Friction Flow Loop Testing with Dual-Tank Hydration Control

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Solution Overview

Problem

Existing friction flow loop test methods and apparatuses fail to accurately simulate well bore hydraulic conditions during fracturing, leading to overstatement of friction reducer capabilities and unreliable data prediction of field performance due to incomplete hydration, improper mixing, and recirculation issues.

Innovation Solution

A dual-tank system with inline chemical injection and controlled shear rates, simulating well bore conditions by using a primary feed tank and secondary receiving tank, along with a pump suction spool piece for precise chemical introduction and mixing, and a fritted disc plate to prevent vortexing, allowing for accurate hydration and shear stability measurement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a single tank operation with recirculation is used, then the test apparatus is simple, but the friction reducer polymers become completely hydrated and overstate friction reducer capabilities

Engineering Contradiction:

Improveapparatus simplicityVSAvoidfriction reducer capability measurement

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The system is divided into two separate tanks: a feed tank containing fresh fracturing fluid and a receiving tank for used fluid. This segmentation prevents recirculation of fully hydrated polymers back to the feed tank, allowing accurate measurement of friction reducer performance without overstatement.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The recirculation function is extracted and removed from the system. Instead of recirculating fluid back to the feed tank, the system uses a one-way flow where fluid moves from the feed tank through the friction flow loop to the receiving tank, eliminating the problem of complete polymer hydration.

Inventive Principle:

Principle #2Taking out (Extraction)

2Ease of operation

If a low shear top mounted mixer is used to hydrate friction reducer polymer, then the mixing is effective, but the mixing does not replicate field hydraulic engineering conditions

Engineering Contradiction:

Improvepolymer hydration effectivenessVSAvoidfield performance prediction

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The system copies field hydraulic engineering conditions by using a friction flow loop that simulates actual well bore flow conditions. The loop includes a blender tub with controlled mixing intensity residence time (14.7 seconds) that replicates field blender tub conditions, ensuring the mixing process accurately predicts field performance.

Inventive Principle:

Principle #26Copying

3Reliability

If fluid is recirculated back to the feed tank, then the test can measure shear survivability, but the fluid spends minutes in the feed tank relaxing and does not reflect well bore shear rates

Engineering Contradiction:

Improveshear survivability measurementVSAvoidshear rate simulation accuracy

Core Design Contradiction:

ReliabilityVSMeasurement precision

Solution Approach 1:

The system performs preliminary action by maintaining the friction flow loop in a state that continuously applies well bore shear rates to the fluid. The loop is designed so that fluid spends 3 minutes at shear conditions between the blender tub and the perforation, simulating the actual time polymers experience in the well bore before breaking down.

Inventive Principle:

Principle #10Preliminary action

4Ease of manufacture

If syringe dosage is injected into the top of the tank, then the chemical introduction is simple, but the injection does not simulate field hydraulic engineering conditions

Engineering Contradiction:

Improvechemical injection simplicityVSAvoidfield performance prediction

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

An intermediary injection system is introduced that simulates field chemical injection conditions. The system uses a syringe pump to inject friction reducer at the suction side of the pump, where it mixes with the fracturing fluid under controlled conditions that replicate field hydraulic engineering conditions, ensuring reliable prediction of field performance.

Inventive Principle:

Principle #24Intermediary (Mediator)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution provides reliable data prediction of field performance by accurately simulating well bore hydraulic conditions, ensuring complete hydration and shear stability of friction reducers, reducing pump cavitation, and maintaining shear rates for 3 minutes, thus improving the accuracy of friction reducer evaluation.

Implementation Method 1

A pump suction spool piece for precise chemical introduction and mixing

Methodology Applied

Scientific EffectMechanical mixing: Stirring

Implementation Method 2

a fritted disc plate to prevent vortexing

Methodology Applied

Scientific EffectVortex prevention:

Implementation Method 3

maintaining shear rates for 3 minutes

Methodology Applied

Scientific EffectShear flow: Shear Stress

Data Source

PatentUS12360028B1Friction flow loop test method and apparatus

Publication Date: 2025.07.15 IMPERATIVE CHEMICAL PARTNERS INC

AI summary

A friction flow loop test method and apparatus that simulates well bore hydraulic conditions during fracturing utilizing large dual tanks with a primary feed tank and a secondary receiving tank wherein friction reducer hydration is controlled in an environment matching the well bore and is unaffected by recirculation mixing.