Variable Displacement Pump Turbine Efficiency Optimization
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Solution Overview
Problem
Conventional positive displacement pumping systems face efficiency drops when the turbine is not operated at optimal speed for a particular load, leading to increased fuel costs, engine flameout, and wear on components, while also limiting the ability to pump difficult materials effectively.
Innovation Solution
The system employs variable displacement hydraulic pumps powered by a turbine, which adjusts speed and volumetric displacement based on operational mode to optimize fuel efficiency, incorporating longer stroked hydraulic intensifiers and automatic valve control to minimize cavitation and valve wear, enabling efficient pumping of various materials downhole.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional positive displacement pumping systems operate the turbine at fixed speed, then the pump can maintain consistent flow, but the turbine cannot operate at optimal fuel efficiency under varying loads
Solution Approach 1:
The patent implements variable speed control of the turbine to match varying load requirements, allowing the turbine to operate at optimal speeds for different pumping conditions. This dynamic adjustment resolves the contradiction by making the system adaptable while maintaining energy efficiency across different operating points.
Solution Approach 2:
The system changes the operational parameters of the turbine (speed, volumetric displacement) based on load conditions to optimize fuel efficiency. By adjusting these parameters dynamically, the system achieves both adaptability to varying loads and optimal energy utilization.
2Adaptability or versatility
If the turbine operates at non-optimal speeds, then the system can handle varying loads, but fuel costs increase and engine flameout occurs
Solution Approach 1:
The system incorporates feedback mechanisms that monitor load conditions and adjust turbine speed accordingly. This ensures the turbine operates within optimal efficiency ranges while still accommodating varying loads, preventing both excessive fuel consumption and engine flameout conditions.
Solution Approach 2:
By implementing dynamic speed adjustment capabilities, the system can adapt to varying loads while maintaining operation within the turbine's optimal efficiency range, thereby reducing energy loss and preventing flameout events.
3Device complexity
If conventional pumps use fixed displacement, then the system is simpler, but the turbine cannot be operated at optimal fuel efficiency
Solution Approach 1:
The patent introduces variable displacement capability to the hydraulic pump while maintaining overall system simplicity through electronic control. This allows the turbine to operate at optimal fuel efficiency by matching pump displacement to actual load requirements, resolving the contradiction between simplicity and energy efficiency.
4Volume of moving object
If hydraulic intensifiers have shorter strokes, then the system is more compact, but cavitation potential increases and valve wear increases
Solution Approach 1:
The system incorporates preliminary action by providing sufficient dwell time at the end of hydraulic intensifier strokes before valve closure. This prevents cavitation and reduces valve wear by ensuring proper pressure equalization occurs before valves close, allowing the use of more compact intensifier designs without sacrificing reliability.
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 reduces fuel costs, extends equipment life, and allows for controlled, efficient pumping of materials at required pressures and volumes, including hard-to-pump substances, by optimizing turbine operation and reducing mechanical stress.
Implementation Method 1
These conventional pumps do not allow for the turbine to be operated at an optimal fuel efficiency
Implementation Method 2
a turbine to power a hydraulic intensifier through one or more variable displacement hydraulic pumps
Implementation Method 3
a turbine to power a hydraulic intensifier through one or more variable displacement hydraulic pumps (VDHP)
Implementation Method 4
The pumping system may include a turbine to power a hydraulic intensifier
Data Source
AI summary
A pumping system pumps material downhole, for example, to perform a fracturing operation. The pumping system comprises one or more variable speed engines, one or more variable displacement hydraulic pumps and one or more intensifiers. According to the desired or required load, the speed of the engine is set at an optimal or most efficient operating speed. The volumetric displacement of the variable displacement hydraulic pump is set to provide the desired output volume and pressure of the material from the intensifier. Varying the speed of the engine and the volumetric displacement of the variable displacement pump allows for the pumping system and in particular the engine to operate at an optimal efficiency which reduces at least fuel costs and wear and tear on components.