Recirculation Circuit Proppant Flushing Control

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Solution Overview

Problem

The accumulation of proppant in the flow components of hydraulic fracturing systems restricts fluid flow, requiring time-consuming manual disassembly and shutdown for cleaning, which is inefficient and impractical.

Innovation Solution

A control system with a recirculation circuit and a controller that identifies proppant addition, allowing fluid to flow through the circuit to flush out accumulated proppant, thereby automating the cleaning process without shutting down the system.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual disassembly and cleaning methods are used to remove proppant accumulation, then the proppant can be removed from the system, but the system must be shut down and the process becomes time-consuming

Engineering Contradiction:

Improveproppant removal effectivenessVSAvoidcleaning time and system shutdown duration

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The system performs self-cleaning by using its own hydraulic fracturing fluid to automatically flush proppant from the recirculation circuit. The controller automatically opens the recirculation valve to enable fluid flow through the recirculation circuit, allowing the system to clean itself without external intervention or shutdown, thereby resolving the contradiction between effective proppant removal and system operational time

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The controller proactively initiates the recirculation flushing operation based on detected proppant accumulation conditions, performing the cleaning action before proppant blockage becomes severe. This preliminary action prevents complete system shutdown by addressing proppant accumulation early, maintaining system reliability while minimizing operational disruption

Inventive Principle:

Principle #10Preliminary action

2Use of energy by stationary object

If the recirculation valve remains open during proppant addition, then fluid can circulate continuously, but proppant accumulates in the recirculation circuit restricting flow

Engineering Contradiction:

Improvepump energy utilizationVSAvoidproppant accumulation and flow restriction

Core Design Contradiction:

Use of energy by stationary objectVSObject-generated harmful factors

Solution Approach 1:

The controller implements periodic operation of the recirculation valve, opening it at specific intervals during the hydraulic fracturing process when proppant is being added to the fluid stream. This periodic opening allows proppant to be periodically flushed from the recirculation circuit, preventing accumulation while maintaining overall continuous circulation. The valve opens periodically to a degree sufficient to flush proppant but not so much as to significantly reduce pump energy utilization

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The controller monitors system conditions and uses this feedback to determine when to open the recirculation valve. By detecting proppant addition events and system state, the controller intelligently controls valve timing and degree of opening, balancing the need to prevent proppant accumulation with the need to maintain efficient pump operation and energy utilization

Inventive Principle:

Principle #23Feedback

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 enables efficient and automated removal of proppant from the recirculation circuit, reducing sand packing and improving fluid flow, thus enhancing the performance and efficiency of hydraulic fracturing systems.

Implementation Method 1

a recirculation circuit configured to direct fluid from the outlet of the fluid pump to the inlet of the fluid pump

Methodology Applied

Scientific EffectFluid flow:

Implementation Method 2

cause opening of the control valve to cause the fluid to flow through the recirculation circuit

Methodology Applied

Scientific EffectFluid flow:

Implementation Method 3

The controller may be configured to identify an addition of a proppant to the fluid while the control valve is open

Methodology Applied

Scientific EffectProppant detection:

Implementation Method 4

cause the fluid to flow through the recirculation circuit to flush the recirculation circuit of the proppant

Methodology Applied

Scientific EffectFlushing:

Data Source

PatentUS12116876B2Operation of a recirculation circuit for a fluid pump of a hydraulic fracturing system

Publication Date: 2024.10.15 CATERPILLAR INC

AI summary

A control system may include a recirculation circuit configured to direct fluid from an outlet of a fluid pump of a hydraulic fracturing system to an inlet of the fluid pump. The control system may include a control valve in the recirculation circuit. The control system may include a controller configured to cause opening of the control valve to cause the fluid to flow through the recirculation circuit at a first time when proppant is being added to the fluid. The controller may be configured to cause, after closing of the control valve and at a second time when the proppant is no longer being added to the fluid, re-opening of the control valve to cause the fluid to flow through the recirculation circuit to flush the recirculation circuit of the proppant.