FIELD

The present disclosure relates to fluid flow control systems and methods, and in particular, to a system and method for intelligent flow control and monitoring during production cementing returns.

BACKGROUND

In oil and gas production, cement is used to hold the casing in place and to prevent fluid migration between subsurface formations. “Cementing,” one of the most critical steps, is the process of pumping a slurry of cement, cement additives, and water down through the casing to critical points in the annulus around the casing or in the open hole below the casing string. The cement slurry flows to the bottom of the wellbore through the well casing and displaces the drilling fluids still located within the well and allows the drilling fluids to come back up the well. The cement slurry flows to the bottom of the wellbore through the casing, which will eventually be the pipe through which the hydrocarbons flow to the surface. From there it fills in the space between the casing and the actual wellbore and hardens. This creates a seal so that outside materials cannot enter the well flow, as well as permanently positions the casing in place. Cementing achieves many objectives: it provides a hydraulic seal, creates zonal isolation, protects the environment, provides structural support for the casing, protects the casing from corrosion, and isolates the casing seat for subsequent drilling.

A gas kick is an unscheduled and unwanted entry of gas into the wellbore, which travels up the well and rapidly expands due to change in atmosphere pressure in an uncontrolled fashion. Serious consequences of a gas kick include unsafe conditions for operators where return gas or kick gas has the potential to reach an ignition source, or be released to the atmosphere in an uncontrolled manner in a blowout.

