Dual Blender Layout for Multi-Well Fracturing Fluid Separation
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Solution Overview
Problem
Existing hydraulic fracture treatment systems lack flexibility and adaptability to handle diverse well configurations and chemistry requirements, necessitating transport or replacement of components for different modes of operation.
Innovation Solution
A dual blender system that operates in multiple modes, including dual fracturing, simul-fracturing, and single fracturing, using a movable divider and independent input/output channels to manage distinct fracture treatment fluids for various wellbores, allowing on-site configuration changes without component replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single blender system is used for hydraulic fracture treatments, then the system structure is simple, but the system lacks flexibility and adaptability to handle diverse well configurations and chemistry requirements
Solution Approach 1:
The blender system is segmented into multiple independent blender units (first blender unit, second blender unit), each capable of independent operation. Each blender unit has its own mixing chamber, pump system, and control mechanisms. This segmentation allows each unit to be optimized for specific well configurations while maintaining overall system versatility.
Solution Approach 2:
The dual blender system is designed to perform multiple functions: it can simultaneously service multiple wellbores with different chemistry requirements, switch between single and dual operation modes, and adapt to various fracture treatment scenarios. The system universally handles diverse well configurations through its modular architecture and reconfigurable flow paths.
2Adaptability or versatility
If components are transported or replaced for different modes of operation, then the system can adapt to different well configurations, but this results in loss of time and reduced efficiency
Solution Approach 1:
The system incorporates dynamic reconfiguration capabilities through movable dividers and switchable flow paths that allow transition between operational modes without physical component replacement. The dividers can be repositioned to redirect fluid flow between wellbores, and the system can dynamically switch between single-blender and dual-blender modes based on treatment requirements.
Solution Approach 2:
The system is pre-configured with multiple blender units and associated flow control mechanisms ready for immediate deployment. All necessary components are permanently installed and positioned, eliminating the need for transport or replacement during operations. The system maintains standby capacity and pre-arranged flow paths for rapid mode transitions.
3Ease of manufacture
If distinct fracture treatment fluids are mixed in a single mixing chamber, then the mixing process is simple, but cross-contamination between different chemistries occurs
Solution Approach 1:
The mixing process is segmented into separate mixing chambers (first mixing chamber, second mixing chamber), one for each blender unit. This physical separation prevents cross-contamination between different fracture treatment fluids while maintaining independent mixing control. Each chamber is dedicated to specific fluid chemistry preparation.
Solution Approach 2:
Movable dividers act as intermediaries that can be positioned to separate mixing chambers when different chemistries are being prepared, or repositioned to allow fluid flow between chambers when needed. The divider system mediates between the need for isolation and the need for connectivity, ensuring chemistry purity while maintaining operational flexibility.
Data Source
AI summary
In a general aspect, the present disclosure relates to a blender system for use in a hydraulic fracturing system. The blender system includes a mixing tub and a movable divider associated with the mixing tub. The divider is movable between an open position and a closed position. When the divider is in the open position, liquid can flow between a first portion of the mixing tub and a second, distinct portion of the mixing tub. When the divider is in the closed position, the divider prevents liquid flow between the first and second portions. A divider control system can move the divider between the open and closed positions. A first input pump pumps fluid into the first portion of the mixing tub, and a first output pump pumps fluid from the first portion of the mixing tub. A second input pump pumps fluid into the second portion of the mixing tub, and a second output pump pumps fluid from the second portion of mixing tub.