Bellows Pressure Transfer Device for High-Pressure Slurry Pumping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional mechanical piston pumps used in hydraulic fracturing suffer from limited operational life due to wear and tear from particles and chemicals, leading to leaks, efficiency issues, and frequent breakdowns, and are not suitable for high-pressure applications above 500 bars, which limits their effectiveness and requires redundant systems for maintenance.
Innovation Solution
A pressure transfer device utilizing a radially rigid and axially flexible fluid-tight bellows that separates clean hydraulic fluid from abrasive particles, allowing for smooth and shock-free pumping at high pressures, with a dual acting pressure boosting liquid partition device and flow regulating assembly to manage pressure and flow rates, minimizing wear and enabling seamless operation without mechanical rebuilds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If mechanical piston pumps are used for pumping fracking fluid under high pressures, then pumping capability is achieved, but operating life is limited due to mechanical wear and tear on sliding surfaces
Solution Approach 1:
The pump system is divided into two separate chambers: a first chamber containing the piston and sliding surfaces that contacts only clean hydraulic fluid, and a second chamber containing the bellows that contacts the abrasive fracking fluid. This segmentation isolates the wear-prone mechanical components from the harmful particles, allowing continuous operation while maintaining pumping capability.
Solution Approach 2:
The harmful abrasive particles are extracted from the hydraulic fluid that contacts the mechanical sliding surfaces. The bellows acts as a barrier that prevents particles from reaching the piston and cylinder sliding surfaces, thereby removing the source of mechanical wear and extending operating life.
2Stress or pressure
If mechanical pumps operate at high speeds to achieve high pressure, then pressure delivery is improved, but fatigue cracking occurs due to rapid pressure fluctuations
Solution Approach 1:
The bellows serves as a cushioning element that absorbs and dampens pressure fluctuations before they propagate through the system. By placing the compliant bellows in the fluid path, rapid pressure changes are smoothed out, preventing fatigue cracking in the pump components while maintaining high pressure delivery capability.
3Stress or pressure
If plunger pumps are used to achieve high pressure delivery, then pressure capability is improved, but rod load limitations restrict maximum pressure
Solution Approach 1:
A dual-acting pressure boosting liquid partition device is introduced as an intermediary between the hydraulic power source and the pumping chamber. This device amplifies the pressure generated by the piston, allowing the system to achieve pressures exceeding 500 bars without being limited by rod load constraints, thereby expanding the adaptable pressure range.
4Productivity
If multiple pumps are connected to the same flow line to increase pumping capacity, then flow volume is improved, but interference patterns cause flow line movement and equipment damage
Solution Approach 1:
The system employs synchronized periodic operation of multiple pumping units, where each unit operates in a coordinated cycle that prevents constructive interference. By controlling the timing and phase of each pump's operation, the system maintains stable flow line conditions while achieving high total flow volumes through multiple units working in unison.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enables efficient pumping of high volumes at pressures up to 1500 bars with reduced wear, minimizing the risk of snaking and sedimentation, and extending the operational life of components, while allowing for flexible pressure and flow rate adjustments and synchronization of multiple units.
Implementation Method 1
the inner volume is in fluid communication with the connection port
Implementation Method 2
capable of receiving and expelling hydraulic fluid at pressures of 350-400 bars and amplifying said pressure to a pressure of 1050 bars or higher
Implementation Method 3
Pressure transfer device and associated system, fleet and use, for pumping high volumes of fluids with particles (slurry/sludge) at high pressures, such as pressures above 500 bars and up to 1500 bars or even higher
Data Source
AI summary
The invention relates to pressure transfer device, system comprising the pressure transfer device, a fleet comprising the system and use of a pressure transfer device for pumping fluid at pressures above 500 bars, the pressure transfer device (1′, 1″) comprising a pressure chamber housing (1′, 1″) and at least one connection port (3′, 3″), the at least one connection port (3′, 3″) being connectable to a dual acting pressure boosting liquid partition device (2) via fluid communication means (26′, 27′; 26″, 27″), the pressure chamber housing comprises: - a pressure cavity (4′, 4″) inside the pressure chamber housing, and at least a first port (5′, 5″) for inlet and/or outlet of fluid to the pressure cavity (4′, 4″), - a bellows (6′, 6″) defining an inner volume (7′, 7″) inside the pressure cavity (4′, 4″), and wherein the inner volume (7′, 7″) is in fluid communication with the connection port (3′, 3″), wherein the pressure cavity (4′, 4″) has a center axis (C′, C″) with an axial length (L) defined by the distance between the connection port (3′, 3″) and the first port (5′, 5″) and a varying cross sectional area over at least a part of the axial length (L), and wherein the bellows (6′, 6″) is configured to move in a direction substantially parallel with the center axis (C′, C″) over a part of the axial length (L) of the pressure cavity (4′, 4″).