同心槽的管的布置。另一种或辅助形式的传感器可为可用于指示箱重量的测力计或者可为压力传感器。
用于测量所供给液体的量的装置可为上述类型的流量计或液面传感器。当液体供给装置包括一个或多个排液箱时，液面传感器是优选的。
当混合器包含一些泥浆通过所述箱的再循环形式时，输出流量计在该再循环的下游是重要的。
当固体物质包括水泥和单独加入到混合器中的其他固体添加剂时，还可为每种添加剂的独立供应提供单独的流量计。
在其最简单的构成中，固体分量的测量结果被用作操作者在混合泥浆时将固体(特别是水泥)加入泥浆中的指南。在更先进的形式中，通过自动控制系统用固体分量的计算结果控制固体的直接添加。
本发明还提供了一种改进的用于计算从至少包括一个排液箱的系统中排液容器的方法，所述方法包括随着时间变化(over time)测量箱中的液面高度并如下计算排液量：
∑(V(h1n)-V(h2n))
这里：
V(h)是在液面高度(h)时的精确容积；
h1n是第n排液箱容积的起始液面高度；以及
h2n是第n排液箱容积的终止液面高度。
附图说明
下面将参照附图来描述本发明的示例，在附图中：
图1示出了现有技术的混合系统；
图2示出了本发明第一实施例所涉及的混合系统；
图3示出了箱内液面传感器的部件；
图4示出了装配好的箱内液面传感器的部件；
图5是示出了箱内液面测量的示意图；以及
图6示出了本发明第二实施例所涉及的混合系统。
具体实施方式
图2中的系统用于油井固井作业所使用的水泥的连续混合，并且所述系统包括混合水供给装置100，所述混合水供给装置100通过泵102和流量计104向混合系统106供应混合水。
所述混合水供给装置包括一对排液箱101，每个液储箱101都具有与阀103相连接的独立出口，而阀103为泵102进料。液面传感器105被包含于每个排液箱101中以便于确定供应到泵102的水量。在另一种形式(未示出)中，省略了液面传感器。以如下所述的方式确定所供应的水量。
混合系统106还接收通过阀110而被接纳的来自于振荡罐108中(或者直接来自于振荡罐中)的固体物质。所混合的固体和液体物质通过送料管112被输送到混合桶114中。混合桶114具有连接于再循环泵118的第一出口116，所述再循环泵118将从混合桶114中抽出的水泥反送回混合系统中。混合桶114装配有液面传感器120和/或负载传感器122，以便于提供对于箱容量的指示以及容量方面随时间变化的任何变化。从混合桶114处设有第二输出124，所述第二输出124经由第二泵126和第二流量计128通向泵送系统，从所述泵送系统向所述井(未示出)中输送。另一种输送方法(见图2中的虚线部分)具有从循环线经由流量计128′到井的输出124′。也可有其他的布置。泵102、118、126是固井系统中常见的通用类型的，例如为离心泵。同样，流量计104、128′也是传统类型的，例如科里奥利计量表(诸如在先前申请中已用作比重计的那些)。如本领域所公知的，不同类型的泵和流量计各具有优缺点，可根据需要进行选择。
图3到5示出了用在排液箱和桶中的液面传感器以及安装方式的详图。传感器包括Krohne雷达传感器200、不锈钢杆202、内槽孔套筒204以及外槽孔套筒206。杆202被旋拧在传感器200上，内槽孔套筒204被安装在杆202上并被附属于传感器200的凸缘上。外槽孔套筒206被安装于它所附于其上的内槽孔套筒204上。
对于排液箱中的使用，每个排液箱接收一个液面传感器。该传感器给出关于箱中液面的精确的测量结果。与液面相对的精确容积需要计算排液容器。在不能确切知道箱横截面形状的情况下可进行一种所谓的箱容积测定。装配有数字输出的水表测量相对于箱液面的精确的排液箱容积。对于每个箱来说只执行一次该操作。为了向系统中供水，操作阀103以使得水从一个或另一个箱中流向泵102。当箱排放阀被打开时，使用一种装置(诸如终点开关、压力操纵开关或任何其他合适的装置)以开始排液容器的计算。然后如下计算所述排液容器：
∑(V(h1n)-V(h2n))
这里：
V(h)是在液面高度(h)时的精确容积；
h1n是第n排液箱容积的起始液面高度；以及
h2n是第n排液箱容积的终止液面高度。
当在使用中箱中的液面高度变低时，供给装置切换到另一个箱。
从一个箱到另一个箱的切换操作既可为人工的也可为自动的，并且当一个箱正排空时将另一个箱充满以备再次使用。由于液面传感器可用来提供供应给系统的水量的瞬时测量，因此可确认流量计104所提供的数据，或甚至完全取代对该流量计的需要。当存在流量计时，没必要将液面传感器放置于排液箱中。
除这里所描述的以外，确定排液容器的该方法还适用于其他形式的固井作业，该方法具有以下优点：比较不易受如先前系统中所述的泵效率或操作者误差的影响。
对于混合桶中的使用，传感器装置被安置于混合桶114中的竖直位置中，并且位于当进行混合时补充泥浆的位置中，以防止其位于可能放置水泥的死区中。该传感器提供杆202的长度(LM)与桶液面中泥浆的液面高度(TL)之间的差异的测量结果。通过以下公式获得The free桶液面(FTL)：
FTL＝LM-TL
应该理解的是，对于本发明的总体效果来讲液面传感器的确切形式是不重要的。重要的是获得与桶泥浆容积的时间相对的变化的指示(在文献中称其为“桶流量”)。这可通过使用飘浮或负载传感器或者这些传感器的任意组合或可给出该信息的其他任何传感器来实现。
流量传感器和液面传感器的输出可用于以以下方式监控泥浆的固体分量：
根据如以下关系式中所表示的引入的容积(或量)与输出的容积(或量)之间的差额进行固体分量的计算：
Qwater+Qcement＝Qslurry+Qtub
其中Qtub为桶流率。
桶流率是与桶容积的时间相对的变化并且当桶液面增加时被认为是正的，而当桶液面降低时被认为是负的。桶横截面积越小，测量结果将变化得越敏感。通过以下关系式获得Qtub：
Qtub＝Stubdhtub/dt
其中Stub为桶横截面积，而dhtub/dt为桶随时间变化的液面变化。在最简单的情况中，桶横截面积为常数，而桶流速就变成了桶液面变化/时间与桶横截面积的乘积了。
时间t时的固体分量被计算为(泥浆容积-水容积)占时间t时桶中存在的总泥浆容积的比率。桶泥浆容积的变化Vtub(t+δt)-Vtub(t)可表示为：
Vtub(t+δt)-Vtub(t)＝[Qwater(t)+Qcement(t)-Qslurry(t)]*δt
上述公式可变换为：
Vtub(t+δt)-Vtub(t)＝Qtub(t)*δt
以这种方式，时间t时桶中存在的水容积的变化Vwater(t+δt)-Vwater(t)等于引入水容积减去离开桶的泥浆中存在的水量，并可将其表示为：
Vwater(t+δt)-Vwater(t)＝[Qwater(t)-(1-固体分量(t))*Qslurry(t)]*δt
固体分量表示为：
固体分量(t+δt)＝1-{Vwater(t)+[Qwater(t)-(1-固体分量(t))*Qslurry(t)]*δt}/[Vtub(t)+Qtub(t)*δt]
如果从一开始就要精确的话，计算结果要求初始条件是已知的，即，桶是空的，充满水或已包含泥浆。与初始条件无关，计算结果基本上是稳定的，操作所需的时间取决于桶容积和输出流量Qslurry。
通常用电脑执行这些计算，其中可通过合适的接口直接从传感器中提供测量结果。首选的屏幕显示将显示各种流量或液面以及期望的固体分量(当设计泥浆时所计算的)。通过调节加入到混合器中的水泥和/或水量来控制混合过程以便于将所计算的固体分量保持在期望的水平。或者，可将计算结果馈送到自动控制系统，所述自动控制系统调节输送到混合系统的成分的速度。
当从另一个位置将预混和的干燥成份(水泥和添加剂的混合物)传输到井位时，上述系统是适用的。在这种情况下基本上执行与上述相同的测量和计算，只不过用Qblend替代Qcement。如果作为连续混合程序的部分期望就地混合干燥物质，就需要一个略微不同的步骤。图6示出了本发明另一个实施例所涉及的混合系统，并且图6使用与图2一致的附图标记。图6的系统包括附加干燥物质供给装置130，所述供给装置130经由质量流量计132(也可使用其他流量测量装置)和控制阀134将干燥产品送入到混合系统106中。在这种情况下，基本控制等式变为：
Qwater+Qadditive+Qcement＝Qtub+Qslurry
其中这五个变量中的四个是已知的，而Qcement是最难以精确测量的参数。其中要加入数种添加剂，因此供给装置可包括独立的物质供给装置，每个独立物质供给装置都包括流量计和阀。辅助术语Qadditive1、Qadditive2等等也包含在控制等式中。
应该清楚的是，在实际执行中可进行改变，同时仍然保持在以下范围内，即，使用固体分量作为监控特性以便于使得混合得到有效的控制。
例如，该方法可适用于其他井内流体诸如刺激性流体(压裂液)或甚至是钻井液(淤泥)的混合。在压裂液的情况中，通常使用pod搅拌器混合凝胶体和支撑剂(液相和固相)，并且使用混合器/搅拌器下游的比重计(通常为放射性的)控制凝胶体和支撑剂的比例。放射性传感器的使用产生了许多环境问题，而科里奥利类型仪表是备选的，已知它们在这种方式下使用时在流量方面具有限制性。本发明可通过流量计进行支撑剂和凝胶体浓度方面的控制，无需依赖比重计测量。
通过电磁流量计测量凝胶体和混合流体的流量。从以下关系式中可直接推算出支撑剂的量：
Qgel+QProppant＝QMixedFluid
支撑剂浓度(所加入的每加仑中的磅数或“PPA”)可作为如以上限定的固体分量的函数并可依下式表示：
PPA＝支撑剂密度*固体分量/(1-固体分量)
这样通过用确定支撑剂密度而取代确定水泥密度，上面所述的与水泥相关的固体分量测量方法就适用于压裂液了。
该方法具有无需使用放射性比重计的优点，从而避免了使用时管理因素的局限性并且没有其他测量技术的流量性能方面的局限性。该设备和控制系统基本与上述注水泥系统中所使用的相同。

Claims (17)

1.一种用于混合水泥泥浆的系统，所述系统包括：
i)液体物质供给装置(101)，所述液体物质供给装置(101)包括用于测量所供给的液体物质的量的装置(104)；
ii)固体水泥供给装置(108)；
iii)包括桶(114)的混合器，所述混合器接收所述液体物质和固体物质，并且包括用于将所述物质从混合器中传输到输送系统的输出部分(124)；
iv)输出部分(124)中的流量计(128)；以及
v)计算装置；
其特征在于，
所述系统还包括用于测量混合器中物质的量的装置(120)；
计算装置接收来自于用于测量混合器中物质的量的装置(120)以及来自于流量计(104、128)的输出，并且所述计算装置设置成计算随时间变化桶(114)中物质量的变化，以及混合物中的固体分量；以及
所计算的固体分量用于控制加入到混合器中的固体物质和液体物质的量。
2.如权利要求1中所述的系统，其特征在于，所述流量计是从质量流量计和容积式流量计中选出来的。
3.如上述权利要求中任何一项中所述的系统，其特征在于，所述流量计是从科里奥利仪表和电磁式仪表中选出来的。
4.如上述权利要求1或2所述的系统，其特征在于，所述混合器包括混合段和桶，所述混合物质从所述混合段被送至所述混合桶，并且所述桶中的一部分物质被再循环到所述混合段。
5.如权利要求4中所述的系统，其特征在于，所述装置包括桶中的液面传感器。
6.如权利要求4中所述的系统，其特征在于，所述装置包括负载传感器，所述负载传感器测量桶的重量。
7.如权利要求4所述的系统，其特征在于，所述物质的再循环发生在输出部分中流量计的上游。
8.如上述权利要求1或2所述的系统，包括水泥和干燥添加剂的独立供给装置，设有流量计以测量所述干燥添加剂的流量。
9.如权利要求8中所述的系统，其特征在于，所述干燥添加剂的供给装置包括多个独立的添加剂供给装置，每个供给装置都具有其自己的流量计。
10.如上述权利要求1或2所述的系统，其特征在于，所述液体供给装置包括至少一个箱。
11.如权利要求10中所述的系统，其特征在于，所述用于测量所供给的液体量的装置包括箱中的液面传感器或测量从箱中流出的液体量的流量计。
12.一种混合水泥泥浆的方法，其特征在于，所述水泥和液体成份被连续地输送到混合器中，并且水泥泥浆连续地从混合器中被排出以备使用，所述方法包括：
i)测量进入到混合器中液体成份的流量；以及
ii)测量从混合器中排出的泥浆的流量；
其特征在于，
iii)测量混合器中泥浆的量；
iv)使用泥浆的流率和数量方面的测量结果计算流体中的固体分量；以及
v)依照所计算的固体分量控制水泥和/或液体成份到混合器中的输送。
13.如权利要求12中所述的方法，其特征在于，所述添加剂以与水泥分开的方式被输送到混合器中，该方法还包括：测量输送到混合器的添加剂的流量。
14.如权利要求12或13中所述的方法，其特征在于，所述混合器包括一个桶，混合器中泥浆量的测量装置包括桶中泥浆量的测量装置。
15.如权利要求14中所述的方法，其特征在于，当加入固体和液体成份时，所述桶中泥浆的一部分再循环到混合器中。
16.如权利要求15中所述的方法，其特征在于，所述再循环发生在从混合器中排出泥浆的流量的测量装置的上游。
17.如上述权利要求12或13所述的方法，其特征在于，液体成份从包括至少一个箱的液体供给装置中被传送以便于混合，该方法还包括随时间变化测量箱中的液面以及计算排液容器的步骤，依下式计算排液容器：
∑(V(h1n)-V(h2n))
这里：
V(h)是在液面高度(h)时的精确容积；
h1n是第n排液箱容积的起始液面高度；以及
h2n是第n排液箱容积的终止液面高度。
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