Dual-Acting Pressure Boosting Device for High-Pressure Fracking
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Solution Overview
Problem
Conventional hydraulic fracturing pumps face limitations at high pressures above 500 bars due to mechanical wear, pressure fluctuations, and the inability to synchronize multiple units, leading to reduced operational life, leaks, and inefficiencies, particularly when handling fluids with particles like proppants.
Innovation Solution
A dual acting pressure boosting liquid partition device with a hollow cylinder housing and a rod system that maintains a constant gap between the rod and cylinder, allowing for high-pressure operation without ballooning, and a control system for synchronized operation and flow regulation, ensuring seamless integration and adaptability to pressure and flow demands.
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 mechanical wear and seal damage occur reducing operating life
Solution Approach 1:
The patent replaces the mechanical piston pump system with a hydraulic pump system that uses hydraulic fluid pressure to drive a bellows mechanism. This substitution eliminates direct mechanical contact between pumping components and the abrasive fracking fluid, thereby reducing mechanical wear and extending operating life while maintaining high-pressure pumping capability
Solution Approach 2:
The patent introduces hydraulic fluid as an intermediary medium between the power source and the fracking fluid. The hydraulic pump pressurizes hydraulic fluid, which then acts on the bellows to pump the fracking fluid. This intermediary approach prevents direct mechanical interaction between the pump components and abrasive particles in the fracking fluid, reducing wear and seal damage
2Productivity
If multiple pumps are connected to the same flow line and operated simultaneously, then pumping capacity is increased, but interference patterns cause flow line movement and equipment damage
Solution Approach 1:
The patent incorporates a control system that monitors the operational status of multiple hydraulic pump units and adjusts their operation to prevent synchronous interference patterns. The control system receives feedback from position sensors and pressure sensors, coordinating the operation of multiple pumps to avoid creating harmful vibrations and flow line movements while maintaining increased pumping capacity
3Productivity
If plunger pumps operate at high speeds to meet flow demands, then productivity is improved, but pressure fluctuations cause fatigue cracking and breakdown
Solution Approach 1:
The patent employs a dynamic control system that continuously adjusts the operation of hydraulic pump units based on real-time feedback from sensors. This dynamic adjustment allows the system to maintain high productivity by varying the number and speed of active pump units, while preventing excessive pressure fluctuations that would cause fatigue cracking and structural failure
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 solution enables smooth, shock-free pumping at high pressures with reduced wear and tear, extended component life, and the ability to operate at pressures up to 1500 bars with high volume flow, minimizing the risk of snaking and allowing for seamless integration with existing systems.
Implementation Method 1
The wall thicknesses of the hollow cylinder housing and the rod are chosen such that the hollow rod expands proportionally with the expansion of the hollow cylinder housing at all pressures keeping the gap between the outer surface of the hollow rod and the inner surface of the cylinder housing substantially constant at all pressures
Data Source
AI summary
A dual acting pressure boosting liquid partition device (2) and system, including a hollow cylinder housing (20) having a longitudinal extension, the cylinder housing (20) having at least a first part and a second part having a first transverse cross sectional area (a1) and a third part having a second transverse cross sectional area (a2) of different size than the first transverse cross sectional area (a1), a rod having a cross sectional area corresponding to the first transverse cross sectional area (a1), the rod further having a protruding portion (30) having a cross sectional area corresponding to the second transverse cross sectional area (a2), and the protruding portion and the third part of the cylinder housing (20) defining a first outer chamber (44′) and a second outer chamber (44″).