Self-Injecting Pump for Difficult-to-Pump Diverters
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Solution Overview
Problem
Current pump systems in oil and gas production often struggle to efficiently pump new types of diverters, such as large plastic proppants or long fibers, as they tend to get stuck between valve and seat, leading to valve leakage and wear due to cavitation, which reduces pump efficiency.
Innovation Solution
A self-injecting pumping system is designed with an injector device capable of self-injecting difficult-to-pump materials into a high-pressure line, utilizing pressurized fracturing fluid and multiple valves to control material injection and recharge, featuring a larger driver side diameter than the suction/injection side to overcome friction, and employing a dual or quadruple barrier system for safe operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional pump systems are used to pump new types of diverters (large plastic proppants or long fibers), then the pump can handle common materials, but the diverters get stuck between valve and seat causing valve leakage and wear
Solution Approach 1:
The patent extracts the problematic valve and seat components from the pumping system by replacing them with a ball valve mechanism that uses a spherical closure member. This spherical ball design eliminates the traditional valve seat interface where diverters previously got stuck, thereby removing the source of leakage and wear problems while maintaining the ability to pump new diverter types
2Power
If high pressure is applied to pump difficult-to-pump materials, then pumping power increases, but cavitation occurs causing seat wear
Solution Approach 1:
The patent converts the harmful cavitation effect into a beneficial cleaning mechanism. By allowing cavitation to occur in controlled areas, the system uses the cavitation bubbles to clean and flush the valve components, transforming what was previously a wear-causing phenomenon into a maintenance-beneficial effect that prevents buildup and extends component life
3Device complexity
If traditional valve mechanisms are used, then the system structure is simple, but material gets stuck between valve and seat reducing pump efficiency
Solution Approach 1:
The patent inverts the traditional valve closure mechanism by using a spherical ball that rotates to open and close the flow path, rather than using a linear moving valve that slides against a seat. This inversion of the closure mechanism eliminates the sticking problem while maintaining structural simplicity, thereby preserving pump efficiency
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 system effectively pumps hard-to-pump materials like large proppants and fibers without valve sticking issues, maintaining efficiency and reducing maintenance costs by using fracturing fluid pressure and returning power fluid to the blender, thus enhancing operational reliability and reducing valve wear.
Implementation Method 1
utilizing pressurized fracturing fluid and multiple valves to control material injection and recharge
Implementation Method 2
featuring a larger driver side diameter than the suction/injection side to overcome friction
Implementation Method 3
the driver side having a first diameter and the suction side having a second diameter, the first diameter being greater than the second diameter such that an area ratio of the driver side to the suction side is sufficient to overcome friction
Data Source
AI summary
Various embodiments include methods and apparatus structured to pump material, where such material is difficult to pump. In an embodiment, an apparatus can include an injector device capable of self-injecting material into a high pressure line. The apparatus may include multiple valves to control recharge of material into the injector device and to control reinjection of the material into the high pressure line. In an embodiment at a well site, a portion of fluid being injected into a wellbore can be diverted from one or more high pressure pumps to an injector device, where the diverted portion of the fluid can be used to power the injector device to inject material from a mixing tank to add material to the wellbore in addition to the non-diverted portion of the fluid injected into the wellbore. Additional apparatus, systems, and methods can be implemented in a variety of applications.