Pressure Exchange Piston Isolation for Abrasive Fluid Pressurization
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Solution Overview
Problem
Industrial processes involving hydraulic systems with caustic, abrasive, or acidic fluids lead to increased wear on components, necessitating frequent maintenance and replacement, while hydraulic fracturing operations face similar issues due to abrasive proppants reducing pump lifespan.
Innovation Solution
A pressure exchange device with pistons and coils for detecting properties, separating clean and dirty fluids, and controlling fluid communication to transfer pressure efficiently, minimizing component wear by isolating high-pressure clean fluid from dirty fluid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If high-pressure pumps are used to increase pressure of fracking fluid containing abrasive proppant, then the desired high pressure is achieved, but the pump lifespan is substantially reduced due to abrasive wear
Solution Approach 1:
A pressure exchange device with pistons acts as an intermediary between the clean pressurizing fluid and the dirty fracking fluid. The pistons transfer pressure from the clean fluid to the dirty fluid without direct contact between the two fluids, preventing abrasive wear on pump components while achieving the required high pressure for hydraulic fracturing operations
2Stress or pressure
If pumps handle abrasive, caustic, or acidic fluids directly, then the fluid pressurization is achieved, but component wear increases requiring frequent maintenance and replacement
Solution Approach 1:
The pressure exchange device uses pistons as intermediaries to transfer pressure from clean fluids to dirty fluids containing abrasive, caustic, or acidic substances. This isolation prevents direct contact between clean pump components and harmful fluids, significantly improving component reliability and reducing maintenance requirements
Solution Approach 2:
The system segments the fluid handling into separate zones: a clean fluid side for pressurization and a dirty fluid side for injection. The piston separation creates distinct compartments that prevent contamination and wear, allowing the clean side components to maintain high reliability while the dirty side handles abrasive materials
3Reliability
If worn pumps are rebuilt or replaced, then the hydraulic system functionality is restored, but operational downtime increases reducing productivity
Solution Approach 1:
By introducing the pressure exchange device with pistons as an intermediary, the system protects pump components from abrasive wear, thereby maintaining reliability and avoiding the downtime associated with rebuilding or replacing worn pumps, thus preserving operational productivity
4Productivity
If redundant pumps are deployed to avoid downtime, then continuous operation is maintained, but system complexity and cost increase
Solution Approach 1:
The pressure exchange device with protective pistons serves as an intermediary that prevents wear and extends pump lifespan, eliminating the need for redundant pumps to maintain continuous operation. This reduces system complexity while ensuring uninterrupted productivity
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 transfers pressure from clean to dirty fluids, reducing wear on equipment, extending lifespan, and potentially eliminating the need for redundant pumps, thus lowering maintenance costs and downtime.
Implementation Method 1
The chamber may also include at least one sensor comprising at least one coil arranged circumferentially about the at least one chamber
Implementation Method 2
The valve device may be configured to selectively place the clean fluid in communication with the dirty fluid through the at least one piston in order to at least partially transfer the first property of the clean fluid to the dirty fluid
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.