Multi-Well Blender With Independent Proppant Dilution Outlets
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Solution Overview
Problem
Existing fracturing fleets face challenges in simultaneous multi-well operations due to the need for precise control of proppant concentration and fluid transition between clean and proppant-laden fluids, increased blender downtime, and equipment failure frequency during multi-well fracturing.
Innovation Solution
A multi-well blender design with multiple independent outlets, discharge pumps, and dilution injection ports allows for customized fluid composition to each well, featuring tub bypass valves and crossover lines for backup, enabling independent control of proppant concentration and fluid flushing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single blender is used for multi-well fracturing operations, then equipment simplicity is maintained, but blender downtime increases and operational flexibility is reduced
Solution Approach 1:
The single blender is divided into multiple independent outlets (first outlet, second outlet, third outlet, etc.), each capable of serving different wells independently. This segmentation allows one blender to simultaneously supply multiple wells without requiring multiple separate blenders, thereby reducing downtime while maintaining productivity.
Solution Approach 2:
Each outlet of the blender is configured to provide customized fluid compositions to different wells, making the blender system universal for multi-well operations. The blender can simultaneously perform multiple functions by delivering different proppant concentrations and fluid types to different wells through its multiple outlets.
2Manufacturing precision
If proppant concentration is precisely controlled for each well, then fracturing treatment quality is improved, but system complexity increases
Solution Approach 1:
Each outlet of the blender is equipped with independent dilution injection ports and bypass valves that allow local adjustment of proppant concentration for each well. This enables precise control of fluid composition at each outlet without requiring complex centralized control systems, as each outlet can be independently optimized for its specific well.
Solution Approach 2:
The system controls proppant concentration by changing the dilution parameter at each outlet through independent dilution injection ports. By adjusting the amount of dilution fluid added at each outlet, the proppant concentration can be precisely controlled for each well without complex mixing mechanisms, simplifying the overall system while maintaining precision.
3Adaptability or versatility
If multiple discharge pumps are added for independent well control, then operational flexibility is improved, but equipment failure frequency increases
Solution Approach 1:
The blender system is segmented into multiple independent outlets, each with its own discharge pump and control mechanisms. This segmentation allows independent control of each well's fluid flow, improving operational flexibility while distributing the system so that failures in one outlet do not affect others, thereby maintaining overall reliability.
Solution Approach 2:
The system includes crossover lines and backup valves that provide redundancy between outlets. If one discharge pump or outlet fails, the crossover lines allow fluid flow to be redirected to other outlets, cushioning against complete system failure and maintaining operational continuity despite equipment failures.
4Adaptability or versatility
If dilution injection ports are added to each outlet, then fluid composition customization is improved, but device complexity increases
Solution Approach 1:
Each outlet is equipped with its own dilution injection port and bypass valve, allowing local customization of fluid composition for each well. This localized approach enables independent control of proppant concentration at each outlet without requiring complex centralized mixing systems, as each outlet can be independently adjusted to match specific well requirements.
Data Source
AI summary
A blending unit is provided. The blending unit comprises two or more discharge pumps. Each of the two or more discharge pumps has a suction inlet fluidly connected to a common proppant fluid supply via a concentrated proppant inlet line, and a discharge outlet fluidly connected to a blender outlet line. Each of the two or more discharge pumps also has an injection port upstream of the discharge pump and configured to inject substantially proppant-free fluid into the concentrated proppant inlet line, an injection port downstream from the discharge pump and configured to inject substantially proppant-free fluid into the blender outlet line, or both the injection port upstream of the discharge pump and the injection port downstream from the discharge pump.