Mixing Theory

W E L L S E R V I C E S
Agenda
 Mixing Theory: Mixing Energy and Mixing time effects on slurry performance
 Equipment: Description of mixing equipment – evolution of slurry chief
systems
 Mixing Procedures: Mark III operation
 Mixing Calculations: Water rates and water volume in mix tub
Cement Mixing
 Cement mixing is the process where a flow of pressurized water (possibly
containing additives) meets a flow of cement (possibly containing additives), and a
cement slurry is formed.
 Continuous Mixing (Mixing on FLY): mixing and pumping at the same time
 Batch Mixing: mixing required amount of cement in large tank before pumping
 Cement mixing actually comprises of two actions:
– The accurate proportioning of cement solids and mix water (solids delivery to
a mixing system) that can achieve a desired density.
– Mixing energy, which homogenizes the mix by wetting and deflocculation
(dispersion of solids that have stuck together in a slurry) of the solids.
The Mixing Process
Mixing Energy – a balance

 Minimum amount of energy must be applied during a certain

period of time to ensure complete deflocculation
 Long enough mixing time to guarantee correct cement
hydration
Deflocculation
 Deflocculation is the process by
which a cement particle is wetted
and forcibly separated from other
particles clinging to it.
 For complete dispersion, size of
smallest eddy must approach the
dimensions of an individual cement
grain
 Blending faster and longer improves
deflocculation
 Required energy depends on slurry
density
Mixing energy : Chemical Process
 Cement reacts with water to form hydrates
 Formation of Portlandite and Ettringite
 Rate of nucleation of Portlandite and Ettringite depends on time and
rotational speed
 Rotation speed of mixer has little effect
 Mixing time is the main factor: longer mixing time, greater amount of hydrates
formed during mixing
Mixing Energy - Laboratory
Quality Measurements
– Density
– Rheology
– Thickening Time
– Fluid Loss
– Free Water
– Compressive Strength
1 Unit API mixing energy for 600 ml
- (E/M)Total = (E/M)15 sec-4,000 RPM +
(E/M) 35 sec-12,000 RPM
- (E/M)Total = 0.27 + 5.82
= 5.90 kJ/kg
This is 2.5 times the cutoff that is required in
to ensure deflocculation
Mixing Energy – Effects of Chokes
 Pressure drop generated by the choke results in high velocities (I.e. SME = 1
– 2)
 Chokes are not recommended
when small volumes (<50 bbl.) of batch mixed cement slurry are
recirculated for long periods of time (>30 min.)
when the slurry is to be pumped though coil tubing
when slurry is pumped through the bit or nozzle
Mixing Energy - Field
COILED TUBING
–SME = 1.0 – 7.0
BATCH MIXING
–Slurry recirculation with a C-pump not longer than 5 min/10 bbls of slurry (25
mins for 50bbls)
–Once desired density is attained, stop C pump recirculation. Paddles may be
left turning during shut downs
–Recommended to calculate SME using the slurry volume and duration to
represent field condition in the lab.
Jet Mixing – The Basics
Function of Jets
 Supply mix water
 Accelerate mix water
 Wet and disperse cement grains
 Create “venturi” effect
 Vacuum is created by water
 Pulls more cement in from hopper
Batch Mixing
Advantages Disadvantages
 Good density control  Small slurry volumes
 Good mixing energy
The Slurry Chief
 Advantages over old jet systems
 More accurate control of cement slurry
 More energy added by RA 56
 Gives a second chance to control density
 Can stop pumping downhole and mixing,
leaving recirculating
 Low pressure mixing system
 Recirculating line from a tub goes
back to mixing bowl
 Knife gate to control cement falling
into mixing bowl
 2 bypasses with jets
Slurry Chief Evolution - Mark III Mixing System
Slurry Chief Evolution Mark III Mixing System

Recirculation valve

Gun barrel

Mark III knife gate

Mark III mixing bowl

Recirculation jet line

Mix-water jet line

Mark III, Slurry Gun
 Knife gate parallel to slurry gun to reduce space between knife gate and jet
 Diameter of slurry gun increases at the end of it to enhance stream flow

Knife Gate
Slurry Gun

Mixing Water Jet

 Mark III, Jet
Re-circulation line
Annular jet (Mix water jet)
Mark III, Strainer
 The Strainer has to be mounted in the mixing manifold
 The internal mesh will clean itself when pumping water through the thin up
line

To mixing jet

To Thin up
line
Location of
Internal mesh to
ensure self
cleaning
Vacuum Breaker
 Vacuum Breaker is a check valve that lets air enter the system if the re-
circulation circuit is open and cement valves are closed

Consequence of not
using a vacuum
breaker properly
New Concept: CPF-376
Two mix tubs, 6 and 14 bbls capacity
Two NRD’s: one for mixing, one for
pumping downhole
Mark III mixing system
 CemCAT recording system
 High pumping rates
 High reliability due to PTO’s used for
C-pumps
Mixing Calculations Water Rate Calculations
 Set the mix-water manifold valves to the pre-set position. Use the mix-water
jet first during mixing
Mixing Calculations Water Rate Calculations
 15.8-ppg class G neat cement slurry class G @ 6 bpm
Mixing Calculations Water Rate Calculations
 12.6-ppg, class G, Extended slurry @ 8 bpm
Summary
 Mixing Theory: Mixing Energy and Mixing time effects on slurry performance
 Equipment: Description of mixing equipment – evolution of slurry chief
systems
 Mixing Procedures: Mark III operation
 Mixing Calculations: Water rates and water volume in mix tub