Split Stream Pressure Exchangers for Dirty Fluid Handling
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Solution Overview
Problem
Pressure exchangers in oil and gas operations face limitations in flow rates, leakage, and compression losses, particularly when handling dirty fluids, which reduces the efficiency and lifespan of high-pressure pumps and increases maintenance costs.
Innovation Solution
A wellsite system that utilizes pressure exchangers to transfer pressure from a clean fluid to a dirty fluid, allowing the clean fluid to be pumped by high-pressure pumps while the pressure exchangers increase the pressure of the dirty fluid for injection into a wellbore, thereby reducing the workload on the pumps and improving fluid control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If pressure exchangers are used to handle dirty fluids, then pump lifespan is extended, but flow rate is limited
Solution Approach 1:
The system divides the fluid handling into separate streams: a clean fluid stream that passes through the pressure exchanger and a dirty fluid stream that is pressurized by conventional pumps. This segmentation allows the pressure exchanger to operate with clean fluid only, extending its lifespan, while multiple pumps handle the dirty fluid to achieve required flow rates.
Solution Approach 2:
A clean fluid acts as an intermediary medium that transfers pressure to the dirty fluid through a mixer or injection system. The clean fluid is pressurized by the pressure exchanger and then used to pressurize the dirty fluid, allowing the pressure exchanger to avoid direct contact with abrasive particles.
2Productivity
If more pumps are used to achieve higher flow rates, then productivity increases, but system weight increases
Solution Approach 1:
The system uses hydraulic principles where a clean fluid pressurized by the pressure exchanger is injected into the dirty fluid stream to transfer pressure. This hydraulic pressure transfer mechanism reduces the need for multiple heavy-duty pumps, thereby reducing overall system weight while maintaining required flow rates.
3Ease of operation
If pressure exchangers handle dirty fluids directly, then fluid control is simplified, but compression losses increase
Solution Approach 1:
The harmful abrasive particles are extracted from the fluid stream that passes through the pressure exchanger. Only clean fluid is circulated through the pressure exchanger, eliminating compression losses associated with handling dirty fluids while maintaining simplified fluid control through the pressure exchanger system.
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
This approach enhances the operational efficiency and extends the lifespan of high-pressure pumps by reducing the need to pump abrasive dirty fluids directly, minimizing leakage and compression losses, and maintaining consistent fluid flow and pressure.
Implementation Method 1
pressure exchangers are operable to receive the concentrated dirty fluid from the mixer, receive the pressurized first clean fluid from the first fluid pumps to pressurize the concentrated dirty fluid
Data Source
AI summary
Apparatus and method for performing split stream operations with pressure exchangers. An example method may include operating a mixer to form a stream of concentrated dirty fluid, operating a first pump to form a pressurized stream of first clean fluid, operating a second pump to form a pressurized stream of second clean fluid, and transferring the pressurized stream of first clean fluid and the stream of concentrated dirty fluid through a plurality of pressure exchangers to pressurize the stream of concentrated dirty fluid. Thereafter, the method may further include combining the pressurized stream of concentrated dirty fluid with the pressurized stream of second clean fluid to form a pressurized stream of diluted dirty fluid, and injecting the pressurized stream of diluted dirty fluid into a wellbore during a subterranean well treatment operation.