Trapezoidal Orifice Metering Gate for Proppant Flow Control
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Solution Overview
Problem
Current proppant placement techniques in hydraulic fracturing, particularly in heterogeneous proppant placement (HPP) operations, face challenges in achieving consistent and accurate proppant metering due to slow densitometer response times and irregular metering orifice geometries, which affect the efficiency of fracturing fluid conductivity.
Innovation Solution
A system and method for controlling the discharge rate of proppant using a metering gate with a trapezoidal orifice, where the gate's open area is adjusted based on mathematical modeling equations considering physical and environmental factors to achieve a desired flow rate, enabling precise proppant placement in fracturing fluids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If automatic proppant concentration control based on densitometer feedback is used, then proppant metering can be automated, but the response time becomes excessively slow
Solution Approach 1:
The patent replaces the mechanical/densitometer-based feedback system with a mathematical modeling approach that calculates required gate opening based on physical equations. This substitution eliminates the slow densitometer response while maintaining automated control, as the mathematical model provides instantaneous calculations without physical measurement delays.
Solution Approach 2:
The system performs preliminary calculations using mathematical models to determine the required gate opening before actual proppant flow begins. By pre-calculating the optimal gate position based on desired flow rates and physical parameters, the system avoids the lag inherent in reactive densitometer feedback systems.
2Ease of manufacture
If conventional metering gate designs with irregular orifice geometries are used, then existing blending equipment can be utilized, but proppant flow control accuracy deteriorates
Solution Approach 1:
The patent changes the geometric parameters of the metering orifice from irregular conventional shapes to a precise trapezoidal geometry. This parameter change improves flow control accuracy and predictability, as the trapezoidal shape provides well-defined flow characteristics that respond consistently to gate opening adjustments, while still being manufacturable with standard equipment.
Solution Approach 2:
The trapezoidal orifice geometry introduces intentional asymmetry in the flow path, with different widths at the top and bottom. This asymmetric design creates more predictable flow patterns and improves the relationship between gate opening percentage and actual flow rate, enhancing metering precision compared to symmetric or irregular conventional designs.
3Ease of operation
If auger systems are used to supply proppant, then proppant can be metered by calculating volume at given rpm, but the required area becomes larger
Solution Approach 1:
The patent extracts the proppant metering function from the mechanical auger system and implements it through a gravity-fed system with a metering gate. By removing the auger component entirely and using gravity as the driving force, the system achieves proppant metering through orifice geometry and gate opening control, significantly reducing the spatial footprint while maintaining metering capability.
Solution Approach 2:
The system uses gravity (a form of potential energy conversion similar to pneumatic/hydraulic principles) to drive proppant flow through the metering gate, replacing the mechanical auger system. This gravity-fed approach eliminates the need for large auger mechanisms and their associated motor housings, reducing the overall area required for proppant supply while maintaining precise flow control through the metering gate.
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 allows for consistent and well-behaved proppant metering, improving the efficiency of fracturing fluid conductivity by optimizing proppant distribution within the fracture, enhancing the effectiveness of hydraulic fracturing treatments.
Implementation Method 1
The proppant may be delivered to the fracturing fluid, pumps, or mixer from an oilfield material reservoir, commonly called a proppant hopper or receiver. The auger meters the proppant volumes and rates into a fluid stream or mixer.
Data Source
AI summary
An oilfield material reservoir is disclosed. The oilfield material reservoir has a body, the body having an upper end, a lower end, a sidewall extending between the upper and lower ends, the sidewall defining a recess within the body, an opening defined by the upper end, and a first orifice defined by the lower end. The oilfield material reservoir is also provided with a metering gate connected to the body at the lower end. The metering gate has a base having a second orifice aligned with the first orifice, and a knife gate connected to the base. The second orifice has a substantially trapezoidal shape. The knife gate is configured to slidably cover the second orifice. A method is also disclosed for controlling a discharge rate of oilfield material within the oilfield material reservoir by adjusting a metering open area of the second orifice according to mathematical modeling equations.