Gas Separation in Hydraulic Fracturing Fluid Blending
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Solution Overview
Problem
High-pressure hydraulic fracturing pumps experience cavitation and erosion due to entrained gas bubbles, leading to decreased performance and shortened operational life, as existing components are not designed to withstand the impact of gas bubbles like they do with proppants.
Innovation Solution
A two-phase flow separator system is introduced inline between the blender and high-pressure pumps, utilizing a curvilinear flow line system and vortex cluster system to separate gas bubbles from hydraulic fracturing fluids before they reach the pumps, ensuring only the liquid and proppant mixture is pumped into the wellbore.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If high-pressure pumps are used to pump hydraulic fracturing fluid into the formation, then the fluid pressure necessary for hydraulic fracturing is achieved, but the entrained gas bubbles cause cavitation that erodes the internal pump components
Solution Approach 1:
The patent applies preliminary action by installing a gas separation system upstream of the high-pressure pump to remove entrained gas bubbles from the hydraulic fracturing fluid before it enters the pump. This preliminary removal of gas prevents cavitation and erosion of pump components, allowing the pump to reliably achieve the necessary high fluid pressures for hydraulic fracturing without damage from gas bubble impact
2Ease of manufacture
If proppant is blended with liquids to form hydraulic fracturing fluid, then the fluid is prepared for injection, but air bubbles become entrained in the fluid during the blending process
Solution Approach 1:
The patent applies the extraction principle by introducing a gas separation system that specifically removes entrained air bubbles from the hydraulic fracturing fluid after blending but before pump injection. The separation system extracts the harmful gas phase from the liquid-proppant mixture, allowing the fluid to be properly prepared for injection without the damaging effect of entrained bubbles
3Duration of action of stationary object
If gas bubbles are removed from hydraulic fracturing fluids before pumping, then pump performance is maintained and operational life is extended, but additional equipment is required in the fluid handling system
Solution Approach 1:
The patent applies the intermediary principle by introducing a gas separation system as an intermediate component between the blender and the high-pressure pump. This intermediary device removes entrained gas bubbles from the fluid stream, protecting the pump from cavitation and erosion, thereby extending pump operational life while adding only the necessary minimum equipment to achieve the protection
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 separation of gas bubbles extends the operational life and improves the efficiency of hydraulic fracturing pumps by preventing cavitation and erosion, maintaining pump performance and reducing maintenance needs.
Implementation Method 1
a curvilinear flow line system to separate gas bubbles from hydraulic fracturing fluids
Implementation Method 2
vortex cluster system to separate gas bubbles from hydraulic fracturing fluids
Data Source
AI summary
A hydraulic fracturing system utilizes a multi-phase separation apparatus to separate gas entrained in hydraulic fracturing fluids during the blending process prior to introduction of hydraulic fracturing fluid into high pressure fracturing pumps by directing hydraulic fracturing fluids from a blender through a plurality of loops and thereafter, directing a portion of the separated fluid into a vortex cluster system.