Patent Application
20240183259
The present invention relates generally to systems and processes for improved drag reduction estimation and measurement and more specifically to portable drag reduction analyzers and processes for upscaling drag reduction data for a variety of field applications. The present invention also relates to improved processes for delivering a produced water mixture to a well to be used during fracking.
Drag reducing agents also called, among other names, drag reducers or friction reducers are commonly employed in many applications to, for example, reduce frictional pressure loss during fluid flow in a conduit or pipeline in a variety of applications. A few common applications include, for example, hydraulic fracturing (fracking), pipelines, injecting fluid, produced water, water transportation, disposal wells, irrigation or other well systems, and the like. There are a wide variety of drag reducing agents that include, for example, various polymers, fibers, surfactants, and boosters.
Unfortunately, current testing procedures of drag reducing properties of various agents requires large stationary equipment. Moreover, testing results are performed in the laboratory or small-scale flow loop and do not accurately predict drag reduction on a larger scale such as in the field. In particular, typical field conditions are not easily producible in a laboratory or small-scale flow loop. Accordingly, what is needed are systems and methods that more reliably predict or estimate drag reduction on a larger scale in the field. It would further be advantageous if testing systems could be made to be portable for small scale testing in the field. Advantageously, the instant inventions meet those needs and may have additional advantages that can lead to, for example, improved oil and/or gas production, better control of fracturing, and improved well design.
In one embodiment the application pertains to a process comprising preparing a fluid mixture for an oil field operation or a pipeline operation. The fluid mixture may comprise a concentration of a drag reducing agent determined based on a drag reduction parameter ΔB for the fluid mixture. The fluid mixture may then be used in the oil field operation or the pipeline operation.
In another embodiment the application pertains to a process comprising preparing a fluid mixture for an oil field operation or a pipeline operation. The fluid mixture generally comprises a concentration of a drag reducing agent determined based on a drag reduction parameter ΔB for the fluid mixture. The fluid mixture may be used in the oil field operation or the pipeline operation. The process may further comprise measuring one or more fluid properties of the fluid mixture in a laboratory, a flow loop, a portable apparatus, or any combination thereof. A small-scale drag reduction parameter ΔB may be determined for the fluid mixture based on the one or more fluid properties of the fluid mixture measured in the laboratory or the flow loop. The small-scale drag reduction parameter ΔB may be upscaled for use in the oil field operation or the pipeline operation. An analytical model may be used for upscaling the small-scale drag reduction parameter ΔB for use in the oil field operation or the pipeline operation.
In another embodiment the application pertains to a process to determine drag reduction for a fluid mixture for an oil field operation or a pipeline operation. The process comprises measuring one or more fluid properties of a fluid mixture comprising a concentration of a drag reducing agent in a laboratory, flow loop, or with a portable apparatus, or any combination thereof. A small-scale drag reduction parameter ΔB may be determined for the fluid mixture based on the one or more fluid properties. The small-scale drag reduction parameter ΔB may be used to determine a target fluid mixture for use in the oil field operation or the pipeline operation.
Currently, the industry is using more produced water for fracking. The produced water is typically transferred via a truck or other transportation means to a pad near the well to be fracked. Various chemical tanks are located on the pad so that chemicals appropriate for the fracking job can be added to the produced water on the pad before injecting it into the well during fracking. This often results in a pad crowded with water trucks and chemical tanks that could present a danger to the workers on the pad. It would be desirable if alternative processes could be employed that reduced the footprint of the pad by reducing the number of tanks and/or trucks at the pad. It would also be advantageous if such alternative processes provided additional benefits. Advantageously, the processes described here reduce the number of tanks and/or trucks at the pad and also were found to have additional surprising and unexpected benefits.
In one embodiment the application pertains to a process comprising adding a chemical composition to a produced water mixture upstream of a pad related to a well to be fracked. The produced water mixture comprising the added chemical composition is then transferred in a pipeline to the well to be fracked. The added chemical composition comprises a drag reducing agent, or a biocide, or a scale inhibitor, or any combination thereof. Fracking can then be done using the transferred produced water composition.
So that the manner in which the above recited features, advantages, and objects of the present invention are attained and can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to the embodiments thereof which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings only illustrate preferred embodiments of this invention, and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments that vary only in detail. In the drawings:
Certain terms are used throughout the following description and claims to refer to particular system components. As one skilled in the art will appreciate, different companies may refer to a component by different names. This document does not intend to distinguish between components that differ in name but not function.
Other definitions: The terms “comprise” (as well as forms, derivatives, or variations thereof, such as “comprising” and “comprises”) and “include” (as well as forms, derivatives, or variations thereof, such as “including” and “includes”) are inclusive (i.e., open-ended) and do not exclude additional elements or steps. For example, the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. Accordingly, these terms are intended to not only cover the recited element(s) or step(s), but may also include other elements or steps not expressly recited. Furthermore, as used herein, the use of the terms “a” or “an” when used in conjunction with an element may mean “one,” but it is also consistent with the meaning of “one or more,” “at least one,” and “one or more than one.” Therefore, an element preceded by “a” or “an” does not, without more constraints, preclude the existence of additional identical elements.
The use of the term “about” applies to all numeric values, whether or not explicitly indicated. This term generally refers to a range of numbers that one of ordinary skill in the art would consider as a reasonable amount of deviation to the recited numeric values (i.e., having the equivalent function or result). For example, this term can be construed as including a deviation of ±10 percent of the given numeric value provided such a deviation does not alter the end function or result of the value. Therefore, a value of about 1% can be construed to be a range from 0.9% to 1.1%. Furthermore, a range may be construed to include the start and the end of the range. For example, a range of 10% to 20% (i.e., range of 10%-20%) includes 10% and also includes 20%, and includes percentages in between 10% and 20%, unless explicitly stated otherwise herein. Similarly, a range of between 10% and 20% (i.e., range between 10%-20%) includes 10% and also includes 20%, and includes percentages in between 10% and 20%, unless explicitly stated otherwise herein.
The term “if” may be construed to mean “when” or “upon” or “in response to determining” or “in accordance with a determination” or “in response to detecting,” that a stated condition precedent is true, depending on the context. Similarly, the phrase “if it is determined [that a stated condition precedent is true]” or “if [a stated condition precedent is true]” or “when [a stated condition precedent is true]” may be construed to mean “upon determining” or “in response to determining” or “in accordance with a determination” or “upon detecting” or “in response to detecting” that the stated condition precedent is true, depending on the context.
It is understood that when combinations, subsets, groups, etc. of elements are disclosed (e.g., combinations of components in a composition, or combinations of steps in a method), that while specific reference of each of the various individual and collective combinations and permutations of these elements may not be explicitly disclosed, each is specifically contemplated and described herein. By way of example, if an item is described herein as including a component of type A, a component of type B, a component of type C, or any combination thereof, it is understood that this phrase describes all of the various individual and collective combinations and permutations of these components. For example, in some embodiments, the item described by this phrase could include only a component of type A. In some embodiments, the item described by this phrase could include only a component of type B. In some embodiments, the item described by this phrase could include only a component of type C. In some embodiments, the item described by this phrase could include a component of type A and a component of type B. In some embodiments, the item described by this phrase could include a component of type A and a component of type C. In some embodiments, the item described by this phrase could include a component of type B and a component of type C. In some embodiments, the item described by this phrase could include a component of type A, a component of type B, and a component of type C. In some embodiments, the item described by this phrase could include two or more components of type A (e.g., A1 and A2). In some embodiments, the item described by this phrase could include two or more components of type B (e.g., B1 and B2). In some embodiments, the item described by this phrase could include two or more components of type C (e.g., C1 and C2). In some embodiments, the item described by this phrase could include two or more of a first component (e.g., two or more components of type A (A1 and A2)), optionally one or more of a second component (e.g., optionally one or more components of type B), and optionally one or more of a third component (e.g., optionally one or more components of type C). In some embodiments, the item described by this phrase could include two or more of a first component (e.g., two or more components of type B (B1 and B2)), optionally one or more of a second component (e.g., optionally one or more components of type A), and optionally one or more of a third component (e.g., optionally one or more components of type C). In some embodiments, the item described by this phrase could include two or more of a first component (e.g., two or more components of type C (C1 and C2)), optionally one or more of a second component (e.g., optionally one or more components of type A), and optionally one or more of a third component (e.g., optionally one or more components of type B).
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to make and use the invention. The patentable scope is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have elements that do not differ from the literal language of the claims, or if they include equivalent elements with insubstantial differences from the literal language of the claims.
Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of skill in the art to which the disclosed invention belongs. All citations referred herein are expressly incorporated by reference.
In one embodiment the invention pertains to a portable apparatus for analyzing drag reduction. By portable, it is meant that the apparatus may easily be transported from site to site. For example, the portable design of the apparatus can permit the apparatus to be readily transported to often remote locations (e.g., to sites in the field where fluids are being used) and used to analyze fluids, particularly those that include one or more drag reducing agents. In addition to improving portability, the relatively small footprint of the apparatus allows for the apparatus to be deployed in a wider variety of locales (e.g., in smaller rooms or facilities that lack the available space for a full-scale analytical laboratory). This allows for once complex analytical operations to be efficiently performed on-site using a single, portable piece of equipment.
In some embodiments, the assembled portable apparatus can have a footprint of 25 square feet or less (e.g., 20 square feet or less, 15 square feet or less, 12.5 square feet or less, 10 square feet or less, 9 square feet or less, 8 square feet or less, 7 square feet or less, 6 square feet or less, 5 square feet or less, or 4 square feet or less). In some embodiments, the assembled portable apparatus can have a footprint of at least 2 square feet (e.g., at least 3 square feet, at least 4 square feet, at least 5 square feet, or at least 6 square feet).
The assembled portable apparatus can have a footprint ranging from any of the minimum values described above to any of the maximum values described above. For example, the assembled portable apparatus can have a footprint of from 2 to 25 square feet (e.g., from 2 to 15 square feet, from 2 to 10 square feet, or from 4 to 8 square feet).
In some embodiments, the assembled portable apparatus can occupy a volume of 35 cubic feet or less (e.g., 30 cubic feet or less, 25 cubic feet or less, 20 cubic feet or less, 15 cubic feet or less, 12.5 cubic feet or less, 10 cubic feet or less, 9 cubic feet or less, 8 cubic feet or less, 7 cubic feet or less, 6 cubic feet or less, 5 cubic feet or less, or 4 cubic feet or less). In some embodiments, the assembled portable apparatus can occupy a volume of at least 2 cubic feet (e.g., at least 3 cubic feet, at least 4 cubic feet, at least 5 cubic feet, at least 6 cubic feet, at least 7 cubic feet, or at least 8 cubic feet).
The assembled portable apparatus can occupy a volume ranging from any of the minimum values described above to any of the maximum values described above. For example, the assembled portable apparatus can occupy a volume of from 2 to 35 cubic feet (e.g., from 2 to 15 cubic feet, from 2 to 10 cubic feet, or from 2 to 8 cubic feet).
The components of the apparatus can be self-contained and assembled within a housing. This allows for the apparatus to be rapidly deployed. For example, setup times can be short enough to allow the portable apparatus to be up and running in a matter of hours. This is significantly shorter than the setup time required for a typical full-scale analytical laboratory.
Typically, the apparatus comprises a housing encompassing a pipe with an inlet to receive a fluid. The pipe may be of any suitable conduit, dimensions, and material so long as it is capable of carrying the fluid from the inlet to an outlet of the pipe. Thus, the specific pipe, dimensions, and material may vary depending upon the desired application, type of fluid, and properties to be analyzed by the apparatus. A suitable range to allow for drag reduction measurements in a portable apparatus for the pipe inner diameter is greater than approximately 0.25 inches and less than approximately 0.75 inches. For example, the portable apparatus can have a single pipe diameter of approximately 0.25 inches, approximately 0.3 inches, approximately 0.4 inches, approximately 0.5 inches, approximately 0.6 inches, or approximately 0.75 inches. In one example, the portable apparatus comprises two pipes of different diameters (e.g., a first pipe having a diameter ranging from approximately 0.25 inches to approximately 0.4 inches such as 0.3 inches and a second pipe having a diameter of approximately 0.5 inches to approximately 0.75 inches such as 0.6 inches). In another example, the portable apparatus three pipes of various diameters (e.g., a first pipe having a diameter ranging from approximately 0.25 inches to approximately 0.35 inches such as 0.3 inches, a second pipe having a diameter of approximately 0.35 inches to approximately 0.55 inches such as 0.4 inches, and a third pipe having a diameter of approximately 0.55 inches to approximately 0.75 inches such as 0.6 inches).
The apparatus typically has a pump to direct the fluid from the inlet through the pipe to an outlet of the pipe. The type of pump is not particularly critical so long as it can appropriately direct the fluid to be tested at a desired flow rate without degrading the drag reducer within the fluid. Examples of pumps that can be utilized include low-shear positive displacement pumps such as progressive cavity pumps commercially available by Moyno and Seepex GmbH. Typically, the pump and/or one or more of the other components of the apparatus is capable of adjusting the flow rate of the fluid. The manner of adjusting the flow rate is not critical so long as it is adjustable over the range of flow rates to be studied or employed. In one embodiment, the pump is able to generate a flow rate of between at least 2 gallons per minute and to less than 30 gallons per minute. If the pump does not directly adjust the flow rate, then the flow rate may be adjusted by, for example, a pressure regulator, a control valve and a vent port, a pressure relief valve, or any combination of these or other devices.
In some embodiments, a pump is not necessary. For example, the portable apparatus can be connected or teed into a main flow line (e.g., injection line in a hydraulic fracturing operation) such that it obtains a slipstream sample of the fluid to be tested. In this case flow can be controlled using a pressure regulator, a control valve and a vent port, a pressure relief valve, a needle valve or any combination of these or other devices. The pressure and flow rate in the main flow line is sufficient to supply the portable apparatus such that fluid properties of the fluid can be measured.
Typically, the apparatus is configured with one or more instruments to measure one or more fluid properties. Such properties may be selected from flow rate, fluid temperature, inlet pressure, outlet pressure, a differential pressure across the pipe, or any combination thereof. Thus, typical instruments may include, for example, a pressure gauge or pressure transducer or pressure indicator transmitter (PIT), thermocouple or temperature probe or temperature indicator transmitter (TIT), a flow meter or flow transducer or flow indicator transmitter (FIT), or any combination thereof. In some embodiments, the apparatus may also be configured with additional instruments to measure fluid properties such as a pH probe, a conductivity probe, an Oxidation-Reduction Potential (ORP) probe, or any combination thereof.
A data acquisition system is usually provided to receive data from the one or more instruments to measure one or more fluid properties. The data acquisition system is often programmed so that it is capable of determining drag reduction of the fluid from data it receives. The data acquisition system may be any convenient system and may comprise, for example, a processor, a monitor, and/or a keyboard or other data entry capability. A power supply is typically coupled to the pump, the one or more instruments, and the data acquisition system. The power supply employed is not particularly critical so long as it is capable of supplying the necessary power at the locations where the portable apparatus may be employed. Thus, a source of power may include, for example, electrical, solar, battery such as lithium ion or other battery, wind, etc.
If it is desired to measure more than one fluid simultaneously, then the portable apparatus may comprise a second, a third, or even more additional pipes. The additional pipes can receive fluid from the inlet (e.g., via a tee or multi-way valve) and expel fluid to the outlet (e.g., via a tee or multi-way valve), or alternatively each pipe in the apparatus can be associated with a separate inlet to receive fluid and a separate outlet to expel the fluid from the apparatus. The effluent fluid can be recirculated back to inlet 15 for additional testing, can be reintroduced into the fluid being injected into a subterranean reservoir, can be treated and disposed of as waste, or any combination thereof. The additional pipes, if any, are usually configured with one or more instruments to measure one or more additional pipe fluid properties selected from flow rate, fluid temperature, inlet pressure, outlet pressure, a differential pressure across the second pipe, or any combination thereof. The instruments associated with added pipes may be configured to operably connect to the same or a different data acquisition system. In this manner, data received from the one or more instruments to measure one or more added pipe fluid properties may be used to determine drag reduction from data received.
If desired, the portable apparatus may be operably connected to a hydraulic fracturing system. In this manner, drag reduction of a potential fracturing fluid comprising drag reducing agents (or even lacking such agents) may be determined at any desirable stage in the fracturing process. For example, drag reduction of a potential fracturing fluid may be determined prior to pumping the fracturing fluid into a borehole. In this manner one could, for example, employ a portable apparatus downstream, upstream, or both of a blender to determine the effects the blender may have on a potential fracturing fluid.
The processes of using the portable apparatus typically comprise flowing a fluid through the apparatus and then determining the drag reduction. For example, if employed with a hydraulic fracturing system comprising a blender, then one portable apparatus may operably be connected to the hydraulic fracturing system upstream of the blender while a second portable apparatus is operably connected to the hydraulic fracturing system downstream of the blender to determine drag reduction of the fracturing fluid. In some embodiments drag reduction of a first fluid can be compared with drag reduction of a second fluid such that adjustments may be made. For example, one or more hydraulic fracturing parameters could be adjusted based on the comparison. Such parameters include, for example, those selected from drag reducing agent, amount of drag reducing agent, flow rate, proppant, amount of proppant, or any combination thereof. The portable apparatus may also be used in conjunction with the below upscaling embodiments to obtain laboratory data or flow loop data which can then be upscaled.
Various instruments may be utilized to measure one or more fluid properties. The location of each instrument may vary depending upon the desired configuration and testing conditions.
While
For example, since apparatus 10 of
A data acquisition system 33, which is usually provided to receive data from the one or more instruments (21, 23, 25) to measure one or more fluid properties. The data acquisition system 33 may be located within housing 12 of apparatus 10 as shown in
As previously discussed, testing results performed in the laboratory or flow loop do not accurately predict drag reduction observed in field applications. In general, this is due to the laboratory or flow loop conditions being measured on much smaller equipment than what is used in the field. For example, laboratory or flow loop equipment typically measure drag reduction in pipe sizes less than 1 inch, whereas in field applications fluid is flowing through pipes with a diameter typically around 4 or 5 inches. Flow in laboratory equipment or flow loops is typically around 10-20, or 30 gallons per minute, whereas in field applications it can be 60-120 or 100-150 barrels per minute or higher. Laboratory equipment or flow loops also do not mimic other field conditions as well (e.g., pipe wall roughness). This generally results in a range of Reynolds number produced in the laboratory being much lower (e.g., between 50,000-200,000) compared to those observed in the field (e.g., between 1,500,000-3,000,000).
In step 53, laboratory or flow loop data is measured to populate or calibrate analytical model 51. In embodiments, this data is measured using portable apparatus 10 previously described. In some embodiments, laboratory or flow loop data 53 comprises yard-scale flow loop data (i.e., measurements using larger sized equipment such as 2-3 inch diameter piping). Fluid can be measured at various concentrations of drag reducing agent. For example, initially a fluid (e.g., water plus other chemicals to be injected in the subterranean reservoir) can be measured at a range of flow rates between 2 and 30 gallons per minute (e.g., in increments of 2 gallons per minute each for 15 to 60 seconds). The drag reducing agent can then be added for a range of concentrations between 0.1 to 5 gallons of drag reducing agent per thousand gallons of fluid (e.g., at concentrations 0.1, 0.25, 0.5, 0.75, 1.0, 1.5, 2.0, 2.5, 3.0 3.5, 4.0, 4.5, and 5 gpt) and for each concentration a pressure drop can be recorded as the flow rate is altered (e.g., increased, decreased, or both). Typically, the pressure drop reaches steady state for a change in flow rate within 60 seconds (e.g., 15-30 seconds). Note that at higher flow rates the flow duration should be closely monitored to ensure degradation of the drag reducing agent is limited while still acquiring steady state pressure drops.
Once the analytical model 51 is populated or conditioned with the laboratory or flow loop data, it can then be used to upscale the drag reduction percentage and applied to predict, design and/or modify field operations 57 to enhance field performance. Field data 55 can further be used to validate analytical model 51, as well as, guide testing to obtain additional laboratory or flow loop data 53. Field data 55 can comprise measurements or estimates of drag reduction based on wellhead pressure, bottom hole pressures, estimated hydrostatic pressure, perforation pressure friction loss, tubing pressure differentials, tubing or pipe lengths, flow rates, or any combination thereof. Analytical model 51 can then be used to predict, design and/or modify field operations 57 to enhance field performance.
Process 50 can additionally include database 59 to store properties of drag reducing agents (e.g., relaxation time, drag reduction parameters, molecular weight) obtained from laboratory or flow loop data 53, field data 55, or any combination thereof. Information contained in database 59 can be used by analytical model 51 to predict, design and/or modify field operations 57 to enhance field performance. In particular, storing properties of drag reducing agents in database 59 can help reduce the need for future testing of fluids comprising a drag reducing agent as this information can be utilized as an alternative to, or in addition to, new laboratory or flow loop data 53, field data 55, or any combination thereof.
In one embodiment, a process comprises first preparing a fluid mixture and pumping the fluid mixture through a wellbore into a formation. The specific composition of the fluid mixture will vary depending upon, for example, the well characteristics and/or desired results. In some embodiments the fluid mixture comprises a concentration of a drag reducing agent. Of course, the concentration and the specific drag reducing agent may vary depending upon the desired results and other parameters. In some embodiments the drag reducing agent is selected from agents which have a ΔBmax in said formation of from about 10, or from about 15, or from about 20, or from about 25, or from about 40, or from about 45, or from about 50 up to about 70, or up to about 65, or up to about 60, or up to about 55, or up to about 50, or up to about 30 during at least a portion of the process. Representative useful processes include, for example, hydraulic fracturing, injecting fluid, produced water, transportation of water for reinjection, pipelining fluids in turbulent flow conditions, and/or disposal well processes. As the ordinary skilled artisan appreciates such representative processes alone or any combination thereof may be referred to generally as an oil field operation or a pipeline operation.
In another embodiment, the present application relates to a process useful in oil and gas industry such as hydraulic fracturing an oil or gas formation. Such processes first typically comprise obtaining data on one or more potential drag reducing agents by conducting flow loop testing. Next, upscaling is conducted using obtained flow loop data on the one or more potential drag reducing agents to obtain predicted drag reduction of the one or more potential drag reducing agents in a process such as hydraulic fracturing. A drag reducing agent and a concentration of the drag reducing agent based at least in part on the predicted drag reduction can be selected, and the selected process (e.g., hydraulically fracturing) may be conducted using the selected concentration of the selected drag reducing agent. That is, in the case of hydraulically fracturing, one may pump a fluid mixture comprising the selected concentration of the selected drag reducing agent through a wellbore into the formation.
Obtaining predicted drag reduction comprises using one or more parameters selected from the group consisting of polymer relaxation time, shear rate, polymer drag reduction parameter AB, pipe diameter, flow rate, pipe roughness, shear stress on pipe, or any combination thereof. In some embodiments, one may obtain or measure actual drag reduction during hydraulic fracturing and use it advantageously. For example, predicted drag reduction of the selected drag reducing agent and selected concentration of the drag reducing agent may be compared with actual or measured drag reduction to calibrate the upscaling parameters and models.
In other embodiments, viscosity of the one or more potential drag reducing agents may be measured prior to conducting flow loop testing and then viscosity can be measured again subsequent to conducting flow loop testing. An understanding of the differences may be favorably employed in upscaling.
In another embodiment, the application pertains to a process to determine drag resistance. The process typically comprises obtaining data on viscosity as a function of shear rate, drag reduction percentage as a function of velocity, or both for a plurality of drag reducing agents. Preferably, the data is obtained on at least one diameter or preferably a plurality of diameters of conduit. Such conduit may be any shape but it typically substantially cylindrical such as a tubing or a pipe.
Data may be obtained on at least one concentration, however, a plurality of concentrations may be preferable depending upon the specific drag reducing agent or agents and other parameters employed. In embodiments, data can be obtained for concentrations drag reducing agent of approximately 0.1 gallons per one thousand gallons of water (0.1 gpt), approximately 0.25 gallons per one thousand gallons of water (0.25 gpt), approximately 0.5 gallons per one thousand gallons of water (0.5 gpt), approximately 0.75 gallons per one thousand gallons of water (0.75 gpt), approximately 1 gallons per one thousand gallons of water (1.0 gpt), approximately 1.5 gallons per one thousand gallons of water (1.5 gpt), approximately 2 gallons per one thousand gallons of water (2 gpt), approximately 5 gallons per one thousand gallons of water (5 gpt), or any combination thereof.
Data may be obtained on at least one flow rate, however, a plurality of flow rates may be preferable depending upon the specific drag reducing agent or agents and other parameters employed. In embodiments, data can be obtained for flow rates of approximately 2 gallons per minute, approximately 3 gallons per minute, approximately 4 gallons per minute, approximately 5 gallons per minute, approximately 7 gallons per minute, approximately 9 gallons per minute, approximately 11 gallons per minute, approximately 13 gallons per minute, approximately 15 gallons per minute, approximately 20 gallons per minute, approximately 25 gallons per minute, approximately 30 gallons per minute, or any combination thereof. Generally, flow rates are tested for a time period in order for a pressure drop to reach steady state. Flow duration at higher flow rates should be minimized to limit mechanical polymer degradation while still acquiring steady state pressure drop recordings.
The drag reduction of the plurality of drag reducing agents may then be estimated. Typically, estimating uses parameters such as polymer drag reduction parameter ΔB, shear rate, and polymer relaxation time. If desired, the estimates may be stored in an analytical model which advantageously may be used in the future as estimates and actual field data are accumulated. In this manner the analytical model may even be more accurate in the future. That is, estimated drag reduction of the plurality of drag reducing agents may be compared with actual drag reduction if desired. In this manner the estimated drag reduction(s) in the analytical model may be modified based on the actual drag reductions.
In some embodiments, the process may comprise hydraulically fracturing a well using estimated drag reduction or modified estimated drag reduction to select a drag reducing agent, a concentration of drag reducing agent, or both. For example, the concentration of drag reducing agent may be modified (e.g., increased or decreased) in slickwater pumping stages or linear gel pumping stages to maximize recovery performance. Information may be advantageous for a number of additional reasons including, for example, so that a selection may be to reduce required horsepower or energy during hydraulically fracturing. Alternatively, or additionally the process could be used to design a well or completion (e.g., determine length of lateral, casing size) or enhance operation performance such that if fracturing is required, then it will be of less cost, more efficient, more productive, and/or provide other advantages to the designed well. The pumping schedule and design for a hydraulic fracturing operation could also be modified (e.g., pumping rate, perforation design, number of pumps).
The specific drag reducing agent or agents employed are not particularly limited and may include, for example, a polymer, a fiber, a surfactant (e.g., a higher molecular weight surfactant), a booster such as a solvent, or any combination thereof.
While the aforementioned upscaling processes for drag reduction agents may be accomplished in a number of ways, the specifics of a representative process are described below.
One may first make a solution with a specific concentration of drag reduction agents. Such a solution may be brine with any salinity and may include other chemicals such as surfactants, scale inhibitors, biocide, corrosion inhibitors. One then measures viscosity versus shear rate on the solution using, for example, a rheometer. This can be plotted as viscosity (e.g., units in centipoise: cP) on the Y-axis versus shear rate (e.g., units in reciprocal seconds: 1/sec) on the X-axis.
η=η∞+(η0−η∞)[1+({dot over (γ)} λ)2](n−1)/2
where η represents dynamic or shear viscosity such that η0 is the zero shear viscosity and η∞ is the infinite shear viscosity, {dot over (γ)} represents shear rate, λ represents relaxation time, and n is a power law index. The relaxation time from Carreau-Yasuda is a fitting parameter and may not represent the physical properties of the polymer solution. Relaxation time can be measured using a rheometer by a person trained in the art. For such lower concentration of friction reducers, specialized Rheometers such as a micro-rheometer or extensional Rheometer may be utilized to obtain accurate relaxation time and viscosity vs shear rate data. Alternatively, analytical models can be utilized to estimate extensional or Zimm relaxation time and viscosity vs shear rate data for lower concentrations of friction reducers from viscosity measurements at high concentrations using conventional rheometers. Useful information about analytical models may be found in, for example, in Jouenne et al. Conference Proceedings, IOR 2019—20th European Symposium on Improved Oil Recovery, Apr 2019, Volume 2019, p. 1-23 (2019) (https://doi.org/10.3997/2214-4609.201900140) which is incorporated herein by reference and was modified to show relaxation time dependency on concentration below c/c*<1 where c is polymer concentration and c* is critical polymer concentration equal to inverse of intrinsic viscosity. As used herein the shear rate {dot over (γ)} multiplied by the relaxation time λ is the Weissenberg number (We or Wi), which is a dimensionless number that compares elastic to viscous forces.
The equation to model viscosity as function of shear rate can be transformed to shear stress versus shear rate as follows:
τw=ηw{dot over (γ)} w
τw=η∞{dot over (γ)} w+(η0−η∞){dot over (γ)} w[1+({dot over (γ)} wλ)2](n−1)/2
where τw represents shear stress at the wall of the pipe.
Pressure drop in a pipe is generally a function of shear stress. Shear rate at the wall can be calculated for any flow rate in a pipe using the above equation with measured viscosity versus shear rate data.
Using a flow-loop (e.g., 1 or more tube diameters), one can measure flow rate versus pressure drop for a wide range of flow rates. This is generally done quickly by switching to a new flow rate when the pressure stabilizes. Pressure drop can be converted to a drag reduction percentage (DR %) using the equation below.
Drag reduction percentage (DR %) can then be plotted on the Y-axis with flow rate (e.g., gallons per minute) on X-axis using the measured pressure drop data.
Drag reduction percentage (DR %) can also be plotted compared to shear rate (1/s) as shown in
τw=ηw{dot over (γ)} w
τw=η∞{dot over (γ)} w+(η0−η∞){dot over (γ)} w[1+({dot over (γ)} wλ)2](n−1)/2
Accordingly, the results using the flow loop experiment using the various pipe diameters shown in
In order to obtain the plot in
ΔB=ΔBmaxBN
BN=0 for Wi≤1
BN=CDF for 0<BN≤1
where ΔBmax is the maximum drag reduction at Wi>>1, BN is the normalized drag reduction as a function of shear, Wi={dot over (γ)} wλ is Weissenberg number, {dot over (γ)} w is the wall shear rate, λ is the longest relaxation time, and CDF is a cumulative distribution function. An example of CDF utilized is lognormal distribution function,
where u is mean and σ standard deviation.
Where fwater is friction factor of water, fFR is friction factor of friction reducer, and fVirk is friction factor of Virk's asymptote and all are at the same Reynolds number.
Once ΔB and relaxation time are known, flow rates for imposed pressure gradients can be estimated for turbulent flow in a pipe by deriving the velocity profile of fluid. In the literature, the velocity profile of turbulent flow in a pipe has been measured and derived for water and water with drag reducing agents. The profile comprises three layers: a viscous sublayer near the wall, a buffer layer, and a log-law layer. It has been demonstrated that drag reducing agents function by increasing the buffer layer thickness, and ΔB from
In particular,
Once maximum drag reduction and relaxation times are tuned based on the measured flow loop data, the model can be used to upscale to estimate Darcy Friction Factor vs. Reynolds number for any pipe diameter. When a Darcy Friction Factor versus Reynolds number curve is generated, using the equation
then a pressure drop versus flow rate table can be estimated.
The preceding steps can be repeated for various concentrations of drag reducing agents. And if one desired to evaluate two or more drag reducing agents, then the preceding steps may be repeated for each drag reducing agent or call of agents being considered.
The table below shows the analytical model fit parameters of a range of partially hydrolyzed polyacrylamide friction reducer solutions that were tested utilizing the flow-loop procedure outlined in this patent. The properties tested were 20-300 ppm polymer concentration, 0.1-12% TDS brines, and a range of polymer molecular weights.
The key for friction reducer/polymer table describes estimated molecular weight of partially hydrolyzed polyacrylamide polymers utilized. Low describes FRs with average MW of from about 0.5 MDa to about 5 MDa. Mid describes FRs with average molecular weight between about 5 to about 15 MDa. High describes FRs with average molecular weight of from about 15 MDa to about 30 MDa. A Mid-High polymer is one that is on the upper end of the Mid range and lower end of the High range.
When normalized concentrations (concentration times intrinsic viscosity, C[n]) is plotted vs. ΔBmax for all friction reducers tested with lab flow-loop apparatus, the data appear to collapse into a master curve observed in
It has been discovered that it is advantageous to chemically dose a produced water mixture or other water mixtures prior to the water being transferred to a pad related to a well to be fracked. That is, the chemical dosing may occur remote from the pad such that chemical storage tanks for one or more of the chemicals in the chemical dosing are not on the pad. Advantages oof such dosing techniques may include, for example, reducing the footprint at the pad, improved efficacy of biocide, reduced time to transfer produced water, and/or reduced pumping time during the fracking.
Generally, the processes involve adding a chemical composition to a produced water mixture upstream of a pad related to a well to be fracked. The specific chemical composition added may vary and often may depend upon the chemicals desired for the specific fracking job, the specific characteristics of the well, the specific characteristics of the produced water mixture, and/or desired results. In some embodiments, the added chemical composition comprises a drag reducing agent, or a biocide, or a scale inhibitor, or any combination thereof. The produced water mixture that comprises the added chemical composition is then transferred by, for example, a pipeline to the well to be fracked. The pipeline employed is not particularly critical so long as it is capable for transferring the produced water mixture with added chemical composition. As described below, the pipeline may be configured such that the added chemicals in the chemical composition are added directly to the pipeline separately, together, or partially together and partially separate. The well may then be fracked using at least a portion of the transferred produced water mixture comprising the added chemical composition.
The chemical composition may be added to the produced water mixture in any convenient manner at any convenient place upstream from the pad. In some embodiments the specific ingredients of the chemical composition may be added separately while in other embodiments the chemical composition may be added together. In some embodiments one or more components of the chemical composition is added to the produced water mixture in a pipeline. In some embodiments one or more components of the chemical composition is added to the produced water mixture in one or more tanks and/or ponds. In some embodiments, one or more components of the chemical is added to the produced water mixture in a pipeline while other components of the chemical composition are added to the produced water mixture in one or more tanks and/or ponds.
The produced water mixture employed herein may be any mixture comprising produced water so long as the produced water mixture is suitable for fracking or may be made suitable for fracking prior to injection into the well. Produced water as used herein comprises naturally occurring water that comes out of a well with crude oil or gas during production. Produced water may contain soluble and/or non-soluble oil/organics, suspended solids, dissolved solids, and/or various chemicals used in the production process. The produced water employed in the produced water mixture herein may be treated to make it suitable for use in fracking or suitable for use in fracking with one or more added chemicals. The produced water in the produced water mixture may originate from the well to be fracked, a surrounding well, a distant well, or any combination thereof.
In some embodiments, water and/or other ingredients may be included in and/or added to the produced water mixture. Such added water and/or other ingredients may be added prior to the adding of the chemical composition, after the adding of the chemical composition, or even in between adding of potential added chemicals of the chemical composition. When adding water to the produced water mixture the added water may be from a pond or a tank and in some embodiments may comprise brackish water from a pond, tank, or other source.
The amount and specific drag reducing agent, if any, that may be included as part of the added chemical composition may vary depend upon the chemicals desired for the specific fracking job, the specific characteristics of the well, the specific characteristics of the produced water mixture, and/or desired results. If desired, the techniques described above may be employed to determine the specific drag reducing agent and/or concentration to be employed in cases employing a drag reducing agent. That is, the added chemical composition may comprise a concentration of the drag reducing agent determined based on a drag reduction parameter ΔB for the produced water mixture wherein the drag reduction parameter ΔB is defined by an equation:
ΔB=ΔBmaxBN
wherein BN=0 for Wi≤1 and BN=CDF for 0<BN≤1 wherein ΔBmax is maximum drag reduction at Wi>>1, BN is normalized drag reduction as a function of shear, Wi={dot over (γ)} wλ is Weissenberg number, {dot over (γ)} w is the wall shear rate, λ is the longest relaxation time, and CDF is a cumulative distribution function.
As described above, the drag reducing agent may be selected from agents which have a ΔBmax in said formation of from about 10, or from about 15, or from about 20, or from about 25, or from about 40, or from about 45, or from about 50 up to about 70, or up to about 65, or up to about 60, or up to about 55, or up to about 50, or up to about 30 during at least a portion of the process.
In some embodiments the added chemical composition comprises the initial drag reducing agent that is added at a place remote from the pad while the process may further comprise adding an amount of a second drag reducing agent to the transferred produced water mixture. The adding of the amount of the second drag reducing agent to the transferred produced water mixture may be done at or near the pad. The second drag reducing agent may be the same or different than the drag reducing agent of the added chemical composition.
In some embodiments the concentration of the second drag reducing agent to be added may be determined based on a drag reduction parameter ΔB for the transferred produced water mixture wherein the drag reduction parameter ΔB is defined by an equation:
ΔB=ΔBmaxBN
wherein
BN=0 for Wi≤1 and
BN=CDF for 0<BN≤1
wherein ΔBmax is maximum drag reduction at Wi>>1, BN is normalized drag reduction as a function of shear, Wi={dot over (γ)} wλ is Weissenberg number, {dot over (γ)} w is the wall shear rate, λ is the longest relaxation time, and CDF is a cumulative distribution function.
The amount and specific biocide, if any, that may be included as part of the added chemical composition may vary depending upon the chemicals desired for the specific fracking job, the specific characteristics of the well, the specific characteristics of the produced water mixture, and/or desired results.
The amount and specific scale inhibitor, if any, that may be included as part of the added chemical composition may vary depending upon the chemicals desired for the specific fracking job, the specific characteristics of the well, the specific characteristics of the produced water mixture, and/or desired results.
Surprising and/or Unexpected Benefits Such as Reduced Friction Loss, Reduced Energy, Reduced CO2 Emissions, Enhanced Bacterial Activity, and/or Reduced Fracking Pressures
As described above, the addition of the chemical composition upstream of the pad may result in one or more surprising and/or unexpected benefits. Such benefits may include, for example, enhanced transfer efficiency of the produced water mixture. That is, the added chemical composition may comprise a concentration of a suitable drag reducing agent such that pipeline friction loss during the transferring is reduced by at least about 10%, or at least 20%, or at least 30%, or at least 40% or more as compared to a transfer of a comparable volume of a produced water mixture lacking the drag reducing agent over a comparable distance in a comparable pipeline.
Other benefits of adding the chemical composition upstream of the pad may include a reduced amount of energy needed to transfer a produced water mixture. For example, the energy for transferring the produced water mixture may be supplied by a pump fuel comprising diesel. The added chemical composition may comprise a concentration of drag reducing agent such that an amount of diesel used during the transferring is reduced by at least about 10%, or at least about 20%, or at least about 30%, or at least about 40% as compared to a transfer of a comparable volume of a produced water mixture lacking the drag reducing agent over a comparable distance in a comparable pipeline. Advantageously, a carbon dioxide emission associated with the transferring may also be reduced by about 10 Kg or more of carbon dioxide per gallon of diesel used during the transferring.
Another advantage of adding the chemical composition upstream may be that a biocide, if employed, may reduce bacterial activity in the produced water mixture by at least about 80%, or at least about 90%, or at least about 99% or more as compared to a produced water mixture lacking the biocide.
What's more, it has been surprisingly discovered when adding a drag reducing agent upstream of the pad then often an average pressure employed during a subsequent fracking may be lower than a comparable fracking that employs a transferred produced water mixture lacking the upstream added chemical composition comprising the drag reducing agent. Additionally or alternatively, when adding drag reducing agent upstream of the pad, then a reduced amount of drag reducing agent may be necessary for a similar fracking pressure.
The example results below show a 99% reduction in bacterial activity when adding biocide upstream of the pad. This may reduce the risk of produced water potentially souring in water lines and/or working tanks while, for example, there is a shutdown or reduced activity at the wellsite.
This application is a continuation-in-part of U.S. application Ser. No. 17/104,514 filed on Nov. 25, 2020, and allowed on Oct. 3, 2023 and issuing as U.S. Pat. No. 11,898,094 on Feb. 13, 2024. U.S. application Ser. No. 17/104,514 claims priority to U.S. provisional patent application no. 62/941,008 filed on Nov. 27, 2019, the entire application which is incorporated herein by reference. U.S. application Ser. No. 17/104,514 also claims priority to U.S. non-provisional application Ser. No. 16/697,426 filed on Nov. 27, 2020, which is also incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 62941008 | Nov 2019 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 17104514 | Nov 2020 | US |
| Child | 18437718 | US | |
| Parent | 16697426 | Nov 2019 | US |
| Child | 17104514 | US |
