Bellows Pump Cooling With Make-Up Fluid Synchronization
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Solution Overview
Problem
Existing pumps used in well operations for hydraulic fracturing face challenges due to difficult conditions and reliability issues, necessitating improved systems and methods for pumping treatment fluids in hydrocarbon wells.
Innovation Solution
The use of bellows pumps, which segregate treatment fluid from drive fluid using an expandable bellows to prevent fluid mixing, combined with a control system to maintain synchronization and a make-up system to correct fluid imbalances, enhances the reliability and efficiency of fluid pumping in well operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional pumps are used for hydraulic fracturing, then pumping capability is provided, but reliability and wear resistance deteriorate due to difficult downhole conditions
Solution Approach 1:
The pump is divided into two separate fluid systems: drive fluid that powers the pump mechanism and treatment fluid that is pumped downhole. This segmentation prevents treatment fluid from contacting wear-prone mechanical components, isolating the harmful effects to only the drive fluid system.
Solution Approach 2:
A bellows mechanism acts as an intermediary between the drive fluid system and treatment fluid system. The bellows transmits power from the drive fluid while maintaining complete fluid isolation, preventing direct contact between treatment fluid and mechanical components.
2Device complexity
If drive fluid and treatment fluid are mixed, then pump operation is simplified, but fluid contamination and performance deterioration occur
Solution Approach 1:
The pump architecture segments the fluid systems into distinct chambers: a drive fluid chamber containing the piston and bellows, and a treatment fluid chamber separated by the bellows membrane. This physical segmentation ensures complete fluid isolation while maintaining pump functionality.
Solution Approach 2:
The bellows acts as a flexible thin film barrier that separates the two fluid systems. It is sufficiently flexible to transmit mechanical motion for pumping while being impermeable to both fluids, preventing contamination.
3Reliability
If bellows pumps with fluid separation are used, then fluid mixing is prevented, but system complexity increases due to synchronization requirements
Solution Approach 1:
Sensors monitor the positions of the piston and bellows in real-time, providing feedback to the control system. This feedback enables the controller to detect desynchronization and activate the make-up fluid system to restore proper synchronization, managing complexity through automated control.
Solution Approach 2:
The make-up fluid system automatically corrects synchronization issues without external intervention. When desynchronization is detected, the system self-corrects by adjusting fluid volumes to restore proper piston-bellows alignment.
4Reliability
If make-up fluid is added to correct imbalances, then synchronization is restored, but fluid volume control complexity increases
Solution Approach 1:
Position sensors continuously monitor piston and bellows locations, providing real-time feedback on synchronization status. This feedback triggers make-up fluid addition only when needed, automating the volume control process and reducing operational complexity.
Solution Approach 2:
The system automatically manages fluid volume adjustments through the make-up fluid system. When desynchronization occurs, the system self-corrects by adding or removing make-up fluid without requiring manual intervention or complex external control.
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 bellows pumps effectively separate and pump treatment fluids, maintaining pressure and preventing wear, thereby improving the reliability and efficiency of hydraulic fracturing operations.
Implementation Method 1
an expandable bellows to prevent fluid mixing
Implementation Method 2
maintain a controlled volume of fluid between the piston and the bellows
Data Source
AI summary
Exemplary systems may have a bellows pump and a make-up system, with the make-up system being configured to both keep the piston and bellows of the pump in sync and to cool fluid from at least one additional component of the system. In some embodiments, the make-up system may be configured as the sole cooling mechanism for the overall system, while in other embodiments the make-up system may work with one or more external cooler to jointly cool the overall system. In embodiments, the system may further include a control system which may be configured to determine and control appropriate fluid circulation, for example to optimize cooling as well as to maintain synchronous movement of the bellows and the piston. Related methods are also disclosed.