Systems and methods using a bellows pump to perform operations for a subterranean formation
Exemplary systems for introducing treatment fluid into a well can include a bellows pump and a make-up system configured to maintain a controlled volume of fluid between the piston and the bellows of the bellows pump. The make-up system can be fluidly coupled to the bellows and to at least one additional component of the system. In embodiments, the make-up system can be configured to receive heat via circulation of fluid with the at least one additional component of the system, and to discharge heat via circulation of the fluid with the bellows, for example with the bellows conducting heat from the fluid to the treatment fluid for heat discharge.
1. A system for pumping treatment fluid into a well, comprising:
a bellows pump configured to pump treatment fluid into the well, comprising:
a power end comprising a piston;
a fluid end having a chamber; and
an expandable bellows, wherein the power end is configured to reciprocally expand and contract the bellows within the chamber based on movement of fluid by the piston;
a make-up system configured to maintain a controlled volume of fluid between the piston and the bellows; and
a control system having one or more sensor configured to detect one or more parameters of the system;
wherein:
the make-up system comprises a make-up fluid source fluidly coupled to the bellows and to at least one additional component of the system;
the make-up system is configured to receive heat via circulation of fluid with the at least one additional component of the system, and to discharge heat via circulation of the fluid with the bellows, wherein the at least one additional component comprises another pump;
the control system is configured to receive data from the one or more sensor, to evaluate the sensor data to detect a leak, and responsive to detecting a leak, to fluidly isolate the make-up system from the bellows; and
the control system is further configured to evaluate the sensor data to determine whether the bellows and piston are out of sync, and responsive to determining that the bellows and piston are out of sync, to use the make-up system to adjust the amount of fluid between the piston and the bellows to return the piston and bellows to sync.
2. The system of claim 1 , wherein the control system is configured to evaluate the sensor data to determine a circulation protocol for circulating fluid between the make-up system and bellows for cooling, and responsive to determining a circulation protocol, to circulate fluid between the make-up system and the bellows based on the circulation protocol.
3. The system of claim 2 , wherein the control system determines an amount of time to hold fluid in the bellows, which source of fluid to circulate to the bellows, and/or an amount of fluid to circulate to optimize cooling of the fluid.
4. The system of claim 2 , wherein the control system determines the circulation protocol based on temperature, prioritizing flow from whichever of the make-up fluid source or the at least one additional component is hotter to the bellows.
5. The system of claim 1 , wherein the one or more sensor is configured to detect one or more of the following parameters at one or more location within the system: pressure, temperature, flow rate, viscosity, contamination, and/or position of one or more component of the system; and wherein the control system detects a leak based on the sensor data by comparing the sensor data to a corresponding threshold.
6. The system of claim 1 , wherein the make-up system further comprises at least one make-up valve and/or at least one make-up pump configured to pump fluid between the bellows and the make-up fluid source, and wherein fluidly isolating the make-up system from the bellows comprises closing the make-up valve and/or deactivating the make-up pump.
7. A system for pumping treatment fluid into a well, comprising:
a bellows pump configured to pump treatment fluid into the well, comprising:
a power end comprising a piston;
a fluid end having a chamber; and
an expandable double-walled bellows, wherein the power end is configured to reciprocally expand and contract the bellows within the chamber based on movement of fluid by the piston;
a make-up system configured to maintain a controlled volume of fluid between the piston and the bellows; and
a control system having one or more sensor configured to detect one or more parameters of the system;
wherein:
the expandable double-walled bellows comprises an inner wall, enclosing an inner volume, and an outer wall encompassing the inner wall;
an annulus is disposed between the inner wall and the outer wall of the bellows;
the annulus is in fluid communication with a port;
the one or more sensor comprises one or more annulus sensor disposed in proximity to the port;
the make-up system comprises a make-up fluid source fluidly coupled to the bellows and to at least one additional component of the system;
the control system is configured to receive data from the one or more sensor, to evaluate the sensor data to detect a leak, and responsive to detecting a leak, to fluidly isolate the make-up system from the bellows; and
the control system is further configured to evaluate the sensor data to determine whether the bellows and piston are out of sync, and responsive to determining that the bellows and piston are out of sync, to use the make-up system to adjust the amount of fluid between the piston and the bellows to return the piston and bellows to sync.
8. The system of claim 7 , wherein the inner and outer walls are uncoupled within the chamber.
9. The system of claim 7 , wherein the one or more annulus sensor comprises a fluid sensor and/or a contamination sensor.
10. The system of claim 7 , wherein the make-up system further comprises at least one make-up valve and/or at least one make-up pump, wherein fluidly isolating the make-up system from the bellows comprises closing the make-up valve and/or deactivating the make-up pump.
11. The system of claim 7 , wherein the make-up system is configured to receive heat via circulation of fluid with the at least one additional component of the system, and to discharge heat via circulation of the fluid with the bellows.
12. The system of claim 11 , wherein the control system determines an amount of time to hold fluid in the bellows, which source of fluid to circulate to the bellows, and/or an amount of fluid to circulate to optimize cooling of the fluid.
13. The system of claim 11 , wherein the control system determines a circulation protocol based on temperature, prioritizing flow from whichever of the make-up fluid source or the at least one additional component is hotter to the bellows.
14. The system of claim 11 , further comprising an external cooler fluidly coupled to the make-up system.
15. A system for pumping treatment fluid into a well, comprising:
a bellows pump configured to pump treatment fluid into the well, comprising:
a power end comprising a piston;
a fluid end having a chamber; and
an expandable bellows, wherein the power end is configured to reciprocally expand and contract the bellows within the chamber based on movement of by the piston;
a make-up system configured to maintain a controlled volume of fluid between the piston and the bellows; and
a control system having one or more sensor configured to detect one or more parameters of the system;
wherein:
the make-up system comprises a make-up fluid source fluidly coupled to the bellows and to at least one additional component of the system;
the make-up system is configured to receive heat via circulation of fluid with the at least one additional component of the system, and to discharge heat via circulation of the fluid to the bellows, wherein the bellows is configured to discharge heat to the treatment fluid in the chamber by conduction;
the control system is configured to receive data from the one or more sensor, to evaluate the sensor data to detect a leak, and responsive to detecting a leak, to fluidly isolate the make-up system from the bellows;
the control system is further configured to evaluate the sensor data to determine whether the bellows and piston are out of sync, and responsive to determining that the bellows and piston are out of sync, to use the make-up system to adjust the amount of fluid between the piston and the bellows to return the piston and bellows to sync; and
the control system is further configured to evaluate the sensor data to determine a circulation protocol for circulating fluid between the make-up system and bellows for cooling, and responsive to determining a circulation protocol, to circulate fluid between the make-up system and the bellows based on the circulation protocol.
16. The system of claim 15 , wherein the control system determines an amount of time to hold fluid in the bellows, which source of fluid to circulate to within the bellows, and/or an amount of fluid to circulate to optimize cooling of the fluid.
17. The system of claim 16 , wherein the control system determines the circulation protocol based on temperature, prioritizing flow from whichever of the make-up fluid source or the at least one additional component is hotter to the bellows.
18. The system of claim 15 , wherein the one or more sensor is configured to detect one or more of the following parameters at one or more location within the system: pressure, temperature, flow rate, viscosity, contamination, and/or position of one or more component of the system; and wherein the control system detects a leak based on the sensor data by comparing the sensor data to a corresponding threshold.
19. The system of claim 15 , wherein the one or more sensor comprises a temperature sensor at the make-up fluid source and a temperature sensor at the bellows.
20. The system of claim 19 , wherein the one or more sensor further comprises a temperature sensor at the at least one additional component of the system.