Non-Mechanical Eductor Pump Lock Hopper Fracking Fluid Delivery

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Solution Overview

Problem

Current wellhead fracking systems face significant maintenance and replacement challenges due to the deterioration of mechanical pumps from abrasive and chemical-laden treatment fluids, leading to increased costs and operational disruptions.

Innovation Solution

A non-mechanical eductor pump system coupled with a lock hopper is used to deliver fluids, where the lock hopper contains a pressurized treatment fluid that is mixed with a motive fluid, creating a fluid mixture which is then expanded for delivery, eliminating the need for mechanical pumps and reducing wear and tear.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If mechanical pumps are used to pump treatment fluid containing sand and chemicals, then the fluid can be delivered to the wellbore, but the pump components deteriorate rapidly due to abrasion, erosion, and corrosion

Engineering Contradiction:

Improvefluid delivery capabilityVSAvoidpump component durability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent replaces mechanical pumps with a hydraulic system consisting of a hydraulic power unit, hydraulic lines, and a hydraulic actuator. This substitution eliminates mechanical contact between pump components and the abrasive treatment fluid, thereby preventing wear, erosion, and corrosion while maintaining fluid delivery capability to the wellbore

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent employs a hydraulic system where a hydraulic power unit generates hydraulic pressure that is transmitted through hydraulic lines to a hydraulic actuator. This hydraulic mechanism delivers the treatment fluid to the wellbore without requiring mechanical pump components that would be subject to abrasion and corrosion from the fluid

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Productivity

If mechanical pumps with close tolerances and sealing features are used, then pumping efficiency is maintained, but solid particles become trapped and cause abrasion between mating parts

Engineering Contradiction:

Improvepumping efficiencyVSAvoidsolid particle abrasion

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent eliminates mechanical pump components with mating surfaces and sealing features by replacing them with a hydraulic system. This substitution removes the mechanism by which solid particles could become trapped and cause abrasion between mating parts, while maintaining the ability to deliver treatment fluid efficiently to the wellbore

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If spare parts and complete spare fracking pumps are kept on hand for rapid repair, then operational continuity is maintained, but significant space and cost are required

Engineering Contradiction:

Improveoperational continuityVSAvoidspace for spare equipment

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The patent replaces mechanical pumps that require frequent maintenance and spare parts with a hydraulic system that has no mechanical pump components subject to wear. This substitution eliminates the need to store spare parts and complete spare fracking pumps, freeing up significant space while maintaining operational continuity through the durability of the hydraulic system

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 system significantly reduces maintenance requirements and extends the lifespan of the pumping mechanism, allowing for more efficient and cost-effective fluid delivery at elevated pressures, while maintaining consistent fluid quality and quantity.

Implementation Method 1

a suction chamber coupled to the lock hopper, the suction chamber in fluidic communication with the eductor motive fluid inlet, the suction flow outlet and a fluid mixture outlet, the suction chamber configured to output a fluid mixture

Methodology Applied

Scientific EffectPressure differential: Pressure Gradient

Implementation Method 2

an expansion feature coupled to the mixing chamber and configured to expand the fluid mixture therein for delivery to a downstream component

Methodology Applied

Scientific EffectFluid expansion:

Data Source

PatentUS9086164B2Apparatus and method of delivering a fluid using a non-mechanical eductor pump and lock hopper

Publication Date: 2015.07.21 BAKER HUGHES CO

AI summary

An apparatus and method for delivering a fluid using non-mechanical lock hopper eductor assembly. The assembly including at least one lock hopper coupled to an eductor motive fluid inlet, a source of a treatment material and a suction flow outlet. The lock hopper configured to contain therein a pressurized treatment fluid as an output suction flow. The lock hopper is coupled to an eductor pump assembly. The eductor pump assembly including a suction chamber in fluidic communication with the eductor motive fluid inlet, the suction flow outlet and a fluid mixture outlet. The suction chamber configured to output a fluid mixture to a mixing chamber coupled to said fluid mixture outlet and configured to mix the fluid mixture therein. The eductor pump assembly further including an expansion feature coupled to said mixing chamber and configured to expand the fluid mixture therein for delivery to a downstream component.