Bellows failure detection for a pump
In a bellows pump, detecting any leakage with respect to the bellows can be important, for example for pump durability and life. Disclosed embodiments relate to a bellows pump system in which the bellows is configured to form an annulus, such that fluid in the annulus may be monitored in order to detect leakage. For example, a double-walled bellows may include an annulus between the walls, and the annulus may be in fluid communication with a port. Detection of fluid at the port may be indicative of leakage, and one or more action may be taken in response to such fluid detection. In some embodiments, the double-walled bellows may be formed by having an elastomeric liner disposed within a single-walled bellows, which may have an accordion-like configuration. Related methods and systems are also disclosed.
1 . A pump for introducing high-pressure treatment fluid into a well, comprising:
one or more sensors;
a control system, and
an expandable double-walled bellows configured to extend into a chamber of a fluid end of the pump based on application of drive fluid within the bellows, comprising:
an inner wall enclosing an inner volume; and
an outer wall encompassing the inner wall, such that the inner wall is disposed within the outer wall;
wherein:
a space is disposed between the inner wall and the outer wall of the bellows, and the space is in fluid communication with a port;
at least one of the inner wall and the outer wall comprises an accordion-like body; and
the bellows comprises a single opening configured to allow application of drive fluid into the inner volume of the bellows;
the one or more sensors are configured to detect a fluid leak in the space; and
the control system is configured to:
determine, based on the one or more sensors, whether the detected fluid leak is drive fluid or treatment fluid;
responsive to determining that the fluid leak is drive fluid, inject drive fluid between the piston and the bellows using a make-up system to ensure that the bellows and piston are in sync; and
responsive to determining that the fluid leak is treatment fluid, stop introduction of treatment fluid into the well.
2 . The pump of claim 1 , wherein the inner wall is sealingly coupled to an interior surface of the outer wall in proximity to the port, but the inner wall and the outer wall are substantially uncoupled within the chamber.
3 . The pump of claim 1 , wherein the one or more sensors are disposed in proximity to the port.
4 . The pump of claim 1 , wherein the one or more sensors comprise a fluid sensor in proximity to the port, configured to detect the presence of fluid, or a contamination sensor in proximity to the port.
5 . The pump of claim 1 , wherein the inner wall is configured to be at least as expandable as the outer wall.
6 . The pump of claim 1 , wherein a first one of the inner wall and the outer wall is formed of metal having an accordion-like configuration, and a second one of the inner wall and the outer wall is formed of an elastomeric material.
7 . The pump of claim 3 , wherein the control system is configured to receive data from the one or more sensors, compare the data to a corresponding threshold, and responsive to the data exceeding the threshold, initiate an action.
8 . A bellows pump for introducing treatment fluid into a well for treatment of the well, comprising:
a power end;
a fluid end having a fluid end housing with a chamber, a suction valve configured for introduction of treatment fluid into the chamber, and a discharge valve configured for injection of treatment fluid from the chamber into the well;
an expandable bellows configured to expand into the chamber of the fluid end based on movement of drive fluid from the power end and configured to separate drive fluid from treatment fluid;
an elastomeric liner disposed within the bellows;
one or more sensors; and
a control system,
wherein:
a space is disposed between the liner and the bellows,
the space is in fluid communication with a port,
the treatment fluid comprises one of the following: fracturing fluid, abrasive material, corrosive material, cement, proppant, or combinations thereof,
the one or more sensors are configured to detect a fluid leak in the space; and
the control system is configured to:
determine based on the one or more sensors, whether the detected fluid leak is drive fluid or treatment fluid;
responsive to determining that the fluid leak is drive fluid, inject drive fluid between the piston and the bellows using a make-up system to ensure that the bellows and piston are in sync; and
responsive to determining that the fluid leak is treatment fluid, stop introduction of treatment fluid into the well.
9 . The bellows pump of claim 8 , wherein the elastomeric liner is sealingly coupled to an interior surface of the bellows in proximity to the port, but otherwise is loose or slip fit within the bellows.
10 . The bellows pump of claim 8 , wherein the one or more sensors are disposed in proximity to the port, wherein the one or more sensors are selected from the following: a fluid sensor configured to detect the presence of fluid and/or a contamination sensor configured to detect contaminants within fluid.
11 . The bellow pump of claim 10 , wherein the control system is configured to receive data from the one or more sensors, compare the data to a corresponding threshold, and, responsive to the data exceeding the threshold, initiate an action.
12 . The bellows pump of claim 8 , wherein the elastomeric liner is configured to be at least as expandable as the bellows.
13 . The bellows pump of claim 8 , wherein the bellows is formed of a metal and has an accordion-like configuration.
14 . A method of detecting leakage in a bellows pump, comprising:
placing the bellows pump in fluid communication with a hydrocarbon well wherein the bellows pump comprises an expandable double-walled bellows having space between the walls,
using the bellows pump to introduce treatment fluid into the well for one of the following:
a hydraulic fracturing operation, a fracturing acidizing operation, a proppant hydraulic fracturing operation, a well stimulation treatment drilling, cementing or combinations thereof; and
detecting leak fluid in the space between the walls of the expandable double-walled bellows,
wherein detecting leak fluid comprises detecting via one or more sensors in proximity to a port in fluid communication with the space;
wherein responsive to detecting leak fluid, determining based on the one or more sensors whether the detected leak fluid is drive fluid or treatment fluid;
responsive to determining that the leak fluid is drive fluid, injecting drive fluid between the piston and the bellows; and
responsive to determining that the leak fluid is treatment fluid, stopping introduction of treatment fluid into the well.
15 . The method of claim 14 , further comprising comparing detected leak fluid to a corresponding threshold, and acting responsive to the detected leak fluid exceeding the threshold.
16 . The method of claim 14 , wherein the double-walled bellows comprises an elastomeric liner disposed within a single-walled bellows, further comprising, responsive to determining that the leak fluid is drive fluid, replacing the elastomeric liner; or responsive to determining that the leak fluid is treatment fluid, replacing the single-walled bellows.
17 . The method of claim 14 , wherein:
a control system determines, based on the one or more sensors, whether the detected leak fluid is drive fluid or treatment fluid;
responsive to determining that the leak fluid is drive fluid, the control system injects drive fluid between the piston and the bellows using a make-up system to ensure that the bellows and piston are in sync; and
responsive to determining that the leak fluid is treatment fluid, the control system stops introduction of treatment fluid into the well.
18 . A pump for introducing high-pressure treatment fluid into a well, comprising:
an expandable double-walled bellows configured to extend into a chamber of a fluid end of the pump based on application of drive fluid within the bellows, comprising:
an inner wall enclosing an inner volume; and
an outer wall encompassing the inner wall;
wherein:
a space is disposed between the inner wall and the outer wall of the bellows, the space is in fluid communication with a port, the inner wall and the outer wall have rubbing interaction based on application of drive fluid within the bellows and an interior surface of the outer wall or an exterior surface of the inner wall comprises a low-friction material configured to minimize friction due to rubbing of the inner and outer walls.
19 . The pump of claim 18 , wherein the low-friction material comprises grease, PTFE, or other lubricant.