Proppant Mixing Pump Layout to Reduce Fracturing Pump Wear
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Solution Overview
Problem
Proppant accumulation in fluid pumps of hydraulic fracturing systems causes mechanical wear, reducing their efficiency and lifespan.
Innovation Solution
A fluid system with a mixing pump that separates proppant-containing fluid from proppant-free fluid, using a camshaft system to control valve operations, ensuring proppant is introduced only at the mixing pump, thereby protecting upstream pumps from wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If proppant is added to fracturing fluid before pumping, then the hydraulic fracturing efficacy is improved, but mechanical wear to pumps increases
Solution Approach 1:
The system segments the fluid handling process into separate zones: a first fluid path for proppant-free fluid, a second fluid path for proppant-containing fluid, and a mixing pump interface where the paths converge. This segmentation allows pumps to operate without direct contact with proppant while still achieving the required fracturing efficacy through controlled mixing at the pump outlet.
Solution Approach 2:
The mixing pump acts as an intermediary device that receives proppant-free fluid from the first fluid path and proppant-containing fluid from the second fluid path, then delivers mixed fluid to the wellbore. This intermediary function protects upstream pumps from proppant wear while maintaining the benefits of proppant-enhanced fracturing.
2Duration of action of stationary object
If proppant is introduced at the mixing pump, then pump lifespan is extended, but system complexity increases
Solution Approach 1:
The mixing pump is designed with multi-functionality, serving both as a fluid mixing device and as a protective barrier for upstream pumps. The single pump component performs multiple functions: receiving proppant-free fluid, receiving proppant-containing fluid, mixing the fluids, and delivering the mixture, thereby extending pump lifespan without requiring multiple separate protective components.
Solution Approach 2:
The system merges the first fluid path and second fluid path into a single mixing pump outlet. By combining the fluid paths at the mixing pump interface, the system achieves proppant separation and pump protection while using a single pump component rather than requiring multiple separate pumps or complex valve arrangements.
3Object-affected harmful factors
If separate fluid paths are used for proppant-containing and proppant-free fluid, then mechanical wear is reduced, but device complexity increases
Solution Approach 1:
The system implements separate fluid paths for proppant-containing and proppant-free fluid, with distinct intake valves and flow control mechanisms. This segmentation physically separates the harmful proppant from the pumps while maintaining the ability to deliver mixed fluid to the wellbore, thereby reducing mechanical wear without requiring overly complex system architecture.
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
Prevents proppant accumulation and mechanical wear in high-pressure and low-pressure pumps, extending their lifespan and improving system uptime.
Implementation Method 1
The mixing pump may include a cylinder defining a bore in fluid communication with a first fluid intake, a second fluid intake, and a fluid outlet
Implementation Method 2
a first intake valve configured to control flow of the first fluid containing proppant through the first fluid intake
Implementation Method 3
a second intake valve configured to control flow of the second fluid free of proppant through the second fluid intake
Implementation Method 4
an outlet valve configured to control flow of a mixture of the first fluid containing proppant and the second fluid free of proppant through the fluid outlet
Data Source
AI summary
A fluid system may include a first fluid path including a blender configured to mix fluid with proppant. The fluid system may include a second fluid path, fluidly isolated from the blender, including a pump. The fluid system may include a mixing pump configured to receive first fluid containing proppant from the first fluid path and second fluid free of proppant from the second fluid path. The mixing pump may include a cylinder defining a bore. The mixing pump may include a first intake valve configured to control flow of the first fluid, a second intake valve configured to control flow of the second fluid, and an outlet valve configured to control flow of a mixture of the first fluid and the second fluid.