Integrating Valves and Flow Manifold into Pressure Exchanger Housing
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Solution Overview
Problem
High-pressure, high-volume pumps used in hydraulic fracturing operations experience accelerated wear and erosion due to the properties of fracing fluids, leading to increased costs and decreased efficiency.
Innovation Solution
The use of isobaric pressure exchangers (IPXs) that transfer pressure between high-pressure and low-pressure fluid streams with minimal mixing, allowing high-pressure water to pressurize fracing fluids while protecting the pumps from the abrasive nature of the fracing fluids, and integrating these IPXs with manifolds and valves within a compact, mobile system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-pressure pumps are used to directly pump fracing fluids, then hydrocarbon production can be increased, but the pumps experience accelerated wear and erosion
Solution Approach 1:
The patent introduces an isobaric pressure exchanger as an intermediary device between the pump and the fracing fluid injection system. The pressure exchanger allows high-pressure water to transfer pressure to the fracing fluid without direct contact between the pump and the abrasive fracing fluid, thus protecting the pump from wear and erosion while maintaining the ability to inject fracing fluid at high pressure for hydrocarbon production
Solution Approach 2:
The system is segmented into separate functional components: a pump that handles only water, a pressure exchanger that transfers pressure between water and fracing fluid, and then the fracing fluid injection system. This segmentation allows each component to be optimized for its specific function, with the pump being protected from the harmful effects of fracing fluid
2Ease of operation
If traditional separate components (pumps, manifolds, valves) are used, then system functionality is achieved, but equipment congestion and operational complexity increase
Solution Approach 1:
The patent merges the manifold and valve components directly into the housing of the pressure exchanger. The manifold is formed as an integral part of the housing structure, and valves are incorporated within the same housing, eliminating the need for separate manifold and valve assemblies. This integration reduces the number of external connections and components, thereby reducing equipment congestion and simplifying operational procedures
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
This solution extends the life of high-pressure pumps, reduces maintenance costs, and increases hydrocarbon production rates by efficiently handling viscous and abrasive fracing fluids while minimizing equipment congestion and operational complexity.
Implementation Method 1
isobaric pressure exchangers (IPXs) that transfer pressure between high-pressure and low-pressure fluid streams with minimal mixing, allowing high-pressure water to pressurize fracing fluids
Data Source
AI summary
A system includes an isobaric pressure exchanger (IPX) configured to couple to a manifold. The IPX is also configured to exchange pressure within the IPX between a first fluid at a first pressure and a second fluid at a second pressure. The IPX also includes a housing and at least one manifold connector disposed within the housing that is configured to couple the IPX to the manifold.