Bellows Pump Valve Control to Prevent Pressure Buildup Damage
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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 effectively.
Innovation Solution
The use of bellows pumps, which segregate treatment fluid from drive fluid using an expandable bellows to prevent fluid mixing, and a control system to maintain synchronization between the piston and bellows, ensuring efficient and reliable fluid pumping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional pumps are used in well operations, then fluid pumping can be achieved, but reliability and wear resistance deteriorate due to difficult well conditions
Solution Approach 1:
The pump is divided into two separate fluid chambers: a drive fluid chamber and a treatment fluid chamber. The drive fluid (hydraulic fluid) powers the piston mechanism, while the treatment fluid (fracturing fluid with proppant) is pumped through the bellows. This segmentation prevents the abrasive treatment fluid from contacting wear-prone mechanical components, isolating wear to only the bellows which is designed to withstand such conditions.
Solution Approach 2:
The bellows acts as an intermediary flexible barrier between the drive fluid and treatment fluid. It transmits the mechanical motion from the drive fluid chamber to the treatment fluid chamber without allowing direct contact between the two fluids. The bellows absorbs and transmits pressure waves while preventing abrasive treatment fluid from contaminating the drive fluid system.
2Reliability
If treatment fluid and drive fluid are mixed, then pumping operation can continue, but fluid contamination occurs reducing effectiveness
Solution Approach 1:
The pump chamber is segmented into distinct zones separated by the bellows. The drive fluid occupies one chamber while treatment fluid occupies another, with the bellows forming a flexible but impermeable barrier between them. This physical segmentation ensures complete fluid separation while allowing pressure transmission.
Solution Approach 2:
The bellows is constructed as a flexible membrane or thin-walled structure that separates the two fluid chambers. This flexible barrier maintains fluid separation while accommodating pressure changes and volume variations during the pumping cycle, preventing contamination while allowing operational flexibility.
3Reliability
If bellows pump is used to separate fluids, then fluid mixing is prevented, but device complexity increases
Solution Approach 1:
The bellows simultaneously performs multiple functions: it acts as a fluid barrier, a pressure transmission medium, a mechanical coupling element, and a seal. By combining these functions into a single component, the design avoids the need for multiple separate parts (such as pistons, rings, valves, and seals) that would increase complexity.
Solution Approach 2:
The bellows is a multi-functional component that replaces several traditional pump elements. It provides sealing, pressure transmission, motion conversion, and fluid isolation all in one element, simplifying the overall pump architecture while maintaining effective fluid separation.
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 treatment and drive fluids, enhancing the reliability and efficiency of fluid pumping operations, particularly in harsh well conditions, while maintaining consistent pressure and preventing wear.
Implementation Method 1
an expandable bellows to prevent fluid mixing
Data Source
AI summary
Disclosed embodiments may relate to bellows pumps for introducing treatment fluid into a well. Wear issues, for example causing leakage of the discharge valve, can lead to pressure build-up in the pump chamber which may eventually damage the bellows. Disclosed embodiments may be configured to prevent such damage to the bellows due to discharge valve leakage. For example, in some embodiments a mechanism may hold open the suction valve during pump stoppage, to prevent pressure accumulation. Alternate embodiments may be configured to protect the bellows, even when the pump continues to run. Related methods are also disclosed.