Injection Valve for Proppant Mixing in Hydraulic Fracturing

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Solution Overview

Problem

Conventional hydraulic fracturing systems face challenges in efficiently injecting and handling abrasive proppants, which can cause damage to pumps and limit the effective plugging of large fractures in hydrocarbon-producing wells.

Innovation Solution

A fluid injection system that includes a valve assembly and high-pressure pump capable of injecting a fluid-particulate mixture into fractures, using a particulate reservoir and a piston or plunger mechanism to mix and discharge proppants without direct contact with the pump, allowing for the injection of proppants into fractures exceeding 2 inches in width and facilitating fracture plugging in non-producing formations or salt mines.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If abrasive proppants are injected directly through the pump, then the proppants can be delivered to fractures, but the pump components suffer damage and wear

Engineering Contradiction:

Improveproppant delivery capabilityVSAvoidpump component durability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system divides the proppant delivery function into two separate components: the pump handles only fluid delivery, while a separate injection valve assembly handles proppant injection. This segmentation prevents abrasive proppants from contacting and damaging pump components, thereby resolving the contradiction between maintaining productivity and ensuring reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The injection valve assembly acts as an intermediary device between the pump and the fracture. It receives fluid from the pump, mixes it with proppants, and injects the mixture into the fracture. This intermediary protects the pump from direct contact with abrasive proppants while enabling continuous proppant delivery.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If large sized proppants are used to bridge and plug large fractures, then fracture plugging effectiveness is improved, but the complexity of handling and injecting diverse particle sizes increases

Engineering Contradiction:

Improvefracture plugging effectivenessVSAvoidinjection system complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The injection valve assembly is designed with movable components including a plunger and adjustable orifices that can be dynamically positioned. This dynamic design allows the system to adapt to different proppant sizes and fracture conditions without requiring multiple specialized devices, thereby achieving versatility while controlling complexity.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The injection valve assembly is designed as a universal device capable of handling various proppant sizes and shapes (from 20 mesh to 2 inches in diameter). The single device performs multiple functions including mixing, injecting, and adapting to different fracture conditions, eliminating the need for multiple specialized injection systems.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Productivity

If proppants are injected into high pressure lines, then fracture stimulation is achieved, but the abrasive nature of proppants causes wear and damage to injection components

Engineering Contradiction:

Improvefracture stimulation effectivenessVSAvoidcomponent wear and damage

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The harmful abrasive proppants are extracted from the pump system and handled separately by the injection valve assembly. The pump is taken out of the proppant handling function and dedicated solely to fluid delivery, eliminating the wear and damage caused by abrasive proppants to pump components while maintaining fracture stimulation effectiveness.

Inventive Principle:

Principle #2Taking out (Extraction)

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

Enables efficient injection and plugging of large fractures, extending the life of fracturing pumps by preventing abrasive proppant damage and effectively managing the injection of diverse particulate sizes and shapes into hydrocarbon formations.

Implementation Method 1

Methodology Applied

Scientific EffectFluid mixing:

Implementation Method 2

A fluid injection system that includes a valve assembly and high-pressure pump capable of injecting a fluid-particulate mixture into fractures

Methodology Applied

Scientific EffectHydraulic pressure: Pressure Increase

Data Source

PatentUS11371331B2Injection valve for injecting randomly sized and shaped items into high pressure lines

Publication Date: 2022.06.28 HALLIBURTON ENERGY SERVICES INC

AI summary

A fluid injection system for injecting a particulate in a fluid, including a high-pressure pump operable to output the fluid from an outlet flow channel and a reservoir configured to hold the particulate. The system also includes a valve assembly in fluid communication with the reservoir and the outlet flow channel of the pump, the valve assembly operable to discharge the particulate into a fluid stream output by the pump while the reservoir is sealed from the outlet flow channel of the pump.