Automated Acid Mixing Control for Precise Fracturing Concentrations
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional systems for mixing acid and water in hydrocarbon formation fracturing operations are complex, leading to safety concerns and inefficiency, and lack consistency in delivering precise acid concentrations.
Innovation Solution
A self-contained, automated system that includes a tank, acid and water pumps, flow meters, control valves, and a controller to monitor and control the flow, ensuring precise acid concentrations and safety by automatically adjusting the acid to water ratio and maintaining desired output pressures, with features like vapor recovery and variable frequency drives to minimize emissions and optimize operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional systems are used to mix acid and water, then the mixing function is provided, but the system complexity increases leading to safety concerns and inefficiency
Solution Approach 1:
The system is divided into separate functional modules: acid storage tank, water storage tank, acid pump, water pump, flow meters, control valves, and vapor recovery unit. Each component performs a specific function, allowing for easier operation and reduced complexity while maintaining safety through modular design
Solution Approach 2:
Manual mechanical mixing systems are replaced with an automated electronic control system that uses flow meters, electronic control valves, and a controller to automatically regulate acid and water flow rates, eliminating the need for complex manual operation and improving safety
2Manufacturing precision
If conventional systems are used to mix acid and water, then the mixing function is provided, but consistency in delivering precise acid concentrations is lacking
Solution Approach 1:
Flow meters are installed on both acid and water lines to continuously monitor flow rates. The controller receives feedback from these flow meters and automatically adjusts the electronic control valves to maintain the desired acid concentration ratio, ensuring precise and consistent mixing results
Solution Approach 2:
Manual flow control mechanisms are replaced with electronic control valves that can be precisely regulated by the controller based on flow meter readings, providing accurate and consistent acid concentration control without requiring complex manual adjustment procedures
3Manufacturing precision
If automated control is implemented to ensure precise acid concentrations, then consistency and safety improve, but system complexity increases
Solution Approach 1:
The controller serves multiple functions: it monitors flow meters, controls electronic control valves, manages the vapor recovery unit, and coordinates acid and water pumps. This multi-functionality consolidates what could be multiple separate control systems into a single unit, reducing overall system complexity while maintaining precise acid concentration consistency
Solution Approach 2:
The system is designed to automatically self-regulate the mixing process. The flow meters continuously monitor flow rates, the controller automatically adjusts valve positions to maintain the correct acid-to-water ratio, and the system self-corrects any deviations without requiring manual intervention, simplifying operation while ensuring consistent precision
Data Source
AI summary
A system for mixing acid and water can include a tank for holding acid, an acid pump for pumping acid out of the tank, an acid flow meter, an acid control valve, a water pump for pumping water, a water flow meter, a water control valve, a flush valve to selectively flush the system with water, and a controller to monitor the flow meters and control the pumps and the valves. The acid control valve and/or the water control valve can be an electronically controlled valve. The flush valve can be an electronically controlled valve to selectively permit water to flow from downstream of the water pump to upstream of the acid pump. The acid control valve, the water control valve, the flush valve, or any combination thereof can be throttled by the controller to control flow therethrough.