Bellows Pump Fluid Separation for Subterranean Well Treatment
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Solution Overview
Problem
Existing pumps used in well operations for hydraulic fracturing face challenges due to difficult conditions and wear, 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 and protect the pump components from wear, combined with monitoring systems to ensure optimal operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional pumps are used for hydraulic fracturing, then pumping operations can be performed, but the pump components suffer from wear and reliability issues due to difficult downhole conditions
Solution Approach 1:
The pump is divided into two separate fluid chambers: a drive fluid chamber and a treatment fluid chamber. These chambers are physically segmented by bellows, allowing each fluid to be pumped independently without mixing. This segmentation protects the drive fluid and pump components from contamination and wear caused by treatment fluid conditions.
Solution Approach 2:
The bellows act as an intermediary element between the drive fluid and treatment fluid. This flexible membrane transfers mechanical energy from the drive fluid to pump the treatment fluid without direct contact between the two fluids, preventing wear and contamination while maintaining pumping efficiency.
2Reliability
If drive fluid and treatment fluid are mixed in conventional pumps, then pumping operation is simpler, but fluid contamination occurs and pump components experience increased wear
Solution Approach 1:
The pump incorporates separate chambers for drive fluid and treatment fluid, divided by expandable and contractible bellows. This physical segmentation prevents fluid mixing and contamination while maintaining a relatively simple overall pump structure that can be integrated into existing hydraulic fracturing equipment.
3Productivity
If pump components are exposed to harsh downhole conditions, then treatment fluid can be pumped effectively, but the components suffer from wear and reduced service life
Solution Approach 1:
The bellows serve as a protective intermediary that allows the pump to handle harsh treatment fluids while protecting the drive fluid and sensitive pump components from direct exposure to abrasive and corrosive conditions, thereby extending component service life while maintaining pumping efficiency.
Solution Approach 2:
The bellows are constructed as flexible membranes that can withstand the pressures and conditions of hydraulic fracturing operations. These flexible shells expand and contract to pump fluid while protecting internal components from the harsh external environment, extending pump component durability.
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
Enhances the reliability and efficiency of fluid pumping in well operations by protecting the pump components from wear and ensuring consistent performance under harsh conditions.
Implementation Method 1
segregate treatment fluid from drive fluid using an expandable bellows to prevent fluid mixing
Data Source
AI summary
Exemplary systems for introducing treatment fluid into a well can include a bellows pump and a make-up system configured to maintain a controlled volume of fluid between the piston and the bellows of the bellows pump. The make-up system can be fluidly coupled to the bellows and to at least one additional component of the system. In embodiments, the make-up system can be configured to receive heat via circulation of fluid with the at least one additional component of the system, and to discharge heat via circulation of the fluid with the bellows, for example with the bellows conducting heat from the fluid to the treatment fluid for heat discharge.