Pressure Exchange Control for Abrasive Fracking Fluids
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Solution Overview
Problem
Industrial hydraulic systems, particularly those used in fracking, face significant wear and maintenance issues due to the use of abrasive, caustic, or acidic fluids, leading to increased costs and downtime, as well as the need for frequent equipment replacement.
Innovation Solution
A pressure exchange device and method that utilize a piston with detection features and sensors to efficiently transfer pressure from a clean, high-pressure fluid to a dirty, low-pressure fluid, minimizing direct contact and contamination, while controlling the flow to reduce wear on system components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If high-pressure pumps are used to increase the pressure of fracking fluid, then the pressure of the fluid is increased, but the proppant in the fracking fluid increases wear and maintenance on the pumps
Solution Approach 1:
The system divides the fluid handling into two separate pathways: a clean fluid pathway for pressurization and a dirty fluid pathway for proppant transport. The pressure exchanger separates these functions, allowing the pump to only handle clean fluid while still achieving the required pressure for fracking operations.
Solution Approach 2:
A clean pressurization fluid acts as an intermediary to transfer pressure to the dirty fracking fluid containing proppant. This intermediary fluid absorbs the wear that would otherwise affect the pump, allowing the pump to operate with clean fluid while still pressurizing the abrasive mixture.
2Ease of operation
If pumps and valves are used to control fluid flow in hydraulic systems, then fluid flow is controlled, but abrasive, caustic, or acidic fluids increase wear on internal components
Solution Approach 1:
The pressure exchanger uses a clean pressurization fluid as an intermediary to control and transfer pressure to the dirty process fluid. This eliminates direct exposure of control components to abrasive, caustic, or acidic fluids while maintaining full flow control capability.
Solution Approach 2:
The harmful abrasive, caustic, or acidic components are extracted from the pressurization fluid pathway and confined to the process fluid pathway. The pressurization function is separated from the contaminated fluid, leaving only clean fluid in contact with pump and control components.
3Reliability
If worn pumps are rebuilt or replaced, then the hydraulic system can continue operating, but this results in extended periods of downtime or increased costs
Solution Approach 1:
The system converts the potentially harmful effect of abrasive, caustic, or acidic fluids by using them only in the process fluid pathway while maintaining a separate clean pressurization pathway. This transforms a wear-inducing situation into a protected configuration where critical components only handle clean fluid.
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 effectively reduces wear on hydraulic system components, decreases maintenance costs, and extends equipment lifespan by efficiently exchanging pressure between fluid streams, thereby enhancing operational efficiency and productivity.
Implementation Method 1
The at least one coil may be configured to produce a signal based on a proximity of the one or more magnets
Data Source
AI summary
Devices, systems, and methods for detecting properties of motion of at least one component of fluid exchange devices, such as, for example, a pressure exchange device or system.