Modular Pumping System for Abrasive Fluids
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The abrasive nature of fracturing fluids and other downhole fluids in oilfield applications leads to high maintenance and replacement costs for pump components due to wear and tear, resulting in a low life expectancy for pumps used in high-pressure operations.
Innovation Solution
A modular pumping system with rotatable rotor and stator pairs within a cylindrical housing, where the rotor is magnetically coupled to a shaft and the stator is fixed, allowing for efficient fluid transfer and minimizing wear by distributing pressure across multiple stages, with a higher-pressure outer housing supporting the pumping modules and enabling adjustable configurations for series or parallel pump arrangements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If pumps are used to pump abrasive fracturing fluids at high pressures, then fluid pumping capability is achieved, but pump component wear increases and life expectancy decreases
Solution Approach 1:
The pump is divided into multiple independent pumping modules, each containing its own rotor-stator pair. This segmentation allows individual modules to be replaced without replacing the entire pump assembly, reducing downtime and maintenance costs while maintaining high-pressure pumping capability through the modular architecture.
Solution Approach 2:
The patent employs progressive cavity pump technology where the rotor and stator create moving cavities that propel fluid forward. This changes the pumping mechanism from direct mechanical contact to cavity-based fluid movement, significantly reducing wear on pump components while maintaining effective high-pressure fracturing fluid delivery.
2Power
If traditional pump designs are used for high-pressure fracturing, then initial pumping performance is achieved, but maintenance and replacement costs increase
Solution Approach 1:
The pump assembly is segmented into multiple interchangeable modules that can be independently manufactured, tested, and replaced. This modular approach reduces maintenance costs by allowing only the worn module to be replaced rather than the entire pump, while maintaining high-pressure performance through the coordinated operation of multiple modules.
Solution Approach 2:
The pumping modules are designed with nested components where the rotor fits within the stator, which in turn fits within the module housing. This nested structure optimizes space utilization, reduces material requirements, and simplifies assembly and replacement procedures, thereby reducing overall system costs while maintaining pumping effectiveness.
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 modular design extends pump life, reduces maintenance costs, and allows for efficient high-pressure fluid pumping with adjustable configurations to meet operational demands, effectively managing the abrasive effects of fracturing fluids and enhancing well production.
Implementation Method 1
the rotor is magnetically coupled to a shaft
Data Source
AI summary
A pumping module is positionable within a pump housing for pumping fluid into a wellbore. The pumping module includes a cylindrical housing with an inlet end and an outlet end, an inlet cap positioned on the inlet end of the cylindrical housing and including an inlet formed through the inlet cap, and an outlet cap positioned on the outlet end of the cylindrical housing and including an outlet formed through the outlet cap. A shaft is rotatable with respect to the cylindrical housing, and a rotor is positioned within the cylindrical housing and rotatable by the shaft to push fluid through the cylindrical housing.