Pump Bellows Working Range Control via Hydraulic Volume Adjustment
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Solution Overview
Problem
Conventional pumps used in hydraulic fracturing at high pressures suffer from mechanical wear, rapid pressure fluctuations, and limited operational life due to the presence of particles and abrasive chemicals, leading to leaks, efficiency issues, and frequent breakdowns, with existing solutions failing to effectively control bellows movement and synchronize multiple units.
Innovation Solution
A method and system that control the working range of pump bellows by monitoring position signals and adjusting hydraulic fluid volume using an oil management system to prevent excessive compression or extension, ensuring the bellows operate within predefined limits, thus reducing wear and tear and minimizing the risk of damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If mechanical piston pumps are used for pumping fracking fluid under high pressures, then high pressure delivery is achieved, but mechanical wear and tear on sliding surfaces occurs due to sand and particles, leading to limited operating time
Solution Approach 1:
The pump system is divided into separate chambers: a first chamber containing the bellows that contacts the particle-laden fracking fluid, and a second chamber containing hydraulic fluid that drives the bellows. This segmentation prevents particles from contacting mechanical sliding surfaces, eliminating wear while maintaining high pressure capability
Solution Approach 2:
The bellows acts as an intermediary element between the particle-laden fracking fluid and the clean hydraulic fluid. It transmits the driving force from the hydraulic side to the pumped fluid side without allowing direct contact between particles and mechanical components, thus preventing wear
2Productivity
If plunger pumps operate at high speeds to increase productivity, then pumping rate is improved, but rapid pressure fluctuations cause fatigue cracking and breakdown
Solution Approach 1:
The bellows provides a compliant, flexible barrier that cushions and dampens pressure fluctuations before they propagate through the system. Its elastic nature absorbs shock loads and reduces rapid pressure variations, preventing fatigue cracking while allowing high-speed operation
Solution Approach 2:
The bellows is constructed as a flexible membrane that can deform elastically under pressure changes. This flexibility allows it to absorb and dampen pressure fluctuations, reducing shock loads on the system while maintaining high pumping speeds
3Productivity
If multiple pumps are connected to the same flow line to increase productivity, then flow rate is improved, but interference patterns cause flow line movement and equipment damage
Solution Approach 1:
The system uses controlled periodic operation of multiple pump units, where pumps are activated in a coordinated sequence rather than simultaneously. This periodic activation pattern prevents interference patterns and flow line movement while maintaining high overall productivity
4Reliability
If pump components are designed to withstand maximum pressure to ensure reliability, then pressure capacity is improved, but mechanical complexity and cost increase
Solution Approach 1:
The system replaces traditional mechanical pressure-containing components (such as heavy-duty seals and rigid pressure boundaries) with a hydraulic bellows mechanism. The bellows provides pressure containment through its flexible structure and hydraulic principle, reducing mechanical complexity while maintaining high pressure capability
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 extends the life cycle of pump components, prevents damage from particle contact, and ensures seamless operation at high pressures with synchronized multiple units, reducing maintenance needs and preventing equipment snaking.
Implementation Method 1
a bellows (6) defining an inner volume (7) inside the pressure cavity (4), and wherein an inner volume (7) is in fluid communication with the connection port (3) and is prevented from fluid communicating with the pressure cavity (4)
Implementation Method 2
The bellows (6) is configured to move in a direction substantially in the longitudinal direction, which in the drawing is coinciding with the center axis (C) of the pressure cavity (4)
Data Source
AI summary
Method, and associated system, computer program and use, of controlling working range of a pump bellows, including maximum limitations such as maximum retracting position and maximum extension position of the bellows, the method comprising the steps of: a) reading at least a first position of a bellows (6′, 6″) in a closed hydraulic loop volume using at least one position sensor (12′, 12″), g) transmitting a first position signal representing the first position to a control system, h) wherein the control system, based on the at least first position signal: c1) determines the position of the bellows (6′, 6″) represented by the at least first position signal, c2) compares the position of the bellows (6′, 6″) with a predetermined bellows position operating range, and c3) if the position is outside the predetermined bellows position operating range, instructs an oil management system valve (16′, 16″) allowing a dual acting pressure boosting liquid partition device (2) to recalibrate the hydraulic fluid volume in the closed hydraulic loop volume to re-establish a hydraulic fluid volume that causes the at least first position to return to a position within the predetermined bellows position operating range.