English:
[0001] This application claims priority to and benefit of U.S. Provisional Patent Application No. 61/978,097, entitled "Pressure Exchange System with Motor System," filed April 10, 2014, which is herein incorporated by reference in its entirety.
[0004] Various features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying figures in which like characters represent like parts throughout the figures, wherein:
[0005] FIG. 1 is a schematic diagram of an embodiment of a hydraulic energy transfer system with a motor system;
[0006] FIG. 2 is an exploded perspective view of an embodiment of a rotary IPX;
[0007] FIG. 3 is an exploded perspective view of an embodiment of a rotary IPX in a first operating position;
[0008] FIG. 4 is an exploded perspective view of an embodiment of a rotary IPX in a second operating position;
[0009] FIG. 5 is an exploded perspective view of an embodiment of a rotary IPX in a third operating position;
[0010] FIG. 6 is an exploded perspective view of an embodiment of a rotary IPX in a fourth operating position;
[0011] FIG. 7 is a cross-sectional view of an embodiment of a rotary IPX with a motor system;
[0012] FIG. 8 is a cross-sectional view of an embodiment of a rotary IPX and a motor system within line 8-8 of FIG. 7;
[0013] FIG. 9 is a cross-sectional view of an embodiment of a rotary IPX and a motor system within line 8-8 of FIG. 7;
[0014] FIG. 10 is a side view of embodiment of a motor system that drives multiple rotary IPXs; and
[0015] FIG. 11 is a cross-sectional side view of an embodiment of a hydraulic motor system coupled to a rotary IPX.
[0016] One or more specific embodiments of the present invention will be described below. These described embodiments are only exemplary of the present invention. Additionally, in an effort to provide a concise description of these exemplary embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation- specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.
[0017] As discussed in detail below, the frac system or hydraulic fracturing system includes a hydraulic energy transfer system that transfers work and/or pressure between a first fluid (e.g., a pressure exchange fluid, such as a substantially proppant free fluid) and a second fluid (e.g., frac fluid, such as a proppant-laden fluid). For example, the first fluid may be at a first pressure between approximately 5,000 kPa to 25,000 kPa, 20,000 kPa to 50,000 kPa, 40,000 kPa to 75,000 kPa, 75,000 kPa to 100,000 kPa or greater than a second pressure of the second fluid. In operation, the hydraulic energy transfer system may or may not completely equalize pressures between the first and second fluids. Accordingly, the hydraulic energy transfer system may operate isobarically, or substantially isobarically (e.g., wherein the pressures of the first and second fluids equalize within approximately +/- 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 percent of each other).
[0018] The hydraulic energy transfer system may also be described as a hydraulic protection system a, hydraulic buffer system, or a hydraulic isolation system, because it blocks or limits contact between a frac fluid and various hydraulic fracturing equipment (e.g., high-pressure pumps), while still exchanging work and/or pressure between the first and second fluids. By blocking or limiting contact between various pieces of hydraulic fracturing equipment and the second fluid (e.g., proppant containing fluid), the hydraulic energy transfer system reduces abrasion and wear, thus increasing the life and performance of this equipment (e.g., high-pressure pumps). Moreover, the hydraulic energy transfer system may enable the frac system to use less expensive equipment in the fracturing system, for example, high-pressure pumps that are not designed for abrasive fluids (e.g., frac fluids and/or corrosive fluids). In some embodiments, the hydraulic energy transfer system may be a rotating isobaric pressure exchanger (e.g., rotary IPX). Rotating isobaric pressure exchangers may be generally defined as devices that transfer fluid pressure between a high-pressure inlet stream and a low-pressure inlet stream at efficiencies in excess of approximately 50%, 60%, 70%, 80%, or 90% without utilizing centrifugal technology.
[0019] In operation, the hydraulic energy transfer system transfers work and/or pressure between first and second fluids. These fluids may be multi-phase fluids such as gas/liquid flows, gas/solid particulate flows, liquid/solid particulate flows, gas/liquid/solid particulate flows, or any other multi-phase flow. For example, the multiphase fluids may include sand, solid particles, powders, debris, ceramics, or any combination therefore. These fluids may also be non-Newtonian fluids (e.g., shear thinning fluid), highly viscous fluids, non-Newtonian fluids containing proppant, or highly viscous fluids containing proppant. To facilitate rotation, the hydraulic energy transfer system may couple to a motor system (e.g., electric motor, combustion engine, hydraulic motor, pneumatic motor, and/or other rotary drive). In operation, the motor system enables the hydraulic energy transfer system to rotate with highly viscous and/or fluids that have solid particles, powders, debris, etc. For example, the motor system may facilitate startup with highly viscous or particulate laden fluids, which enables a rapid start of the hydraulic energy transfer system. The motor system may also provide additional force that enables the hydraulic energy transfer system to grind through particulate to maintain a proper operating speed (e.g., rpm) with a highly viscous/particulate laden fluid. In some embodiments, the motor system may also facilitate more precise mixing between fluids in hydraulic energy transfer system, by controlling an operating speed.
[0020] FIG. 1 is a schematic diagram of an embodiment of a frac system 8 (e.g., fluid handling system) with a hydraulic energy transfer system 10 coupled to a motor system 12. As explained above, the motor system 12 facilitates rotation of the hydraulic energy transfer system 10 when using highly viscous and/or particulate laden fluids. For example, during well completion operations the frac system 8 pumps a pressurized particulate laden fluid that increases the release of oil and gas in rock formations 14 by propagating and increasing the size of cracks 16. In order to block the cracks 16 from closing once the frac system 8 depressurizes, the frac system 8 uses fluids that have solid particles, powders, debris, etc. that enter and keep the cracks 16 open.
[0021] In order to pump this particulate laden fluid into the well, the frac system 8 may include one or more first fluid pumps 18 and one or more second fluid pumps 20 coupled to the hydraulic energy transfer system 10. For example, the hydraulic energy transfer system 10 may be a rotary IPX. In operation, the hydraulic energy transfer system 10 transfers pressures without any substantial mixing between a first fluid (e.g., proppant free fluid) pumped by the first fluid pumps 18 and a second fluid (e.g., proppant containing fluid or frac fluid) pumped by the second fluid pumps 20. In this manner, the hydraulic energy transfer system 10 blocks or limits wear on the first fluid pumps 18 (e.g., high-pressure pumps), while enabling the frac system 8 to pump a high-pressure frac fluid into the well 14 to release oil and gas. In order to operate in corrosive and abrasive environments, the hydraulic energy transfer system 10 may be made from materials resistant to corrosive and abrasive substances in either the first and second fluids. For example, the hydraulic energy transfer system 10 may be made out of ceramics (e.g., alumina, cermets, such as carbide, oxide, nitride, or boride hard phases) within a metal matrix (e.g., Co, Cr or Ni or any combination thereof) such as tungsten carbide in a matrix of CoCr, Ni, NiCr or Co.
[0022] FIG. 2 is an exploded perspective view of an embodiment of a rotary isobaric pressure exchanger 40 (rotary IPX) capable of transferring pressure and/or work between first and second fluids (e.g., proppant free fluid and proppant laden fluid) with minimal mixing of the fluids. The rotary IPX 40 may include a generally cylindrical body portion 42 that includes a sleeve 44 (e.g., rotor sleeve) and a rotor 46. The rotary IPX 40 may also include two end caps 48 and 50 that include manifolds 52 and 54, respectively. Manifold 52 includes respective inlet and outlet ports 56 and 58, while manifold 54 includes respective inlet and outlet ports 60 and 62. In operation, these inlet ports 56, 60 enabling the first and second fluids (e.g., proppant free fluid) to enter the rotary IPX 40 to exchange pressure, while the outlet ports 58, 62 enable the first and second fluids to then exit the rotary IPX 40. In operation, the inlet port 56 may receive a high-pressure first fluid, and after exchanging pressure, the outlet port 58 may be used to route a low- pressure first fluid out of the rotary IPX 40. Similarly, the inlet port 60 may receive a low-pressure second fluid (e.g., proppant containing fluid, frac fluid) and the outlet port 62 may be used to route a high-pressure second fluid out of the rotary IPX 40. The end caps 48 and 50 include respective end covers 64 and 66 disposed within respective manifolds 52 and 54 that enable fluid sealing contact with the rotor 46. The rotor 46 may be cylindrical and disposed in the sleeve 44, which enables the rotor 46 to rotate about the axis 68. The rotor 46 may have a plurality of channels 70 extending substantially longitudinally through the rotor 46 with openings 72 and 74 at each end arranged symmetrically about the longitudinal axis 68. The openings 72 and 74 of the rotor 46 are arranged for hydraulic communication with inlet and outlet apertures 76 and 78; and 80 and 82 in the end covers 52 and 54, in such a manner that during rotation the channels 70 are exposed to fluid at high-pressure and fluid at low-pressure. As illustrated, the inlet and outlet apertures 76 and 78; and 80 and 82 may be designed in the form of arcs or segments of a circle (e.g., C-shaped).
[0023] In some embodiments, a controller using sensor feedback may control the extent of mixing between the first and second fluids in the rotary IPX 40, which may be used to improve the operability of the fluid handling system. For example, varying the proportions of the first and second fluids entering the rotary IPX 40 allows the plant operator to control the amount of fluid mixing within the hydraulic energy transfer system 10. Three characteristics of the rotary IPX 40 that affect mixing are: (1) the aspect ratio of the rotor channels 70, (2) the short duration of exposure between the first and second fluids, and (3) the creation of a fluid barrier (e.g., an interface) between the first and second fluids within the rotor channels 70. First, the rotor channels 70 are generally long and narrow, which stabilizes the flow within the rotary IPX 40. In addition, the first and second fluids may move through the channels 70 in a plug flow regime with minimal axial mixing. Second, in certain embodiments, the speed of the rotor 46 reduces contact between the first and second fluids. For example, the speed of the rotor 46 may reduce contact times between the first and second fluids to less than approximately 0.15 seconds, 0.10 seconds, or 0.05 seconds. Third, a small portion of the rotor channel 70 is used for the exchange of pressure between the first and second fluids. Therefore, a volume of fluid remains in the channel 70 as a barrier between the first and second fluids. All these mechanisms may limit mixing within the rotary IPX 40.
[0024] FIGS. 3-6 are exploded views of an embodiment of the rotary IPX 40 illustrating the sequence of positions of a single channel 70 in the rotor 46 as the channel 70 rotates through a complete cycle. It is noted that FIGS. 3-6 are simplifications of the rotary IPX 40 showing one channel 70, and the channel 70 is shown as having a circular cross-sectional shape. In other embodiments, the rotary IPX 40 may include a plurality of channels 70 with the same or different cross-sectional shapes (e.g., circular, oval, square, rectangular, polygonal, etc.). Thus, FIGS. 3-6 are simplifications for purposes of illustration, and other embodiments of the rotary IPX 40 may have configurations different from that shown in FIGS. 3-6. As described in detail below, the rotary IPX 40 facilitates pressure exchange between first and second fluids (e.g., proppant free fluid and proppant-laden fluid) by enabling the first and second fluids to briefly contact each other within the rotor 46. In certain embodiments, this exchange happens at speeds that result in limited mixing of the first and second fluids.
[0025] In FIG. 3, the channel opening 72 is in a first position. In the first position, the channel opening 72 is in fluid communication with the aperture 78 in endplate 64 and therefore with the manifold 52, while the opposing channel opening 74 is in hydraulic communication with the aperture 82 in end cover 66 and by extension with the manifold 54. As will be discussed below, the rotor 46 may rotate in the clockwise direction indicated by arrow 84. In operation, low-pressure second fluid 86 passes through end cover 66 and enters the channel 70, where it contacts the first fluid 88 at a dynamic fluid interface 90. The second fluid 86 then drives the first fluid 88 out of the channel 70, through end cover 64, and out of the rotary IPX 40. However, because of the short duration of contact, there is minimal mixing between the second fluid 86 and the first fluid 88.
[0026] In FIG. 4, the channel 70 has rotated clockwise through an arc of approximately 90 degrees. In this position, the outlet 74 is no longer in fluid communication with the apertures 80 and 82 of end cover 66, and the opening 72 is no longer in fluid communication with the apertures 76 and 78 of end cover 64.
[0027] In FIG. 5, the channel 70 has rotated through approximately 60 degrees of arc from the position shown in FIG. 6. The opening 74 is now in fluid communication with aperture 80 in end cover 66, and the opening 72 of the channel 70 is now in fluid communication with aperture 76 of the end cover 64. In this position, high-pressure first fluid 88 enters and pressurizes the low-pressure second fluid 86 driving the second fluid 86 out of the fluid channel 70 and through the aperture 80 for use in the frac system 8.
[0028] In FIG. 6, the channel 70 has rotated through approximately 270 degrees of arc from the position shown in FIG. 6. In this position, the outlet 74 is no longer in fluid communication with the apertures 80 and 82 of end cover 66, and the opening 72 is no longer in fluid communication with the apertures 76 and 78 of end cover 64. Accordingly, the first fluid 88 is no longer pressurized and is temporarily contained within the channel 70 until the rotor 46 rotates another 90 degrees, starting the cycle over again.
[0029] FIG. 7 is a cross-sectional view of an embodiment of a motor system 12 (e.g., external motor system) coupled to a rotary IPX 40. As illustrated, the motor system 12 includes a shaft 98 that couples to the rotor 46 through a casing 100. Specifically, the shaft 98 extends through an aperture 102 in the casing 100, an aperture 104 in the end cover 64, and into an aperture 106 in the rotor 46. To facilitate rotation of the shaft 98, the motor system 12 may also include one or more bearings 108 that support the shaft 98. The bearings 108 may be within or without the casing 100. In some embodiments, the shaft 98 may extend completely through the rotor 46 and the end cover 66 enabling the shaft 98 to be supported by bearings 108 on opposite sides of the rotor 46.
[0030] In operation, the motor system 12 facilitates operation of the rotary IPX 40 by providing torque for grinding through particulate, maintaining the operating speed of the rotor 46, controlling the mixing of fluids within the rotary IPX 40 (e.g., changing the rotating speed of the rotor 46), or starting the rotary IPX 40 with highly viscous or particulate laden fluids. As illustrated, a controller 110 couples to the motor system 12 and one or more sensors 112 (e.g., flow, pressure, torque, rotational speed sensors, acoustic, magnetic, optical, etc.). In operation, the controller uses feedback from the sensors 112 to control the motor system 12. The controller 110 may include a processor 114 and a memory 116 that stores non- transitory computer instructions executable by the processor 114. For example, as the controller 110 receives feedback from one or more sensors 112, the processor 114 executes instructions stored in the memory 116 to control power output from the motor system 12.
[0031] The instructions stored in the memory 116 may include various operating modes for the motor system 12 (e.g., a startup mode, a speed control mode, a continuous power mode, a periodic power mode, etc.). For example, in startup mode, the controller 110 may execute instructions in the memory 116 that signals the motor system 12 to begin rotating a shaft 98. As the motor system 12 operates, the sensors 112 may provide feedback to the controller 110 that indicates whether the shaft 98 is rotating at the proper speed (e.g., rpm) or within a threshold range. When the shaft 98 reaches the desired speed or range, the controller 110 may signal the motor system 12 to stop rotating the shaft 98 enabling the first and second fluids flowing through the rotary IPX 40 to take over and provide the rotational power to the rotor 46. However, in some embodiments, the rotary IPX 40 may use the motor system 12 to periodically supplement rotation of the rotor 46 (e.g., a periodic power mode). For example, during steady state operation of the rotary IPX 40, the rotor 46 may slow as particulate enters a gap 120 between the rotor 46 and a sleeve 44, a gap 122 between the rotor 46 and first end cover 64, and/or a gap 124 between the rotor 46 and a second end cover 66. Over time, the particulate may slow the rotor 46 if the rotor 46 is unable to grind or breakup the particulate fast enough to return the rotary IPX 40 to a steady state rotating speed. In these situations, the controller 110 may receive feedback from sensors 112 indicating that the rotor 46 is slowing or outside a threshold range. The controller 110 may then signal the motor system 12 to provide power to the shaft 98 that returns the rotor 46 to a steady state rotating speed or threshold range. After returning the rotor 46 to the proper rotating speed, the controller 110 may again shutdown the motor system 12. In some embodiments, the motor system 12 may provide continuous input/control of the rotor 46 rotating speed (e.g., a continuous power mode and/or speed control mode). For example, in some embodiments, the rotary IPX 40 may operate with fluids that have mixing requirements (e.g., exposure requirements). In other words, the rotary IPX 40 may limit the exposure between the first and second fluids to block or limit the amount of the first fluid exiting the rotary IPX 40 with the second fluid through the aperture 78.
[0032] FIG. 8 is a cross-sectional view of an embodiment of a rotary IPX 40 and a motor system 12 within line 8-8 of FIG. 7. In the embodiment of FIG. 8, the motor system 12 is an electric motor with permanent magnets 160 circumferentially spaced about the rotor 46 that interact with electromagnets 162 (e.g., stator windings) within the sleeve 44 (e.g., the stator). In some embodiments, the sleeve 44 may include the permanent magnets 160 while the rotor 46 includes electromagnets 162, or the rotor 46 and sleeve 44 may both include electromagnets 162. Furthermore, in some embodiments, the sleeve 44 or rotor 46 may be made out of a magnetic material (e.g., permanent magnetic material) that interacts with the electromagnets 162. As illustrated, the electromagnets 162 (e.g., stator windings) and permanent magnets 160 rest within the sleeve 44 and rotor 46 respectively to protect them from contact with fluids flowing through the rotary IPX. However, in some embodiments, the electromagnets 162 (e.g., stator windings) and/or permanent magnets 160 may be placed on external surfaces of the sleeve 44 and rotor 46.
[0033] In operation, the controller 110 controls the rotation of the rotor 46 by turning the electromagnets 162 on and off to attract and/or repel the permanent magnets 160. As the magnets 1606, 162 attract and/or repel each other they drive rotation or reduce rotation of the rotor 46. In this way, the power from the motor system 12 facilitates operation of the rotary IPX 40 by enabling the rotor 46 to grind through particulate, maintain a specific operating speed, control the mixing of fluids within the rotary IPX 40 (e.g., controlling rotating speed of the rotor 46), or starting the rotary IPX 40 with highly viscous or particulate laden fluids. In some embodiments, the controller 110 may control operation of the motor system in response to feedback from one or more sensors 112 (e.g., flow, pressure, torque, rotational speed sensors, acoustic, magnetic, optical, etc.).
[0034] FIG. 9 is a cross-sectional view of an embodiment of a rotary IPX 40 and a motor system 12 within line 8-8 of FIG. 7. In the embodiment of FIG. 9, the motor system 12 is an electric motor with permanent magnets 160 circumferentially spaced about the rotor 46 that interact with electromagnets 162 (e.g., stator windings) on an outer surface 180 of the casing 100. In some embodiments, the outer surface 180 of the rotary IPX 40 may include permanent magnets 160 while the rotor 46 includes electromagnets 162, or both the outer surface 180 of the rotary IPX 40 and the rotor 46 may have electromagnets 162. In certain embodiments, the rotor 46 may be made out of a magnetic material that enables the entire rotor 46 to interact with the electromagnets 162. By coupling the electromagnets 162 to the exterior surface 180 of the rotary IPX 40, the motor system 12 protects the electromagnets 162 from fluid flowing through the rotary IPX 40. Moreover, with the electromagnets 162 on an exterior surface 180 of the rotary IPX 40, the motor system 12 facilitates access to the electromagnets 162 for maintenance and inspection. As explained above, in operation the controller 110 controls power to the electromagnets 162 to drive rotation of the rotor 46, which enables the rotor 46 to grind through particulate, maintain a specific operating speed, control the mixing of fluids within the rotary IPX 40, or start the rotary IPX 40 with highly viscous or particulate laden fluids.
[0035] FIG. 10 is a side view of an embodiment of a motor system 12 capable of simultaneously driving multiple rotary IPXs 40. For example, each rotary IPX 40 may include a respective shaft 198 that couples to a rotor 46. The shafts 198 in turn couple to the shaft 98 of the motor system 12 using connectors 200 (e.g., belts, chains, etc.). During operation, the motor system 12 transfers rotational power from the shaft 98 to each of the rotary IPXs 40, thus driving multiple rotary IPXs 40 with one motor system 12. In the present embodiment, there are two rotary IPXs 40 coupled to the motor system 12. However, in some embodiments, there may be 1, 2, 3, 5, 10, 15, or more rotary IPXs 40 coupled to the motor system 12. For example, the rotary IPXs 40 may be circumferentially positioned about the motor enabling multiple rotary IPXs 40 to couple to a single motor system 12.
[0036] In certain embodiments, the rotary IPXs 40 may include clutches 202 that selectively connect and disconnect rotational input from the motor system 12. For example, the controller 110 may receive feedback from sensors 112 that indicates one or more of the rotary IPXs 40 are slowing (e.g., unable to grind through particulate). Accordingly, the controller 110 may close the corresponding clutches 202 enabling the motor system 12 to transfer rotational energy to the appropriate rotary IPX(s) 40. As explained above, the controller 110 controls when, how much, and for how long the motor drives rotation of the rotary IPXs 40. The controller 110 may control the motor based on sensor feedback from one rotary IPX, or from multiple rotary IPXs 40. For example, the controller 110 may start the motor system 12 when one rotary IPX is unable to grind through particulate, maintain a specific operating speed, or control the mixing of fluids within the rotary IPX 40. However, in other embodiments, the controller 110 may start the motor system 12 only when more than one rotary IPX 40 needs additional power.
[0037] FIG. 11 is a cross-sectional side view of an embodiment of a motor system 12 (e.g., hydraulic motor) coupled to a rotary IPX 40. The motor system 12 facilitates operation of the rotary IPX 40 by providing torque for grinding through particulate, maintaining the operating speed of the rotary IPX 40, controlling the mixing of fluids within the rotary IPX 40, or starting the rotary IPX 40 with highly viscous or particulate laden fluids. For example, the hydraulic motor system 12 may include a hydraulic turbine 220 coupled to the rotary IPX 40 with a shaft 98. In operation, the motor system 12 receives fluid flow (e.g., high-pressure proppant free fluid) from a fluid source 222 that drives rotation of the hydraulic turbine 220 and therefore the shaft 98. The fluid source 222 may be the same fluid source used to operate the rotary IPX 40 or a different fluid source. As the shaft 98 rotates, the shaft 98 rotates the rotor 46. In some embodiments, the controller 110 may control a valve 224 in order to control fluid flow through the hydraulic turbine 220. For example, as the controller 110 receives feedback from the sensors 112 (e.g., flow, pressure, torque, rotational speed sensors, acoustic, magnetic, optical, etc.), the processor 114 executes non-transitory computer instructions stored in the memory 116 to control the opening and closing of the valve 224, thus starting and stopping the hydraulic turbine 220.
[0038] While the invention may be susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and have been described in detail herein. However, it should be understood that the invention is not intended to be limited to the particular forms disclosed. Rather, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the following appended claims.

中文:
[0001]本申请要求保护在2014年4月10日提交的名称为“Pressure Exchange Systemwith Motor System”的美国临时专利申请No.61/978,097的优先权和权益,该专利申请以全文引用的方式并入到本文中。
[0004]当参看附图来阅读本发明下文的详细描述时,本发明的各种特点、方面和优点将变得更好理解,在所有附图中,相似的附图标记表示相似的部件,其中:
[0005]图1是具有马达系统的液压能转移系统的实施例的示意图;
[0006]图2是旋转式IPX的实施例的分解透视图;
[0007]图3是在第一操作位置的旋转式IPX的实施例的分解透视图;
[0008]图4是在第二操作位置的旋转式IPX的实施例的分解透视图;
[0009]图5是在第三操作位置的旋转式IPX的实施例的分解透视图;
[0010]图6是在第四操作位置的旋转式IPX的实施例的分解透视图;
[0011]图7是具有马达系统的旋转式IPX的实施例的截面图;
[0012]图8是在图7的线8-8内的旋转式IPX和马达系统的实施例的截面图;
[0013]图9是在图7的线8-8内的旋转式IPX和马达系统的实施例的截面图;
[0014]图10是驱动多个旋转式IPX的马达系统的实施例的侧视图;以及
[0015]图11是联接到旋转式IPX的液压马达系统的实施例的截面侧视图。
[0016]将在下文中描述本发明的一个或多个具体实施例。这些描述的实施例只是例示本发明。此外,为了提供这些实施例的简洁描述,在说明书中可能未描述实际实施方式的所有特点。应了解在任何这样实际实施方式的发展中,如在任何工程或设计项目中,必须做出许多具体实施决策来实现开发者的具体目的,诸如符合系统相关和商务相关约束,对于不同的实施方式,这些约束可不同。此外,应了解,这些开发努力可为复杂的且耗时的,但仍是受益于本公开内容的本领域普通技术人员设计、制作和制造的常规任务。
[0017]如在下文中详细地讨论,压裂系统或者液压致裂系统包括液压能转移系统,液压能转移系统在第一流体(例如,压力交换流体,诸如基本上无支撑剂的流体)与第二流体(例如,压裂流体,诸如带有支撑剂的流体)之间转移功和/或压力。例如,第一流体处在第一压力,该第一压力可以在大约5,000kPa至25,000kPa、20,000kPa至50,000kPa、40,000kPa至75,000kPa、75,000kPa至100,000kPa之间或者大于第二流体的第二压力。在操作中,液压能转移系统可以或可以不均衡在第一流体与第二流体之间的压力。因此,液压能转移系统可以恒压或基本上恒地压操作(例如,其中第一流体与第二流体的压力彼此在大约+/-1%、2%、3%、4%、5%、6%、7%、8%、9%或10%内均衡)。
[0018]液压能转移系统也可以被描述为液压保护系统、液压缓冲系统或液压隔离系统,因为其阻挡或限制在压裂流体与各种液压致裂设备(例如,高压泵)之间的接触,同时仍能在第一流体与第二流体之间交换功和/或压力。通过阻挡或限制在液压致裂设备的各个零件与第二流体(例如,含支撑剂的流体)之间的接触,液压能转移系统减小了研磨和磨损,因此延长了这种设备(例如,高压泵)的寿命并且提高了这种设备的性能。此外,液压能转移系统可以允许压裂系统将不太昂贵的设备用于压裂系统中,例如,并未被设计用于研磨流体(例如,压裂流体和/或腐蚀性流体)的泵。在某些实施例中,液压能转移系统可以是旋转式等压交换器(例如,旋转式IPX)。旋转式等压交换器可以总体上被定义为在高压入口流与低压入口流之间以超过大约50%、60%、70%、80%、80%或90%的效率转移流体压力而不利用离心技术的装置。
[0019]在操作中,液压能转移系统在第一流体与第二流体之间转移功和/或压力。这些流体可以是多相流体,诸如气体/液体流、气体/固体颗粒流、液体/固体颗粒流、气体/液体/固体颗粒流或者任何其它多相流。例如,多相流体可以包括沙、固体粒子、粉末、碎屑、陶瓷或其任何组合。这些流体也可以是非牛顿流体(例如,剪切致稀流体)、高粘度流体、包含支撑剂的非牛顿流体或者包含支撑剂的高粘度流体。为了便于旋转,液压能转移系统可以联接到马达系统(例如,电动马达、燃烧发动机、液压马达、气动马达和/或其它旋转驱动装置)。在操作中,马达系统允许液压能转移系统利用高粘度流体或者具有固体粒子、粉末、碎屑等的流体操作。例如,马达系统可以便于利用高粘度流体或者带有颗粒的流体启动,这允许快速地启动液压能转移系统。马达系统也可以提供额外力,额外力允许液压能转移系统磨碎颗粒来维持高粘度流体和/或带有颗粒的流体的适当操作速度(例如,rpm)。在某些实施例中,马达系统也可以通过控制操作速度来便于在液压能转移系统中的流体之间的更精确混合。
[0020]图1是压裂系统8(例如,流体处置系统)的示意图,其中液压能转移系统10联接到马达系统12。如上文所解释,当使用高粘度流体和/或带有颗粒的流体时,马达系统12便于液压能转移系统10旋转。例如,在完井操作期间,压裂系统8泵送加压的带有颗粒的流体,这通过使裂缝16传播并且增加裂缝16尺寸而增加岩层14中的油气释放。为了在压裂系统8减压之后阻止裂缝16闭合,压裂系统8使用具有固体粒子、粉末、碎屑等的流体,这些颗粒进入裂缝16并且保持裂缝16打开。
[0021]为了将这种带有颗粒的流体泵送到井内,压裂系统8可以包括联接到液压能转移系统10的一个或多个第一流体泵18和一个或多个第二流体泵20。例如,液压能转移系统10可以是旋转式IPX。在操作中,液压能转移系统10转移压力而不造成由第一流体泵18泵送的第一流体(例如,无支撑剂的流体)与由第二流体泵20泵送的第二流体(例如,含支撑剂的流体或压裂流体)之间的任何显著混合。以此方式,液压能转移系统10阻挡或限制在第一流体泵18(例如,高压泵)上的磨损,同时允许压裂系统8将高压压裂流体泵送到井14内以释放油气。为了在腐蚀性和研磨性环境中操作,液压能转移系统10可以由耐受第一流体和第二流体中的腐蚀性和研磨性物质的材料制成。例如,液压能转移系统10可以由在金属基质(例如,Co、Cr或Ni或其任何组合)内的陶瓷(例如,氧化铝、金属陶瓷、诸如碳化物、氧化物、氮化物或硼化物硬质相)诸如在CoCr、Ni、NiCr或Co基质内的碳化钨制成。
[0022]图2是能在第一流体与第二流体(例如,无支撑剂的流体与带有支撑剂的流体)之间转移压力和/或功而仅造成流体很少混合的旋转式等压交换器40(旋转式IPX)的实施例的分解透视图。旋转式IPX 40可以包括大体上圆柱形的主体部分42,大体上圆柱形的主体部分42包括套筒44(例如,转子套筒)和转子46。旋转式IPX 40还可以包括两个端帽48和50,端帽48和50分别包括歧管52和54。歧管52包括相应入口端口56和出口端口58,而歧管54包括相应入口端口60和出口端口62。在操作中,这些入口端口56、60允许第一流体和第二流体(例如,无支撑剂的流体)进入旋转式IPX 40以交换压力,而出口端口58、62允许第一流体和第二流体随后离开旋转式IPX 40。在操作中,入口端口56可以接收高压第一流体,并且在交换压力之后,出口端口58可以用来引导低压第一流体从旋转式IPX 40出来。同样,入口端口60可以接收低压第二流体(例如,含支撑剂的流体,压裂流体)并且出口端口62可以用来引导高压第二流体从旋转式IPX 40出来。端帽48和50包括安置于相应歧管52和54内的相应端部覆盖物64和66,端部覆盖物64和66允许与转子46进行流体密封接触。转子46可以是圆柱形并且安置于套筒44中,套筒44允许转子46绕轴线46旋转。转子46可以具有基本上在纵向穿过转子46延伸的多个通道70,在每一端的开口72和74绕纵向轴线68对称布置。转子46的开口72和74被布置成与端部覆盖物52和54中的入口孔口和出口孔口76和78以及80和82成液压连通以使得在旋转期间,通道70向高压流体和低压流体暴露。如图所示,入口孔口和出口孔口76和78以及80和82可以被设计成圆弧或者圆形区段(例如,C形)的形式。
[0023]在某些实施例中,使用传感器反馈的控制器可以控制在旋转式IPX 40中在第一流体与第二流体之间的混合程度,这可以用于改进流体处置系统的可操作性。例如,改变进入旋转式IPX 40的第一流体和第二流体的比例可允许设施操作者控制在液压能转移系统10内流体混合量。影响混合的旋转式IPX 40的三个特征为:(1)转子通道70的纵横比;(2)在第一流体与第二流体之间暴露的短持续时间;以及,(3)在转子通道70内第一流体与第二流体之间形成流体屏障(例如,界面)。首先,转子通道70大体上是长且窄的,这使旋转式IPX 40内的流动稳定。此外,第一流体和第二流体可以以栓塞式流态(plug flow regime)移动通过通道70,造成最小的轴向混合。其次,在某些实施例中,转子46的速度减小了第一流体与第二流体之间接触。例如,转子46的速度将第一流体与第二流体之间的接触时间缩短到小于大约0.15秒,0.10秒,或者0.05秒。第三,转子通道70的一小部分用来在第一流体与第二流体之间交换压力。因此,一定体积的流体保持在通道70中,作为在第一流体与第二流体之间的屏障。所有这些机制可以限制在旋转式IPX 40内的混合。此外,在某些实施例中,旋转式IPX 40可以被设计成利用内部活塞操作,内部活塞隔离第一流体与第二流体,同时允许压力转移。
[0024]图3至图6是旋转式IPX 40的实施例的分解图,示出了在通道70旋转了整个循环之后,在转子46中的单个通道70的位置顺序。应当指出的是图3至图6是旋转式IPX 40的简化图,示出了一个通道70,并且该通道70被示出为具有圆形截面形状。在其它实施例中,旋转式IPX 40可以包括具有相同或不同截面形状(例如,圆形、椭圆形、正方形、矩形、多边形等)的多个通道70。因此,图3至图6是出于说明目的的简化图并且旋转式IPX 40的其它实施例可以具有与图3至图6所示的配置不同的配置。如在下文中详细地描述,旋转式IPX 40通过允许第一流体与第二流体在转子46内短暂地彼此接触而便于在第一流体与第二流体(例如,无支撑剂的流体与带有支撑剂的流体)之间的压力交换。在某些实施例中,这种交换以导致第一流体与第二流体有限混合的速度发生。
[0025]在图3中,通道开口72处于第一位置。在第一位置,通道开口72与端板64中的孔口78和因此与歧管52成流体连通,而相对的通道开口74与端部覆盖物66中的孔口82成液压连通,并且通过延伸部与歧管54成液压连通。如将在下文中所讨论,转子46可以在箭头84所示的顺时针方向上旋转。在操作中,低压第二流体86通过端部覆盖物66并且进入通道70,在通道70中,其在动态流体界面90处接触第一流体88。第二流体86然后将第一流体88从通道70驱出,通过端部覆盖物64,并且从旋转式IPX 40出来。然而,由于接触的短持续时间,在第二流体86与第一流体88之间只有很少混合。
[0026]在图4中,通道70顺时针旋转大约90度的弧度。在这个位置,出口74不再与端部覆盖物66的孔口80和82成流体连通并且开口72不再与端部覆盖物64的孔口76和78成流体连通。因此,低压第二流体86暂时容纳于通道70内。
[0027]在图5中,通道70从图6所示的位置旋转大约60度弧度。开口74现在与端部覆盖物66中的孔口80成流体连通,并且通道70的开口72现与端部覆盖物64的孔口76成流体连通。在这个位置,高压第一流体88进入低压第二流体86并且向低压第二流体86加压,将第二流体86从流体通道70驱出并且通过孔口80以用于压裂系统8中。
[0028]在图6中,通道70从图6所示的位置旋转大约270度弧度。在这个位置,出口74不再与端部覆盖物66的孔口80和80流体连通,并且开口72不再与端部覆盖物64的孔口76和78成流体连通。因此,第一流体88不再被加压并且暂时容纳于通道70内直到转子46旋转另一90度,再次开始循环。
[0029]图7是联接到旋转式IPX 40的马达系统12(例如,外部马达系统)的实施例的截面图。如图所示,马达系统12包括轴98,轴98通过壳体100,联接到转子46。具体而言,轴98延伸穿过壳体100中的孔口102、端部覆盖物64中的孔口104并且进入到转子46中的孔口106内。为了便于轴98旋转,马达系统12也可以包括一个或多个轴承108,轴承108支承轴97。轴承108可以在壳体100内或者不在壳体100内。在某些实施例中,轴98可以完全穿过转子46和端部覆盖物66,允许轴98由轴承108支承于转子46的相对侧上。
[0030]在操作时,马达系统12通过提供扭矩以磨碎颗粒,维持转子46的操作速度,控制旋转式IPX 40内的流体混合(例如,改变转子46的旋转速度)或者利用高粘度流体或者带有颗粒的流体启动旋转式IPX 40而便于旋转式IPX 40的操作。如图所示,控制器110联接到马达系统12和一个或多个传感器112(例如,流量、扭矩、旋转速度传感器、声学、磁性、光学等)。在操作时,控制器使用来自传感器112的反馈来控制马达系统12。控制器110可以包括处理器114和存储器116,存储器116存储可由处理器114执行的非暂时计算机指令。例如,在控制器110从一个或多个传感器112接收反馈时,处理器114执行储存在存储器116中的指令以控制来自马达系统12的动力输出。
[0031]在存储器116中存储的指令可以包括用于马达系统12的各种操作模式(例如,启动模式、速度控制模式、持续动力模式、周期性动力模式等)。例如,在启动模式,控制器110可以执行在存储器116中的指令,其向马达系统12发信号以开始轴98的旋转。在马达系统12操作时,传感器112可以向控制器10提供反馈,指示轴98是否以适当速度(例如,rpm)或者在阈值范围内旋转。当轴98到达所希望的速度或范围时,控制器110可以向马达系统11发出信号来停止轴98的旋转,允许第一流体和第二流体流过旋转式IPX 40以接管并且向转子46提供旋转动力。然而,在某些实施例中,旋转式IPX 40可以使用马达系统12以周期性地补充转子46的旋转(例如,周期性动力模式)。例如,在旋转式IPX 40稳态操作期间,随着颗粒进入到转子46与套筒44之间的间隙120、转子46与第一端部覆盖物64之间的间隙122和/或转子46与第二端部覆盖物66之间的间隙124内,转子46可变慢。久而久之,如果转子46不能足够快地磨碎或粉碎颗粒以使旋转式IPX 40返回到稳态旋转速度,颗粒可能会减缓转子46。在这些情形下,控制器110可以从传感器112接收反馈,指示转子46减缓或者在阈值范围之外。控制器10然后可以向马达系统12发出信号以向轴98提供动力,轴98使转子46返回到稳态旋转速度或阈值范围。在使转子46返回到适当旋转速度后,控制器110可以再次使马达系统12停机。在某些实施例中,马达系统12可以对转子46旋转速度提供连续输入/控制(例如,连续动力模式和/或速度控制模式)。例如,在某些实施例中,旋转式IPX 40可以利用具有混合要求(例如,暴露要求)的流体来操作。换言之,旋转式IPX 40可以限制在第一流体与第二流体之间的暴露以阻挡或者限制离开旋转式IPX 40的第一流体和通过孔口7的第二流体的量。
[0032]图8是在图7的线8-8内的旋转式IPX 40和马达系统12的实施例的截面图。在图8的实施例中,马达系统12是电动马达,其永磁体160绕转子46在周向间隔开,永磁体160与在套筒44(例如,定子)内的电磁体162(例如,定子绕组)相互作用。在某些实施例中,套筒44可以包括永磁体160,而转子46包括电磁体162或者转子46和套筒44可以都包括电磁体162。而且,在某些实施例中,套筒44或者转子46可以由与电磁体162相互作用的磁性材料(例如,永磁体材料)制成。如图所示,电磁体162(例如,定子绕组)和永磁体160分别搁置于套筒44和转子46内以保护它们防止与通过旋转式IPX流动的流体接触。然而,在某些实施例中,电磁体161(例如,定子绕组)和/或永磁体160可以放置于套筒44和转子46的外表面上。
[0033]在操作时,控制器110通过接通和切断电磁体162来吸引和/或排斥永磁体160,从而控制转子46。由于磁体160、162彼此吸引和/或排斥,它们驱动转子46旋转或者减弱转子46旋转。以此方式,来自马达系统12的动力通过允许转子46磨碎颗粒,维持具体操作速度,控制旋转式IPX 40内流体的混合(例如,控制转子46的旋转速度),或者利用高粘度流体或者带有颗粒的流体启动旋转式IPX 40而便于旋转式IPX 40的操作。在某些实施例中,控制器110可以响应于来自一个或多个传感器112的反馈来控制马达系统的操作(例如,流量、压力、扭矩、旋转速度传感器、声学、磁性、光学等)。
[0034]图9是在图7的线8-8内的旋转式IPX 40和马达系统12的实施例的截面图。在图9的实施例中,马达系统12是电动马达,其永磁体160绕转子46在周向间隔开,永磁体160与壳体100的外表面180上的电磁体162(例如,定子绕组)相互作用。在某些实施例中,旋转式IPX40的外表面180可以包括永磁体160,而转子46包括永磁体162,或者旋转式IPX 40的外表面180和转子46可以都具有永磁体162。在某些实施例中,转子46可以由磁性材料制成,这使得整个转子46与电磁体162相互作用。通过将电磁体162联接到旋转式IPX 40的外表面180,马达系统12保护电磁体162,防止流体通过旋转式IPX 40流动。此外,在电磁体162处于旋转式IPX 40的外表面180上的情况下,马达系统12便于接近电磁体162以进行维护和检查。如上文所解释,在操作中,控制器110控制通向电磁体162的电力以驱动转子46旋转,这使得转子46磨碎颗粒,维持特定操作速度,控制旋转式IPX 40内流体的混合,或者利用高粘度或带有颗粒的流体来启动旋转式IPX 40。
[0035]在图10是能同时驱动多个旋转式IPX 40的马达系统12的实施例的侧视图。例如,每个旋转式IPX 40可以包括相应轴198,轴198联接到转子46。轴198进而使用连接器200(例如,皮带、链条等)联接到马达系统12的轴98。在操作期间,马达系统12将来自轴98的旋转动力转移到旋转式IPX 40中的每一个,因此能利用一个马达系统12来驱动多个旋转式IPX40。在本实施例中,可以存在联接到马达系统12的两个旋转式IPX 40。然而,在某些实施例中,可以存在联接到马达系统12的1个、2个、3个、5个、10个、15个或更多个IPX 40。例如,旋转式IPX 40可以绕马达在周向定位,允许多个旋转式IPX 40联接到单个马达系统12。
[0036]在某些实施例中,旋转式IPX 40可以包括离合器202,离合器202使旋转输入与马达系统12选择性地连接和断开连接。例如,控制器110可以从传感器112接收反馈,该反馈指示旋转式IPX 40中的一个或多个是否减慢(例如,不能磨碎颗粒)。因此,控制器110可以闭合相对应离合器202,允许马达系统12将旋转能量转移到适当的旋转式IPX 40。如上文所解释的那样,控制器110控制马达何时驱动旋转式IPX 40旋转,以多少量驱动旋转式IPX 40旋转和驱动IPX 40旋转多久。控制器110可以基于来自一个旋转式IPX或者多个旋转式IPX 40的传感器反馈来控制马达。例如,当一个旋转式IPX不能磨碎颗粒,维持具体规定速度,或者控制旋转式IPX 40内的流体混合时,控制器110可以启动马达系统12。然而,在其它实施例中,仅当多于一个旋转IPX 40需要旋转动力时,控制器110才可以启动马达系统12。
[0037]图11是联接到旋转式IPX 40的马达系统12(例如,液压马达)的一实施例的截面侧视图。马达系统12通过提供扭矩来磨碎颗粒、维持旋转式IPX 40的操作速度、控制旋转式IPX 40内的流体混合或者利用高粘度或者带有颗粒的流体启动旋转式IPX 40来便于旋转式IPX 40的操作。例如,液压马达系统12可以包括液压涡轮220,液压涡轮220利用轴98联接到旋转式IPX 40。在操作中,马达系统12从流体源222接收流体流(例如,高压无支撑剂流体),这驱动液体涡轮220和因此轴98旋转。流体源222可以是用来操作旋转式IPX 40的相同流体源或者不同流体源。随着轴98旋转,轴98带动转子46旋转。在某些实施例中,控制器110可以控制阀224以便控制流体通过液压涡轮220的流量。例如,在控制器110从传感器112(例如,流量、压力、扭矩、旋转速度传感器、声学、磁性、光学等)接收反馈时,处理器114执行存储于存储器116中的非暂时计算机指令以控制阀224的打开和闭合,因此启动和停止液压涡轮220。
[0038]虽然本发明易于做出各种修改和替代形式,在附图中以举例说明的方式示出了具体实施例,并且在本文中展开了详细描述。然而,应了解本发明预期并不限制所公开的特定形式。然而,本发明预期涵盖属于权利要求限定的本发明的精神和范围内的所有修改、等效物和替代物。