U.S. patent application number 15/004417 was filed with the patent office on 2016-07-28 for economical high pressure wear resistant cylinder that utilizes a high pressure field for strength.
This patent application is currently assigned to TRINITY PUMPWORKS LLC. The applicant listed for this patent is TRINITY PUMPWORKS LLC. Invention is credited to KEVIN NEWCOMER, ROBERT ELI OKLEJAS.
Application Number | 20160215774 15/004417 |
Document ID | / |
Family ID | 56432467 |
Filed Date | 2016-07-28 |
United States Patent
Application |
20160215774 |
Kind Code |
A1 |
OKLEJAS; ROBERT ELI ; et
al. |
July 28, 2016 |
Economical High Pressure Wear Resistant Cylinder That Utilizes A
High Pressure Field For Strength
Abstract
A high-pressure wear resistant cylinder that utilizes a
high-pressure field for strength is an economical method of, or
device for, handling very high pressures and the pumping of
abrasive and corrosive fluids. The economic considerations are so
favorable, that the invention may be considered a replacement part.
The invention is suitable for a variety of applications,
particularly a reciprocating flow work exchanger in the well
stimulation or hydraulic fracturing industry. Using a high pressure
field to strengthen the external surface (outside) of a pipe that
is precision honed and plated or sleeved internally (inside), it is
now possible to construct various high pressure machines in a
relatively inexpensive manner. This invention makes it possible to
use pipe with internal operating pressures greater than their
nominal operating pressure ratings permit. This invention will be
used in various high pressure piping and machinery
applications.
Inventors: |
OKLEJAS; ROBERT ELI;
(MONROE, MI) ; NEWCOMER; KEVIN; (MONROE,
MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
TRINITY PUMPWORKS LLC |
MONROE |
MI |
US |
|
|
Assignee: |
TRINITY PUMPWORKS LLC
MONROE
MI
|
Family ID: |
56432467 |
Appl. No.: |
15/004417 |
Filed: |
January 22, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62106668 |
Jan 22, 2015 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F04B 15/02 20130101;
F04B 53/166 20130101; F04B 9/103 20130101; F04F 13/00 20130101;
E21B 43/26 20130101 |
International
Class: |
F04B 53/16 20060101
F04B053/16; E21B 43/12 20060101 E21B043/12; E21B 43/26 20060101
E21B043/26; F04B 15/02 20060101 F04B015/02 |
Claims
1. An apparatus for pumping fluid comprising: an inner cylinder
defining an interior cavity and an exterior surface, an outer
cylinder, encompassing the inner cylinder, having an interior
surface and an exterior surface, the interior surface of the outer
cylinder being in communication with the exterior surface of the
inner cylinder, a means for sealing one end of the inner and outer
cylinders, an end assembly fixed attached to the opposed end of the
inner and outer cylinders for moving fluid into and out of the
interior cavity of the inner cylinder, wherein the outer cylinder
has a higher pressure rating than the inner cylinder, and provides
greater structural integrity to the inner cylinder, and a piston
located within the inner cylinder cavity for moving the fluid
contained in the inner cavity.
2. The apparatus of claim 1 wherein the interior surface of the
outer cylinder is spaced apart from the exterior surface of the
inner cylinder, and a pressure field is created between the
exterior of the inner cylinder and the interior of the outer
cylinder wherein pressurized fluid is added to increase the
pressure capability of the inner cylinder.
3. The apparatus of claim 2 wherein the pressure field is charged
through ports contained in the inner cylinder.
4. The apparatus of claim 2 wherein the pressure field contains a
plurality of dividers creating a plurality of smaller pressure
fields.
5. The apparatus of claim 2 wherein the pressure field is charged
through ports contained in the outer cylinder.
6. The apparatus of claim 1 wherein interior surface of the outer
cylinder is in direct contact with the exterior surface of the
inner cylinder thereby providing greater structural integrity to
the inner cylinder.
7. An apparatus for pumping abrasive fluid comprising: an inner
cylinder defining an interior cavity and a specified pressure
rating, an outer cylinder defining an interior cavity and a second
specified pressure rating which is greater than the pressure rating
of the inner cylinder, a piston contained within the inner cylinder
cavity for moving the fluid contained in the inner cavity, and
wherein, the inner cylinder is fitted within the inner cavity of
the outer cylinder, creating a pressure field between the exterior
of the inner cylinder and the interior of the outer cylinder
wherein pressurized fluid is added to increase the pressure
capability of the inner cylinder
8. An apparatus for pumping fluid comprising: an inner cylinder
defining an interior cavity, an exterior surface, and a specified
pressure rating, an outer cylinder, encompassing the inner
cylinder, having an interior surface, an exterior surface, and a
second specified pressure rating which is greater than the pressure
rating of the inner cylinder, a piston located within the inner
cylinder cavity for moving the fluid contained in the inner cavity,
the interior surface of the outer cylinder is spaced apart from the
exterior surface of the inner cylinder, and a pressure field is
created between the exterior of the inner cylinder and the interior
of the outer cylinder wherein pressurized fluid is added to
increase the pressure capability of the inner cylinder. a means for
sealing one end of the inner and outer cylinders, an end assembly
fixed to the opposed end of the inner and outer cylinders for
moving fluid into and out of the interior cavity of the inner
cylinder, and wherein the outer cylinder, having a higher-pressure
rating than the inner cylinder, provides greater structural
integrity to the inner cylinder.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present patent application is based upon and claims the
benefit of provisional patent application No. 62/106,668, filed on
Jan. 22, 2015
BACKGROUND OF THE INVENTION
[0002] Hydraulic fracturing (also hydrofracturing, hydrofracking,
fracking or fraccing), is a well-stimulation technique in which
rock is fractured by a hydraulically pressurized liquid made of
water, sand, and chemicals. Some hydraulic fractures form
naturally--certain veins or dikes are examples. A high-pressure
fluid (usually chemicals and sand suspended in water) is injected
into a wellbore to create cracks in the deep-rock formations
through which natural gas, petroleum, and brine will flow more
freely. When the hydraulic pressure is removed from the well, small
grains of hydraulic fracturing proppants (either sand or aluminum
oxide) hold the fractures open. Traditionally, the fracking fluid
(including proppants) is delivered to the well with powerful and
expensive reciprocating plunger pumps. The pressure required to
fracture these formations ranges can exceed 15,000 psi.
[0003] High pressure pump failures are the number one operational
challenge faced by the industry. The challenges faced include the
following:
[0004] 1. High pump maintenance costs
[0005] 2. Sporadic and excessive downtime (pump failures)
[0006] 3. High levels of redundancy (mitigate pump failures)
[0007] These challenges are all due to the pumping of abrasive and
highly viscous frac fluids. It is the equivalent of adding sand to
your car's engine. The best way to improve the above problems is to
avoid sending the fracking fluid through the high pressure plunger
pumps. Plunger pumps that pump or move clean and ph neutral fluids
last longer, are more economical to operate, and require less
maintenance.
[0008] Industry professionals are currently evaluating different
methods of delivering the fracking fluid to the well (borehole) at
the required pressures with newly developed or modified devices
other than traditional reciprocating plunger pumps.
[0009] If these new technologies are able to move the fracking
fluid with new and more robust equipment, the industry will
experience a paradigm shift. The primary benefits will be reduced
maintenance costs, decreased pump redundancy, and lower capital
expenditures. Any new technologies must improve the total cost of
owning and operating the equipment that transports the fracking
fluid and proppants at high pressure into the well. These new
technologies must be in-expensive to manufacture, easy to service,
and economical to maintain with affordable spare parts (wear
items).
[0010] Two new ideas concerning the delivery of the fracking fluid
into the well without sending the fracking fluid through the high
pressure plunger pump are being explored. Both of these potential
solutions rely upon new machines that are conceived from fluid
transfer equipment originally developed for low pressure and highly
filtered fluid applications such as reverse osmosis desalination.
One approach is to use a modified rotating pressure exchanger
energy recovery unit and the other is a reciprocating dual work
exchange energy recovery unit. Again, both of these new ideas/new
pumping machines are based on experience gained in handling very
clean filtered water at low pressure (rarely exceeds 1200 psi), and
with pH values not far from neutral.
[0011] This invention is applicable to many different industries.
Of the numerous industries being evaluated, it appears that the
fracking industry may benefit the most at this time. For this
reason, this description will reference a reciprocating dual work
exchange unit to help explain a practical application of subject
invention.
[0012] In designing and constructing a reciprocating dual work
exchanger for handling high pressure and abrasive fluids such as
fracking fluid, complex challenges arise. Of several challenges,
two of the biggest are working with high pressure and abrasive
fluids including but not limited to water, sand, aluminum balls,
acid and corrosion inhibitors.
[0013] Also of significance, is the fact that the reciprocating
dual work exchanger's total cost of ownership (purchase price of an
asset plus the costs of operation) must be more favorable than the
current methods. This invention makes the design, production,
operation, and ownership of a fracking work exchanger and other
products economically feasable.
SUMMARY OF THE INVENTION
[0014] The invention is based upon a pipe, tube, or pressure vessel
located within another pressure containing vessel such as a pipe,
tube or other similar form. The cavity between the inner wall of
the outer vessel and the outer wall of the inner vessel is
pressurized. In this way, the inner vessel or pipe can be much
lighter and less expensive because the inner pipe is no longer
required to withstand the required working pressure of the inner
pipe alone. This invention relies upon the creation of a pressure
field to support the demand placed on the internal pipe or pressure
vessel. For example, if a pipe that is expected to wear-out
frequently, must safely operate at 10,000 psi, this invention makes
it possible to construct an outer vessel rated to 10,000 psi, place
an internal pipe of vessel rated for only 5,000 psi and charge the
space between the two up to 5,000 or 6,000 psi, thus reaching the
desired 10,000 psi. This allows the inner pipe to absorb all wear
and to be constructed of cheaper and lighter material. The
expensive outer vessel does not see any wear. The inner tube or
vessel is mounted in a way to allow of easy and quick
replacement.
[0015] To design a reciprocating work exchanger pumping machine,
the diameter of the barrel, the length of the barrel, and the speed
at which the plunger/piston will travel must be established. These
three factors define the capacity (or how much fluid the pumping
machine can move) of the work exchanger. The capacity is expressed
in terms of a volume unit per time unit such as liters per minute
(Ipm) or gallons per minute (gpm).
[0016] Next, consideration must be given to what fluid is being
pumped so that a suitable piston seal material can be selected. In
the case of very abrasive fracking fluid a good choice for a piston
seal would be high-intensity acrylonitrile butadiene rubber or NBR.
The reciprocating plunger needs to seal tightly against the walls
of the work exchanger just as the piston in our syringe must seal
against the walls of the syringe barrel or the fluid can not be
moved. Depending on the type of seal being used, the maximum speed
of the reciprocating plunger (expressed in distance unit per time
unit) will be defined. For example, if the seal is made of rubber
and the speed is very high, the rubber will overheat and fail
prematurely.
[0017] The length of the barrel is a design criteria established
initially by the desired overall size of the work exchanger. For
fracking applications, a length of ten feet is a good place to
start. With this dimension, a finished work exchanger solution can
be easily transported on a trailer from jobsite to jobsite.
[0018] Other objects and advantages of the present invention will
become apparent to those skilled in the art upon a review of the
following detailed description of the preferred embodiments and the
accompanying drawings.
IN THE DRAWINGS
[0019] FIG. 1 is a crosssection view of a reciprocating dual work
exchanger having a high-pressure wear resistant cylinder that
utilizes a high-pressure field to strengthen the inner vessel,
based upon charging lines and an external pressure source such as a
dedicated pressure circuit or pressure from the pressure source
that drives the work exchanger.
[0020] FIG. 2 is a crosssection view of an alternative
reciprocating dual work exchanger with a high-pressure wear
resistant cylinder that utilizes a high-pressure field for strength
based upon charging ports that use pressure from the pressure work
exchanger itself.
[0021] FIG. 3 is a crosssection view of an alternative
reciprocating dual work exchanger with a high-pressure wear
resistant cylinder that utilizes multiple high-pressure fields for
strength based upon charging multiple ports and chambers that use
pressure from the pressure work exchanger itself.
[0022] FIG. 4 is a crosssection view of an alternative
reciprocating dual work exchanger with a high-pressure wear
resistant cylinder that utilizes two high-pressure fields for
strength based upon charging ports that use pressure from the
pressure work exchanger itself.
[0023] FIG. 5 is a crosssection view of an alternative
reciprocating dual work exchanger with a high-pressure wear
resistant cylinder that utilizes a high-pressure field for strength
based upon charging lines and an external pressure source such as a
dedicated pressure circuit or pressure from the pressure source
that drives the work exchanger. Different from figure one in the
simple symmetrical design of the internal high-pressure tube.
[0024] FIG. 6 is a representation of a traditional work exchanger
without a high-pressure wear resistant cylinder and without a
high-pressure field for strengthening purposes.
[0025] FIG. 7 is a crosssection view of an alternative
reciprocating dual work exchanger where the fluid end assembly has
been replaced by a simpler system of check valves and isolation
valves.
[0026] FIG. 8 is a crosssection view of an alternative
reciprocating dual work exchanger without the fluid end assembly or
system of check valves and isolation valves
DETAILED DESCRIPTION OF THE INVENTION
[0027] Referring now to FIG. 1, a reciprocating dual work exchanger
is shown. The reciprocating dual work exchanger having a special
high-pressure flange (1) that is connected to a main casing flange
(2), which holds a support piece (3), for securing a high-pressure
wear resistant cylinder (10) that utilizes a high-pressure field
(7) for strength. The high-pressure field (7) is created between an
outer pressure chamber (6) and the high-pressure wear resistant
cylinder (10). The high-pressure field (7) may be fed with charging
lines (5 and 8) together with an external pressure source (not
shown) such as a dedicated pressure circuit or pressure from the
source that drives the work exchanger. A piston (9) will move back
and forth through the high-pressure wear resistant cylinder (10).
The high-pressure wear resistant cylinder (10) is positioned and
sealed in with positioning pieces (3 and 11) in the sealing region
(4) through use of O-rings, gaskets or other methods suitable for
handling the required system pressure (not shown). The outer
pressure chamber (6) is connected to a fluid end assembly (40). The
fluid end assembly contains a valve block (13) and a valve block
carrier (12). The fluid end assembly (40) may be fabricated from
individual components (12 and 13) which house the two check valves
(30 and 32). Alternatively, the fluid end assembly (40) may be
constructed of a single forging depending upon the desired pressure
to be safely handled. The valve cover (34) of the valve block 13
may contain a special high-pressure flange (14) and an access cover
(15) that allows the high-pressure wear resistant cylinder (10) and
support piece (11) to be removed without disrupting/disconnecting
any piping connected to the unit. A pressure gauge (20) is used to
monitor pressure within the high-pressure field (7) at all times.
Pressure gauge (20) may alternatively be an electronic sensor or
other mechanical pressure-monitoring device.
[0028] The piston (9) is moved in one direction by pumping fluid
into check valve 32. When fluid is pumped into the special
high-pressure flange (1), the piston (9) moves in an opposite
direction forcing the fluid out of the inner cavity and through the
exit check valve (30).
[0029] Referring now to FIG. 2, an alternative reciprocating dual
work exchanger is shown. The high-pressure field (7) is
created/energized through charging ports (16) contained within the
high-pressure wear resistant cylinder (10). The charging ports (16)
use the pressure generated from the piston (9) and system pressure
(not shown) that moves piston (9).
[0030] FIG. 3 is an alternative reciprocating dual work exchanger
having the high-pressure wear resistant cylinder (10) that utilizes
multiple high-pressure fields (19) for strength. The multiple
high-pressure chambers (19) are energized/charged through a
plurality of charging ports (17). The multiple high-pressure
chambers (19) are created with a plurality of partitions (18) that
use pressure from the piston (9) and system pressure that moves the
piston (9).
[0031] FIG. 4 is yet another alternative reciprocating dual work
exchanger. The pressure field (7) is created/energized through
charging ports (16) that use pressure generated from the piston (9)
and system pressure that moves the piston (9). A divider (21) is
inserted in the high-pressure field (7) to created two individual
pressure fields. The divider (21) is stationary in the preferred
embodiment, but may move depending on the desired application. FIG.
5 is an alternative reciprocating dual work exchanger. FIG. 5
differs from FIGS. 1-4 in that the high-pressure wear resistant
cylinder (10) is symmetrically designed with plain end to reduce
production costs. This symmetrical design also allows the fluid end
assembly (40) to be attached and removed in quicker and easier
fashion, thus reducing down time. In FIG. 1, the high-pressure wear
resistant cylinder (10) attaches to the fluid end assembly (40) at
position 22 (shown on FIG. 5). Conversely, the high-pressure wear
resistant cylinder (10) depicted in FIG. 5, attaches to the fluid
end assembly (40) at seal point (4).
[0032] FIG. 6 is a representation of a traditional work exchanger
without a high-pressure wear resistant cylinder (10) and without a
high-pressure field (7) for strengthening purposes. Of importance
is the friction between the piston (9) and the main pressure unit
housing (6). As the piston (9) and housing (6) rub on each other
through the reciprocating action, both components will wear and
need to be replaced quickly in the abrasive and corrosive fracking
industry. In this conventional design, the very expensive housing
(6) will need to be replaced at prohibitive rate.
[0033] Referring now to FIGS. 6 and 7, an alternative reciprocating
dual work exchanger is shown without the fluid end assembly (40) of
FIG. 1. The fluid end assembly has been replaced in FIG. 7 by a
simpler system comprising a primary seal cap (55) attached to a
pump manifold (56) and pipe nipples (57). Isolation valves (58) are
attached to control fluid flow. Check valve (59) controls the
direction of fluid flow, preventing backflow. The check valves (59)
are connected to the pipe nipple (57) with a union (60). A gasket
may be used on piston 9 to create a better seal. FIG. 8 shows the
reciprocating dual work exchanger without a fluid end assembly or a
series of check valves and isolation valves. The pump manifold (56)
is welded to the outer pressure chamber (6) at weld point (56).
This allows the high-pressure wear resistant cylinder (10) to be
removed at the opposite end.
[0034] Through use of this invention, the high-pressure wear
resistant cylinder (10) utilizes the high-pressure field (7) for
strength, and the method of installing, implementing, and
manufacturing the reciprocating dual work exchanger for abrasive
and corrosive application, such as fracking, becomes economically
viable.
[0035] The above detailed description of the present invention is
given for explanatory purposes. It will be apparent to those
skilled in the art that numerous changes and modifications can be
made without departing from the scope of the invention.
Accordingly, the whole of the foregoing description is to be
construed in an illustrative and not a limitative sense, the scope
of the invention being defined solely by the appended claims.
* * * * *