Slurry Injection System Wear Reduction via Clear Fluid Pressurization
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Solution Overview
Problem
Slurry pumps used in high-pressure applications such as hydraulic fracturing experience severe wear due to abrasive slurries, leading to poor reliability and increased maintenance costs, and other system components like check valves and pipes suffer from erosion and metal fatigue.
Innovation Solution
An elongated tank system with a vertical side wall and angled bottom surface is used in conjunction with a high-pressure pump and clear fluid management system, including multiple tanks and valves, to minimize wear by controlling slurry pressure and flow, and a pulsation damper reduces pressure fluctuations during valve state changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If slurry pumps are used to provide high-pressure slurry for hydraulic fracturing, then the required flow rate and pressure are achieved, but severe wear occurs due to the abrasive nature of the slurry
Solution Approach 1:
The harmful abrasive slurry is extracted from the high-pressure system by using a check valve to separate the slurry injection function from the pressure generation function. The pump only handles clear fluid at low pressure, while the slurry is introduced separately and pressurized only when needed for injection, minimizing its exposure to high-speed mechanical components.
Solution Approach 2:
A check valve acts as an intermediary component that allows the abrasive slurry to be introduced into the high-pressure clear fluid stream without requiring the slurry to pass through the pump. This mediator enables the slurry to achieve high pressure through the fluid dynamic interaction rather than direct mechanical pumping.
2Productivity
If high velocity slurry flows through check valves and pipes, then the slurry injection function is achieved, but rapid erosion and wire drawing occur
Solution Approach 1:
The clear fluid is pressurized in advance by the pump before the slurry is introduced. This preliminary pressurization of the clear fluid creates a high-velocity stream that carries the slurry forward, achieving the required injection rate without requiring the slurry itself to be pumped at high speed, thereby reducing erosion.
Solution Approach 2:
The system uses hydraulic principles where high-pressure clear fluid acts as a carrier medium for the slurry. The slurry is injected into the high-velocity clear fluid stream, and the hydraulic energy of the clear fluid propels the slurry mixture through the injection point, minimizing direct mechanical wear on valves and pipes.
3Adaptability or versatility
If pressure vessels with multiple penetrations are used, then the required flow distribution is achieved, but cracking failure occurs from stress concentrations and metal fatigue
Solution Approach 1:
The system is segmented into separate functional components: a pressure vessel for clear fluid, a separate slurry injection point, and external piping for slurry introduction. This segmentation eliminates the need for multiple penetrations in the pressure vessel, as the slurry is introduced through a single dedicated injection point that does not compromise the structural integrity of the pressure vessel.
4Productivity
If slurry pumps operate continuously at high pressure, then the hydraulic fracturing process is maintained, but downtime increases due to frequent repairs
Solution Approach 1:
The slurry pumping function is extracted from the continuous high-pressure operation. The pump only operates continuously to provide low-pressure clear fluid, while the slurry is periodically injected through the check valve system. This extraction allows the pump to operate in a wear-free environment, eliminating the need for frequent repairs and reducing downtime.
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 significantly reduces wear on components, enhancing the reliability and longevity of slurry injection equipment, and maintains high-pressure performance with minimal downtime and maintenance.
Implementation Method 1
A pulsation damper disposed between the high pressure pump and the first clear fluid valve reducing a pressure reduction when the first clear fluid valve changes between the first state and the second state
Implementation Method 2
The bottom side is angled downward from the side wall toward the slurring injection channel
Data Source
AI summary
A slurry injection system includes low and high pressure clear fluid manifolds. Low pressure clear fluid is pressurized and communicated to high pressure manifold. A blender unit communicates slurry through a sensor system that generates a flow rate signal and a density signal of the low pressure slurry. The slurry pressurizer is in fluid communication with the high pressure clear fluid manifold through a bypass pump, a mixer, the blender unit and the low pressure clear fluid manifold. The slurry pressurizer forms high pressure slurry that is communicated to the mixer and communicates fluid to the low pressure clear fluid manifold. The mixer mixes the high pressure slurry and high pressure clear fluid from the high pressure clear fluid manifold to form a mixture that is communicated to a slurry injection site. A controller controls the bypass pump using the flow rate and density to control a density of slurry.