Bellows Pump Leakage Detection via Annulus Monitoring
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Solution Overview
Problem
Existing pumping technologies face challenges in effectively handling difficult conditions and ensuring reliability during hydrocarbon well stimulation operations, particularly in hydraulic fracturing, due to wear and reliability issues.
Innovation Solution
The use of a bellows pump system that segregates treatment fluid from drive fluid, utilizing an expandable bellows to maintain pressure and prevent fluid transfer, combined with a control system for monitoring and controlling the pumping process to prevent leakage and maintain synchronization between the bellows and piston.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional pump is used for hydraulic fracturing, then the pump can handle treatment fluid, but the pump experiences wear and reliability issues due to difficult downhole conditions
Solution Approach 1:
The pump is divided into two separate chambers: a power chamber containing the piston and drive fluid, and a bellows chamber containing the treatment fluid. This segmentation isolates the treatment fluid from direct contact with wear-prone components, reducing wear and improving reliability
Solution Approach 2:
The bellows acts as an intermediary element between the drive fluid and treatment fluid. It transmits the expanding and contracting motion from the drive fluid to the treatment fluid without allowing direct contact between the two fluids, preventing contamination and wear
2Device complexity
If treatment fluid and drive fluid are mixed in the same chamber, then the pump structure is simpler, but fluid contamination and leakage occur
Solution Approach 1:
The pump chamber is segmented into distinct power and bellows chambers separated by a piston and bellows assembly, preventing fluid mixing while maintaining a relatively simple overall structure
Solution Approach 2:
The bellows is constructed as a flexible membrane that acts as a physical barrier between the two fluids. This flexible shell allows for volume changes while maintaining fluid separation, preventing contamination and leakage
3Productivity
If the bellows expands and contracts freely, then the pumping action is more efficient, but synchronization with the piston becomes difficult to maintain
Solution Approach 1:
The system uses sensors to monitor the position and state of both the piston and bellows, providing feedback to a controller that adjusts the drive fluid pressure to maintain proper synchronization between the mechanical piston movement and the flexible bellows expansion/contraction
Solution Approach 2:
The bellows is designed with dynamic flexibility to adapt its expansion and contraction rates based on the pumping cycle phase. The flexible material allows the bellows to naturally synchronize with the piston motion while maintaining efficient pumping action
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 hydrocarbon well stimulation by maintaining fluid separation and preventing wear, thereby improving the durability and performance of the pumping system.
Implementation Method 1
an expandable bellows to maintain pressure and prevent fluid transfer
Data Source
AI summary
In a bellows pump, detecting any leakage with respect to the bellows can be important, for example for pump durability and life. Disclosed embodiments relate to a bellows pump system in which the bellows is configured to form an annulus, such that fluid in the annulus may be monitored in order to detect leakage. For example, a double-walled bellows may include an annulus between the walls, and the annulus may be in fluid communication with a port. Detection of fluid at the port may be indicative of leakage, and one or more action may be taken in response to such fluid detection. In some embodiments, the double-walled bellows may be formed by having an elastomeric liner disposed within a single-walled bellows, which may have an accordion-like configuration. Related methods and systems are also disclosed.