Proppant Concentration Accuracy via Moisture Compensation
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Solution Overview
Problem
The use of wet proppant in fracturing treatments leads to inaccuracies in proppant concentration calculations due to unaccounted moisture content, resulting in excessive proppant usage and reduced effectiveness, as traditional radioactive densometers are replaced by flowmeter-based methods that are sensitive to fluid flow rates and do not account for moisture.
Innovation Solution
A system and method that measures the moisture content of the proppant using a moisture sensor, combining this data with flow rates to accurately calculate proppant concentration and density in the fracturing fluid, eliminating the need for radioactive densometers and ensuring precise proppant delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If wet proppant is used to reduce cost, then proppant cost decreases, but proppant concentration measurement accuracy deteriorates
Solution Approach 1:
The patent introduces moisture content measurement as an intermediary parameter to bridge the gap between wet proppant usage and accurate concentration calculation. By measuring moisture content separately and using it as a correction factor in the concentration calculation formula, the system accurately determines proppant concentration despite the presence of moisture that confounds direct flowmeter measurements.
2Object-affected harmful factors
If radioactive densometers are removed to reduce safety risks, then personnel and environmental safety improve, but proppant concentration measurement accuracy deteriorates
Solution Approach 1:
The patent replaces the radioactive densometer (which used nuclear density detection) with a combination of non-radioactive flowmeters and moisture content measurement. This substitution eliminates radiation hazards while maintaining measurement capability through an alternative approach that measures fluid flow rate and moisture content separately to calculate proppant concentration.
Solution Approach 2:
The patent introduces moisture content measurement as an intermediary parameter to enable accurate proppant concentration calculation using non-radioactive flowmeters. The moisture content measurement acts as a correction factor that compensates for the limitations of flowmeter-based measurement in wet proppant applications.
3Device complexity
If flowmeter-based measurement is used instead of radioactive densometers, then device complexity and safety improve, but proppant concentration calculation accuracy deteriorates
Solution Approach 1:
The patent introduces moisture content measurement as an intermediary parameter that enables accurate proppant concentration calculation when using simpler flowmeter-based measurement systems. This additional measurement allows the system to compensate for the moisture's effect on flow rate measurements.
Solution Approach 2:
The patent implements a feedback mechanism where moisture content measurement results are used to correct the proppant concentration calculation in real-time. The system continuously monitors moisture content and adjusts the concentration calculation accordingly, creating a closed-loop measurement system that maintains accuracy despite using simpler components.
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
This approach improves the accuracy of proppant concentration and density calculations, reducing errors by up to 54% and optimizing proppant usage, leading to more effective fracturing treatments with reduced costs and enhanced permeability in subterranean formations.
Implementation Method 1
A moisture sensor installed on either the blender at the proppant inlet or on the proppant metering device may be used to indicate percent moisture
Data Source
AI summary
A method of determining a dry proppant concentration in a fracturing fluid includes combining a wet proppant with a carrier fluid in a mixer to form the fracturing fluid. The dry proppant concentration of the fracturing fluid leaving the mixer is determined using a moisture content of the wet proppant entering the mixer, wherein use of the moisture content prevents overestimation of the dry proppant concentration. The method can be preformed using a system for injecting fracturing fluid into a borehole, the fracturing fluid including a carrier fluid mixed with a wet proppant including a dry proppant dampened with a dampening liquid. The system includes a mixer operable to receive and mix the carrier fluid and the wet proppant to form the fracturing fluid, a frac pump operable to inject the fracturing fluid into the borehole, and a control system comprising a processor operable to receive a moisture content of the wet proppant before being mixed with the carrier fluid and programmed to determine a dry proppant concentration of the fracturing fluid formed in the mixer using a moisture content of the wet proppant, wherein use of the moisture content prevents overestimation of the dry proppant concentration.