Hydraulic energy transmission system with filtration system

Abstract

A system includes a hydraulic energy transfer system configured to exchange pressure between a first fluid and a second fluid, wherein the pressure of the first fluid is higher than the pressure of the second fluid. The system also includes a lubrication system coupled to the hydraulic energy transfer system and configured to pump or direct a lubricating fluid into the hydraulic energy transfer system.

Description

[0001] This application is a divisional application of the patent application filed on May 21, 2018, with application number 201880049461.4 (international application number PCT / US2018 / 033595) and entitled "Hydraulic Energy Transmission System with Filtering System". Background Technology

[0002] This section is intended to introduce the reader to various aspects of the technology that may be related to the aspects of the invention described and / or defined below. It is believed that this discussion will help provide the reader with background information to better understand the various aspects of the invention. Therefore, it should be understood that these statements should be read in this context and not as an endorsement of the prior art.

[0003] The subject matter disclosed herein relates to fluid handling equipment, and more particularly to fluid handling equipment for applications involving multiple fluids. Some of these fluids may contain solids (e.g., particles, powders, debris, microparticles) and / or contaminants (e.g., thickeners, chemical additives, or any fluid not desired for bearing lubrication), which may interfere with the operation of the fluid handling equipment. Fluid handling equipment can be used in a variety of applications. For example, fluid handling equipment can be used in hydraulic fracturing, drilling applications (circulating drilling fluids and / or mud), or similar processes. In particular, well completion operations in the oil and gas industry often involve hydraulic fracturing (also commonly referred to as "fracking" or "fracing") to increase the release of oil and gas from the formation. Hydraulic fracturing involves pumping a fluid comprising a composition of water, chemicals, and proppant (e.g., sand, ceramics) into the well at high pressure. The high pressure of the fluid increases the size and propagation of fractures through the formation to release oil and gas, while the proppant prevents the fractures from closing once the fluid pressure decreases.

[0004] Fracturing operations utilize various rotating equipment, such as hydraulic power transmission systems, to handle a variety of fluids that may include solids (e.g., particles, powders, debris, microparticles) and / or contaminants (e.g., thickeners, chemical additives, or any fluid not desired for bearing lubrication). In certain situations, solids can prevent the rotating components of the equipment from rotating. Therefore, it may be necessary to decommission the rotating equipment to allow for the removal of solids and / or to allow the rotating components to rotate. In some cases, lubrication systems can facilitate the rotation of rotating components within the hydraulic power transmission system. However, the fluids used in lubrication systems may contain additional solids or contaminants, such as particles, powders, debris, etc., and these solids or contaminants may negatively impact the performance of rotating components (e.g., reduced performance / efficiency, component wear, etc.). Summary of the Invention

[0005] In one embodiment, the system includes a hydraulic power transfer system configured to exchange pressure between a first fluid and a second fluid, wherein the pressure of the first fluid is higher than the pressure of the second fluid. The system also includes a lubrication system coupled to the hydraulic power transfer system and configured to pump or direct lubricating fluid into the hydraulic power transfer system.

[0006] In another embodiment, the system includes a hydraulic power transfer system configured to exchange pressure between a first fluid and a second fluid, wherein the pressure of the first fluid is higher than the pressure of the second fluid. The system includes a lubrication system coupled to the hydraulic power transfer system and configured to pump or direct lubricating fluid into the hydraulic power transfer system. The system includes a filtration system coupled to the hydraulic power transfer system and configured to filter the lubricating fluid before it enters the hydraulic power transfer system. The system includes one or more valves and one or more pumps disposed along the fluid flow path of the system. The system also includes a controller programmed to control one or more valves and / or one or more pumps of the system to selectively direct lubricating fluid into the hydraulic power transfer system based on the operating conditions of the system.

[0007] In another embodiment, the system includes a hydraulic power transfer system configured to exchange pressure between a first fluid and a second fluid, wherein the pressure of the first fluid is higher than the pressure of the second fluid. The system includes a lubrication system coupled to the hydraulic power transfer system and including a dedicated pump to direct lubricating fluid into the hydraulic power transfer system. The system includes a filtration system coupled to the hydraulic power transfer system and configured to filter the lubricating fluid before it enters the hydraulic power transfer system, wherein the lubricating fluid includes a portion of the first fluid or fluid from a fluid supply source external to the hydraulic power transfer system. The system also includes a controller programmed to control one or more valves and / or one or more pumps disposed along the fluid flow path of the system to selectively direct lubricating fluid into the hydraulic power transfer system based on the operating conditions of the system. Attached Figure Description

[0008] The various features, aspects, and advantages of the invention will be better understood when the following detailed description is read with reference to the accompanying drawings, in which the same characters represent the same parts, wherein:

[0009] Figure 1 This is a schematic diagram of an embodiment of a fracturing system with a hydraulic energy transmission system;

[0010] Figure 2 This is shown as a rotating isobaric pressure exchanger (IPX) system. Figure 1 An exploded perspective view of an embodiment of the hydraulic energy transfer system shown.

[0011] Figure 3 yes Figure 2 The schematic diagram of an embodiment of the IPX system shown illustrates the filtration system.

[0012] Figure 4 yes Figure 2 The schematic diagram of an embodiment of the IPX system shown illustrates an embodiment of an integrated filtration system with multiple filters;

[0013] Figure 5 yes Figure 4 The schematic diagram of an embodiment of the integrated filtration system shown illustrates a sedimentation filtration system.

[0014] Figure 6 yes Figure 3 The schematic diagram of an embodiment of the filtration system shown illustrates a centrifugal separation filtration system.

[0015] Figure 7 yes Figure 2 The schematic diagram of an embodiment of the IPX system shown illustrates the filtration system disposed within the rotor.

[0016] Figure 8 yes Figure 2 The block diagram shown is of an embodiment of the IPX system, which is connected to a lubrication system having a dedicated lubricating fluid supply source;

[0017] Figure 9 yes Figure 2 The block diagram shown is of an embodiment of the IPX system, which is connected to a lubrication section having a dedicated pump to guide lubricating fluid;

[0018] Figure 10 This is a block diagram of an embodiment of a controller operatively connected to a lubrication system;

[0019] Figure 11 This is a local loop diagram of the lubricating fluid, showing the path of the lubricating fluid; and

[0020] Figure 12 It is connected to the lubrication system Figure 2 The schematic diagram shows an embodiment of the IPX system. Detailed Implementation

[0021] One or more specific embodiments of the present invention will now be described. These described embodiments are merely examples of the invention. Furthermore, in the effort to provide a precise description of these exemplary embodiments, not all features of the actual implementation may be described in the specification. It should be understood that, as with any engineering or design project, the development of any such actual implementation involves numerous implementation-specific decisions to achieve the developer's specific goals, such as compliance with limitations of the relevant systems and related businesses that may vary in different implementations. Furthermore, it should be understood that such development work can be complex and time-consuming, but is a routine task of design, fabrication, and processing for those skilled in the art who will benefit from the present invention.

[0022] As mentioned above, clean lubricating fluid can be critical for the operation of rotating equipment, such as rotating components within a hydraulic power transmission system (e.g., a rotary pressure exchanger). Even small amounts of particulate matter or contaminants in the lubricating fluid or oil can affect equipment performance, causing rotating components to stop, wear or abrasion, or otherwise adversely impacting performance. With this in mind, embodiments of the present invention relate to systems and methods for providing clean / suitable fluid to lubricating oil flows and fluid bearings and seals. A dedicated external pump can be used to provide the lubricating oil flow, and the filtration system can filter or clean only a small portion of the total fluid flow entering the rotating equipment compared to the entire fluid flow. Thus, embodiments of the present invention offer advantages such as cost savings, easier maintenance, and energy savings compared to filtering the entire fluid flow.

[0023] As discussed in detail below, the embodiments disclosed herein generally relate to fluid handling apparatuses that can be used in many applications to handle a variety of fluids, which may include solids (e.g., particles, powders, debris, microparticles) and / or contaminants (e.g., thickeners, chemical additives, or any fluid not desired for bearing lubrication). For example, the fluid handling apparatus can be used in fracturing applications, such as in hydraulic fracturing systems. Various hydraulic fracturing systems and operations use various rotating devices, such as hydraulic power transmission systems, to handle various fluids. As mentioned above, lubrication systems facilitate the rotation of rotating components within hydraulic power transmission systems. However, in some cases, the fluid used within a lubrication system may include additional solids such as particles, powders, debris, etc. Therefore, the disclosed embodiments relate to filtering lubricating fluids within a lubrication system that can be used in a hydraulic power transmission system.

[0024] A fracturing system (or hydraulic fracturing system) includes a hydraulic energy transfer system that transfers work and / or pressure between a first fluid and a second fluid, such as a pressure exchange fluid (e.g., a fluid substantially free of proppant) and a hydraulic fracturing fluid (e.g., a proppant-loaded fracturing fluid). Because the hydraulic energy transfer system exchanges work and / or pressure with another fluid while impeding or limiting contact between the fracturing fluid and various hydraulic fracturing devices (e.g., high-pressure pumps), it can also be described as a hydraulic protection system, a hydraulic buffer system, or a hydraulic isolation system. The hydraulic energy transfer system may include a hydraulic turbocharger or a hydraulic pressure exchange system, such as a rotating isobaric pressure exchanger (IPX).

[0025] In certain embodiments, the IPX may include one or more chambers (e.g., 1 to 100) to facilitate pressure transfer and equalization between the volumes of a first fluid and a second fluid (e.g., a gas, liquid, or multiphase fluid). For example, one of these fluids (e.g., a fracturing fluid) may be a multiphase fluid, which may include a gas / liquid flow, a gas / solid particle flow, a liquid / solid particle flow, a gas / liquid / solid particle flow, or any other multiphase flow. In some embodiments, the pressures of the volumes of the first and second fluids may not be perfectly equalized. Thus, in some embodiments, the IPX may operate isobarically, or the IPX may operate substantially isobarically (e.g., where the pressures are equalized within approximately + / - 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 percent of each other). In some embodiments, the first pressure of the first fluid (e.g., a pressure exchange fluid) may be greater than the second pressure of the second fluid (e.g., a fracturing fluid). For example, the first pressure may be between about 5,000 kPa and 25,000 kPa, between 20,000 kPa and 50,000 kPa, between 40,000 kPa and 75,000 kPa, between 75,000 kPa and 100,000 kPa, or greater than the second pressure. Thus, the IPX can be used to transfer pressure from a first fluid at high pressure (e.g., a pressure exchange fluid) to a second fluid at low pressure (e.g., a fracturing fluid). In some embodiments, the IPX can transfer pressure between a first fluid (e.g., a pressure exchange fluid, such as a first fluid without proppant or substantially without proppant) and a second fluid that may be highly viscous and / or contain proppant (e.g., a fracturing fluid containing sand, solid particles, powder, debris, or ceramics). During operation, the hydraulic energy transfer system helps to impede or limit contact between the fluid containing the second proppant and various fracturing devices (e.g., high-pressure pumps) during fracturing operations. By hindering or limiting contact between various fracturing devices and a second fluid containing proppant, hydraulic power transfer systems reduce erosion and wear on various fracturing devices (e.g., high-pressure pumps) while increasing lifespan / performance. Furthermore, hydraulic power transfer systems enable the use of less expensive equipment in fracturing systems, by employing devices not designed for abrasive fluids (e.g., fracturing fluid and / or corrosive fluids) (e.g., high-pressure pumps).

[0026] Considering the foregoing, Figure 1This is a schematic diagram of an embodiment of a fracturing apparatus or fracturing system 10 with a hydraulic power delivery system. It should be noted that the hydraulic power delivery system discussed herein can also be used in any suitable application to handle a variety of fluids, and its use in fracturing applications is illustrated herein by way of example. In operation, the fracturing system 10 enables well completion operations to increase the release of oil and gas from the formation. Specifically, the fracturing system 10 pumps fracturing fluid, comprising a composition of water, chemicals, and proppant (e.g., sand, ceramics), into the well using a high-pressure pump. The high pressure of the fracturing fluid increases the size and propagation of fractures through the formation, thereby releasing more oil and gas, while the proppant prevents the fractures from closing once the fracturing fluid decompresses. As shown, the fracturing system 10 includes a high-pressure pump 12 and a low-pressure pump 14 coupled to a hydraulic power delivery system 16 (e.g., a hydraulic turbocharger or IPX). During operation, the hydraulic power transfer system 16 transmits pressure between a first fluid 18 (e.g., a proppant-free fluid) pumped by the high-pressure pump 12 and a second fluid 20 (e.g., a proppant-containing fluid or fracturing fluid) pumped by the low-pressure pump 14. In this way, the hydraulic power transfer system 16 prevents or limits wear on the high-pressure pump 12 while enabling the fracturing system 10 to pump the high-pressure fracturing fluid 22 to downstream applications 24 such as wells and to pump the low-pressure fracturing fluid 23 (e.g., a proppant-free fluid or fracturing fluid) out of the hydraulic power transfer system 16.

[0027] In one embodiment, the hydraulic power delivery system 16 may include a hydraulic turbocharger 26, with a first fluid 18 (e.g., a high-pressure, proppant-free fluid) entering a first side of the hydraulic turbocharger 26 and a second fluid 20 (e.g., a low-pressure fracturing fluid) entering the hydraulic turbocharger 26 on a second side. During operation, the flow of the first fluid 18 drives a first turbine coupled to a shaft. As the first turbine rotates, the shaft transmits power to a second turbine, which increases the pressure of the second fluid 20, thereby driving the second fluid 20 away from the hydraulic turbocharger 26 and downstream to a downstream application 24 (e.g., a well) during fracturing operations. In another embodiment, the hydraulic power delivery system 16 may include an isobaric pressure exchanger (IPX) 28, with the first fluid 18 (e.g., a high-pressure, proppant-free fluid) entering the first side of the hydraulic power delivery system, where the first fluid contacts the second fluid 20 (e.g., a low-pressure fracturing fluid) entering the IPX 28 on the second side. The contact between the fluids allows the first fluid 18 to increase the pressure of the second fluid 20, thereby driving the second fluid out of IPX 28 and downstream to the downstream application 24 (e.g., a well) for fracturing operations. Similarly, the first fluid 18 leaves IPX 28, but leaves at a low pressure after exchanging pressure with the second fluid 20.

[0028] As used herein, IPX 28 can be generally defined as a device that transmits fluid pressure between a high-pressure inlet flow and a low-pressure inlet flow with an efficiency greater than about 50%, 60%, 70%, or 80% without the use of centrifugal technology. Herein, high pressure refers to a pressure greater than low pressure. The low-pressure inlet flow of IPX 28 can be pressurized and exit IPX 28 at a high pressure (e.g., a pressure greater than the low-pressure inlet flow pressure), and the high-pressure inlet flow can be depressurized and exit IPX 28 at a low pressure (e.g., a pressure less than the high-pressure inlet flow pressure). Furthermore, IPX 28 can operate by directly applying force with the high-pressure fluid to pressurize the low-pressure fluid, with or without fluid separators. Examples of fluid separators that can be used in IPX 28 include, but are not limited to, pistons, bladders, diaphragms, etc. In certain embodiments, IPX 28 may include one or more rotating devices (e.g., rotating IPX), such as those manufactured by Energy Recovery Inc. of San Leandro, California. As shown below relative to… Figure 2 As described in detail, a rotary IPX may not have any separate valves because effective valve actuation is achieved within the device via the relative movement of a rotor relative to an end cap. A rotary IPX may be designed to operate by means of an internal piston to isolate fluids and transmit pressure, with relatively little mixing of the inlet fluid flows. In a particular embodiment, IPX 28 may include one or more reciprocating rotary IPXs, each of which may include a piston that moves back and forth in a cylinder to transmit pressure between fluid flows. One or more IPX 28s may be used in the disclosed embodiments, such as, but not limited to, rotary IPXs, reciprocating IPXs, or any combination thereof. Furthermore, IPX 28 may be located on a skid separate from other components of the fluid handling system (e.g., a fracturing apparatus or fracturing system 10), which is desirable when IPX 28 is attached to an existing fluid handling system.

[0029] Figure 2This is an exploded view of an embodiment of IPX 28 (e.g., a rotating IPX). In the illustrated embodiment, IPX 28 may include a generally cylindrical body portion 40, which includes a housing 42 and a rotor 44. IPX 28 may also include two end structures 46 and 48, which include manifolds 50 and 52, respectively. Manifold 50 includes an inlet port 54 and an outlet port 56, and manifold 52 includes an inlet port 60 and an outlet port 58. For example, inlet port 54 may receive a high-pressure first fluid, and outlet port 56 may be used to direct a low-pressure first fluid away from IPX 28. Similarly, inlet port 60 may receive a low-pressure second fluid, and outlet port 58 may be used to direct a high-pressure second fluid away from IPX 28. End structures 46 and 48 include generally flat end plates 62 and 64, respectively, which are disposed within manifolds 50 and 52 and adapted to fluid-tightly contact rotor 44. The rotor 44 may be cylindrical and housed within the housing 42, and arranged to rotate about a longitudinal axis 66. The rotor 44 may have a plurality of passages 68 extending substantially longitudinally through it, each passage having openings 70 and 72 symmetrically arranged about the longitudinal axis 66 at its ends. The openings 70 and 72 of the rotor 44 are arranged for hydraulic communication with end plates 62 and 64, and with inlet ports 74 and 78 and outlet ports 76 and 80, such that during rotation, the openings 70 and 72 alternately hydraulically expose high-pressure and low-pressure fluids to corresponding manifolds 50 and 52. The inlet ports 54 and 60 and outlet ports 56 and 58 of the manifolds 50 and 52 form at least one pair of high-pressure fluid ports in one end element 46 or 48, and at least one pair of low-pressure fluid ports in the opposite end element 46 or 48. The end plates 62 and 64, the inlet ports 74 and 78, and the outlet ports 76 and 80 are designed with vertical flow sections in the form of arcuate or circular segments.

[0030] Regarding IPX 28, the plant operator has control over the degree of mixing between the first fluid 18 and the second fluid 20, which can be used to improve the operability of the fluid handling system (e.g., fracturing equipment or fracturing system 10). For example, changing the ratio of the first fluid 18 and the second fluid 20 entering IPX 28 allows the plant operator to control the amount of fluid mixed in the fluid handling system. Three characteristics of IPX 28 that may affect mixing are: (1) the aspect ratio of rotor passage 68, (2) the short duration of exposure between the first fluid 18 and the second fluid 20, and (3) the formation of fluid barriers (e.g., interfaces) between the first and second fluids in rotor passage 68. First, rotor passage 68 is generally long and narrow, which stabilizes the flow within IPX 28. Furthermore, the first fluid 18 and the second fluid 20 can move through passage 68 in a plug flow manner with almost no axial mixing. Second, in a particular embodiment, at a rotor speed of approximately 1200 revolutions per minute (RPM), the contact time between the first fluid 18 and the second fluid 20 can be less than approximately 0.15 seconds, 0.10 seconds, or 0.05 seconds, which further limits the mixing of flows 18 and 30. Third, a small portion of the rotor passage 68 is used for pressure exchange between the first fluid 18 and the second fluid 20. Thus, a certain volume of fluid is maintained within the passage 68 as a barrier between the first fluid 18 and the second fluid 20. All these mechanisms limit mixing within IPX 28.

[0031] Furthermore, since IPX 28 is configured to be exposed to the first fluid 18 and the second fluid 20, certain components of IPX 28 may be made of materials compatible with the composition of the first fluid 18 and the second fluid 20. Additionally, certain components of IPX 28 may be configured to be physically compatible with other components of the fluid handling system (e.g., a fracturing apparatus or fracturing system 10). For example, ports 54, 56, 58, and 60 may include flanged connections to be compatible with other flanged connections present in the piping system of the fluid handling system. In other embodiments, ports 54, 56, 58, and 60 may include threaded connections or other types of connections.

[0032] Figure 3 It is connected to the filtration system 90. Figure 2 A schematic diagram of an embodiment of the IPX 28 (e.g., a rotating IPX). In the illustrated embodiment, the IPX 28 is oriented relative to the axial axis 92, the radial axis 94, and the circumferential axis 96. In operation, the IPX 28 uses a rotor 100 (e.g., Figure 2The rotor 44 (shown) transfers pressure from a first fluid 18 pumped by a high-pressure pump 12 to a second fluid 20 pumped by a low-pressure pump 14. The first fluid 18 and / or the second fluid 20 may be highly viscous or contain particulate matter. Over time, these fluids 18 and 20 may slow or impede the rotation of the rotor 100, or even impede the start-up of the IPX 28, and will leave behind fluids from the previously operated system. Therefore, the IPX 28 includes a lubrication system 98 that can be pumped (e.g., via a pump, such as the high-pressure pump 12, or as will be pumped) before, during, and / or after the operation of the IPX 28. Figure 8 (The dedicated pump discussed in -10) or guides lubricating fluid through IPX 28 to lubricate the rotating parts of IPX 28 during operation.

[0033] In a particular embodiment, the lubrication system 98 is fluidly coupled to a filtration system 90, which filters out particulate matter suspended within the lubrication fluid before supplying it to the IPX 28. In another embodiment, the filtration system 90 receives a small portion of high-pressure fluid 18 from the high-pressure pump 12, such as a small amount of high-pressure, proppant-free fluid (e.g., water). Thus, the filtration system 90 can filter out the small portion of high-pressure fluid (e.g., the first fluid 18) flowing into the IPX 28 as lubrication fluid.

[0034] As can be understood, the clean lubricating fluid indicated by arrow 91 can be guided into IPX 28 via a lubrication flow channel separated from the total high-pressure fluid (e.g., first fluid 18) flow. The separated lubrication channel can be external to IPX housing 102 (e.g., housing 42) or integrated with IPX housing 102, such as... Figure 4 As illustrated in embodiment -7, the separate channels allow the filtration system 90 to operate independently of or simultaneously with the steady-state operation of IPX 28. For example, the lubrication system 98 can provide clean lubricating fluid to IPX 28 before and / or during the steady-state operation of IPX 28.

[0035] In a particular embodiment, IPX 28 includes a controller 104 coupled to processor 106 and memory 108, which stores instructions executable by processor 106 to control filtration system 90 and / or lubrication system 98. For example, controller 104 may control one or more valves (e.g., electronic actuators for opening and closing valves), filters, flow rates, etc., of filtration system 90 and / or lubrication system 98. Furthermore, controller 104 may communicate with one or more sensors located throughout the hydraulic power transmission system 16, such as speed sensors, pressure sensors, flow sensors, acoustic sensors, etc. Sensors may provide controller 104 with inputs relating to the operation of various systems, including any reduced efficiency within IPX 28. For example, sensors may sense an increase in the amount of particulate matter in the lubricating fluid, which could prevent the lubricating fluid from properly lubricating IPX 28. In response to inputs from sensors, controller 104 may monitor and control IPX 28 to determine any necessary operational changes to filtration system 90. For example, controller 104 can increase the flow rate of lubricating fluid to filtration system 90, increase the number of operating filters, increase or decrease the flow rate of lubricating fluid within filtration system 90, increase the amount of particles removed from lubricating fluid, and so on.

[0036] In a particular embodiment, lubrication channels and cleaning lubricating fluid (e.g., lubricating fluid with particulates removed via a filtration system) can be supplied through one or more holes 110 disposed along axial axis 92. One or more holes 110 may pass through the IPX body, such as through IPX housing 102 and / or rotor sleeve 112. For example, holes 110 may be circumferentially positioned along axial axis 92 of IPX 28 and / or around circumferential axis 96 of IPX 28. For example, IPX housing 102 may have a first hole 114 axially located between a first end cap 116 and rotor 100 and a second hole 118 axially located between a second end cap 120 and rotor 100, such that the first hole 114 and the second hole 118 provide passages through IPX housing 102. As another example, IPX housing 102 may include a third hole 122 axially positioned along rotor 100 to provide a passage 124 through IPX housing 102 and rotor sleeve 112. One or more orifices 110 guide clean lubricating fluid into the gap between rotor 100 and rotor sleeve 112, providing particulate-free lubricating fluid for lubricating the rotating components of IPX 28. In a particular embodiment, end caps 116 and 120, along with one or more washers or O-rings 126, may retain the clean lubricating fluid within the gap between rotor 100 and rotor sleeve 112.

[0037] In a particular embodiment, rotor 100 may be coupled to motor 101 to drive rotor 100 to rotate. Motor 101 may be coupled to controller 104 such that the operation of motor 101 is controlled by controller 104 to regulate the operation and / or speed of rotor 100. Rotor 100 may be partially or entirely driven by motor 101. Motor 101 may be an electric motor, pneumatic actuator, hydraulic actuator, etc. In some embodiments, the pump of lubrication system 98 (e.g., high-pressure pump 12 or...) may be... Figure 8-10 The dedicated pump described herein is connected to the motor 101. Thus, the operation of the pump (e.g., pumping rate, speed, pressure, volume, etc.) can be matched to the operation of the rotor 100. For example, the operation of the positive displacement pump can be adjusted to provide a lubricating fluid flow rate proportional to the rotational speed of the rotor 100.

[0038] In certain embodiments, lubricating fluid (e.g., lubricating fluid before entering filtration system 90 and / or lubrication system 98, or lubricating fluid after being treated by filtration system 90 and / or lubrication system 98) may be directed (e.g., via an internal or external guide path to IPX 28) to temperature control system 99 to regulate (e.g., increase or decrease) the temperature of the lubricating fluid. Temperature control system 99 may be any suitable heat exchanger. As will be discussed in more detail, lubricating fluid may be used to provide localized and / or overall cooling or heating of IPX 28.

[0039] Figure 4 yes Figure 2 The schematic diagram of an embodiment of IPX 28 illustrates an embodiment of an integrated filtration system 90 with multiple filters 132. In the illustrated embodiment, the filtration system 90 is integrated with the IPX housing 102. Furthermore, the filtration system 90 receives a small portion 130 of a first fluid 18 pumped from the total high-pressure fluid flow supplied to the IPX 28 by the high-pressure pump 12. In this way, a small portion 134 of the first fluid 18 pumped to the IPX 28 serves as a lubricating fluid, which can be filtered via separate channels 136 before being guided through one or more orifices 110 to the gap between the rotor 100 and the rotor sleeve 112.

[0040] The filtration system 90 may utilize one or more different types of filtration technologies and may include one or more different types of filtration devices or equipment. For example, in a particular embodiment, the filtration system 90 includes one or more different types of filters, including cartridge filters, slow sand filters, fast sand filters, pressure filters, bag filters, membrane filters, particulate micromedia filters, backwashable filters, backwashable sand filters, hydrocyclones, etc. Furthermore, the filtration system 90 may include a plurality of filters 132, comprising one or more filters of each type within the filtration system 90. In a particular embodiment, the filters 132 may be arranged around an axial axis 92, a radial axis 94, a circumferential axis 96, or in any other combination. For example, the plurality of filters 132 may be arranged concentrically around the circumferential axis 96 of the filtration system 90. In other embodiments, the plurality of filters 132 may be arranged in other patterns or arrangements, and may be spaced apart at specific distances, randomly arranged, etc.

[0041] Figure 5 yes Figure 4 The schematic diagram of an embodiment of the integrated filtration system 130 illustrates a sedimentation filtration system 140. For example, the sedimentation filtration system 140 may include one or more regions 142 in which particles 144 of different types and sizes accumulate before being guided away from the sedimentation filtration system 140. In some embodiments, the sedimentation filtration system 140 may include a sedimentation tank, cavity, reservoir, container, etc., 141. Furthermore, the cavity or tank 141 of the sedimentation filtration system 140 may be adjacent to and / or surround the IPX 28. In the illustrated embodiment, the filtration system 90 is integrated into the IPX housing 102, such as... Figure 4 As shown. Specifically, the filtration system 90 may be a sedimentation filtration system 140, which may extend along the body of the IPX 28 at a distance 146. In some embodiments, the length or distance 146 of the sedimentation filtration system 140 may be customized based on the desired type and / or degree of filtration of the IPX 28. In a particular embodiment, accumulated particles 142 (e.g., particles filtered out of the lubricating flow) may be directed back into the high-pressure fluid flow.

[0042] In the illustrated embodiment, the sedimentation filtration system 140 receives a small portion 134 of the high-pressure fluid (e.g., first fluid 18) supplied to the IPX 28, such as a small amount of high-pressure, proppant-free fluid (e.g., water). This small amount of high-pressure fluid can be used as a lubricating fluid within the IPX 28. (See above regarding...) Figure 4As noted, a small portion 134 of the first fluid 18, used as lubricating fluid, pumped to IPX 28 may be filtered via separate channels 136 before being guided through one or more orifices 110 to the gap between rotor 100 and rotor sleeve 112 and / or to the gap between other bearings or lubrication areas. Thus, it should be noted that in the illustrated embodiment, a portion of the total high-pressure fluid (e.g., the first fluid 18) flow may not be filtered, while in other embodiments, an additional portion or the entire total high-pressure fluid flow may be filtered by the filtration system 90. In some embodiments, this portion may be a small portion, while in other embodiments, it may be a large portion of the entire total high-pressure fluid flow. The portion of the total high-pressure fluid flow may be determined by the desired amount of lubricating fluid.

[0043] Before the cleaning lubricating fluid 91 is guided through one or more orifices 110 to the gap between the rotor 100 and the rotor sleeve 112, the lubricating fluid can be treated by the sedimentation filtration system 140 to clean and remove any particles. The sedimentation tank 141 can be a single tank or cavity, or it can comprise one or more series of tanks, each configured to filter out particles 144 of various sizes. In certain embodiments, the lubricating fluid may flow through the sedimentation tank 141 at a slow rate, causing the particles 144 to settle due to gravity. For example, in the illustrated embodiment, larger and coarser particles 148 may settle out of the lubricating fluid first, followed by intermediate particles 150 and / or finer particles 152. It should be noted that, based on the flow rate and / or length 146 of the sedimentation filtration system 140, intermediate particles 150 and / or finer particles 152 may settle out of the lubricating fluid. For example, finer particles 152 may be filtered through a region 142 of the sedimentation filtration system 140 where the flow rate is very slow. In some embodiments, a portion of the lubricating fluid (e.g., excess lubricating fluid), as indicated by arrow 154, may be directed to a high-pressure fluid (e.g., first fluid 18) flow provided to IPX28.

[0044] Figure 6 yes Figure 3 The schematic diagram of an embodiment of the filtration system 90 shown illustrates a centrifugal separation filtration system 160. In the illustrated embodiment, the filtration system 90 can be integrated into an IPX housing 102, such as... Figure 4 As shown; and / or the filtration system 90 may be external to the IPX component, such as Figure 3 The centrifugal filtration system 160 shown can use centripetal force and fluid resistance to separate and / or sort particles, thereby filtering and / or cleaning the lubricating fluid before providing the cleaning lubricating fluid 91 to the gap between the rotor 100 and the rotor sleeve 112 and / or to the gap between other bearings or lubrication areas.

[0045] In a particular embodiment, the centrifugal filtration system 160 may include an inlet 162 and be configured to receive a small portion 134 of high-pressure fluid (e.g., first fluid 18) from the total high-pressure fluid flow supplied to the IPX 28, such as a small amount of high-pressure, proppant-free fluid (e.g., water). In other embodiments, the inlet 162 may be configured to receive a small portion 134 of high-pressure fluid directly from the high-pressure pump 12. The centrifugal filtration system 160 may include various geometries and may include a swirling region 164 having vortices and / or apexes 166. In particular, the centrifugal filtration system 160 may be configured to remove particles suspended in the lubricating fluid with a density greater than or less than that of the surrounding fluid, and may do so based on the characteristics of the fluid flow through the inlet and geometry of the swirling region 164. In the illustrated embodiment, denser particles 168 may be removed at apex 166 and directed back (e.g., as indicated by arrow 170) to the high-pressure fluid (e.g., first fluid 18) flow supplied to the IPX 28. Furthermore, a cleaning lubricating fluid may be available at the overflow region 172 of the swirling region 164 and may be supplied to the IPX 28 such that it is present between the rotor 100 and the rotor sleeve 112 and / or between other bearings or lubrication areas. In practice, the centrifugal filtration system 160 may require no additional moving parts and / or maintenance, as any unwanted particles filtered from the lubricating fluid can be directed back to the first fluid 18 (e.g., a high-pressure fluid).

[0046] Figure 7 yes Figure 2 The schematic diagram of an embodiment of the IPX 28 shown illustrates a filtration system 90 disposed within a rotor 100. In the illustrated embodiment, the filtration system 90 may be integrated into the rotor 100 of the IPX 28. Specifically, the filtration system 90 may be incorporated into the central region 180 of the IPX 28, for example, through a cylindrical space within the rotor 100. Specifically, the filtration system 90 receives a small portion 134 of a first fluid 18 pumped by the high-pressure pump 12 from the total high-pressure fluid flow supplied to the IPX 28. Furthermore, the filtration system 90 disposed through the rotor 100 may include one or more filtration techniques / methods and / or one or more filtration devices, such as those described above. Figure 3 -6. In a particular embodiment, the filtration system 90 may utilize the rotation of the rotor 100 to enhance centrifugal separation. Once the lubricating fluid is filtered, the clean lubricating fluid 91 may exit the rotor region of IPX 28 through one or more orifices 110 and may flow to the gap between the rotor 100 and the rotor sleeve 112 and / or to the gap between other bearings or lubrication areas, as described above.

[0047] Figure 8 yes Figure 2The block diagram illustrates an embodiment of IPX 28 coupled to a lubrication system 98 to provide lubricating fluid to IPX 28. In the illustrated embodiment, the lubrication system 98 may include a dedicated fluid source 190 and a dedicated pump 192 (e.g., an external or internal pump) to pump fluid from the fluid source 190 to IPX 28. Pump 192 may be a positive displacement pump or a centrifugal pump and may be used in combination with one or more valves. In particular, pump 192 may increase the pressure of the fluid entering IPX 28. The fluid provided by fluid source 190 may be a lubricating fluid and / or a flushing fluid (e.g., flushing contaminants and / or particles from bearing and sealing areas). In a particular embodiment, the lubrication system 98 may include a filter and / or separator 194 to filter and / or clean the fluid before it enters IPX 28. Filter and / or separator 194 may be any suitable filtration system proposed above (e.g., systems 90, 130, 140, and 160) or a combination thereof.

[0048] Figure 9 yes Figure 2 The block diagram illustrates an embodiment of IPX 28 coupled to a lubrication system 98 to provide lubricating fluid to the IPX 28. In the illustrated embodiment, the lubrication system 98 includes a dedicated pump 192 as described above, and instead of a dedicated fluid source 190, a portion (e.g., a small portion 134) of a first fluid 18 is used as the lubricating fluid. In a particular embodiment, the lubrication system 98 may include a filter and / or separator 194 to filter and / or clean a portion of the small portion 134 of the first fluid 18 before the fluid enters the IPX 28. The filter and / or separator 194 may be any suitable filtration system proposed above (e.g., systems 90, 130, 140, and 160) or a combination thereof. The pump 192 may increase the pressure of the small portion 134 of the first fluid 18. The pump 192 may provide pressure to overcome pressure losses due to passage through the filter and / or separator 194. The pump 192 may provide additional pressure to the fluid or lubricating fluid flowing into the IPX 28.

[0049] It should be noted that the term "lubricating fluid" can serve several functions or combinations thereof. First, the lubricating fluid can be used to supply fluid bearings, such as hydrostatic bearings, hydrodynamic bearings, or combinations thereof. Second, the lubricating fluid can be used to flush and / or clean sealing areas, such as seals formed by narrow gaps in IPX 28. Third, the lubricating fluid can be used to flush and / or clean debris or particles from bearing areas. Fourth, the lubricating fluid can be used to provide partial and / or overall cooling or heating of IPX 28. Therefore, several embodiments of the invention relate to controlling the fluid entering and / or flowing within IPX 28 (e.g., controlling one or more fluid flow paths) and / or the operation of IPX 28. For example, the lubricating fluid can flow to one or more flow paths, such as the flow paths of first fluid 18, second fluid 20, high-pressure fracturing fluid 22, and low-pressure fracturing fluid 23. For example, the lubricating fluid can be controlled to enter IPX 28 at a pressure equal to or greater than that of the first fluid 18.

[0050] Considering the foregoing, Figure 10 A block diagram of an embodiment of a lubrication system 98 operatively coupled to a controller 200 is shown. In the illustrated embodiment, the lubrication fluid system 98 includes a fluid source 202, which may be, for example... Figure 8 The dedicated fluid source 190 discussed in the text may be, for example, as... Figure 9 A small portion 134 of the first fluid 18 discussed herein. The lubrication fluid system 118 also includes a pump 192 (e.g., a dedicated pump, internal or external) and may optionally include filters and / or separators 194 as presented above. It will be understood that the operation of IPX 28 and at least a portion thereof is controlled by controller 200 to regulate the flow rate, flow rate, pressure, and / or temperature of the lubrication fluid and / or other fluids (e.g., the first fluid 18) according to the path of the lubrication fluid (e.g., the flow path and the location where the lubrication fluid enters IPX 28).

[0051] Controller 200 includes memory 204 (e.g., non-transitory computer-readable medium / memory circuitry) that stores one or more sets of instructions (e.g., processor-executable instructions) implemented to control or regulate at least a portion of the operation of the IPX 28 and the lubrication system 98. Controller 200 also includes one or more processors 206 configured to access and execute one or more sets of instructions encoded by memory 204, which are associated with at least a portion of the operation of the IPX 28 and the lubrication system 98. Memory 204 may include volatile memory, random access memory (RAM), and / or non-volatile memory such as read-only memory (ROM), optical disc drives, hard disk drives, or solid-state drives. One or more processors 206 may include one or more application-specific integrated circuits (ASICs), one or more field-programmable gate arrays (FPGAs), one or more general-purpose processors, or any combination thereof. Furthermore, the term "processor" is not limited to those integrated circuits referred to as processors in the art, but broadly refers to computers, processors, microcontrollers, microcomputers, programmable logic controllers, application-specific integrated circuits, and other programmable circuits.

[0052] Furthermore, the controller 200 may be communicatively coupled to one or more sensors 208 to collect data related to fluid flow, such as the velocity, flow rate, pressure, and temperature of the lubricating fluid, the first fluid 18, the second fluid 20, and the main process fluid (e.g., the first fluid 18 and / or the second fluid 20 after cleaning or filtration). The one or more sensors 208 may include, but are not limited to, pressure sensors, temperature sensors, flow meters, and flow sensors. The one or more sensors 208 may be positioned at any suitable location along the fluid flow path to obtain data related to the fluid flow of interest after receiving instructions or control signals from the controller 200. In some embodiments, the controller 200 and controller 104 (in...) Figure 3 (The two controllers in the middle) are the same.

[0053] The pressure of the lubricating fluid entering IPX 28 can be as follows Figure 9 As in the case where the pressure of the first fluid 18 depends (e.g., a small portion 134 of the first fluid 18 is directed to act as a lubricating fluid) and / or may be as Figure 8 and 9The pressure of the lubricating fluid entering IPX 28 depends on the pressure of the fluid flowing from pump 192. Furthermore, the pressure of the lubricating fluid entering IPX 28 may depend on the operation of the filter and / or separator 194. For example, the fluid passing through the filter and / or separator 194 may experience a certain pressure loss. Thus, in one embodiment, to control or regulate the pressure of the lubricating fluid entering IPX 28, to control the pressure of the first fluid 18 and / or the pressure of a portion 134 of the first fluid 18 directed as lubricating fluid, controller 200 is operatively coupled to one or more valves, high-pressure pumps 12, or combinations thereof arranged along the flow path of the first fluid 18 and along the flow path of the portion 134 of the first fluid 18. In one embodiment, controller 200 is operatively coupled to pump 192 to control or regulate the pressure of the fluid flow (e.g., lubricating fluid) exiting pump 192. In one embodiment, controller 200 may control or regulate pump 192 to increase pressure, thereby overcoming the pressure loss at the filter and / or separator 194.

[0054] In certain embodiments, such as Figure 8 The pump 192 shown in Figure 10 can be connected to the motor 101. Thus, the operation of the pump 192 (e.g., pumping rate, speed, pressure, volume, etc.) can be adjusted to match the operation of the rotor 100. For example, the pump 192 can be a displacement pump and can be adjusted to provide a lubricating fluid flow rate proportional to the rotational speed of the rotor 100.

[0055] Furthermore, the controller 200 can control or regulate the flow (e.g., velocity, flow rate) of the lubricating fluid entering the IPX 28 based on the path of the lubricating fluid (e.g., the location where the lubricating fluid enters the IPX 28), as shown in [the diagram]. Figure 11 As discussed in the text. Figure 11 A partial loop diagram of the lubricating fluid is shown. In the illustrated embodiment, resistance symbol 210 represents resistance to the lubricating fluid path (e.g., flow resistance) or other fluid resistance, arrows indicate the flow direction, and circles represent pressure at the location of interest. Specifically, circle 212 represents the pressure of the lubricating fluid at the inlet of IPX 28, circle 214 represents the pressure of the first fluid 18 at the high-pressure fluid inlet of IPX 28, circle 216 represents the pressure of the fluid within IPX 28, where mixing may occur between the first fluid 18 and the second fluid 20, and circle 218 represents the pressure of the second fluid 20 at the low-pressure fluid inlet of IPX 28.

[0056] In exemplary partial loop diagram 220, the lubricating fluid flows into the interior region of IPX 28, where pressure 216 is an intermediate value between pressure 214 and pressure 218. Thus, the pressure of lubricating fluid 212 can be higher or lower than pressure 214. In another exemplary partial loop diagram 222, the lubricating fluid can flow into any one or a combination of the interior region of IPX 28, the high-pressure inlet of the first fluid 18, and the low-pressure inlet of the second fluid 20. Therefore, it may be desirable that the pressure of the lubricating fluid (e.g., pressure 212) is equal to or greater than pressure 214. It should also be noted that as the fluid flow rate increases, the downstream (e.g., at the confluence of fluids) pressure will tend to increase as a larger volume of fluid flows through each given time. In a particular embodiment, the resistance between pressure 212 at the lubricating fluid inlet and pressure 214 at the high-pressure inlet of the first fluid 18 is negligible, and in this case, an increase in the pressure or flow rate of the lubricating fluid can substantially displace the first fluid 18.

[0057] Therefore, controller 200 can control or regulate corresponding components of IPX 28 and components of the lubricating fluid system 98 (e.g., one or more valves, high-pressure pump 12, low-pressure pump 14, pump 192, etc.) to increase or decrease their pressure, flow rate, flow rate, or combinations thereof, at least in part based on the concepts discussed in partial loop diagrams 220 and 222. For example, in the case where lubricating fluid is directed into the internal region of IPX 28, controller 200 can control pump 192 and / or the corresponding valve to regulate the pressure of lubricating fluid 212 to be higher or lower than pressure 214. For example, in the case where lubricating fluid is directed into any one or a combination of the internal region of IPX 28, the high-pressure inlet of the first fluid 18, and / or the low-pressure inlet of the second fluid 20, controller 200 can control pump 192 and / or the corresponding valve to increase the pressure of the lubricating fluid such that the pressure of the lubricating fluid is equal to or greater than the pressure of the first fluid 18 at the high-pressure inlet.

[0058] In some embodiments, the control algorithm may be stored in memory 204 and executed by processor 206 of controller 200. When executed, the control algorithm modulates the flow rate of various fluids (e.g., fluid pumped by pump 92, a small portion 134 of the first fluid 18) to be proportional to the operating pressure of IPX 28 or some function thereof, in order to supply an appropriate amount of lubricating fluid to IPX 28. In some embodiments, controller 200 may change the flow rate or pressure of the lubricating fluid in response to other variables such as the performance or operating conditions of IPX 28. For example, if the performance of IPX 28 is reduced due to a contaminated bearing, controller 200 may control the flow rate of the corresponding fluid (e.g., fluid pumped by pump 192, a small portion 134 of the first fluid 18) to increase the flow rate and / or velocity of the lubricating fluid entering IPX 28. In some embodiments, the controller 200 may control the flow rate of a corresponding fluid (e.g., the fluid pumped by pump 92, a small portion 134 of the first fluid 18) based on the operating conditions of the IPX, such as temperature (e.g., measured or expected temperature), to provide sufficient cooling or heating to the IPX 28. In some embodiments, the controller 200 may control the temperature of a corresponding fluid (e.g., the fluid pumped by pump 92, a small portion 134 of the first fluid 18) based on the temperature in the IPX 28 (e.g., expected temperature or temperature measured via one or more sensors 208) to provide sufficient cooling or heating to the IPX 28.

[0059] As described above, controller 200 can increase fluid flow rate by controlling pump 192 (e.g., positive displacement pump, centrifugal pump) and / or by controlling one or more valves positioned along their respective flow paths. In some embodiments, controller 200 may also control pump 192 and / or the corresponding valves to cause an excess flow that overflows into the main process fluid (e.g., a first fluid 18 and / or a second fluid 20 that has been cleaned or filtered). Figure 12This is a schematic diagram of an embodiment of IPX 28 connected to lubrication system 98. In the illustrated embodiment, lubricating fluid supplied by lubrication system 98 flows into IPX 28 as indicated by arrow 230. As shown in view 232, IPX 28 includes one or more gaskets, O-rings, or other suitable seals 126 disposed at both axial ends between a first end cap 116 and IPX housing 102 and between a second end cap 120 and IPX housing 102, such that the lubricating fluid is separated or isolated from the main process fluid (e.g., a first fluid 18 and / or a second fluid 20 after cleaning or filtering). As shown in view 234, one of the one or more gaskets, O-rings, or other suitable seals 126 disposed between the first end cap 116 and IPX housing 102 is replaced by a valve 236, such that the lubricating fluid can come into contact with or communicate with the main process fluid (e.g., the first fluid 18 and / or the second fluid 20 after cleaning or filtering) depending on the operation of valve 236 (e.g., the open / closed position of the valve). In some embodiments, valve 236 is a check valve to allow lubricating fluid to overflow into the main process fluid, but not to allow reverse flow. In some embodiments, valve 236 is a pressure relief valve for adjusting or limiting the pressure of the lubricating fluid. As can be understood, if the lubricating fluid is supplied to IPX 28 via a separate flow path to separate or isolate the lubricating fluid from the main process fluid (e.g., as shown in view 232), the pressure of the lubricating fluid can be controlled primarily by the operation of pump 192. However, if the lubricating fluid is in contact with or in communication with the main process fluid (e.g., as shown in view 234), the pressure of the lubricating fluid may be affected by the operation of pump 192, the operation of valve 236, the pressure of the main process fluid, or a combination thereof.

[0060] This document illustrates specific embodiments with reference to the accompanying drawings, and provides a detailed description of these embodiments. Various modifications and alternatives to the invention are possible. However, it should be understood that the invention is not intended to be limited to the specific forms disclosed. Rather, the invention covers all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the following appended claims.

Claims

1. A fluid treatment system comprising: a pump configured to provide a first fluid at a first pressure; a pressure exchanger configured to exchange pressure between the first fluid and a second fluid, wherein the first pressure of the first fluid is higher than a second pressure of the second fluid; a bearing disposed within a housing of the pressure exchanger; and one or more filters coupled to the pressure exchanger, wherein a passageway within the housing of the pressure exchanger enables a portion of the first fluid to be diverted to be filtered by the one or more filters to produce a lubrication fluid for the pressure exchanger to lubricate the bearing.

2. The fluid treatment system of claim 1 wherein, the second fluid includes one or more of water, chemicals, proppants, sand, ceramic, particulates, solids, granules, powder, debris, contaminants, tackifiers, or chemical additives.

3. The fluid treatment system of claim 1 wherein, the first fluid has fewer particulates than the second fluid.

4. The fluid treatment system of claim 1 wherein, the pressure exchanger includes a rotor configured to exchange pressure between the first fluid and the second fluid.

5. The fluid treatment system of claim 1 wherein, a temperature control system configured to adjust a temperature of at least a portion of the first fluid to heat or cool at least a portion of the pressure exchanger.

6. The fluid treatment system of claim 5 wherein, the temperature control system includes a heat exchanger.

7. The fluid treatment system of claim 1 wherein, after being filtered, a portion of the first fluid is directed through one or more apertures formed by the housing to a gap between: the rotor sleeve of the pressure exchanger and the rotor of the pressure exchanger; the bearings; the lubrication regions of the pressure exchanger; or the sealing regions of the pressure exchanger.

8. The fluid treatment system of claim 1 wherein, the one or more filters include at least one of a cartridge filter, a sand filter, a pressure filter, a bag filter, a membrane filter, a particulate micromedia filter, a backwashable filter, a backwashable sand filter, a hydrocyclone, a sedimentation filtration system, or a centrifugal separation filtration system.

9. The fluid treatment system of claim 1 wherein, further comprising a controller configured to adjust one or more of a flow rate, a flow volume, a pressure, or a temperature of at least a portion of the first fluid.

10. The fluid treatment system of claim 9 wherein, the controller is configured to receive sensor data from one or more sensors to adjust one or more of a flow rate, a flow volume, a pressure, or a temperature of at least a portion of the first fluid, wherein the one or more sensors include one or more of a pressure sensor, a temperature sensor, a flow meter, or a flow sensor.

Images