Viscous fluid dilution system and method thereof
A dilution system for a hydraulic fracturing fluid, the dilution system including a dilution manifold; a hydration unit configured to provide a source of liquid; a diluent line connecting the hydration unit to the dilution manifold. A diluent flow control valve on the diluent line. A hydration tank configured to hydrate a mixed additive. A gravity-driven viscous fluid line connecting an exit of the hydration tank to the dilution manifold. A viscous fluid flow meter on the viscous fluid line; and, a viscous fluid control valve on the viscous fluid line. Also included is a method of processing a fracturing fluid.
1. A method of processing a fracturing fluid, the method comprising:
mixing an additive in a mixer with liquid to form a mixed additive;
hydrating the mixed additive within a hydration tank to achieve a viscous fluid;
directing the viscous fluid from the hydration tank to a dilution manifold via gravity along a pumpless viscous fluid line, a viscous fluid control valve and flow meter positioned along the viscous fluid line;
directing a diluent stream from a hydration unit to the dilution manifold;
diluting the viscous fluid with the diluent stream at the dilution manifold to achieve a diluted viscous fluid; and,
subsequently directing the diluted viscous fluid to a proppant blender.
2. The method of claim 1 , wherein the viscous fluid line has a shear rate of approximately 200 (l/s) or less from the hydration tank to the dilution manifold.
3. The method of claim 1 , further comprising measuring viscous fluid flow via the flow meter on the viscous fluid line.
4. The method of claim 3 , further comprising throttling the viscous fluid control valve on the viscous fluid line and a diluent flow control valve on a diluent line from the hydration unit to the dilution manifold to achieve a selected additive to diluent ratio within the dilution manifold.
5. The method of claim 1 , wherein, prior to hydrating the mixed additive, the mixed additive has a first additive concentration, and further comprising blending the fracturing fluid at the blender using the diluted viscous fluid, the diluted viscous fluid having a second additive concentration less than the first additive concentration.
6. The method of claim 1 , wherein mixing the additive in the mixer with liquid includes mixing a shear sensitive polymer with liquid.
7. The method of claim 6 , wherein mixing the shear sensitive polymer with the liquid includes mixing one of a polyacrylamide, copolymer of acrylamide, and terpolymer of acrylamide with the liquid.
8. The method of claim 1 , wherein subsequently directing diluted viscous fluid to the proppant blender includes pumping diluted viscous fluid from the dilution manifold to the blender.
9. The method of claim 8 , further comprising measuring a flow rate of diluted viscous fluid flow pumped to the blender and employing the flow rate to ascertain a ratio of additive to fluid.
10. The method of claim 9 , further comprising achieving a selected ratio of viscous fluid to diluent by measuring a flow rate of the viscous fluid from the hydration tank, throttling the viscous fluid control valve, and throttling a diluent flow control valve.
11. The method of claim 1 , wherein directing a diluent stream from a hydration source to the dilution manifold includes directing the diluent stream on a pumpless diluent line.