Isobaric Pressure Exchanger for Abrasive Frac Fluid Isolation
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Solution Overview
Problem
Hydraulic fracturing operations face equipment wear and maintenance challenges due to the abrasive nature of proppant-laden fluids, which increases the wear and maintenance costs of high-pressure pumps used in the process.
Innovation Solution
A hydraulic energy transfer system that transfers work and pressure between proppant-free and proppant-laden fluids, using devices like hydraulic turbochargers and isobaric pressure exchangers to isolate the high-pressure pumps from direct contact with the abrasive fluids, thereby reducing wear and allowing the use of less expensive equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-pressure pumps are used to pump proppant-laden frac fluid, then fracturing operation can be performed, but equipment wear and maintenance increase
Solution Approach 1:
The patent introduces a proppant-free carrier fluid as an intermediary between the pump and the proppant-laden frac fluid. The pump only handles the carrier fluid, which then transfers energy to the proppant-laden fluid through a hydraulic coupling device (such as a hydraulic turbocharger or pressure exchanger). This intermediary approach allows the pump to operate without direct contact with abrasive proppant, significantly reducing wear and maintenance while maintaining the ability to perform fracturing operations.
2Reliability
If proppant-free carrier fluid is used to reduce pump wear, then equipment life is extended, but pressure transfer efficiency must be maintained
Solution Approach 1:
The hydraulic coupling device acts as an energy transfer intermediary that efficiently transfers pressure and energy from the proppant-free carrier fluid to the proppant-laden frac fluid. Devices such as hydraulic turbochargers use rotating impellers to convert hydraulic energy from the carrier fluid into mechanical rotation, which then drives a second impeller to pressurize the proppant-laden fluid. Pressure exchangers use reciprocating pistons or diaphragms to transfer pressure energy while isolating the two fluids. These intermediary mechanisms maintain high pressure transfer efficiency while allowing the pump to only handle the cleaner carrier fluid.
Solution Approach 2:
The patent replaces the direct mechanical connection between the pump and proppant-laden fluid with a hydraulic energy transfer system. Instead of mechanically pumping the abrasive proppant-laden fluid, the system uses hydraulic energy transfer through fluid coupling devices. This substitution eliminates direct mechanical contact between the pump components and abrasive proppant, extending equipment life while maintaining effective pressure delivery through the hydraulic energy transfer mechanism.
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 effectively reduces abrasion and wear on hydraulic fracturing equipment, extends the life of high-pressure pumps, and enables the use of less expensive equipment by blocking contact between the proppant-laden fluid and the pumps, while maintaining efficient pressure transfer, thus enhancing the performance and longevity of fracturing operations.
Implementation Method 1
A frac system with hydraulic energy transfer system... hydraulic energy transfer system that transfers work and pressure between proppant-free and proppant-laden fluids
Data Source
AI summary
A pumping system that includes a reciprocating isobaric pressure exchanger (reciprocating IPX) designed to exchange pressures between a first fluid and a second fluid. The first fluid includes a substantially particulate free fluid and the second fluid includes a particulate laden fluid. The reciprocating IPX includes a valve having a first and second piston. The value further includes a shaft coupling the first piston to the second piston and a drive coupled to the shaft.