U.S. patent application number 14/357507 was filed with the patent office on 2014-10-30 for pump system.
The applicant listed for this patent is J-Mac Tool, Inc.. Invention is credited to Saul Dominguez, Michael David Marette.
Application Number | 20140322050 14/357507 |
Document ID | / |
Family ID | 48290676 |
Filed Date | 2014-10-30 |
United States Patent
Application |
20140322050 |
Kind Code |
A1 |
Marette; Michael David ; et
al. |
October 30, 2014 |
Pump System
Abstract
A pump system that has a power end and a fluid end assembly. The
fluid end assembly includes a plunger configured to translate
within a plunger bore. The fluid end further includes a suction
valve assembly and a discharge valve assembly. The power end is
configured to use a pony rod to induce movement of the plunger
within the fluid end assembly to generate a pressure differential.
The suction valve assembly and the discharge assembly operate in
response to the pressure differential to move the fluid. A straight
valve seal is located within the suction valve assembly and/or the
discharge valve assembly to distribute forces incurred by movement
of valves within the fluid end assembly.
Inventors: |
Marette; Michael David;
(Forth Worth, TX) ; Dominguez; Saul; (Forth Worth,
TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
J-Mac Tool, Inc. |
Fort Worth |
TX |
US |
|
|
Family ID: |
48290676 |
Appl. No.: |
14/357507 |
Filed: |
November 13, 2012 |
PCT Filed: |
November 13, 2012 |
PCT NO: |
PCT/US2012/064806 |
371 Date: |
May 9, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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61558333 |
Nov 10, 2011 |
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61558311 |
Nov 10, 2011 |
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61558330 |
Nov 10, 2011 |
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61558317 |
Nov 10, 2011 |
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61558323 |
Nov 10, 2011 |
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61561156 |
Nov 17, 2011 |
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61585067 |
Jan 10, 2012 |
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Current U.S.
Class: |
417/437 |
Current CPC
Class: |
F04B 47/02 20130101;
F04B 49/22 20130101; F04B 53/1087 20130101; F04B 53/10 20130101;
F04B 53/102 20130101; F04B 53/144 20130101 |
Class at
Publication: |
417/437 |
International
Class: |
F04B 49/22 20060101
F04B049/22 |
Claims
1. A pump system, comprising: a power end assembly having a pony
rod; a fluid end assembly having a plunger for generating an
alternating pressure differential in the fluid system, the power
end being configured to induce translation of the plunger within
the plunger chamber to pressurize a charge fluid; a suction valve
assembly and a discharge valve assembly configured to selectively
operate in response to the pressure differential; and a straight
valve seal configured to seal the suction valve assembly and
discharge valve assembly in a straight bore within the fluid end
assembly.
2. The pump system of claim 1, wherein the power end includes a
multi-piece connecting rod configured to use a plurality of
threaded fasteners to couple individual portions together to reduce
wear of the connecting rod.
3. The pump system claim 1, wherein power end includes a connecting
rod bearing housing in communication with a connecting rod, the
bearing housing including a channel and associated bevel area for
the distribution of lubrication.
4. The pump system claim 1, wherein the plunger and the pony rod
are coupled together via a pony rod adapter.
5. The pump system claim 1, wherein the pony rod adapter is a
dove-tail clamp.
6. The pump system claim 5, wherein the pony rod adapter uses a
non-threaded relationship to couple the pony rod and the plunger
together.
7. The pump system claim 1, wherein the suction valve and the
discharge valve are intersect a centerline of the fluid end at an
obtuse angle, the centerline being coaxial with an axis of the
plunger.
8. The pump system claim 1, wherein the suction valve defines a
first centerline and the discharge valve defines a second
centerline, the first centerline and the second centerline being
parallel with each other and perpendicular to a third centerline
defined by the plunger.
9. The pump system of claim 1, wherein the suction valve assembly
includes a seat portion and a guide portion configured to properly
align the valve.
10. The pump system of claim 1, wherein at least one of the suction
valve assembly and the discharge valve assembly includes a valve
insert to seal a valve opening.
11. The pump system of claim 1, further comprising: a recirculating
manifold having a reducer configured to optimize the distribution
of charge fluid through a feeder, the feeder coupled to a suction
valve assembly.
12. The pump system claim 1, further comprising: a rock screen
insert configured to filter out particulates from the charge fluid;
the rock screen insert being located within the suction valve
assembly.
13. The pump system of claim 12, wherein the rock screen insert
maintains a front valve guide to improve performance of the suction
valve assembly.
14. The pump system of claim 1, wherein the fluid end assembly
includes a packing nut configured to seal around the plunger, the
packing nut configured to receive automated adjustment during
operation of the pump system.
15. The pump system of claim 1, wherein the packing nut includes a
monitor to provide an operator operational feedback concerning the
condition of the packing nut during operation of the pump
system.
16. The pump system of claim 14, wherein the packing nut includes a
bellows forming an annular volume for reception of a working fluid
configured to regulate the pressure on the packing nut.
17. The pump system of claim 14, wherein the packing nut includes
an annular volume between a piston and a body for reception of a
working fluid configured to regulate the pressure on the packing
nut.
18. The pump system of claim 1, wherein the suction valve assembly
and the discharge valve assembly are configured to accept a dual
guided valve.
19. The pump system of claim 1, wherein the suction valve assembly
includes a locking mechanism configured to permit removal of a
suction valve with a single hand.
20. The pump system of claim 1, wherein the fluid end assembly is
configured to receive bores and cutouts configured to reduce stress
concentrations within a fluid end.
Description
TECHNICAL FIELD
[0001] The application relates generally to pump systems having a
power end in operative communication with a fluid end and, more
particularly, to a pump system for delivering fracture fluids.
DESCRIPTION OF THE PRIOR ART
[0002] It is difficult to economically produce hydrocarbons from
low permeability reservoir rocks. Oil and gas production rates are
often boosted by hydraulic fracturing, a technique that increases
rock permeability by opening channels through which hydrocarbons
can flow to recovery wells. During hydraulic fracturing, a fluid is
pumped into the earth under high pressure (sometimes as high as
50,000 PSI) where it enters a reservoir rock and cracks or
fractures it. Large quantities of proppants are carried in
suspension by the fluid into the fractures. When the pressure is
released, the fractures partially close on the proppants, leaving
channels for oil and gas to flow.
[0003] Specialized pump systems are used to deliver fracture fluids
at sufficiently high rates and pressures to complete a hydraulic
fracturing procedure or "frac job." Positive displacement pumps
used in Oil Field Well Service Applications are operated, serviced
& maintained in harsh environments & operating conditions.
The four main issues that contribute to reduced performance and the
loss of service life in these pumps are: 1) Pump cavitation due to
inadequate and or inconsistent charge flow; 2) Cracking and Failure
due to metal fatigue in the pump fluid ends which are also known as
the liquid or pressure sides of the pump. This is caused by the
continual high pressurization & de-pressurization that occurs
up to three times per second as the pump reciprocates to displace
liquid under pressure; 3) Improper maintenance; and 4) Improper
operation.
[0004] These pump systems are usually provided with power ends and
fluid ends. Power ends induce movement of a plunger within the
fluid end that places fluids under pressure. Within these fluid
ends are a number of reciprocating plungers that pressurize
fracture fluids. Suction valves and discharge valves control fluid
flow to, and from, the plungers.
[0005] A valve that has too many internal projections can capture
or "knock out" enough proppant to block the flow of fluid through a
pump, requiring that time and effort be invested to clear the
blockage--a costly undertaking. Also, these projections can create
substantial pressure losses that require more energy to be expended
than is necessary to perform hydraulic fracturing work. Commonly
used discharge valves possess a number of guides or "wings" that
project into the center of a valve to hold a piston in place. These
wings are known to capture proppants suspended in fracture fluids.
A need exists for an improved, discharge valve without wings.
[0006] Within these valves are pistons that normally press against
valve seats to selectively stop the flow of fluid. Pressure
differentials from the motion of the plunger typically open and
close the valves. To reduce leaks around valve seats and maximize
pumping efficiencies, the pistons found in suction and discharge
valves are typically equipped with sealing elements. These sealing
elements or inserts are typically rings formed of a resilient
material. The rings are fitted into grooves in the pistons that are
positioned to facilitate contact with valve seats. Typical designs
of sealing elements have permitted them to move about in their
retaining grooves after installation, permitting them to wear
excessively in the presence of abrasive proppants and other
materials carried by fracture fluids. Thus, the known sealing
elements required frequent replacement.
[0007] Sealing elements are located deep within the fluid end of a
pump that is held together by a large number of heavy, threaded
fasteners. To access the worn sealing elements, the fluid end
frequently required substantial disassembly. Although manufacturers
provide strong and robust pumps, disassembly of pumps in the field
is especially time-consuming and difficult to perform. Increasing
the longevity of the sealing elements found in suction and
discharge valves can, therefore, provide substantial cost savings
to an oilfield operator.
[0008] The plungers reciprocate within a pumping chamber to produce
the extremely high pressures necessary to break reservoir rocks
underground. As the plungers reciprocate within the pumping
chamber, the plungers cycle between high and low pressures and are
subjected to high stress variations. The plungers also rub against
sealing elements in the ends of the pumping chambers and,
consequently, are worn and abraded by proppants and other materials
carried in the pumped fluids.
[0009] These pumps often have connecting rods that join a crosshead
within the power end and drive the plunger. A conventional
connecting rod is cast as a single unit and is subsequently
machined to its finished dimensions. When portions of such a
connecting rod wear out, the rod must be replaced in its
entirety--a time-consuming and costly project. Multi-piece
connecting rods have been developed as a substitute for one-piece
rods so as to minimize rod replacement time by permitting just the
worn portions of a rod to be swapped. Multi-piece rods have not,
however, gained widespread acceptance since wear tends to occur not
only in the usual spots, but, also, at the junctions between the
joined pieces.
[0010] These pumps have bearings that couple connecting rods to a
crankshaft within the power end. These bearings usually incorporate
bronze sleeves that encircle the crankshaft and prevent or limit
friction. Improper design of these sleeves, however, can restrict
the flow of lubricant to the surfaces contacting the crankshaft. If
flow is impeded, the sleeves and the pump can be damaged. Damage
can be caused by the sleeves seizing upon the crankshaft so that
they grind against their housings and by galling where they wear
against the crankshaft. In either case, the affected pump must be
immediately shut down and the bearings repaired. Such an event can
be time consuming and costly for an oilfield operator conducting a
frac job.
[0011] The pump systems have many parts that are releasably
fastened to one another so that they can be easily repaired or
replaced. It is the connections between the parts and the
supporting features within the pump system that tend to weaken the
pump system, limiting its pressure rating, and making it
susceptible to corrosion, leaks, and cracks under high, cyclical
stresses. Thus, pump systems sometimes fail under load
prematurely.
[0012] In an effort to increase pressure ratings and decrease
failure rates, improved fluid ends have been proposed by pump
manufacturers, however the designs have not seen widespread use or
commercial success since they have been difficult and costly to
make and equally difficult to service in the field. A continuing
need, therefore, exists for a pump system that addresses the
disadvantages described.
[0013] Although great strides have been made in pump systems,
considerable shortcomings remain.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] For a more complete understanding of the present invention,
including its features and advantages, reference is now made to the
detailed description of the invention taken in conjunction with the
accompanying drawings in which like numerals identify like parts,
and in which:
[0015] FIG. 1 is a section view of a pump system according to the
preferred embodiment of the present application;
[0016] FIG. 2 is a side elevational view of a connecting rod
bearing housing mounted on a connecting rod and carrying a
connecting rod bearing according to the preferred embodiment of the
present application;
[0017] FIG. 3 is an exploded, cross-sectional view of the housing
and rod bearing of FIG. 2;
[0018] FIG. 4 is a top view of the connecting rod bearing housing
of FIG. 2;
[0019] FIG. 5 is a bottom view of the upper bearing segment carried
by the housing of FIG. 3;
[0020] FIG. 6 is a top view of the lower bearing segment carried by
the housing of FIG. 3;
[0021] FIG. 7 is a front elevational view of a connecting rod with
portions broken away to reveal interior details thereof according
to the preferred embodiment of the present application;
[0022] FIG. 8 is a side elevational view of the top portion of the
connecting rod of FIG. 7 with portions broken away to reveal
interior details thereof;
[0023] FIG. 9 is a bottom view of the connecting rod of FIG. 7;
[0024] FIG. 10 is a top view of the connecting rod of FIG. 7;
[0025] FIG. 11 is a schematic view showing the relative positions
of the four drawing sheets carrying FIGS. 12A, 12B, 12C, and 12D,
each representing corresponding portions of a first embodiment of a
fluid end assembly;
[0026] FIG. 12A is a cross-sectional view of the left portion of a
first embodiment of the fluid end assembly of according to the
preferred embodiment of the present application;
[0027] FIG. 12B is a cross-sectional view of a central portion of
the first embodiment of the fluid end assembly according to the
preferred embodiment of the present application;
[0028] FIG. 12C is a cross-sectional view of an upper, right
portion of the first embodiment of the fluid end assembly according
to the preferred embodiment of the present application;
[0029] FIG. 12D is a cross-sectional view of a lower right portion
of the first embodiment of the fluid end assembly according to the
preferred embodiment of the present application;
[0030] FIG. 13 is a schematic view showing the relative positions
of the four drawing sheets carrying FIGS. 14A, 14B, 14C, and 14D,
each representing corresponding portions of an alternative
embodiment of the fluid end assembly of FIGS. 11-12;
[0031] FIG. 14A is a cross-sectional view of the left portion of a
second embodiment of the fluid end assembly of FIGS. 11-12;
[0032] FIG. 14B is a cross-sectional view of the central portion of
the second embodiment of the fluid end assembly of FIGS. 11-12;
[0033] FIG. 14C is a cross-sectional view of the upper, right
portion of the second embodiment of the fluid end assembly of FIGS.
11-12;
[0034] FIG. 14D is a cross-sectional view of the lower right
portion of the second embodiment of the fluid end assembly of FIGS.
11-12;
[0035] FIG. 15 is a schematic view showing the relative positions
of the three drawing sheets carrying FIGS. 16A, 16B, and 16C, each
representing corresponding portions of an alternative embodiment of
the fluid end assembly of FIGS. 11-14;
[0036] FIG. 16A is an enlarged, cross-sectional view of the top
portion of the fluid end assembly of FIG. 15;
[0037] FIG. 16B is an enlarged, cross-sectional view of the middle
portion of the fluid end assembly of FIG. 15;
[0038] FIG. 16C is an enlarged, cross-sectional view of the bottom
portion of the fluid end assembly of FIG. 15;
[0039] FIG. 17 is a longitudinal, cross-sectional view of an
alternative embodiment of the plunger assembly of FIGS. 11-14;
[0040] FIG. 18 is an exploded, side elevational view of the pony
rod adapter of the plunger assembly of FIG. 17;
[0041] FIG. 19 is a bottom view of the pony rod adapter of FIG.
18;
[0042] FIG. 20 is a top view of the pony rod adapter of FIG.
18;
[0043] FIG. 21 is a cross-sectional view taken along line 21-21 of
FIG. 18;
[0044] FIG. 22 is a cross-sectional view taken along line 22-22 of
FIG. 18;
[0045] FIG. 23 is a cross-sectional view taken along line 23-23 of
FIG. 18;
[0046] FIG. 24 is a side elevational view of the plunger of the
plunger assembly of FIG. 17 with portions broken away to reveal
details thereof;
[0047] FIG. 25 is a top view of the plunger of FIG. 24;
[0048] FIG. 26 is a cross-sectional view of an alternate plunger
for use in the plunger assembly of FIG. 17 with portions broken
away;
[0049] FIG. 27 is an outer end view of the pony rod of the plunger
assembly;
[0050] FIG. 28 is a side elevational view of the pony rod with
portions broken away;
[0051] FIG. 29 is a perspective view of a clamp assembly as an
alternative embodiment of the pony rod adapter of FIGS. 11-14 and
17;
[0052] FIG. 30 is a partial section view of a plunger and pony rod
used in with the fluid end of FIG. 29;
[0053] FIG. 31 is side view of a stud in the clamp assembly of FIG.
29;
[0054] FIG. 32 is a perspective view of a clamp in the clamp
assembly of FIG. 29, the clamp having an integral deflector;
[0055] FIG. 33 is an exploded view of the clamp of FIG. 32;
[0056] FIG. 34 is a side view of an alignment pin for use within
the clamp assembly of FIG. 29;
[0057] FIG. 35 is a section view of the stud of FIG. 31 in the pony
rod and plunger of FIG. 30;
[0058] FIGS. 36 and 37 are illustrative section views of an
alternative clamp assembly using an alternative plunger and pony
rod having a flange portion;
[0059] FIG. 38 is a side elevational view of an alternate
embodiment of a suction valve with portions broken away to reveal
details thereof according to the present application;
[0060] FIG. 39 is a bottom view of the valve seat and guide
assembly of the suction valve of FIG. 38;
[0061] FIG. 40 is a bottom view of the valve retainer of the
suction valve of FIG. 38;
[0062] FIG. 41 is a side elevational view of an alternative
embodiment of a discharge valve with portions broken away to reveal
details thereof according to the present application;
[0063] FIG. 42 is a top view of a piston of the discharge valve of
FIG. 41;
[0064] FIG. 43 is a perspective view of an alternative embodiment
of a valve insert according to the present application;
[0065] FIG. 44 is a top view of the valve insert of FIG. 43 with
the right-hand portion broken away;
[0066] FIG. 45 is a bottom view of the valve insert of FIG. 43 with
the left-hand portion broken away;
[0067] FIG. 46 is a side elevational view of the valve insert of
FIG. 43 with portions broken away to reveal details thereof;
[0068] FIG. 47 is an exploded, perspective view of the circle and
quadrilateral that are superposed to form a polygon that defines
the cross section of the valve insert of FIG. 43;
[0069] FIG. 48 is the polygon of FIG. 47 that is rotated about a
vertical axis so as to form the valve insert;
[0070] FIG. 49 is a side elevational view of a discharge valve with
portions broken away to reveal details thereof, the discharge valve
comprising the valve insert of FIG. 43;
[0071] FIG. 50 is a side elevational view of a suction valve with
portions broken away to reveal details thereof, the suction valve
comprising the valve insert of FIG. 43;
[0072] FIG. 51 is a perspective view of a manifold used in the pump
system of FIG. 1;
[0073] FIG. 52 is an end view of the manifold of FIG. 51 as seen
through a connecting pipe;
[0074] FIG. 53 is an end view of the manifold of FIG. 51 adjacent a
third feeder;
[0075] FIG. 54 is a section view of a top reducer pipe used in the
manifold of FIG. 51;
[0076] FIG. 55 is a section view of a bottom reducer pipe used in
the manifold of FIG. 51;
[0077] FIG. 56 is a perspective view of a rock screen insert in the
pump system of FIG. 1 according to the present application;
[0078] FIG. 57 is a partial section view of a first suction valve
with the rock screen insert of FIG. 51;
[0079] FIGS. 58 and 59 are perspective views of a second suction
valve wherein the second suction valve is partially removed to
illustrate the rock screen insert of FIG. 1;
[0080] FIGS. 60-67 are perspective and section views of alternative
embodiments of a packing nut in the pump system of FIG. 1;
[0081] FIGS. 68-70 are views of a discharge valve guided assembly
and a suction valve guided assembly used in the fluid ends of FIGS.
15-16;
[0082] FIG. 71 is an embodiment of a discharge valve guide for use
in the fluid end of FIGS. 11-14;
[0083] FIGS. 72-76 are assorted views of an embodiment of a suction
valve guide assembly used in the fluid end of FIGS. 11-14;
[0084] FIG. 77 is a perspective view of a straight seal used in the
pump system of FIG. 1;
[0085] FIGS. 78-79 are views of a seat deck for housing the
straight seal of FIG. 77 in the fluid ends used in the pump system
of FIG. 1; and
[0086] FIGS. 80A and 80B are front and side views of a vertical
passage and a horizontal passage with sectional views showing the
shape of peanut shaped bores used in the pump system of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0087] Illustrative embodiments of the preferred embodiment are
described below. In the interest of clarity, not all features of an
actual implementation are described in this specification. It will
of course be appreciated that in the development of any such actual
embodiment, numerous implementation-specific decisions must be made
to achieve the developer's specific goals, such as compliance with
system-related and business-related constraints, which will vary
from one implementation to another. Moreover, it will be
appreciated that such a development effort might be complex and
time-consuming but would nevertheless be a routine undertaking for
those of ordinary skill in the art having the benefit of this
disclosure.
[0088] In the specification, reference may be made to the spatial
relationships between various components and to the spatial
orientation of various aspects of components as the devices are
depicted in the attached drawings. However, as will be recognized
by those skilled in the art after a complete reading of the present
application, the devices, members, apparatuses, etc. described
herein may be positioned in any desired orientation. Thus, the use
of terms to describe a spatial relationship between various
components or to describe the spatial orientation of aspects of
such components should be understood to describe a relative
relationship between the components or a spatial orientation of
aspects of such components, respectively, as the device described
herein may be oriented in any desired direction.
[0089] The pump system of the present application will be
understood, both as to its structure and operation, from the
accompanying drawings, taken in conjunction with the accompanying
description. Several embodiments of the pump system and its
associated components or parts are presented herein. It should be
understood that various components, parts, and features of the
different embodiments may be combined together and/or interchanged
with one another, all of which are within the scope of the present
application, even though not all variations and particular
embodiments may be specifically illustrated in the drawings.
[0090] Furthermore, the associated components and parts will be
described and numbered with a numerical identifier on multiple sets
of drawings with respect to individual embodiments of the pump
system. The numerical identifiers may vary between embodiments.
When done, it is understood that such renumbered components or
parts will retain a similar form and function throughout all sets
of drawings despite the varied numerical identifiers.
[0091] Referring to FIG. 1 in the drawings, a pump system 1
according to the preferred embodiment is illustrated. Pump system 1
includes a power end 2 and a fluid end 10. Power end 2 is
configured to have a crankshaft 3 coupled to a connecting rod 4 and
bearings 5. The bearings having crosshead sleeves 6 to improve
bearing life and permit fully pressurized lubrication. Power end 2
is configured to drive a pony rod that is coupled to a plunger 7
with a pony rod adapter 8 within fluid end 10. As plunger 3
reciprocates within fluid end 10, a suction valve 9a and a
discharge valve 9b are operated according to pressure differentials
generated from reciprocating movement of plunger 7. Suction valve
9a receives pumping fluid through a suction or supply manifold 28.
The accompanying description will detail various portions of pump
system 1.
[0092] Connecting Rod Bearing
[0093] Referring now also to the FIGS. 2-6, a connecting rod
bearing housing in accordance with the present application is shown
at 1010. Housing 1010 includes an attaching portion 1012 for
fastening to the bottom of a connecting rod 1014. Housing 1010 also
has a retaining portion 1016 that is fastened to attaching portion
1012 to form a ring-like assembly sized to accept a bearing 1018.
Bearing 1018 has an upper segment 1020 that is carried within
attaching portion 1012 and a lower segment 1022 that is carried
within retaining portion 1016. In use, a crankshaft 1024, of a
high-pressure pump passed through segments 1020 and 1022, freely
rotates within housing 1010.
[0094] Attaching portion 1012 resembles an inverted "U" when viewed
from the front. In this regard, attaching portion 1012 has a top
plate 1026 and a pair of downwardly extending arms 1028 that are
affixed to the opposite sides of top plate 1026. Together, plate
1026 and arms 1028 are configured to define a cylindrical concavity
1030 in the bottom of attaching portion 1012 for snugly, yet
releasably, receiving upper segment 1020 of bearing 1018.
Cylindrical concavity 30 has a central, longitudinal axis 1032.
[0095] An upwardly extending, alignment bore 1034 is provided in
the bottom of each of arms 1028. Each bore 1034 is helically
threaded to accept the threaded shaft 1036 of a bolt 1038. Each
bore 1034 includes a lower, countersunk part 1040 of increased
diameter at its bottom end within which an alignment washer 1042
positioned on threaded shaft 1036 is set. Each bore 1034 is located
in an arm 1028 so that countersunk part 1040 intersects a side of
concavity 1030. Thus, when positioned in countersunk part 1040, a
washer 1042 with a sufficient height and diameter projects
downwardly from the bottom of an arm 1028 and inwardly into
concavity 1030.
[0096] A pair of upwardly extending, attachment bores 1044 is
provided in the bottom of each of arms 1028. As shown, one of bores
1044 is positioned in front of alignment bore 1034 and the other of
bores 1044 is positioned to the rear of alignment bore 1034. Each
of bores 1044 is helically threaded to accept the threaded shaft
1046 of a bolt 1048 for the releasable fastening of retaining
portion 1016 to attaching portion 1012 as will be described more
fully below. With the centers of alignment bores 1034 positioned
the same small distance in front of a lateral axis 1050, oriented
at right angles to axis 1032 midway between the front and back of
attaching portion 1012, it can be seen that attachment bores 1044
in each arm 1028 are positioned on opposite sides of bore 1034,
equidistantly from axis 1050.
[0097] To keep attachment portion 1012 centered on connecting rod
1014, an alignment plug 1052 extends upwardly from the top of top
plate 1026. Alignment plug 1052 is integrally formed with top plate
1026 for strength. Plug 1052 is cylindrical in form so as to fit
snugly into a close-fitting socket 1054 of circular outline in the
bottom of connecting rod 1014.
[0098] A pair of downwardly extending, alignment bores 1056 is
provided in the top of attachment portion 1012. Bores 1056 are
aligned with respect to axes 1032 and 1050. As shown, bores 1056
are positioned on a plane that extends vertically upward through
axis 1050. When viewed from above, bores 1056 are also seen to be
equidistantly spaced from axis 1032 for balance.
[0099] Bores 1056 penetrate plug 1052 to pass into top plate 1026.
Each of bores 1056 has a lower, helically threaded part 1058 for
accepting the threaded shaft of a bolt 1064. Also, each of bores
1056 includes an upper, countersunk part 1060 of increased diameter
for receiving an alignment pin 1066.
[0100] Each of a pair of alignment pins 1066 includes a disk 1068
sized for positioning within a countersunk part 1060. Disk 1068 has
a central opening 1070 sized for the passage of a threaded shaft
1062. Projecting upwardly from the periphery of disk 1068 is a
cylindrical, side wall 1072 having a height sufficient to project
from countersunk part 1060 when disk 1068 is fully inserted
therein. The inner diameter of side wall 1072 is sufficient to
receive the enlarged head 1074 of a bolt 1064 therein. So, when
bolt 1064 is tightened, head 1074 presses downwardly on the top of
disk 1068, fastening alignment pin 1066 to top plate 1026.
[0101] Top plate 1026 is provided with a number of downwardly
extending, helically threaded bores 1076 and 1078 positioned around
plug 1052 through which bolts 1080 are passed downwardly to attach
bearing housing 1010 to connecting rod 1014. As shown, three bores
1076 and 1080 are positioned on opposite sides of axis 1032. The
central bores 1076 are centered on a vertical plane extending
through axis 1050. The lateral bores 1078 are positioned
equidistantly from axis 1050.
[0102] Retaining portion 1016 resembles the letter "U" when viewed
from the front. Retaining portion 1016 has a pair of arms 1082 that
are affixed together at a location that serves as the bottom of
housing 1010. Arms 1082 extend upwardly and outwardly from their
junction with one another and terminate at top ends that are
reinforced by outwardly extending flanges 1084. Arms 1082,
together, define an upwardly opening, cylindrical concavity 1086 in
the top of retaining portion 1016. Concavity 1086 has the same
radius of curvature as concavity 1030 in attaching portion 1012 and
is similarly aligned with axis 1032. Lower segment 1022 of bearing
1018 is fitted into concavity 1086.
[0103] A downwardly extending, alignment bore 1088 is provided in
the top of each of arms 1082 and is adapted for registration with a
respective one of alignment bores 1034 in attaching portion 1012
when attaching portion 1012 and retaining portion 1016 are mated
together. The bottom part 1090 of each bore 1088 is sized to accept
the enlarged head 1092 of a bolt 1038. Additionally, each bore 1088
includes a top, countersunk part 1094 within which the bottom
portion of an alignment washer 1042 held by bolt 1038 onto
attaching portion 1012 is snugly set. Each bore 1088 is located in
an arm 1082 so that countersunk part 1094 intersects a side of
concavity 1086. When positioned in countersunk part 1094, a washer
1042 of sufficient size projects inwardly into concavity 1086.
[0104] A pair of upwardly extending, attachment bores 1096 is
provided in the top of each of arms 1082 for registration with
bores 1044 in attaching portion 1012. One of bores 1096 is
positioned forward of alignment bore 1088 and the other of bores
1096 is positioned rearward of alignment bore 1088. Each of bores
1096 is sized to accept the threaded shaft 1046 of a bolt 1048
passed upwardly through retaining portion 1016. The bores 1096 in
each arm 1082 are positioned on opposite sides of bore 1088,
equidistantly from axis 1050. The enlarged heads 1098 of bolts 1048
engage the bottoms of flanges 1084 when bolts 1048 fasten attaching
portion 1012 and retaining portion 1016 together.
[0105] Bearing 1018 is assembled from upper segment 1020 and lower
segment 1022, each resembling one-half of a tube cut lengthwise.
Each of the opposed, free ends of segment 1020 is provided with a
circular notch 1100 that engages a washer 1042 projecting into
concavity 1030. Also, each of the opposed, free ends of segment
1022 is provided with a circular notch 1102 that engages a washer
1042 projecting into concavity 1086. Each washer 1042, therefore,
serves as a stop to prevent the rotation of upper segment 1020 and
lower segment 1022 within housing 1010.
[0106] Bearing 1018 has features to distribute a liquid lubricant.
Each of the opposed, free ends of upper segment 1020 are provided
with a beveled area 1104 adjacent notch 1100. Additionally, each of
the opposed, free ends of lower segment 1022 are provided with a
beveled area 1106 adjacent notch 1102. When positioned
side-by-side, beveled areas 1104 and 1106 form a lubricant
reservoir extending from the front to the back of bearing 1018. A
channel 1108 extends circumferentially around lower segment 1022 to
connect both beveled areas 1106 together. Channel 1108 provides a
lubricant distribution pathway and ensures that the lubricant
reservoirs formed from beveled areas 1104 and 1106 always contain
similar quantities of lubricant under similar pressures.
[0107] Bearing housing 1010 is attached to connecting rod 1014 and
installed in a pump with conventional tools. When the pump is
running, bearing 1018 is supplied with pressurized lubricating oil
via passageways within the crankshaft 1024 encircled by bearing
1018. This oil fills channel 1108 which distributes the oil to the
reservoirs formed between beveled areas 1104 and 1106. In this way,
large volumes of oil are kept between the crankshaft 1024 and
bearing 1018 tending to: minimize the Frictional forces acting upon
bearing 1018, keep operating temperature of bearing 1018 low, and
prolong the operating life of bearing 1018.
[0108] Bearing 1018 is easily removed from housing 1010 for
inspection or replacement if it is thought to become worn during
use in a pump. To do this, attaching portion 1012 is disconnected
from retaining portion 1016 by first unscrewing bolts 1048. (An
upwardly extending, helically threaded bore 1110 permits a user to
gain a mechanical lock on retaining portion 1016 while bolts 1048
are removed). Then, retaining portion 1016 is pulled away from
attaching portion 1012. With lower segment 1022 being free of the
crankshaft 1024, it can be withdrawn from retaining portion 1016
with the application of a light pulling force. Now, by rotating the
crankshaft 24 somewhat, upper segment 1020 can be pulled free of
crankshaft 1024 and inspected or replaced as needed. Installing a
new bearing 1018 is done by reversing the steps performed for
bearing 1018 removal. Inspection and replacement of bearing 1018
can be accomplished quickly under optimal circumstances.
[0109] While bearing housing 1010 has been described in great
detail, it will be appreciated by individuals having knowledge of
rotary bearings that modifications can be made to housing 1010. It
is understood that the description above is not limited solely to
housing 1010, but encompasses any, and all, bearing housings within
the scope of the following claims.
[0110] Connecting Rod
[0111] Referring now to the FIGS. 7-10, a connecting rod in
accordance with the present invention is shown at 1014. Connecting
rod 1014 includes a shaft 2012 having a major flange 2014 affixed
to its bottom end that is adapted for releasable attachment to a
bearing housing 1010. A minor flange 2018 is affixed to the top end
of shaft 2012 to which a crosshead link 2020 is releasably
attached.
[0112] Shaft 2012 is a hollow tube with an upper, cylindrical
section 2022 and a lower, gusset section 2024 affixed to the bottom
of cylindrical section 2022. Cylindrical section 2022 has a
constant, outer diameter along its length. Gusset section 2024,
however, has an outer diameter that gradually increases in diameter
as the distance away from cylindrical section 2022 increases.
Gusset section 2024 serves to reinforce major flange 2014 that is
larger in size than minor flange 2018.
[0113] Shaft 2012 is provided with a weight-reducing passageway
2026 that extends longitudinally through both gusset section 2024
and cylindrical section 2022. Passageway 2026 has an elongated
section bounded by a first inner wall 2028 that extends through
gusset section 2024 and cylindrical section 2022. Beneath the
elongated section, passageway 2026 is enlarged, being bounded by a
second inner wall 2030 having an inner diameter that is greater
than that of first inner wall 2028. Above the elongated section,
however, passageway 2026 is restricted, being bounded by a third
inner wall 2032 having an inner diameter that is less than that of
first inner wall 2028. Immediately above third inner wall 2032 is a
fourth inner wall 2034 having an inner diameter that is greater
than that of third inner wall 2032.
[0114] The section of passageway 2026 bounded by second inner wall
2032 forms a socket for snugly receiving an alignment plug 1052
projecting upwardly from bearing housing 1010. A planar shoulder
2038 is formed in the bottom end of first inner wall 2028 at the
junction of first inner wall 2028 and second inner wall 2030. A
pair of alignment bores 2040, for receiving a pair of alignment
pins 1066 extending upwardly from alignment plug 1052, is provided
in shoulder 2038. The centers of bores 2040 define a lateral axis
2044 through shaft 2012.
[0115] The section of passageway 2026 bounded by fourth inner wall
2034 forms a socket for snugly, yet releasably, receiving an
alignment pin 2046 being part of link 2020. A shoulder 2048 is
formed in the top end of third inner wall 2032 at the junction of
third inner wall 2032 and fourth inner wall 2034. Shoulder 2048
slopes downwardly and inwardly.
[0116] Alignment pin 2046 of crosshead link 2020 is stopped by
shoulder 2048 from falling downwardly into shaft 2012. Pin 2046 is
dimensioned such that it projects upwardly from shaft 2012 when it
is positioned in its socket and against shoulder 2048. Pin 2046 has
a solid cylindrical form with a diameter that is slightly smaller
than that of fourth inner wall 2034. For proper centering and
seating on the top of shoulder 2048, the bottom end of pin 2046 is
tapered. (The top end of pin 2046 is similarly tapered). Pin 2046
assures the proper centering of link 2020 on shaft 2012 and that
link 2020 does not creep or rotate relative to shaft 2012.
[0117] Crosshead link 2020 has a ring 2050 with a longitudinal
aperture 2052 for snugly, yet releasably, receiving the top of pin
2046 extending upwardly from shaft 2012 and a transverse aperture
2054 for receiving a crosshead pin (not shown). To supply a flow of
lubricating oil to the interior of aperture 2054, a lubrication
opening 2056 passes through the top of ring 2050 in axial alignment
with longitudinal aperture 2052 and intersects the top of
transverse aperture 2054. A pair of helically threaded bores 2058
is provided on each of the opposite sides of aperture 2054 such
that bores 2058 define a pattern with a square outline in the
bottom of ring 2050. As shown, bores 2058 incline about 30'' from
vertical and have central axes that radiate outwardly and
downwardly from the central axis of aperture 2054.
[0118] Minor flange 2018 strengthens the connection between shaft
2012 and link 2020 and is integrally formed with shaft 2012. When
viewed from above, minor flange 2018 is seen to have a square
outline. When viewed from the side, however, flange 2018 is seen to
look like a "U" with a central, shoulder portion 60, surrounding
and reinforcing walls 2032 and 2034, and a pair of arm portions 62
that are affixed to the opposite sides of shoulder portion 2060 and
that radiate outwardly and upwardly therefrom. Together, portions
2060 and 2062 define a cylindrical concavity 2064 in the top of
flange 2018 for snugly, yet releasably, receiving ring 2050.
[0119] Each of arm portions 2062 is provided with a pair of holes
2066 for registration with a pair of bores 2058 on one side of
transverse aperture 2054 in ring 2050. The threaded shafts 2068 of
bolts 2070 are extended through holes 2066 and screwed into bores
2058 to releasably attach shaft 2012 to link 2020. Recesses 2072
are provided at the bottoms of holes 2066 for partially receiving
the enlarged, polygonal heads 2074 of bolts 2070 that are incapable
of positioning in holes 2066. When bolts 2070 are firmly tightened,
the longitudinal axis 2076 of transverse aperture 2054 is oriented
at right angles to lateral axis 2044 passing through the centers of
alignment pin receiving holes 2040.
[0120] Major flange 2014 strengthens the connection between shaft
2012 and bearing housing 1010. Major flange 2014 has a pair of
projections 2078 that extend outwardly from opposite sides of
gusset section 2024 perpendicular to the longitudinal axis 2076 of
transverse aperture 2054. Each of projections 2078 has three,
spaced-apart holes 2080 and 2082 through which bolts 1080 are
extended to attach connecting rod 1014 to bearing housing 1010. The
center holes 2080 are centered on lateral axis 2044 and the
remaining holes 2082 are positioned equidistantly from lateral axis
2044.
[0121] The installation of connecting rod 1014 in a pump is
straightforward. First, shaft 2012 and link 2020 together with
bolts 2070. Then, a crosshead pin (not shown) is extended through
transverse aperture 2054 in ring 2050. Next, bolts 1080 are
extended through major flange 2014 and into bearing housing 1010
previously connected to the power end of the pump, and tightened.
The perfect alignment of connecting rod parts is assured by the
arrangement of alignment plug 1052 and pins 1066 and 2046 and bolts
2070 and 1080. After securing all hatches and ancillary parts of
the pump, the pump is ready to drive connecting rod 1014.
[0122] After the pump has been run for substantial period, ring
2050 may show signs of wear around aperture 2054 that serves as a
bearing surface. (Shaft 2012 is unlikely to show any wear since
there is no movement of bearing housing 1010 and relative to link
2020 during the use of connecting rod 1014). By untightening bolts
2070 and manipulating the crosshead, a worn ring 2050 can be
removed from shaft 2012 and replaced by an unworn link 2020.
Reinstalling bolts 2070 in the new ring 2050 permits the pump to be
reenergized. Since service work does not require the removal of
bearing housing 1010 from the pump, it can be completed in minimal
time. Furthermore, since only the worn ring 2050 is replaced, there
is no wastage of costly, machined parts.
[0123] While connecting rod 1014 has been described with a high
degree of particularity, it will be appreciated by those skilled in
the field that modifications can be made to it. Therefore, it must
be understood that connecting rod 1014 is not limited to pumps as
described, but encompasses any and all other uses.
[0124] Both connecting rod 1014 described in FIGS. 7-10 and the
connecting rod bearing described in FIGS. 2-6 are configured to
reduce and correct the improper and laborious maintenance of a pump
system by improving access and simplifying the configurations.
[0125] Fluid End Assemblies
[0126] Referring now to FIGS. 11-14 in the drawings, a first
embodiment of a fluid end assembly 10 is illustrated according to
the present application. Fluid assembly 10 shows a Y-shaped
intersection between plunger 16, suction valve 24, and discharge
valve 26. Fluid end 10 is configured to reduce metal fatigue in the
fluid end and increase ease of maintenance. In particular to FIGS.
11 and 12 of the drawings, fluid end assembly 10 includes a pump
housing 12 having a plunger bore 14 within which a plunger 16
reciprocates. At its inner end, plunger bore 14 terminates in a
pumping chamber 18 that is supplied with fluid from above by a
suction passage 20 in pump housing 12. Fluid pressurized by plunger
16 exits pumping chamber 18 downwardly through a discharge passage
22 in pump housing 12. A suction valve 24 in suction passage 20
establishes the one-way flow of fluid from a supply manifold 28
into pumping chamber 18. A discharge valve 26 in discharge passage
22 sets up the one-way flow of fluid from pumping chamber 18 into
an outlet passage 30 for release from fluid end assembly 10.
[0127] Pump housing 12 is a steel block of suitable size and shape.
To lower its weight and increase its strength, housing 12 is
provided with a plunger section 32 of reduced height that contains
the outer end of plunger bore 14 and is adapted for attachment to
the power end of a high-pressure pump 34 by a number of stay rods
36. A suction section 38, containing suction passage 20, is
integrally formed with plunger section 32 and extends forwardly and
upwardly from plunger section 32. Similarly, a discharge section
40, containing discharge passage 22, is integrally formed with
plunger section 32 and suction section 38, and extends forwardly
and downwardly from plunger section 32. Suction and discharge
sections 38 and 40 generally taper from their inner ends to their
outer ends.
[0128] Plunger bore 14 is provided within pump housing 12 along a
centerline A. At its outer end, plunger bore 14 is widened and
partly threaded at 42 to receive a compressible, packing unit 44
and a rotatable gland nut 46 that provide a fluid-tight seal around
plunger 16. A number of radial apertures 45 in the gland nut 46
permit gland nut to be easily grasped by a spanner wrench (not
shown) and screwed into plunger bore 14. A lubricating port 48 in
plunger section 32 permits a lubricating oil to flow under the
influence of gravity to plunger 16 at a point between packing unit
44 and gland nut 46 so that plunger 16 can be reciprocated without
binding.
[0129] Suction passage 20 intersects the top of pumping chamber 18
and has a centerline B. Centerline B is coplanar with centerline A
and intersects centerline A at a reference point Z in pumping
chamber 18 to define a first obtuse angle .alpha.. Suction passage
20 extends from the bottom to the top of suction section 38.
Suction passage 20 has a bottom part 20a of relatively small
diameter and a helically threaded, top part 20b of large diameter,
with each of parts 20a and 20b measuring about half of the length
of suction passage 20. The top of part 20a forms a deck 50 upon
which a suction valve seat and guide assembly 52, being a feature
of suction valve 24, rests. The innermost portion of deck 50,
located closest to centerline B, is oriented at right angles to
centerline B for optimally transferring forces from valve seat and
guide assembly 52 to pump housing 12 so as to reduce the likelihood
of fatigue-induced cracks forming in housing 12 at this
location.
[0130] Discharge passage 22 intersects the bottom of pumping
chamber 18 and has a third centerline C. Centerline C is coplanar
with centerlines A and B that it intersects at reference point Z
where there is a second obtuse angle .lamda. formed between
centerlines A and C. Additionally, discharge passage 22 has a top
part 22a of relatively small diameter and a helically threaded,
bottom part 22b of large diameter. The bottom of part 22a forms a
deck 54 upon which a discharge valve seat 56, being a feature of
discharge valve 26, rests. The portion of deck 54 closest to
centerline C is oriented at right angles to centerline C for
optimally transferring forces from valve seat 56 to pump housing 12
in a manner that reduces the likelihood of fatigue-induced cracks
forming in housing 12 at this location.
[0131] Reference point Z is placed on centerline A at a location
that facilitates the movement of fluid from suction passage 20 into
pumping chamber 18 and from pumping chamber 18 into discharge
passage 22 as plunger 16 reciprocates from its innermost point of
travel to the right of point Z in FIG. 12D to its outermost point
of travel to the left of point Z in FIG. 12D. (At its innermost
point of travel, illustrated in FIG. 12D, plunger 16 has passed
point Z to move into both suction passage 20 and discharge passage
22. Suction valve piston 58 is provided with a concave cross
section to avoid contact with plunger 16 and so is discharge valve
seat 56). Obtuse angle .alpha., measuring about 120.degree., is
somewhat less than obtuse angle .lamda., measuring about
125.degree., to accommodate outlet passage 30 in discharge section
40. The resulting Y-shaped configuration offered by the
intersections of plunger bore 14, suction passage 20, discharge
passage 22 and their associated centerlines A, B and C reduces
stresses within pump housing 12 during the use of fluid end
assembly 10 to minimize the likelihood of pump housing 12 cracking
over time and maximize the service life of assembly 10.
[0132] Outlet passage 30 passes through discharge section 40,
extending from one end of discharge section to the other. A
connector passage 60 intersects outlet passage 30 at right angles
to place discharge passage 22 in fluid communication with outlet
passage 30. To either end, or both ends, of discharge section 40 is
connected one or more conduits (not shown) for carrying pressurized
fluid away from outlet passage 30 and fluid end assembly 10. This
pressurized fluid is used in oilfield applications to fracture
subterranean rock formations. Placing outlet passage 30 away from
discharge valve 26 limits the transverse or lateral flow of fluid
through the discharge valve 26, especially in fluid end assemblies
constructed with multiple, parallel sets of plungers 16 and valves
24 and 26. Discharge valve 26, therefore, runs without interference
from turbulent flow through outlet passage 30 thereby resulting in
a smoother-running and more efficient fluid end assembly 10.
[0133] Supply manifold 28 includes a tubular body 62 whose opposite
ends are connected to a fluid source when assembly 10 is operated.
A tubular connector 64 extends downwardly from tubular body 62 to
engage the open top of valve retainer 66 of suction valve 24. The
bottom of connector 64 is provided with a peripheral slot 68 and
the top of valve retainer 66 is provided with a similar, peripheral
slot 70. Slots 68 and 70 accommodate a VICTAULIC coupling body 72
of well-known construction for the quick and easy connection of
valve retainer 66 to manifold 28. Within body 72 is positioned a
VICTAULIC rubber seal 74 to prevent fluid leaks from body 72.
[0134] To permit the easy servicing of suction valve 24 without the
need to fully disengage manifold 28 from assembly 10, one or more
hinges 76 join manifold 28 to pump housing 12. Each hinge 76 has a
mounting bracket 78 secured by one or more threaded fasteners (not
shown) to pump housing 12. Mounting bracket 78 has a transverse
aperture 80 that accommodates a hinge pin 82. The inner end of a
swing arm 84 is pivotally attached by hinge pin 82 to mounting
bracket 78. The outer end of swing arm 84 is affixed to tubular
body 62. When VICTAULIC coupling body 72 is removed from assembly
10, manifold 28 is free to pivot 90.degree. on hinge 76 to the
broken line position seen in FIG. 12B.
[0135] Supply manifold 28 can be locked in a pivoted position to
permit suction valve 24 to be easily serviced. To this end, a
second transverse aperture 86 is provided in mounting bracket 78
adjacent first transverse aperture 80 and a third transverse
aperture 88, positioned for registration with second aperture 86
when manifold 28 is in a pivoted position, is provided in swing arm
84. Locking manifold 28 in the pivoted position is afforded by
extending a locking pin 90 through registered apertures 86 and
88.
[0136] Mounting bracket 78 is provided in the form of a loop or
ring to serve as a lifting eye for fluid end assembly 10. By
grasping bracket 78 with suitable lifting hook or chain, assembly
10 can be elevated while mounted upon power end 34 or not. Thus,
assembly 10 can be safely and easily transported from place to
place.
[0137] Suction valve 24 includes valve seat and guide assembly 52
tightly fitted into the bottom part 20a of suction passage 20. A
piston 58 moves within assembly 52 to control the flow of fluid
through suction passage 20. Piston 58 has a head 92 for engaging
the seat portion 52a of assembly 52 and a stem 94 extending
upwardly from head 92 through the guide portion 52b of assembly 52.
A valve keeper 96 is fitted upon the top of stem 94 and is retained
there by a split ring 98. A compressed spring 100 is positioned
between guide portion 52b and keeper 96 for normally retaining head
92 in engagement with seat portion 52a so as to prevent fluid flow
through passage 20. Externally, helically threaded, valve retainer
66 is screwed into top part 20b of suction passage 20 to retain the
balance of valve 24 within pump housing 12 and provide for the
attachment of valve 24 to manifold 28. Valve retainer 66 has a
tapered inner passageway 102 with a small-diameter, orifice portion
104 that serves to maintain a fluid velocity through fluid end
assembly 10 that is sufficient to prevent proppant particles
carried by a pumped fluid from dropping from suspension and
blocking suction valve 24. Of course, the relatively large, outer
diameter of valve retainer 66 permits valve seat and guide assembly
52, piston 58, spring 100, etc., to be accessed from the exterior
of pump housing 12 (once manifold 28 is pivoted out of the way and
retainer 66 is disengaged from housing 12) making the servicing of
suction valve 24 simpler.
[0138] Pump housing 12 is substantially strengthened by helically
threading the entirety of the top part 20b of suction passage 20.
The coextensive threads on the exterior of valve retainer 66
distribute pressure loads evenly to the pump housing 12 thereby
inhibiting the formation of cracks in the pump housing 12 at the
bottom of top part 20b adjacent seat deck 50 caused by cyclical
loading of fluid end assembly 10.
[0139] Discharge valve 26 includes valve seat 56 positioned in top
part 22a of discharge passage 22 and a reciprocating piston 106 for
controlling the flow of fluid through passage 22. Piston 106 has a
head portion 108 for engaging valve seat 56 and a hollow, stem
portion 110 extending downwardly from head portion 108. A valve
guide 112 is positioned below piston 106 in passage 22 and has a
guide rod 114 that projects upwardly into a longitudinal socket 116
provided in stem portion 110 where it is slidably received. A
number of radial apertures 118 penetrate the bottom of stem portion
110 to equalize the pressures in passage 22 and socket 116. A
compressed spring 120 is disposed between the valve guide 112 and
head portion 108 to normally press head portion 108 into engagement
with seat 56. A valve retainer 122 is screwed into the bottom part
22b of passage 22 to retain valve 26 within pump housing 12.
[0140] Plunger assembly 124 includes a pony rod adapter 126,
plunger 16 releasably attached to pony rod adapter 126, and a pony
rod 128 being releasably attached to pony rod adapter 126. Pony rod
adapter 126 has a first cylindrical body 130 and a number of
apertures 132 penetrating first cylindrical body 130 for engagement
by a first spanner wrench (not shown). A first helically threaded
pin 134 is affixed to first cylindrical body 130 and projects from
one of its ends. A second helically threaded pin 136 is affixed to
first cylindrical body 130 and projects from the other of its
ends.
[0141] Plunger 16 has a second cylindrical body 138 for
reciprocating within a pumping chamber 18. Second cylindrical body
138 has a first outer end with a first helically threaded bore 140
for threadably receiving first helically threaded pin 134. Second
cylindrical body 138 also has a first inner end with a socket 142
useful for supporting for body 138 at the time of its manufacture.
A number of radial holes 174 are provided around the outer end of
plunger 16 for engagement by a second spanner wrench (not shown).
In use, with the first spanner wrench engaged with pony rod adapter
126, the second spanner wrench grasps plunger 16 and applies the
torque needed to unscrew plunger 16 from pony rod adapter 126.
[0142] Pony rod 128 has a third cylindrical body 144 for
reciprocating into, and out of, power end 34. Third cylindrical
body 144 has a second inner end with a second helically threaded
bore 146 for threadably receiving second helically threaded pin
136. Third cylindrical body 144 also has a second outer end. A
peripheral flange 148 is affixed to, and extends outwardly from,
the second outer end. Peripheral flange 148 is provided with a
number of holes 150 through which an equal number of threaded
fasteners (not shown) are extended for connecting pony rod 128 to
the reciprocating components of the power end 34.
[0143] Fluid end assembly 10 pressurizes fluid by means of the
reciprocating action of plunger 16. Valves 24 and 26 permit fluid
pressurized by plunger 16 to move only in one direction from
manifold 28 to outlet passage 30. The Y-shaped configuration of
bore 14 and passages 20 and 22 in addition to the thick, tapered
walls provided to plunger section 32, suction section 38, and
discharge section 40 provide pump housing 12 with a construction
that is robust and not prone to fail under the cyclical loading
developed by plunger 16. Should plunger 16, valves 24 and 26,
packing unit 44, gland nut 46, or plunger assembly 124 ever require
servicing, they are easy to repair or replace with ordinary tools
and without major disassembly of the fluid end assembly 10.
[0144] Referring now to FIGS. 13 and 14 of the drawings, a second
embodiment of a fluid end assembly is shown at 410. Fluid end
assembly 410 is substantially the same as fluid end assembly except
that a suction valve 424 and a discharge valve 426, and the
passages 420 and 422 for the valves 424 and 426, have been modified
somewhat. These modifications are believed to further strengthen
valves 424 and 424 and fluid end assembly 410.
[0145] Fluid end assembly 410 includes a pump housing 412 having a
plunger bore 414 within which a plunger 416 reciprocates. At its
inner end, plunger bore 414 terminates in a pumping chamber 418
that is supplied with fluid by a suction passage 420 in pump
housing 412. Fluid pressurized by plunger 416 exits pumping chamber
418 through a discharge passage 422 in pump housing 412 located
opposite suction passage 420. A suction valve 424 in suction
passage 420 permits the one-way flow of fluid from a supply
manifold 428 to pumping chamber 418. A discharge valve 426 in
discharge passage 422 allows that one-way flow of fluid from
chamber 418 into an outlet passage 430 for release from assembly
410.
[0146] Pump housing 412 is a steel forging. Housing 412 has a
plunger section 432 that contains the outer end of plunger bore 414
and is adapted for attachment to the power end of a high-pressure
pump 434 by a number of stay rods 436. A suction section 438,
containing suction passage 420, is integrally formed with plunger
section 432 and extends forwardly and upwardly from plunger section
432. Similarly, a discharge section 440, containing discharge
passage 422, is integrally formed with plunger section 432 and
suction section 438 and extends forwardly and downwardly from
plunger section 432. Suction and discharge sections 438 and 440
taper from their inner ends to their outer ends.
[0147] Plunger bore 414 is provided within pump housing 412 along a
first centerline A'. At its outer end, plunger bore 414 is widened
and partly threaded at 442 to receive a packing unit 444 and a
rotatable gland nut 446 that, together, provide a fluid-tight seal
around plunger 416. A lubricating port 448 in plunger section 432
permits a liquid lubricant to flow to plunger 416 at a point
between packing unit 444 and gland nut 446.
[0148] Suction passage 420 intersects plunger bore 414 and has a
second centerline B' that is coplanar with centerline A' and
intersects centerline A' at a reference point Z' to define a first
obtuse angle .alpha.'. Passage 420 extends from the bottom to the
top of suction section 438. Passage 420 has a tapered, bottom part
420a, increasing in diameter from bottom to top with sides sloping
about 15.degree. relative to centerline A'. Passage 420 also has a
helically threaded, top part 420b of relatively large diameter.
[0149] Passage 420 has a deck 450 that serves as a guide for
installing seat 452 of suction valve 424. The top of part 420a,
being of smaller diameter than the bottom of part 420b, forms deck
450 in housing 412. The innermost portion of deck 450, located
closest to centerline B', is oriented at right angles to centerline
B'. Since no portion of valve 424, described hereinbelow, rests
upon deck 450 there is little likelihood of fatigue-induced cracks
forming in or around deck 450.
[0150] Discharge passage 422 intersects both plunger bore 414 and
suction passage 420 and has a third centerline C'. Centerline C' is
coplanar with centerlines A' and B' that it intersects at reference
point Z' so as to define a second obtuse angle .lamda.'.
Additionally, passage 422 has a tapered, top part 422a, increasing
in diameter from top to bottom with sides sloping about 15.degree.
relative to centerline C'. Passage 422 also has a medial part 422b
of somewhat greater diameter than the bottom of part 422a. Finally,
passage 422 has a helically threaded, bottom part 422c having a
diameter greater than that of part 422b.
[0151] Passage 422 has a deck 454 that serves as a guide for
installing seat 456 of discharge valve 426. The bottom of part
422a, being of smaller diameter than the top of part 422b, forms
deck 454 in housing 412. The innermost portion of deck 450, located
closest to centerline C', is oriented at right angles to centerline
C'. Since no portion of valve 426, described hereinbelow, rests
upon deck 454 there is little likelihood of fatigue-induced cracks
forming in or around deck 454.
[0152] Reference point Z' is placed on centerline A' at a location
that facilitates the movement of fluid from pumping chamber 418
into discharge passage 422 as plunger 416 reciprocates from its
innermost point of travel to the right of point Z' in FIGS. 14B and
14C to its outermost point of travel to the left of point Z' in
FIGS. 14B and 14C. (At its innermost point of travel, illustrated
in FIGS. 14B and 14C, plunger 416 passes point Z' to pass into both
suction passage 420 and discharge passage 422 and penetrates
suction valve 424 and discharge valve 426. Suction valve piston 458
is provided with a concave cross section to avoid contact with
plunger 416 and discharge valve seat 456 is similarly open). Obtuse
angle .alpha.', measuring about 120.degree., is somewhat less than
obtuse angle .lamda.', measuring about 125.degree., to accommodate
outlet passage 430. The resulting Y-shaped configuration offered by
the intersections of plunger bore 414, suction passage 420,
discharge passage 422 and their associated centerlines A', B' and
C' reduces stresses within pump housing 412 during use.
[0153] Outlet passage 430 extends through discharge section 440. A
connector passage 460 intersects outlet passage 430 at right angles
to place discharge passage 422 in fluid communication with outlet
passage 430. To either end of discharge section 440 can be
connected one or more conduits (not shown) to carry pressurized
fluid away from outlet passage 430 and assembly 410. Placing outlet
passage 430 away from discharge valve 426 in an unconventional
manner keeps the flow of fluid over and around the discharge valve
426 to a minimum, limiting vibrations.
[0154] Supply manifold 428 includes a tubular body 462 whose
opposite ends are connected to a fluid source when assembly 410 is
in operation. A tubular connector 464 extends downwardly from
tubular body 462 to engage the open top of valve retainer 466 of
suction valve 424. The bottom of connector 464 is provided with a
peripheral slot 468 and the top of valve retainer 466 is provided
with a similar, peripheral slot 470. Slots 468 and 470 accommodate
a VICTAULIC coupling body 472 for the connection of valve retainer
466 to manifold 428. Within body 472 is positioned a VICTAULIC
rubber seal 474.
[0155] To permit the easy servicing of suction valve 424 without
the need to fully disengage manifold 428 from assembly 410, one or
more hinges 476 join manifold 428 to pump housing 412. Each hinge
476 has a mounting bracket 478 secured by one or more threaded
fasteners (not shown) to pump housing 412. Mounting bracket 478 has
a transverse aperture 480 that accommodates a hinge pin 482. The
inner end of a swing arm 484 is pivotally attached by hinge pin 482
to mounting bracket 478. The outer end of swing arm 484 is affixed
to tubular body 462. When VICTAULIC coupling body 472 is removed
from assembly 410, manifold 428 can pivot 90.degree. on hinge 476
to the broken line position seen in FIG. 14C.
[0156] Supply manifold 428 can be secured in a pivoted position to
permit suction valve 424 to be easily serviced. To this end, a
second transverse aperture 486 is provided in mounting bracket 478
adjacent first transverse aperture 480 and a third transverse
aperture 488, positioned for registration with second aperture 486
when manifold 428 is in a pivoted position, is provided in swing
arm 484. Locking manifold 428 in the pivoted position is afforded
by extending a locking pin 490 through registered apertures 486 and
488.
[0157] Mounting bracket 478 is provided in the form of a loop or
ring to serve as a lifting eye for fluid end assembly 410. By
grasping bracket 478 with suitable lifting apparatus, assembly 410
can be elevated while mounted upon power end 434 or not. Thus,
assembly 410 can be safely and easily transported.
[0158] Suction valve 424 includes a funnel-shaped, valve seat 452
positioned in the bottom part 420a of suction passage 420. As
shown, seat 452 has an outside surface 453 that slopes downwardly
and inwardly at an angle of about 15.degree. relative to axis B'
and fits flush against bottom part 420a. A pair of O-ring seals 455
is inset into outside surface 453 to prevent fluid from leaking
around seat 452. Seat 452 also has an inside surface 457 that is
substantially parallel to outside surface 453 that channels flowing
fluid toward an opening of predetermined size in the bottom of seat
452 that serves as an orifice to regulate the rate of flow of
fluids through suction valve 424. The bottom surface 459 of seat
452 slopes upwardly and inwardly toward axis B' at an angle of
about 45.degree. and the top surface 461 of seat 452 is oriented at
right angles to axis B'. Around the inside of top surface 461, seat
452 is provided with a peripheral channel 463.
[0159] A valve guide 465 is positioned atop valve seat 452. Valve
guide 465 includes an outer ring 467 and an inner ring 469
connected together by a number of radial fins 471. Outer ring 467
fits snugly within peripheral channel 463 and extends upwardly
therefrom. Ring 467 has a circumferential flange 473 that projects
outwardly from the top thereof to engage top surface 461. A pair of
O-ring seals 475 is inset into the top and bottom of flange 473 to
prevent fluid leaks around ring. Ring 467 has a inside surface 477
that slopes downwardly and inwardly at a somewhat shallower angle
than inside surface 457 to direct fluid toward valve seat 452.
[0160] Inner ring 469 is centrally positioned within outer ring
467. Ring 469 has an interior surface 479 for slidably engaging the
stem 494 of a piston 458 and an exterior surface 481. Extending
outwardly from the bottom of exterior surface 481 is a radial
flange 483 that serves as an abutment for the top of a compressed
spring 500.
[0161] Inner ring 469 and outer ring 467 are connected together by
a number of fins 471 integrally formed therewith. Fins 471 radiate
outwardly from flange 483 at 120.degree. intervals and connect to
inside surface 481. Fins 471 are relatively thin and present a
minimal impediment to the flow of fluids through valve 424.
[0162] Piston 458 moves against valve seat 452 to control the flow
of fluid through suction passage 420. Piston 458 has a head 492 for
engaging seat 452 and a stem 494 extending upwardly from head 492
and through inner ring 469. A peripheral groove 485 is provided
around the free end of stem 494 for grasping piston 458 from the
exterior of fluid end assembly 410 during installation of valve
424. Another peripheral groove 487 is provided in stem 494 a short
distance below groove 485.
[0163] A valve keeper 496 is fitted over the top of stem 494 and
has a conical configuration. Keeper 496 is conical and has an
exterior diameter that decreases from its top to its bottom.
Extending outwardly from the top of keeper 496 is a peripheral rim
489 that serves as an abutment for the top of spring 500.
[0164] A recess 491 is provided in the top of keeper 496 for snugly
receiving split ring 498 that is fitted into groove 487 in stem
494. To ensure that split ring 498 does not slide from recess 491,
split ring 498 is outfitted with an inset O-ring 495. O-ring 495
serves as a safety feature to wedge keeper 496 and split ring 498
together even if spring 500 breaks thereby reducing the likelihood
that piston 458 will come loose during the use of valve 424 and
engage plunger 416.
[0165] Compressed spring 500 is positioned between flange 483 and
rim 489 for normally retaining head 492 in engagement with seat 452
to prevent fluid flow through passage 420. Spring 500 is, however,
resilient enough to permit the piston 458 to move away from seat
452 and permit the entry of fluid into pumping chamber 418 when
plunger 416 creates a partial vacuum in pumping chamber 418.
[0166] Externally helically threaded, valve retainer 466 is screwed
into top part 420b of suction passage 420 to retain the balance of
valve 424 within pump housing 412 and provide for the attachment of
valve 424 to manifold 428. Valve retainer 466 has a tapered inner
passageway 502 with a small-diameter, orifice portion 504 that
serves to maintain a fluid velocity through fluid end assembly 510
that is sufficient to prevent proppant from dropping from
suspension and preventing the normal operation of suction valve
424. Of course, the relatively large, outer diameter of valve
retainer 466 permits valve seat and guide assembly 452, piston 458,
spring 500, etc., to be accessed from the exterior of pump housing
412 (once manifold 428 is pivoted out of the way and retainer 466
is disengaged from housing 412) making servicing of suction valve
424 a breeze.
[0167] Pump housing 412 is substantially strengthened by helically
threading the entirety of the top part 420b of suction passage 420.
The coextensive threads on the exterior of valve retainer 466
distribute pressure loads evenly to the pump housing 412 inhibiting
the formation of cracks in the pump housing 412 at the bottom of
top part 420b adjacent seat deck 450.
[0168] Discharge valve 426 includes a funnel-shaped, valve seat 456
positioned in the top part 422a of discharge passage 422. Seat 456
has an outside surface 501 that slopes downwardly and outwardly at
an angle of about 15.degree. relative to axis C' and fits flush
against top part 422a. A pair of O-ring seals 503 is inset into
outside surface 501 to prevent fluid from leaking around seat 456.
Seat 456 also has an inside surface 505 that is substantially
parallel to axis C' that channels flowing fluid toward outlet
passage 430. The bottom surface 507 of seat 456 slopes upwardly and
inwardly toward axis C' at an angle of about 45.degree., and the
top surface 509 of seat 456 is rounded to receive pressurized fluid
from pumping chamber 41 8. Around the outside of bottom surface
507, seat 456 is provided with a peripheral channel 51 1.
Peripheral channel 51 1 has a depth sufficient to bring the bottom
of outside surface 501 flush with seat deck 454.
[0169] Valve 426 has a reciprocating piston 506 controlling the
flow of fluid through passage 422. Piston 506 has a head portion
508 for engaging bottom surface 507 and a hollow, stem portion 510
extending downwardly from head portion 508. A number of radial
apertures 518 penetrate the bottom of stem portion 510.
[0170] A valve guide 512 is positioned below piston 506 in passage
422. Valve guide 512 has a disk-like base plate 513 that fits
snugly into the middle portion 422b of discharge passage 422. A
guide rod 514 is affixed to, and projects upwardly from, the top of
base plate 513 into a longitudinal socket 516 provided in stem
portion 510 where rod 514 is slidably received. An internally
threaded socket 515 is affixed to, and projects downwardly from,
the bottom of base plate 513. Socket 515 is provided for grasping
valve guide 512 to remove it from pump housing 412 during the
servicing of valve 426.
[0171] The top of base plate 513 is provided with a recess 517 that
extends around the bottom of guide rod 514. Recess 517 extends
about half way into base plate 513 and receives the bottom of a
compressed spring 520. Recess 517 has a sloping side wall to
prevent the bunching of spring 520 when such is compressed by the
movement of piston 506.
[0172] A peripheral channel 519 is provided in the top of base
plate 513. Channel 519 is spaced outwardly from recess 517 and has
about one-half the depth thereof. The width of channel 519 is about
the same as its depth.
[0173] A pair of O-ring seals 521 is inset into the outside surface
523 of base plate 513. O-ring seals 521 are closely spaced and are
intended to prevent leaks from discharge passage 422 past valve
guide 512.
[0174] A valve retainer 522 keeps valve 426 within pump housing
412. Retainer 522 has an externally helically threaded plug 525
that is screwed into the bottom part 422c of passage 422. A
tightening stem 527 of hexagonal cross section is affixed to, and
projects downwardly from, the bottom of plug 525. A wrench (not
shown) grasps stem 527 so as to rotate retainer 522.
[0175] A compressed spring 520 is disposed between the valve guide
512 and head portion 508 to normally press head portion 508 into
engagement with seat 456. Spring 520 loosely encircles stem portion
510. Spring is seated, at its top end against the bottom of head
508 and at its bottom end, in recess 517.
[0176] Discharge valve 426 has a liner assembly 529, disposed
between valve seat 456 and valve guide 512, for minimizing the
erosion of the pump housing 412 by pressurized, abrasive,
proppant-bearing fluids. Liner assembly 529 has three parts: a
liner 531, a liner holder 533 that engages valve seat 456, and a
liner retainer 535 that engages valve guide 512. Together, the
parts of liner assembly 529 closely cover the center part 422b of
discharge passage 422. Furthermore, liner 531, liner holder 533 and
liner retainer 535 have a combined height and stiffness that is
sufficient to permit a firm, compressive force, generated by fully
screwing retainer 522 into part 422c, to be imparted to valve seat
456. Thus, valve seat 456 cannot wobble in part 422a since it is
wedged in place.
[0177] Liner 531 is a ring having an outer surface 537 of constant
diameter being slightly less than the diameter of part 422b and an
inner surface 539 that arcs inwardly at its top and bottom so as to
thicken and strengthen liner 531 in these areas. An aperture 541 is
provided in liner 531 for registration with connector passage 460.
Aperture 541 has the same diameter as connector passage 460 so as
to not impede flow into outlet passage 430.
[0178] Liner holder 533 is sized for snug positioning in peripheral
channel 511. Liner holder 533 has a top surface 543 and an inside
surface 545 that bear against valve seat 456. Liner holder 533 also
has a bottom surface 547 that bears against liner 531. A convex,
outside surface 549, having a radius of curvature that is less than
that of seat deck 454 so as to not contact seat deck 454, connects
top surface 543 to bottom surface 547. (By avoiding contact with
seat deck 454, no additional stress is imparted to seat deck 454 by
the addition of liner assembly 529 to fluid end assembly 410). A
medial surface 551 connects inside surface to bottom surface 547
and provides a smooth flow transition between bottom surface 507
and inner surface 539 of liner 531.
[0179] Liner retainer 535 has a ring portion 553 that is sized for
snug positioning in peripheral channel 519. A peripheral flange
portion 555 is affixed to, and projects outwardly from, the top of
ring portion 553. Flange portion 555 has a top surface 557 that
engages the bottom of liner 531. Ring portion 553 has a top surface
559 that slopes downwardly and inwardly from top surface 557 so as
to provide a smooth flow transition between liner 53 1 and the top
of base plate 513.
[0180] Plunger assembly 524 includes a pony rod adapter 526,
plunger 516 releasably attached to pony rod adapter 526, and a pony
rod 528 being releasably attached to pony rod adapter 526. Pony rod
adapter 526 has a first cylindrical body 530 and a number of
apertures 532 penetrating first cylindrical body 530. A first
helically threaded pin 534 is affixed to first cylindrical body 530
and projects from one of its ends. A second helically threaded pin
536 is affixed to first cylindrical body 530 and projects from the
other of its ends. Plunger 416 has a second cylindrical body 538
for reciprocating within a pumping chamber 418. Second cylindrical
body 538 has a first outer end with a first helically threaded bore
540 for threadably receiving first helically threaded pin 534.
Second cylindrical body 538 also has a first inner end with a
polygonal socket 542 for receiving a plunger key (not shown). Pony
rod 528 has a third cylindrical body 544 for reciprocating into,
and out of, power end 434. Third cylindrical body 544 has a second
inner end with a second helically threaded bore 546 for threadably
receiving second helically threaded pin 536. Third cylindrical body
544 also has a second outer end. A peripheral flange 548 is affixed
to, and extends outwardly from, the second outer end. Peripheral
flange 548 is provided with a number of holes 550 through which an
equal number of threaded fasteners (not shown) are extended for
connecting pony rod 528 to the reciprocating components of the
power end 434.
[0181] A number of radial holes 574 are provided around the outer
end of plunger 416 for engagement by a spanner wrench. The wrench
grasps plunger 416 at the holes 574 and applies torque and pulling
force as needed to remove plunger 416 from pump housing 412.
[0182] Fluid end assembly 410 produces useful work by pressurizing
fluid by means of the reciprocating action of plunger 416. Valves
424 and 426 permit fluid pressurized by plunger 416 to move only in
one direction from manifold 428 to outlet passage 430. The Y-shaped
configuration of bore 414 and passages 420 and 422 in addition to
the thick, tapered walls provided to plunger, suction and discharge
sections 432, 438 and 440 pump housing 412 with a construction that
is durable and not prone to fail under repeated cyclic loading
developed by plunger 416. Should plunger 416, valves 424 and 426,
packing unit 444 and gland nut 446, or plunger assembly 524 ever
require servicing, such are easy to repair or replace with ordinary
tools and without major disassembly of fluid end assembly 410.
[0183] While fluid end assemblies 410 and 10 have been described
with a high degree of particularity, it will be appreciated that
modifications can be made to them. For example, while operating
assemblies 410 and 10 with discharge valves 426 and 26 beneath
suction valves 424 and 24 is a good idea, especially in freezing
weather, since it permits the assemblies to be drained of fluid
with a few strokes of plungers 416 and 16, some users may elect to
operate assemblies 410 and 10 in an inverted fashion with discharge
valves 426 and 26 being positioned above suction valves 424 and 24.
Therefore, it is to be understood that this application is not
limited to fluid end assemblies 410 and 10, but encompasses any,
and all, fluid end assemblies within the scope of the claims. For
example, fluid ends in which the suction valve and discharge valve
share a common centerline, located one directly over the other.
[0184] Referring now to FIGS. 15 and 16 in the drawings, an
alternative embodiment of a fluid end assembly is illustrated.
Fluid end assembly 4012 is configured to provide increased
strength, durability, and fatigue resistance. Fluid end assembly
4012 has a suction valve positioned above a discharge valve so that
fluid flow through the fluid end is generally downward (valve over
valve configuration). The hydrostatic head of the pumped fluid in
the fluid end minimizes the likelihood of cavitation as the plunger
reciprocates and causes the fluid end assembly 4012 to operate with
decreased vibration. Furthermore, positioning the discharge valve
in a subordinate location permits the pump to be cleared of fluid
with a few strokes of the plunger and avoids the risk of cracking
the body of the fluid end should the pumped fluid freeze in cold
weather.
[0185] Fluid end assembly 4012 includes an access port for gaining
access to the inner end of the plunger and providing passage for
the suction valve seat during assembly or servicing of the fluid
end. A two-part plug having an inner, access pin and an outer,
retaining nut closes the access port. The access pin is provided
with a concavity at its inner end for receiving therein the inner
end of the plunger when the plunger reaches its innermost point of
travel into the body of the fluid end.
[0186] Fluid end 4012 has a body 4010 as shown. Body 4010 has a
horizontal, plunger passage 4014 that extends from its front to its
back. Body 4010 also has a horizontal, outlet passage 4016 that
extends from one of its sides to the other and that is positioned
beneath, and oriented at right angles to, plunger passage 4014. A
suction passage 4018 extends vertically downward from the top of
body 4010 to intersect plunger passage 4014 and to define a pumping
chamber 4020 at the point of intersection. A discharge passage 4022
extends vertically downward from pumping chamber 4020 to the bottom
of body 4010 and past outlet passage 4016, A horizontal, connector
passage 4024 places discharge passage 4022 and outlet passage 4016
in fluid communication with one another.
[0187] Body 4010 is a metallic block, a machined forging. To lower
its weight and increase its strength, body 4010 is provided with a
plunger section 4026 of reduced height that contains the outer end
of plunger passage 4014 and is adapted for attachment to the power
end of a high-pressure pump by a plurality of stay rods (not
shown). A suction section 4028, containing suction passage 4018, is
integrally formed with plunger section 4026 and extends forwardly
and upwardly from plunger section 4026. Likewise, a discharge
section 4030, containing discharge passage 4022, outlet passage
4016 and connector passage 4024, is integrally formed with plunger
section 4026 and suction section 4028 and extends forwardly and
downwardly from plunger section 4026. Suction section 4028 and
discharge section 4030 both taper from their inner ends to their
outer ends.
[0188] Plunger passage 4014 is provided along a first centerline A
extending through body 4010. At its back end, plunger passage 4014
is increased in diameter and is helically threaded at 4032 to
receive a compressible, packing unit 4034 and a correspondingly
helically threaded, gland nut 4036 that provide a fluid-tight seal
around a plunger assembly 4038 that reciprocates in plunger passage
4014. At its front end, plunger passage 4014 is similarly increased
in diameter and is helically threaded at 4040 to receive a
correspondingly helically threaded plug 4042. A plug deck or
shoulder 4044 is formed at the inner end of threaded portion 4040
that serves as a stop to prevent the continued inward movement of
plug 4042 into plunger passage 4014.
[0189] A small-diameter, lubricating port 4046 extends vertically
downward from the top of body 4010 to intersect the back end of
plunger passage 4014. More particularly, lubricating port 4046
passes through plunger section 4026 and connects with plunger
passage 4014 at the inner end of threads 4032. In use, port 4046
permits lubricating oil to flow to plunger assembly 4038 at a point
between packing unit 4034 and gland nut 4036.
[0190] Suction passage 4018 has a second centerline B that is
coplanar with centerline A and intersects centerline A at a
reference point Z in pumping chamber 4020 at right angles. Suction
passage 4018 extends from the top to the bottom of suction section
4028. Suction passage 4018 has a narrowed, middle part 4018a near
its midpoint that connects a helically threaded, top part 4018b to
a smooth-walled, bottom part 4018c. The bottom of middle part 4018a
defines a suction valve seat deck 4048. The top of middle part
4018a is a terraced surface that defines a suction valve retainer
deck 4050 and a somewhat smaller diameter, suction valve guide deck
4051. The innermost portions of decks 4048 and 4050, located
closest to centerline B, are oriented at right angles to centerline
B to reduce the likelihood of fatigue-induced cracks forming in
body 4010 at these locations. Thus, the top surface of seat deck
4048 is horizontal.
[0191] Discharge passage 4022 is centered on centerline B below
suction passage 4018 and intersects plunger passage 4014 at right
angles. Discharge passage 4022 has a tapered, top part 4022a of
generally small diameter, and a middle part 4022b of a somewhat
greater diameter, and a helically threaded, bottom part 4022c of
even greater diameter. The bottom of part 4022a forms a discharge
valve seat deck 4052. Similarly, the bottom of part 4022b forms a
discharge valve guide deck 4054. The innermost portions of decks
4052 and 4054, located closest to centerline B, are oriented at
right angles to centerline B to reduce the likelihood of
fatigue-induced cracks forming in body 4010 at these locations. The
top surface of seat deck 4052 is, thus, horizontal.
[0192] Reference point Z is placed on centerline A at a location
that facilitates the movement of fluid from suction passage 4018
through pumping chamber 4020 and into discharge passage 4022 while
plunger assembly 4038 reciprocates from its innermost point of
travel (its solid-line position to the right of point Z in FIGS.
16A and 16B) where it penetrates plug 4042 to its outermost point
of travel to the left of point Z. The crossing of centerlines A and
B at right angles reduces stresses within body 4010 during use and
reduces the likelihood of body 4010 cracking.
[0193] Outlet passage 4016 extends across discharge section 4030.
Connector passage 4024 intersects outlet passage 4016 at right
angles to place discharge passage 4022 in fluid communication with
outlet passage 4016. To either end of discharge section 4030 can be
connected one or more conduits (not shown) to carry pressurized
fluid away from outlet passage 4016 and fluid end 4012. This
pressurized fluid is used, in a typical operation, to fracture
subterranean rock formations. Placing outlet passage 4016 away from
a discharge valve 4056 in discharge passage 4022 limits the
transverse flow of fluid over the discharge valve 4056, especially
in triplex and quintuplex pumps where three or five sets of
passages, plungers and valves are provided in a given fluid end.
Discharge valve 4056, therefore, runs without interruption or
interference from jets of pumped fluids flowing through outlet
passage 4016 resulting in a smoother-running and more efficient
fluid end 4012.
[0194] Supply manifold 4058 delivers fluid to fluid end 4012
through suction passage 4018. Manifold 4058 includes a tubular body
4060 whose opposite ends are connected to a fluid source when fluid
end 4012 is operated. A tubular connector 4062 extends downwardly
from tubular body 4060 to engage the open top of valve retainer
4064 of a suction valve 4066 positioned in suction passage 4018.
The bottom of connector 4062 is provided with a peripheral slot
4068 and the top of valve retainer 4064 is provided with a similar,
peripheral slot 4070. Slots 4068 and 4070 accommodate a VICTAULIC
coupling body 4072 of well known construction for the quick and
easy connection of manifold 4058 to valve retainer 4064. Within
body 4072 is positioned a VICTAULIC rubber seal 4074 to prevent
fluid leaks from coupling body 4072.
[0195] To permit the easy servicing of suction valve 4066, one or
more hinges 4076 join manifold 4058 to pump body 4010. Each hinge
4076 has a mounting bracket 4078 secured by one or more threaded
fasteners (not shown) to body 4010. The inner end of a swing arm
4080 is pivotally attached by hinge pin 4082 to mounting bracket
4078. The outer end of swing arm 4080 is affixed to tubular body
4060. When VICTAULIC coupling body 4072 is removed from fluid end
4012, manifold 4058 is free to pivot 90.degree. on hinges 4076 to
the broken line position seen in FIG. 16A.
[0196] Suction valve 4066 includes tubular features that permit the
passage of fluids and support the action of other features. For
example, valve 4066 has a valve seat 4084 that, during its
installation in body 4010, is moved through pumping chamber 4020
and pressed into the bottom part 4018c of suction passage 4018
against seat deck 4048. A suction valve guide 4086 is located
immediately above valve seat 4084 and, during its installation in
body 4010, is moved downwardly through suction passage 4018 and
engaged with guide deck 4051. An externally helically threaded,
suction valve retainer 4088 is screwed downwardly into the
threaded, top part 4018b of suction passage 4018 until engaged with
retainer deck 4050. Valve retainer 4088 has a tapered inner
passageway 4090 with a small-diameter, orifice portion 4092 that
serves to maintain a fluid velocity through fluid end 4012 that is
sized to prevent a proppant from dropping out of suspension from a
pumped fluid in a manner that might clog suction valve 4066.
Neither seat 4084, nor guide 4086, nor retainer 4088 moves during
the normal operation of fluid end 4012.
[0197] Suction valve 4066 has moving features that act in concert
with seat 4084, guide 4086, and retainer 4088. A piston 4092
reciprocates within seat 4084 and has a head 4094 that engages seat
4084 to control the flow of fluid through suction passage 4018.
Piston 4092 also has and a stem 4096 that extends upwardly from
head 4094 through guide 4086. A valve keeper 4098 is fitted upon
the top of stem 4096 and is retained there by a split ring 4100. A
compressed spring 4102 is positioned between guide 4086 and keeper
4098 for normally retaining head 4094 in engagement with seat 4084.
Only when the fluid pressure in suction passage 4018 is higher than
that in pumping chamber 4020 will piston 4092 move against force of
spring 4102 to allow fluid to move through suction passage 4018
into pumping chamber 4020.
[0198] Discharge valve 4056 includes valve seat 4104 positioned in
top part 4022a of discharge passage 4022 and a reciprocating piston
4106 for controlling the flow of fluid through passage 4022. Piston
4106 has a head 4108 for engaging valve seat 4104 and a hollow,
tubular, stem 4110 extending downwardly from head 4108. A discharge
valve guide 4112 is positioned below piston 4106 in passage 4022
and has a guide rod 4114 that projects upwardly into a socket 4116
provided in stem 4110 where it is slidably received. A number of
radial apertures 4118 penetrate the bottom of stem 4110 to equalize
pressures between passage 4022 and socket 4116. A compressed spring
4120 is disposed between the valve guide 4112 and head 4108 to
normally press head 4108 into engagement with seat 4104. A
discharge valve retainer 4122 is screwed into the bottom part 4022c
of passage 4022 to retain valve 4056 within body 4010. When plunger
assembly 4038 is reciprocated to pressurize fluid in pumping
chamber 4020, that fluid flows through seat 4104, past head 4108,
and onward through discharge passage 4022. From discharge passage
4022, the pressurized fluid passes through connector passage 4024
into outlet passage 4016.
[0199] Plunger assembly 4038 includes: a pony rod adapter 4124,
plunger 4126 releasably attached to pony rod adapter 4124, and a
pony rod (not shown) releasably attached to pony rod adapter 4124.
Pony rod adapter 4124 has a first cylindrical body 4128 and a
number of apertures 4130 penetrating first cylindrical body 4128. A
first helically threaded pin 4132 is affixed to first cylindrical
body 4128 and projects from one of its ends. A second helically
threaded pin 4134 is affixed to first cylindrical body 4128 and
projects from the other of its ends. Plunger 4126 has a second
cylindrical body 4136 for reciprocating within plunger passage
4014. Second cylindrical body 4136 has a first outer end with a
first helically threaded bore 4138 for threadably receiving first
helically threaded pin 4132. Second cylindrical body 4136 also has
a first inner end with a polygonal socket 4140 for receiving a
plunger key (not shown) that can be used to unscrew plunger 4126
from pony rod adaptor 4124 or turn plunger 4126 to aid in its
removal from the outer end of plunger passage 4014.
[0200] The front end of plunger passage 4014 provides a port in
body 4010 for gaining access to pumping chamber 4020. This access
is necessary for inserting an elongated key (not shown) into socket
4140 in plunger 4126 for rotating and pushing plunger 4126 in the
event that repair or replacement of plunger 4126 is needed. Access
is also necessary to install or remove suction valve seat 4084 and
piston 4092; so, the front end of plunger passage 4014 is sized to
permit the movement of valve seat 4084 and piston 4092 through
it.
[0201] Two-part plug 4042 normally closes the front end of plunger
passage 4014. Plug 4042 includes an access pin 4142 and a retaining
nut 4144. Access pin 4142 has a rod portion 4146 that is sized to
slide snugly past plug deck 4044 and a peripheral flange portion
4148 located at the front end of rod portion 4146 that is
configured to abut plug deck 4044. Rod portion 4146 has three,
peripheral channels 4150 that receive O-ring seals 4152 therein to
prevent pumped fluids from leaking around rod portion 4146. The
front end of rod portion 4146 is provided with a concavity 4154 for
reducing the weight thereof. A helically threaded bore 4156 is
provided in rod portion 4146 at the center of concavity 4154 for
receiving a threaded tool (not shown) for grasping and pulling pin
4142 from passage 4014. The back end of rod portion 4146 is
provided with another concavity 4158 that receives the convex inner
end of plunger 4126 when plunger 4126 is moved to its deepest point
in plunger passage 4014 when reciprocated.
[0202] When screwed into threaded, outer portion 4040, nut 4144
presses pin 4142, and consequently rod portion 4146, inwardly with
flange 4148 tightly engaging a plug deck 4044. Nut 4144 has an
externally, helically threaded body 4160 that is screwed into
threaded portion 4040 and a hexagonal stem 4162 that projects
outwardly from threaded body 4160 that permits nut 4144 to be
turned by a wrench. A concavity 4164 is provided in the back end of
threaded body 4160 for reducing the weight of body 4160.
[0203] It is believed that a person having a basic knowledge of
high-pressure pumps would have no trouble making and using fluid
end 4012. Fluid end 4012 pressurizes fluids by the reciprocating
action of plunger assembly 4038 that draws fluids from suction
manifold 4058, through valve 4066, into pumping chamber 4020. From
pumping chamber 4020 the continuous reciprocation of plunger
assembly 4038 forces the fluids into discharge passage 4022,
through discharge valve 4056, and finally through passages 4024 and
4016. Valves 4066 and 4056 keep fluid moving in a downward
direction, working with gravity, through fluid end 4012, flushing
proppants and minimizing the likelihood of cavitation. Fluid
leaving fluid end 4012 through outlet passage 4016 can be used, in
an oilfield environment, to fracture subterranean rocks.
[0204] Maintaining fluid end 4012 is easy. Access to suction valve
4066 for servicing is accomplished by removing plug 4042 from
plunger passage 4014 and moving power end so that plunger 4126 is
withdrawn from pumping chamber 4020. Access to discharge valve 4056
is, likewise, accomplished by unscrewing retainer 4122 from
discharge 4022 and pulling the remainder of its components. The
replacement of body 4010 is rare since its configuration inhibits
the development of internal, stress fractures. The useful life of
fluid end 4012 is, therefore, believed to be greater than that
comparable fluid ends now in use.
[0205] While fluid end 4012 has been described with a high degree
of particularity, it will be appreciated by some that modifications
can be made to it. For example, the number and location of passages
4014, 4016, 4018, 4022 and 4024 as well as the features associated
therewith can be varied. Therefore, it is to be understood that the
features in this embodiment are not limited solely to fluid end
4010, but to any and all other fluid ends.
[0206] The fluid end assemblies described with respect to FIGS.
11-16 are configured to reduce and correct cracking and failure due
to metal fatigue in the pump system from continual high
pressurization & de-pressurization that occurs as the pump
reciprocates to displace liquid under pressure.
[0207] Plunger and Pony Rod Assemblies
[0208] Referring now to FIGS. 17-28 in the drawings, a plunger
assembly is illustrated. The plunger assembly is an alternate
embodiment of the plunger, pony rod, and pony rod adapter described
in FIGS. 11-14. A plunger 3010 and a pony rod adapter 3012 are
shown to be positioned within the pumping chamber 3014 of a fluid
end 3016. Fluid is drawn into chamber 3014 at low pressure through
a suction valve 3020 and is pushed from chamber 3014 via a
discharge valve 3018 at high pressure. The pressurization of the
fluid within chamber 3014 is caused by the movement of plunger 3010
into, and out of, the open end 3022 of chamber 3014 as directed by
a pony rod 3024 that projects from the power end 3026 of the pump
of which fluid end 3016 is a part. Pony rod 3024 is connected to
plunger 3010 by means of adapter 3012 and is reciprocated by a
drive mechanism (not shown) located within the power end 3026.
[0209] As plunger 3010 is moved into chamber 3014, the fluid
pressure within chamber 3014 is increased. At a predetermined
point, the fluid pressure is sufficient to open discharge valve
3018 to release fluid from chamber 3014 and into discharge passage
3028 from which fluid flows from fluid end 3016 at high pressure to
perform work. The amount of pressure needed to open discharge valve
3018 may be determined by a spring that keeps discharge valve 3018
closed until the threshold pressure is achieved in chamber
3014.
[0210] Plunger 3010 also creates low-pressure conditions in chamber
3014. When plunger 3010 is withdrawn from its forward-most position
in chamber 3014, the fluid pressure therein decreases. As the
pressure within the chamber 3014 decreases, discharge valve 3018
closes, sealing chamber 3014. Then, as plunger 3010 continues to
move out of chamber 3014, the fluid pressure therein continues to
drop to a point sufficient to open suction valve 3020. The opening
of suction valve 3020 allows fluid to flow into chamber 3014. The
amount of pressure required to open suction valve 3020 may be
determined by a spring that keeps suction valve 3020 closed until
the requisite low pressure is achieved in chamber 3014.
[0211] Plunger 3010 includes an elongated, cylindrical body 3030
adapted for reciprocation within chamber 3014. An enlarged bore
3032 is provided in the outer end of body 3030. Bore 3032 has a
helically threaded, outer portion 3034 for threaded engagement with
adapter 3012 and a non-threaded, inner portion 3036 for reducing
the reciprocating weight of plunger 3010. A socket 3038 is provided
in the convex, inner end of body 3030 and is axially aligned with
bore 3032 at the center of body 3030. Socket 3038 has a tapered,
outer part 3040 for guiding a plunger key (like an enlarged Allen
key, not shown) into a correspondingly shaped, medial part 3042 of
square outline. Medial part 3042 opens into a conical, inner part
3044 for aligning the tapered tip of a plunger key in socket
3038.
[0212] Although medial part 3042 of socket 3038 is shown to have a
square, polygonal outline, it can have any desired outline. That
outline, however, must correspond in terms of shape and size to
that of the plunger key so that plunger 3010 can be prevented from
rotating when adapter 3012 is turned for assembly or disassembly as
described below.
[0213] Pony rod adapter 3012 includes a cylindrical body 3046
having planar, abutment surfaces 3048 and 3050 at its opposite ends
for snug engagement with plunger 3010 and pony rod 3024,
respectively. Between surfaces 3048 and 3050, body 3046 is
penetrated by a number of apertures 3052, 3054 and 3056 spaced
around the perimeter thereof, like the hour indicators on the dial
of a clock, for selectively receiving a lever (not shown) for
turning adapter 3012 during installation of the plunger assembly. A
threaded pin 3058 projects from the center of abutment surface 3048
at the inner end of body 3046 for releasably fastening adapter 3012
to plunger 3010. Another threaded pin 3060 projects from the center
of abutment surface 3050 at the outer end of body 3046 for
releasably fastening adapter 3012 to pony rod 3024.
[0214] Body 3046 has three segments 3062, 3064 and 3066 with middle
segment 3062 joining inner segment 3064 to outer segment 3066. As
shown, middle segment 3062 has a constant outer diameter along its
length. Inner segment 3064, however, has a diameter that increases
evenly from its outer end proximate pony rod 3024 to its inner end
where it joins with middle segment 3062. Outer segment 3066 is
similarly provided with a diameter that increases evenly from its
outer end where it joins middle segment 3062 to its inner end
proximate plunger 3010. Body 3046, therefore, tapers, in stair step
fashion, from its inner end to its outer end so as to evenly
distribute loads between plunger 3010 and pony rod 3024 having a
relatively smaller diameter.
[0215] Apertures 3052 are provided in the outer segment 3066 of
body 3046. Apertures 3052 are provided in opposed pairs on inclined
axes A1 that intersect one another at the center of body 3046. Axes
A1 incline at an angle A of 30.degree. to a vertical line V1 that
also passes through the center of body 3046.
[0216] Apertures 3056 extend through both the middle segment 3062
and the inner segment 3064 of body 3046. Apertures 3056 are
provided in opposed pairs on axes A2 and A3 that intersect one
another at the center of body 3046. Axes A2 and A3 are oriented at
right angles to one another with axis A2 corresponding in position
to vertical line V1 of FIG. 21. One of apertures 3056 on axis A3
has a small diameter, inner portion 3068 that extends to the center
of body 3052 where it intersects with a longitudinal bore 3070 that
extends from the inner end of adapter 3012 to the outer end
thereof, fully through body 3046 and pins 3058 and 3060. Inner
portion 3068 and the associated bore 3056 serve to relieve the
build-up of air pressure when adapter 3012 is being connected to
plunger 3010 and pony rod 3024.
[0217] Apertures 3054 are positioned midway between apertures 3052
and apertures 3056 to maximize the strength of body 3046. Apertures
3054 extend through both the outer segment 3066 and the middle
segment 3062 of body 3046. Apertures 3054 are provided in opposed
pairs on inclined axes A4 that intersect one another at the center
of body 3046. Axes A4 incline at an angle A of 60.degree. to a
vertical line V2 that passes through the center of body 3046.
[0218] Threaded pins 3058 and 3060 have helical threads that can be
screwed, respectively, into tight engagement with threaded bore
3034 in plunger 3010 and a threaded bore 3072 provided in the inner
end of pony rod 3024. The helical threads on pins 3058 and 3060 are
the same size, but their configurations are mirror images. Thus,
pin 3058 has right-handed threads and pin 3060 has left-handed
threads that permit adapter 3012 to be simultaneously engaged to,
or disengaged from, plunger 3010 and pony rod 3024. This
double-action feature makes it a snap to replace a plunger 3010 in
the event that it becomes worn during use.
[0219] Body 3046 is provided with three holes 3074 that penetrate
abutment surface 3050. Holes 3074 are evenly spaced from one
another around threaded pin 3060 at 120.degree. intervals. Also,
holes 3074 have a depth that is substantially equal to their
diameter.
[0220] Body 3046 is provided with three holes 3076 that penetrate
abutment surface 3048. Holes 3076 are evenly spaced from one
another around threaded pin 3058 at 120.degree. intervals. (These
intervals are 60.degree. out of phase with those associated with
holes 3074). Also, holes 3076 have a depth that is substantially
equal to their diameter.
[0221] One of a number of locking pins 3078 is snugly fitted in
each of holes 3074 and 3076. Each of locking pins 3078 is formed of
nylon and projects slightly from its associated hole 3074 or 3076
when initially inserted therein as shown in FIG. 18. When adapter
3012 is fully rotated into threaded engagement with plunger 3010
and pony rod 3024, the outward projections of pins 3078 are
crushed, flattened and compressed into positions even with abutment
surfaces 3048 and 3050. In a compressed state, pins 3078 exert
outward pressure on the outer end of plunger 3010 and the inner end
of pony rod 3024 thereby inhibiting their unintended rotation,
locking adapter 3012 to plunger 3010 and pony rod 3024.
[0222] Pony rod 3024 includes an elongated, cylindrical body 3080
adapted for reciprocation into, and out of, power end 3026. A
helically threaded bore 3072 is provided in the inner end of body
3080 for threaded engagement with adapter 3012. An enlarged bore
3082 is provided in the outer end of body 3080 for reducing the
reciprocating weight of pony rod 3024. A peripheral flange 3084
extends outwardly from the outer end of body 3080 and is integrally
formed with body 3080. Flange 3084 is provided with a number of
holes 3086 through which threaded fasteners (not shown) are
extended to connect pony rod 3024 to the drive mechanism within
power end 3026.
[0223] As was noted above, the reciprocating motion of plunger 3010
within pumping chamber 3014 controls the fluid pressure therein.
Suction valve 3020 and discharge valve 3018 respond accordingly to
dispense pressurized fluid from chamber 3014, and eventually out of
fluid end 3016, at high pressure. The discharged fluid is, then,
replaced with fluid from suction valve 3020. Repeated motion of
plunger 3010 against packing elements 3088 that seal the open end
3022 of chamber 3014 often causes plunger 3010 to wear to the point
where its replacement is necessary.
[0224] To replace plunger 3010, the user must perform a few simple
steps. First, the power end 3026 of the pump is de-energized and,
by suitable movement of the drive mechanism, adapter 3012 is
positioned between the stay rods 3090 that connect the power end
3026 to the fluid end 3016. With adapter 3012 preferably located as
close to power end 3026 as possible (requiring leftward movement of
adapter 3012 from its starting position shown in FIG. 17), a lever
is inserted into a suitable one of apertures 3052, 3054 or 3056.
Now, access plug 3092, providing an entryway into chamber 3014 and
being axially aligned with socket 3038, is unscrewed from fluid end
3016, and a square-ended, plunger key is inserted through the
entryway into socket 3038 in plunger 3010. Next, while holding the
plunger key as still as possible, adapter 3012 is rotated by means
of the lever so as to simultaneously unscrew adapter 3012 from both
plunger 3010 and pony rod 3024. Then, by suitable manipulation,
adapter 3012 and plunger 3010 are removed from fluid end 3016. By
substituting a new plunger 3010 for the old one and reversing the
process steps noted above, the new plunger 3010 is made ready for
operation in fluid end 3016. The entire event requires just a few
minutes to complete.
[0225] It should be noted that although one plunger 3010 is shown
in the Figures, in embodiments where fluid end 3016 has a triplex
arrangement, the associated pump has three plungers 3010 with the
same or similar configurations. Similarly, with a quintiplex
arrangement, there are four plungers 3010. So, the number of
plungers 3010 employed in a pump is variable as is the amount of
time required for replacing the worn plungers 3010 of a pump.
Regardless, the time required is far less than has been possible
with any known plunger designs.
[0226] While plunger 3010, pony rod adapter 3012, and pony rod
3024, comprising the plunger assembly, have been described in great
detail, it will be appreciated by individuals having knowledge of
plunger-type pumps that modifications can be made to plunger 3010,
adapter 3012, and pony rod 3024. For example, FIG. 26 shows an
alternate plunger 3094. Plunger 3094 has an elongated, cylindrical
body 3096 adapted for reciprocation within chamber 3014. An
enlarged bore 3098 is provided in the outer end of body 3096. Bore
3098 has a helically threaded, outer portion 3100 for threaded
engagement with adapter 3012 and a non-threaded, inner portion 3102
for reducing the reciprocating weight of body 3096. Plunger 3094
has no socket like the one shown at 3038, but rather is provided
with twelve, radial holes 3104 penetrating body 3096 around outer
portion 3100. Holes 3104 permit plunger 3094 to be grasped by a
spanner wrench (not shown) extended between stay rods as shown at
3090 during the installation or removal of plunger 3094. Therefore,
it must be understood that these embodiments are not limited solely
to plunger 3010 and adapter 3012, but encompasses any, and all,
plungers and pony rod adapters within the scope of the
description.
[0227] Referring now also to FIGS. 29-37 in the drawings, an
alternative embodiment to the plunger assembly of FIGS. 11-14 and
17 is illustrated. The numerical identifiers referenced in this
section will refer to FIGS. 29-37 and to FIGS. 11-14. This plunger
assembly includes a dove-tail clamp assembly 201 in operation with
the pony rod and plunger. In particular, clamp assembly 201 is an
alternative embodiment of pony rod adapter 126, 526. Clamp assembly
201 is able to operate with assemblies 410 and 10 and any other
fluid end assembly as described previously. Clamp assembly 201 is
configured to operate similarly to that of pony rod adapters 126,
526 in that clamp assembly 201 couples plunger 16 and pony rod 128
together, so as to permit power end 34 to drive plunger 16 within
pump housing 12. Plunger 16 and pony rod 128, as well as the other
portions of assemblies 10 and 410, maintain the same form and
function as was described previously. Clamp assembly 201 includes a
clamp 203, 215 having two symmetric half portions, and a clamp
adapter stud 205. FIG. 29 illustrates a perspective view of one
embodiment of clamp assembly 201 coupled to plunger 16 and pony rod
128. Clamp assembly 201 in FIG. 29 is illustrated without the use
of a deflector 204, seen in FIG. 32. The purpose and function of
deflector 204 within clamp assembly 201 will be described
below.
[0228] Pump housing 12 is a steel block adapted for attachment to
the power end of a high-pressure pump 34 by a number of stay rods
36. Stay rods 36 maintain the relative distance between pump 34 and
housing 12. Conventional fluid ends have typically provided an
aperture in the pump housing, opposite the power end, that permits
plunger 16 to be removed from the assembly by passing through the
fluid end, away from the power end. With fluid ends 10 and 410, the
suction valves and discharge valves are aligned such that the
aperture is not available. Therefore, removal of plunger 16 occurs
in the present application by translating plunger 16 toward pump
34. The space between pump 34 and fluid end 10, 410 is fixed. It is
understood that plungers 16 may be modified in length and diameter
to accommodate removal from the fluid end.
[0229] Referring in particular to FIG. 30, a partial section view
of plunger 16 and pony rod 128 is illustrated. Clamp assembly 201
is configured to operate with conventional plungers and pony rods
of various fluid end assemblies. As noted previously, pony rod 128
includes a helically threaded bore 146 on the second inner end.
Likewise, plunger 16 includes a helically threaded bore 140 on a
first end. Pony rod adapter 126, 526 threadedly coupled to each
part through corresponding helically threaded bores 140, 146.
[0230] Pony rod 128 has an abutment surface 208 relatively
perpendicular to centerline A, located at the second inner end.
Similarly, plunger 16 has an abutment surface 210 located in the
first outer end, oriented relatively perpendicular to centerline
A.
[0231] Referring in particular to FIG. 31, clamp assembly 201
further includes clamp adapter studs 205 configured to threadedly
engage respective helically threaded bores 140, 146 in place of
pins 134, 136 of pony rod adapter 126. Stud 205 includes a threaded
portion 207a, a seat portion 207b, and a flange portion 207c. Studs
205 are sized in diameter and threaded to engage bores 140, 146 of
varied sizes. In so doing, clamp assembly 201 is configured to
function as a retrofit to existing conventional fluid end systems.
It is understood that all members of clamp assembly 201 may be
sized differently to accommodate a range of fluid end assemblies
and power ends.
[0232] Threaded portion 207a includes threads for engaging bore
140, 146. Stud 205 has a central axis 206 that is coaxial with
centerline A when in threaded engagement with bores 140, 146. Seat
portion 207b is adjacent thread portion 207a. The outer surface of
seat portion 207b is relatively smooth for mating with plunger 16
or pony rod 128. Seat portion 207b is recessed within plunger 16 or
pony rod 128 when stud 205 is secured by interference fit via
thread portion 207a. Flange portion 207c is adjacent seat portion
207b. Flange portion 207c includes a flange 211 and a groove 213.
Groove 213 is formed by the contour of the flange surface as flange
211 extends externally away from seat potion 207b, away from
central axis 206. Flange 211 extends radially around central axis
206 forming the relatively bulbous flange shape. When stud 205 is
engaged in bores 140, 146, stud 205 is configured to extend away
from abutment surfaces 208 and/or 210. In this embodiment, flange
211 extends over abutment surfaces 208 and/or 210 so as to form
groove 213. Clamp 203 is configured to contact the groove surface
between flange 211 and abutment surface 208 and/or 210 in a
non-threaded relationship with studs 205. As discussed later, by
engaging the groove surface, clamp 203 couples plunger 16 and pony
rod 128 together without concern for debris-filled threads and the
need to constantly tighten connections.
[0233] Although flange 211 has been described having a radially
extending bulbous shape, it is understood that other shapes are
possible. Furthermore, other embodiments may have one or more
flanges or ribbed surfaces permitting engagement of clamp 203. The
present application conceives of the use of one or more flanges 211
or ribs protruding from abutment surface 208/210 for clamp 203 to
clamp around.
[0234] A setting aperture 214 is formed within flange portion 207c
relatively perpendicular to a flange face 216. Aperture 214 is set
within flange 211a set distance. Setting aperture 214 has an axis
218. Axis 218 is offset from and parallel with central axis 206.
Setting aperture 214 is configured to permit stud 205 to be
tightened and loosened within bores 140, 146. Although described as
extending within flange portion 207c, it is understood that
aperture 214 may extend any distance within stud 205.
[0235] Stud 205 also includes a stud bore 237. Stud bore 237 is an
aperture formed within stud 205 similar to that of aperture 214.
Bore 237 extends internally within stud 205 from flange face 216.
Bore 237 is coaxially aligned with central axis 206. To threadedly
engage stud 205 within bores 140, 146, a setting tool (not shown)
is inserted into both a stud bore 237 and setting aperture 214 and
rotated, so as to apply a torque in either a clockwise or
counterclockwise direction about central axis 206. Rotation of stud
205 engages or releases threaded portion 207a from bores 140,
146.
[0236] Referring now also to FIGS. 32 and 33 in the drawings, a
clamp 215 is illustrated. Clamp 215 is another embodiment of clamp
203. Clamp 203 and 215 operate in a similar form and function
except that clamp 215 is illustrated as having deflector 204
integral within each portion. Description of the functions and form
of clamp 215 will apply equally to that of clamp 203 except with
regard to deflector 204.
[0237] Clamp 215 has a first portion 215a and a second portion
215b. A central axis 217 extends along the center of clamp 215
coaxial with a central bore 219. Central axis 217 is configured to
coaxially align with centerline A when clamp 215 is secured around
studs 205. Clamp 215 includes a plunger end 226 and a pony rod end
228. A cavity 224 is formed in each end 226, 228 of clamp 215.
Cavity 224 is formed internally within clamp 215 and includes a
cavity face 230. Cavity 224 is configured to accept flange portion
207c of studs 205. When assembled, clamp 215 surrounds flange
portion 207c, thereby coupling plunger 16 and pony rod 128
together. Furthermore, when clamp 215 is assembled, clamp 215
operates to conceal internal components of clamp assembly 201,
namely stud 205 and an alignment pin 231 (see FIG. 34).Clamp 215 is
fastened together by use of one or more fasteners (not shown)
through a fastener aperture 225.
[0238] It is understood that each portion 215a and 216b include
some of the same features of clamp 215 as a whole. When describing
features of clamp 215 with respect to each portion 215a and 215b,
the respective reference letters "a" and "b" will be used to denote
the features as seen on each portion 215a and 215b
respectively.
[0239] Each portion 215a and 215b have a mating surface 227a, 227b
that defines a plane running parallel with centerline A and/or axis
217. First portion 215a and second portion 215b contact one another
along each mating surface 227a, 227b. Clamp 215 is symmetric about
the plane defined by the mating surfaces. Being that first portion
215a and second portion 215b are symmetric about mating surface
227, discussion will be given concerning the features and functions
of first portion 215a with the understanding that second portion
215b will have the same features and functions. It is also
understood that the features and functions of clamp 215 apply
equally to that of clamp 203.
[0240] Each portion 215a, 215b included half of cavity 224, lip 223
and recess 221 at both end 226, 228. Cavity 224a extends from
mating surface 227a, radially outward from axis 217. Pony rod end
228 has an exterior face 229 and plunger end 226 has a exterior
face 222. Exterior faces 229a, 229b wrap around and fold over both
cavities 224a so as to form lip 223a at each end 226, 228. Cavity
224a is defined as the area bound by a cavity face 230a and a plane
defined by the exterior faces. A recess 221a is formed within
cavity 224a, being defined by the area between lip 223a and cavity
face 230a.
[0241] In operation, plunger 16 and pony rod 128 are spaced apart a
designated distance. The distance, as measured between flanges 211
of studs 205 within plunger 16 and pony rod 128, coincides with the
distance between recesses 221 on opposing ends of each clamp
portion 215a, 215b. Mating surface 227a, 227b of each clamp portion
215a, 215b are brought into contact. When in contact, flange 211 is
engaged within recess 221 and groove 213 receives lip 223 for studs
205 associated with plunger 16 and pony rod 128 (non-threaded
relationship). Fasteners are inserted into apertures 225 to couple
clamp portions 215a and 215b together. Threaded fasteners are
preferably used but other types of fasteners are possible. Although
portion 215a was described above, the same form and features are
associated with respect to portion 215b due to the symmetric nature
of clamp 215.
[0242] While clamp 215 is installed about studs 205, exterior face
229, 222 is adjacent abutment surfaces 208, 210 respectively.
Exterior faces 229, 222 are configured to permit a small gap of
space between it and each abutment surfaces 208, 210. This avoids
issues with binding and assists in permitting easier removal of
clamp 215, 203.
[0243] Referring now also to FIG. 34 in the drawings, an alignment
pin 231 is illustrated. During installation of clamp 215, 203, each
clamp portion 215a, 215b is to be aligned with respect to
centerline A. Clamp assembly 201 may include the use of alignment
pin 231. Alignment pin 231 is configured to serve as an optional
tool to assist in the alignment of each clamp portion 215a, 215b
with respect to each stud 205. Alignment pin 231 has a center
portion 233 of cylindrical shape and opposing end portions 235a and
235b integrally coupled to center portion 233. End portion 235a is
inserted into stud bores 237 located respectively within stud 205
used with pony rod 128 and plunger 16. Central bore 219 is
configured to contact the outer surface of center portion 233.
Center portion 233 and each end portion is coaxially aligned with
centerline A. It is understood that alignment pin 231 is optionally
used with clamp assembly 201.
[0244] Referring now also to FIG. 35 in the drawings, a cross
sectional view of studs 205 set within plunger 16 and pony rod 128.
Studs 205 are included within clamp assembly 201 to allow for
retrofit capabilities with plungers and pony rods having threaded
bores 140, 146.
[0245] Referring now also to FIGS. 36 and 37 in the drawings, an
alternative embodiment of clamp assembly 201 is illustrated. Clamp
assembly 240 is an alternate embodiment of clamp assembly 201 and
includes similar forms and functions to that of assembly 201 except
as described herein. Clamp assembly 240 includes a plunger 241, a
pony rod 243, and clamps 203, 215. Assembly 240 continues to
include the use of clamps 203 or 215. However, in assembly 240,
studs 205 are removed and a flange portion 245 is integrally formed
into the abutment surfaces of plunger 16 and pony rod 128, thereby
forming plunger 245 and pony rod 243. The form and functions of
plunger 241 and pony rod 243 are similar to those described
previously with respect to assembly 201.
[0246] Flange portions 245 extend from an abutment surface 246a of
plunger 241 and abutment surface 246b of pony rod 243. Each flange
portion 245 includes a respective flange and groove similar in form
and function to that of stud 205. In such an embodiment, no setting
aperture 214 is required due to the integral nature of flange
portion 245. A stud bore 247 is located within plunger 241 and pony
rod 243, having similar form and function to that of stud bore 237.
Stud bore 247 is configured to optionally accept the use of
alignment pin 231 when used.
[0247] Clamp assembly 201 is depicted in FIG. 29 without the use of
a deflector 204. In FIG. 32, clamp portions 215a and 215b are shown
as having integrally formed deflectors 204. Clamp assembly 201
optionally includes a deflector 204. Deflector 204 may be
integrally formed with clamp assembly 201, as seen with clamp 215;
or may be a separate member of clamp assembly 201, as seen with
clamp 203. Deflector 204 is typically located adjacent the
intersection of clamp 215, 203 and pony rod 128, 243. To aid in the
removal of plunger 16, 241, the length of plunger 16, 241 is
typically minimized as much as possible as a result of having to be
removed between the fluid end and power end. In so doing, clamp
assembly 201 and/or pony rod adapter 126, 526 are configured to
translate within fluid end assembly 10 as pony rod 128 cycles
between an extended and retracted position. To avoid contact
between deflector 204 and pump housing 12, deflector 204 is located
more toward pony rod 128, 243. Other locations may be used
depending on whether deflector 204 is integral with clamp 215, 203
or a separate member.
[0248] Seals around rotatable gland nut 46 are susceptible to
failure over time. When the seals fail, a pressurized stream of
fluid can escape from pumping chamber 18 and cause damage to pump
34 or other members. Deflector 204 is configured to include an
angled surface 247 to deflect any streams of escaped fluid.
Deflector 204 thereby is used as a sacrificial part, adapted to
receive the fluid stream as opposed to pump 34. Deflector 204 is
easier to replace and has a drastically reduced price compared to
pump 34. An additional feature of deflector 204 is that the
pressurized stream of fluid is deflected away from centerline A at
some angle thereby making the stream more easily detected to
operators. Once detected, gland nut 46 can be repaired prior to any
significant damage occurring.
[0249] The plunger assemblies described with respect to FIGS. 17-37
are configured to reduce and correct the improper and laborious
maintenance of a pump system by improving access and simplifying
the configurations. Additionally, the plunger assemblies of FIGS.
17-37 are configured to reduce and correct the improper operation
of the pump system.
[0250] Valves and Seal Inserts
[0251] Referring now to FIGS. 38-40 in the drawings, an alternative
embodiment of a suction valve is illustrated. Suction valve 5010 is
similar in form and function to suction valves 20 and 420 described
in FIGS. 12C and 13C respectively. Suction valve 5010 is configured
to minimize the likelihood of proppant being knocked out of
suspension. Suction valve 5010 permits fracture fluids with higher
than normal concentrations of suspended proppants to be pumped with
substantial cost savings accruing to the user. Suction valve 5010
can be seated in a shallow suction passage in a fluid end, thereby
resulting in less metal to be removed from the body of the fluid
end at the time of manufacture. Additionally, suction valve 5010 is
configured to be lightweight in construction, inexpensive to
manufacture, and dependable in use.
[0252] Suction valve 5010 includes a valve seat and guide assembly
5012 for positioning in a suction passage 5014 of a fluid end 5016
and a piston 5018 that moves within assembly 5012 to control the
flow of fluid through passage 5014. Piston 5018 has a head 5020 for
engaging the seat portion 5022 of assembly 5012 and a stem 5024
extending downwardly from head 5020 through the guide portion 5026
of assembly 5012. A valve keeper 5028 is fitted upon the bottom of
stem 5024 and is retained there by a split ring 5030. A compressed
spring 5032 is positioned between guide portion 5026 and keeper
5028 for normally retaining head 5020 in engagement with seat
portion 5022 to prevent fluid flow through passage 5014. A valve
retainer 5034 is screwed into suction passage 5014 to retain the
balance of valve 5010 within fluid end 5016 and provide for the
attachment of valve 5010 to a suction manifold (not shown).
[0253] Seat portion 5022 comprises an outer ring 5036 that fits
snugly within the narrowed, unthreaded, upper part 5014u of passage
5014. The height of outer ring 5036 is sufficient to place the top
of the top surface 5038 thereof flush with the sides of a pumping
chamber 5040 in fluid end 5016. Seat portion 5022 also includes a
peripheral flange 5042 that is integrally formed with outer ring
5036 and projects outwardly from the bottom of outer ring 5036 so
as to rest upon a shoulder or seat deck 5044 where the wide,
internally threaded, lower part 5141 of passage 5014 meets upper
part 5014u.
[0254] Outer ring 5036 has an outer surface 5046 that slopes
upwardly an inwardly at a shallow angle corresponding in slope with
upper part 5014u of passage 5014. A number of peripheral channels
5048, 5050, and 5052 are provided around outer surface 5046 at
spaced-apart intervals. Within channels 5048, 5050 and 5052 are
positioned o-ring seals 5054, 5056 and 5059, respectively. Tapering
outer surface 5046, as described, prolongs the life of seals 5054
and 5056 as well as reduces the likelihood of fatigue cracks
forming in fluid end 5016, a problem encountered in "old style"
fluid ends where valve seats pressed outwardly on the sides of
pumping chambers during pressurizing plunger strokes.
[0255] Outer ring 5036 has an inner surface 5058 that is shaped to
reduce turbulence in fluid moving through valve 5010. Inner surface
5058 has a top part 5058t that is beveled such that it slopes
downwardly and inwardly toward the center of seat portion 5022 at
an angle of about 36.degree., an angle that can be increased as a
matter of design choice to optimize the action of valve 5010. Inner
surface 5058 also has a bottom part 5058b that slopes upwardly and
inwardly at a steeper incline, say 74.degree.. Connecting bottom
part 5058b and top part 5058t together, inner surface 5058 has a
medial part 5058m that slopes upwardly and inwardly at an
inclination that is about 10.degree. less than that of bottom part
5058b. Thus, inner surface 58 is "stepped" to funnel fluids through
a narrowed neck 5060 in seat portion 5022 at the junction of the
top part 5058t and medial part 5058m with minimal pressure
losses.
[0256] Peripheral flange 5042 extends outwardly from the bottom of
outer ring 5036 at right angles. The top of flange 5042 snugly
engages seat deck 5044 thereby ensuring a strong platform for
assembly 5012. To ensure against fluid leaks around seat deck 5044,
the bottom of flange 5042 is provided with a peripheral groove 5062
that receives an o-ring seal 5064 for engaging valve retainer
5034.
[0257] Guide portion 5026 includes an inner ring 5066 that slidably
receives stem 5024 of piston 5018. Inner ring 5066 has an interior
wall 5068 for engaging stem 5024 and an opposed exterior wall 5070.
Exterior wall 5070 has an upper part 5070u and a lower part 5070l
of smaller diameter and substantially equal height. A shoulder 5072
is provided at the junction of the upper and lower parts 5070u and
5070l that serves as an abutment for the top of spring 5032. Upper
part 5070u is positioned within seat portion 5022 adjacent flange
5042 and tapers upwardly and inwardly so as to reduce turbulence in
a fluid flowing through guide portion 5026. Lower part 5070l
projects outwardly from the bottom of seat portion 5022.
[0258] Inner ring 5066 and outer ring 5036 are connected together
by three, vertically oriented fins 5074. Fins 5074 radiate
outwardly from upper part 5070u of exterior wall 5070 of inner ring
5066 at 120.degree. intervals to join bottom part 5058b of outer
ring 5036. Fins 5074 are taller than they are wide to best
withstand axial loads. Also, fins 5074 are horizontally oriented
for minimum weight and maximum strength. Rings 5066 and 5036 and
fins 5074 present minimal impediments to fluid flow through
assembly 5012 and permit valve 5010 to handle fluids with higher
proppant concentrations than normal.
[0259] The top of head 5020 is provided with a shallow recess 5076
such that it resembles a bowl. Recess 5076 reduces the mass of
piston 5018 thereby permitting piston 5018 to reciprocate at
greater speeds and minimize the leakage of fluids through valve
5010. Furthermore, recess 5076 serves to admit the free end of a
reciprocating plunger (not shown) within fluid end 5016 so as to
allow the length and volume of pumping chamber 5040 to be
minimized.
[0260] Head 5020 has a beveled, peripheral edge 5078 that is
adapted to snugly engage top part 5058t of seat portion 5022.
Extending around edge 5078 is an insert 5080, formed of a durable
material, which serves as sealing element for valve 5010. Insert
5080 has a back edge 5082 that is circular in cross section so as
to "snap fit" into a correspondingly shaped recess 5084 around head
5020. Back edge 5082 is easy to press into head 5020 at the time of
manufacture and has little tendency to loosen during use.
[0261] Stem 5024 has a spherical knob 5086 at its bottom end. As
shown, the diameter of knob 5086 is smaller than the diameter of
stem 5024 to easily fit through inner ring 5066. Knob 5086 is
employed to grip piston 5018 during valve servicing operations.
[0262] Above knob 5086, stem 5024 is provided with a peripheral
groove 5088. Groove 5088 has a top surface 5088t, a bottom surface
5088b, and a medial surface 5088m that connects top surface 5088t
and bottom surface 5088b together. Top surface 5088t slopes
outwardly and downwardly at an angle of 5.degree. so as to
positively grip correspondingly shaped split ring 5030 and keep
split ring 5030 from springing outwards during use of valve 5010.
Bottom surface 5088b is horizontally oriented and medial surface
5088m is vertically oriented to permit the easy installation of
split ring 5030.
[0263] Valve keeper 5028 is fitted over the bottom of stem 5024 and
has a conical configuration. Keeper 5028 has an exterior diameter
that increases gradually from its top, where it has the same
diameter as exterior wall 5070l of inner ring 5066, to its bottom.
Extending outwardly from the bottom of keeper 5028 is a peripheral
rim 5090 that serves as an abutment for the bottom of spring
5032.
[0264] A recess 5092 is provided in the bottom of keeper 5028 for
snugly receiving split ring 5030 that is fitted into groove 5088 in
stem 5024. To ensure that split ring 5030 does not slide from
recess 5092, split ring 5030 is provided with a peripheral groove
5094 at its midpoint into which is fitted an o-ring 5096. O-ring
5096 serves as a safety feature to wedge valve keeper 5028 and
split ring 5030 together even if spring 5032 breaks thereby
reducing the likelihood that piston 5018 will come altogether loose
during the use of valve 5010.
[0265] Valve retainer 5034 is segmented, hollow, and cylindrical.
The upper segment 5034u of retainer 5034 is provided with external,
helical threads 5098 that screw tightly into correspondingly
machined threads around lower part 5141 of passage 5014.
[0266] Valve retainer 5034 has a middle segment 5034m that is
integrally formed at the bottom of upper segment 5034u. As shown,
middle segment 5034m has a polygonal cross section with six,
principal, external faces 5100 separated by six, secondary,
external faces 5102 hexagonally arranged. Faces 5100 can be gripped
by a wrench for rotating valve retainer 5034 to unscrew threads
5098 from those of passage 5014 during the installing and servicing
of valve 5010.
[0267] Valve retainer 5034 has a bottom segment 5034b that is
integrally formed at the bottom of middle segment 5034m. Bottom
segment 5034b is circular in cross section and has a peripheral
slot 5104 around the middle thereof. Slot 5104 accommodates a
VICTAULIC coupling (not shown) for the quick and easy connection of
valve retainer 5034 to a suction manifold that delivers fluid to
valve 5010.
[0268] Valve retainer 5034 has a segmented passageway 5106 that
conveys fluid through segments 5034u, 5034m, and 5034b into
assembly 5012. The uppermost fraction of passageway 5106 extends
downwardly from the top of upper segment 5034u and acts as a recess
for snugly receiving flange 5042 of assembly 5012. The uppermost
fraction of passageway 5106 is defined by a circular, side wall
5108 that closely accommodates the periphery of flange 5042 and a
flat, top wall 5110 that projects inwardly from side wall 5108 to
engage the bottom of flange 5042. A middle fraction of passageway
5106 provides an annular flow space around valve keeper 5028 below
the uppermost fraction. The middle fraction, thus, bulges around
valve keeper 5028 with a cascade of five walls 5112-5120. First
wall 5112 extends vertically downward from the inner edge of top
wall 5110. Second wall 5114 slopes downwardly and outwardly from
the bottom of first wall 5112. Third wall 5116 extends vertically
downward from the bottom of second wall 5114. Fourth wall 5118
slopes downwardly and inwardly from the bottom of third wall 5116.
Fifth wall 5120 extends vertically downward from the bottom of
fourth wall 5118. (Fifth wall 5120, being small in diameter and
near the fluid entry into valve 5010, is a narrowed neck that
limits the amount of fluid entering valve 5010 and increases the
velocity of that fluid. By properly sizing the diameter of wall
5120, a user of valve 5010 can establish a jetting action for
fluids passing through valve 5010 that drives any proppant that may
collect in, or around, keeper 5028 into the flow stream and from
valve 5010). The lowermost fraction of passageway 5106 is defined
by a tapered, bottom wall 5122 that slopes upwardly and inwardly
from the bottom of bottom segment 5034b and joins, at its top, the
bottom of fifth wall 5120.
[0269] The assembly, installation, and use of valve 5010 are
straightforward. To assemble valve 5010, insert 5080 is first
positioned in recess 5084 in piston 5020. Then, stem 5024 is
extended through inner ring 5066 of assembly 5012. Next, spring
5032, keeper 5028, and split ring 5030 (with o-ring 5096 attached)
are, in turn, positioned over stem 5024. Now, by compressing spring
5032 against shoulder 5072 of inner ring 5066 with keeper 5028,
split ring 5030 is worked into peripheral groove 5088. Afterward,
the assembled portion of valve 5010 is slid into the upper portion
5014u of passage 5014 in fluid end 5016. At this point, valve
keeper 5028 is screwed into lower portion 5141 of passage 5014 by
means of a wrench gripping external faces 5100 of valve retainer
5034. Finally, VICTAULIC clamps (not shown) are employed to connect
valve 5010 at slot 5104 to a suction manifold associated with fluid
end 5016. Valve 5010 is ready for use after a few minutes work.
[0270] After installation of valve 5010 in fluid end 5016, a
plunger (not shown) is reciprocated above head 5020. As the plunger
moves forward to drive fluid from its cylinder, peripheral edge
5078 of head 5020 is snugly pressed under the influence of spring
5032 against top surface 5058t of seat portion 5022 ensuring that
no fluid leaks through passage 5014. When the plunger travels back
to its starting point, a partial vacuum is created that lifts
piston 5018 against the compressive force of spring 5032 and draws
fluid upwardly through passageway 5106 and valve 5010. The process
of opening and closing valve 5010 is entirely automatic and
requires mere fractions of a second to accomplish. Since the valve
5010 minimizes turbulent flow, proppant is not captured by valve
5010 to block flow through assembly 5012 or retainer 5034 under
normal conditions of use.
[0271] While suction valve 5010 has been described with a high
degree of particularity, it will be appreciated by those skilled in
the art that modifications can be made to it. Therefore, it is to
be understood that valve 5010 encompasses any and all valve
embodiments within the scope of the present application.
[0272] Referring now to FIGS. 41 and 42 in the drawings, an
alternative embodiment of a discharge valve is illustrated.
Discharge valve 6010 features a valve seat and a valve guide
disposed above the valve seat. The valve guide has a discharge
passage plug and a guide rod that is affixed to, and projects
downwardly from, the bottom of the plug. The valve guide also has
an interiorly threaded, lifting sleeve that is affixed to, and
projects upwardly from, the top of the plug. A piston is disposed
between the valve seat and the valve guide. The piston has a head
portion for engaging the top of the valve seat, and a stem portion
that is affixed to, and extends upwardly from, the head portion.
The stem portion has a longitudinal socket within which the guide
rod is slidably received. The stem portion also has a number of
apertures that intersect the socket for providing pressure relief
to the socket. A compressed spring is disposed between the valve
guide and the head portion of the piston for normally retaining the
head portion in engagement with the valve seat. An externally
threaded, valve retainer is disposed above the valve guide for
pressing the valve guide toward the valve seat.
[0273] Discharge valve 6010 is configured to reduce the likelihood
of proppant blockages by offering few impediments to fluid flow so
that fracturing fluids can flow through it with minimum turbulence.
As a result, fracturing fluids with higher than normal
concentrations of suspended proppants can be pumped. Furthermore,
discharge valve 6010 can be seated in a shallow pocket in a fluid
end of a pump. A shallow pocket requires that less load-bearing
material be removed from the fluid end at the time of its
manufacture thereby increasing the strength and durability of a
fluid end. It is less likely, then, that a fluid end configured to
receive discharge valve 6010 will fail from the development of
stress cracks.
[0274] Discharge valve 6010 features a "male" valve guide upon
which a piston rides. The valve guide carries the piston to a valve
seat so as to close the discharge valve with great precision and
minimal wobble that, if present, could induce vibrations in the
pump within which the discharge valve is mounted. Additionally,
discharge valve 6010 features a ported piston that permits the
piston to slide freely on the valve guide and reduces the
likelihood that discharge valve 6010 will become stuck "open" or
"closed" so as to permit valve leakage. Discharge valve is
configured to remain lightweight in construction, inexpensive to
manufacture, and fully dependable in use.
[0275] Discharge valve 6010 includes a valve seat 6012 for
positioning in the bottom of a discharge passage 6014 of a fluid
end 6016 and a reciprocating piston 6018 for controlling the flow
of fluid through passage 6014. Piston 6018 has a head portion 6020
for engaging valve seat 6012 and a hollow, stem portion 6024
extending upwardly from head portion 6020. A valve guide 6026 is
positioned above piston 6018 in passage 6014 and has a guide rod
6028 that projects downwardly into a longitudinal socket 6030
provided in stem portion 6024 where it is slidably received. A
number of radial apertures 6032 penetrate the bottom of stem
portion 6024 equalize pressures between passage 6014 and socket
6030. A compressed spring 6034 is disposed between the valve guide
6026 and head portion 6020 to normally press head portion 6020 into
engagement with seat 6012. A valve retainer 6036 is screwed into
the top of passage 6014 to retain valve 6010 within fluid end
6016.
[0276] Valve seat 6012 is a hollow cylinder with an inner wall 6038
that is shaped to minimize turbulent flow. Wall 6038 has a top part
6038t that slopes downwardly and inwardly toward the center of seat
6012 at an angle of about 36.degree.. Wall 6038 also has a bottom
part 6038b that slopes upwardly and inwardly at an incline that is
substantially equal to that of top part 6038t. Finally, wall 6038
has a substantially vertical, middle part 6038m that connects the
bottom of top part 6038t to the top of bottom part 6038b.
[0277] Valve seat 6012 has an outer wall 6040 that snugly engages
the sides of passage 6014. Outer wall 6040 slopes downwardly an
inwardly at a shallow angle corresponding in slope with a taper
provided in the bottom of passage 6014. A pair of peripheral
channels 6042, 6044 is provided around the middle of wall 6040.
Within each of channels 6042, 6044 is positioned an o-ring seal
6046, 6048 to inhibit leaks around seat 6012. Sloping wall 6040, as
described, prolongs the life of seals 6046, 6048 and reduces the
likelihood of fatigue cracks forming in fluid end 6016.
[0278] Projecting from the top of outer wall 6040 is a peripheral
flange 6050. The bottom of flange 6050 slopes downwardly and
inwardly toward outer wall 6040 at an angle of about 30.degree..
This 30.degree. angle corresponds with that of a seat deck 6052
formed at the junction of the small-diameter, bottom portion 6014b
of passage 6014 and the medium-diameter, middle portion 6014m of
passage 6014. A sloping seat deck 6052, as described, has been
found to provide a strong platform for seat 6012 that minimizes
induced stresses in fluid end 6016.
[0279] Head portion 6020 includes a bottom part 6020b and a rim
part 6020r that extends upwardly and outwardly from the periphery
of bottom part 6020b. Bottom part 6020b is conical with a rounded
bottom wall 6054 and a side wall 6056 that extends upwardly and
outwardly from bottom wall 6054 at a slope of about 60.degree.. Rim
part 6020r, however, has a side wall 6058 that projects upwardly
and outwardly from the top of side wall 6058 at an angle of about
36.degree. so as to permit flush positioning of rim part 6020r
against top part 6038t of seat 6012. In use, bottom part 6020b
projects sharply into the flow of fluid passing through seat 6012
to initiate a radial deflection of the fluid around piston 6018
that keeps piston 6018 centered on guide rod 6028. Centering piston
6018 keeps piston 6018 from sticking on guide rod 6028 and ensures
that rim part 6020r seats perfectly against seat 6012, inhibiting
leaks.
[0280] Rim part 6020r projects above bottom part 6020b so as to
define a circular recess 6060 in the top of head portion 6020.
Recess 6060 reduces the weight of piston 6018 so that piston 6018
can reciprocate more rapidly than it could without it. Recess 6060
further serves as an abutment for the bottom of spring 6034.
[0281] Stem portion 6024 extends upwardly from the center of recess
6060 within spring 6034. Stem portion 6024 is integrally formed
with head portion 6020 and has an exterior diameter that decreases
gradually from its bottom within recess 6060 to its top positioned
above rim part 6020r. The top of stem portion 6024 abuts valve
guide 6026 to define the upper limit of travel of piston 6018.
Socket 6030 extends downwardly through the center of stem portion
6024 and into the center of rim part 6020r. The bottom of stem
portion 6024 has a peripheral, downwardly and outwardly sloping
ledge 6062 that provides a surface through which apertures 6032 can
penetrate to enter the inner/bottom end of socket 6030 and acts to
deflect the bottom of spring 6034 away from apertures 6032 that
might otherwise block apertures 6032. Piston 6018 has apertures
6032 that extend outwardly from socket 6030 at intervals of
60.degree.. If one or several apertures 6032 become blocked, the
remainder serve as backups to balance the pressure within socket
6030 with that in passage 6014.
[0282] Side wall 6058 of rim part 6020r is provided with a
peripheral recess 6064 that snugly receives an insert 6066, formed
of a durable material, serving as a principal, sealing element for
valve 6010. Recess 6064 has a back edge 6068, remote from side wall
6058, that is circular in cross section. Insert 6066 has a back
edge 6070 that is corresponding in shape to that of back edge 6068
so as to "snap fit" into recess 6064. At the time of manufacture,
back edge 6070 is easy to press into head portion 6020 and has
little tendency to loosen over time.
[0283] Valve guide 6026 includes a circular plug 6072 having a
circular, vertical, side wall 6074 and a circumferential flange
6076 projecting outwardly from the top of side wall 6074. Flange
6076 engages a seat deck 6078 in fluid end 6016 at the junction of
the medium-diameter, middle portion 6014m of passage 6014 and the
large-diameter, helically threaded, top portion 6014t of passage
6014. Since guide 6026 transmits smaller loads to fluid end 6016
than valve seat 6012, it is not necessary that seat deck 6078 be
sloped like seat deck 6052. To prevent fluid leaks around plug
6072, side wall 6074 is provided with a pair of peripheral grooves
6080, 6082 beneath flange 6076 within which are positioned o-ring
seals 6084, 6086 for engaging fluid end 6016.
[0284] Plug 6072 has a circular recess 6088 in the bottom thereof.
Recess 6088 is centered on the longitudinal axis of valve 6010. A
circular platform 6090 extends downwardly from the center of recess
partially toward the bottom of plug 6072. Platform 6090 serves as
an abutment for the top of stem portion 6024 of piston 6018. The
annular area in recess 6088, formed around platform 6090, acts an
abutment for the top of spring 6034.
[0285] A cylindrical, guide rod 6028 is integrally formed with plug
6072. Guide rod 6028 is smaller in diameter than platform 6090 and
extends downwardly from the center of platform 6090 so as to be
slidably received within socket 6030 of stem portion 6024. Guide
rod 6028 is long enough to retain stem portion 6024 over the full
range of travel of piston 6018 yet is sufficiently short as to
avoid contacting the bottom of socket 6030 which could cause damage
to both guide rod 6028 and piston 6018.
[0286] Projecting from the top of plug 6072 is a cylindrical sleeve
6092 with an interiorly threaded socket 6094. Sleeve 6092 is used
in a conventional manner to lift valve guide 6026 from passage 6014
when it is desired to service valve 6010.
[0287] Valve retainer 6036 includes a circular cap 6096 having a
helically threaded side wall 6098 that permits retainer 6036 to be
screwed into top portion 6014t of passage 6014. To facilitate the
turning of retainer 6036, a polygonal pin 6100 of hexagonal cross
section is affixed to, and extends upwardly from, the top of cap
6096. Pin 6100 is dimensioned so as to be easily grasped by a
wrench. A cylindrical cutout 6102 is provided in the bottom of cap
6096 to loosely receive sleeve 6092 projecting upwardly from the
center of plug 6072. When screwed fully into passage 6014, the
bottom of cap 6096 presses downwardly upon the top of plug 6072 so
as to hold flange 6076 tightly against seat deck 6078.
[0288] After installing discharge valve 6010 in passage 6014, a
plunger (not shown) is reciprocated in a pumping chamber beneath
valve seat 6012. As the plunger moves forward to drive pressurized
fluid through seat 6012, the compressive force of spring 6034 is
overcome and piston 6018 is elevated to the position shown in FIG.
41. With head portion 6020 being disengaged from seat 6012, fluid
flows past seat 6012, bottom part 6020b serving to guide piston
6018 to a central location in the flow stream, and into middle
portion 6014m of passage 6014. A discharge port (not shown) in
fluid end 6016 conveys pressurized fluid from middle portion 6014m
and from fluid end 6016. When the plunger travels back to its
starting point, the fluid pressure is reduced within seat 6012 such
that the compressive force of spring 6034 drives side wall 6058 and
insert 6066 of piston 6018 onto top part 6038t of seat 6012 thereby
preventing substantial volumes of fluid in middle portion 6014m to
travel back into seat 6012 or the pumping chamber of fluid end
6016.
[0289] The process of opening and closing discharge valve 6010 is
entirely automatic and can be accomplished many times in a second.
Since the valve 6010 minimizes turbulent flow, proppant is not
"knocked out" by valve 6010 so as to block the flow of fracture
fluid through passage 6014. Fluids containing greater proppant
loads than normal can be pumped through valve 6010 providing great
cost savings to a user.
[0290] While discharge valve 6010 has been described with a high
degree of particularity, it will be appreciated by those skilled in
the art that modifications can be made to it. Therefore, it is to
be understood that valve 6010 encompasses any and all valve
embodiments within the scope of the present application.
[0291] The valves described with respect to FIGS. 38-72 are
configured to reduce and correct the improper operation of the pump
system.
[0292] Referring now to FIGS. 43-50 in the drawings, an alternate
embodiment of a valve insert is illustrated. Valve insert 7010
features a ring made of a resilient material like a durable
plastic. The ring has a shape that is defined by the rotation of an
irregular polygon around a central axis. Superposing a
quadrilateral and a circle forms the irregular polygon. Valve
insert 7010 is configured for attachment to the movable piston of a
suction valve or a discharge valve that does not slide, roll or
pivot once installed. Furthermore, valve insert 7010 channels fluid
around its exterior surfaces with minimal turbulence and wear from
abrasive fluids. As a result, valve insert 7010 has a greater
service life than that of any known sealing element.
[0293] Valve insert 7010 is configured to be interchangeably used
in either a suction valve or a discharge valve thus reducing the
inventory of parts that a pump operator must keep on hand for
repairs. Furthermore, valve insert 7010 can be easily installed in
a valve without specialized tools or prolonged training being
required to accomplish the task. This is due to valve insert 7010
being configured to couple to the valves with a "snap fit", of
which a proper fit can be felt, seen, and heard. Valve insert 7010
is lightweight in construction, inexpensive to manufacture, and
fully dependable in use.
[0294] Valve insert 7010 is a ring, made of a durable plastic or
other suitable, resilient material, whose shape is defined by the
rotation of an irregular polygon P around a central axis A. The
superposing of a quadrilateral Q and a circle C forms polygon
P.
[0295] Quadrilateral Q is a plane figure having four sides s1, s2,
s3, and s4 and four angles a1, a2, a3, and a4. Sides s1 and s3,
measuring 0.876 inches and 0.499 inches in length respectively, are
arranged parallel to one another. Side s2 is 0.519 inches long and
connects sides s1 and s3 together. Side s2 meets side s1 at an
angle a1 of 90.degree. and, also, meets side s3 at an angle a2 of
90.degree.. Also, side s4, measuring about 0.641 inches in length,
is positioned opposite side s2 and connects sides s1 and s3
together. Side s4 meets side s3 at an angle a3 of about
13.5.degree. and, also, meets side s1 at an angle a4 of about
55.degree..
[0296] Circle C is a closed plane curve consisting of all points
equally distant from a point within it, called the center c. The
distance from center c to the closed plane curve is the radius r of
circle C. Radius r measures about 0.375 inches in length.
[0297] When superposed, center c is positioned within the bounds of
quadrilateral Q, i.e., the area bounded by sides s1, s2, s3, and
s4, with portions of circle C extending beyond the bounds of
quadrilateral Q. Quadrilateral Q and circle C touch one another at
three points p1, p2, and p3. Circle C crosses side s1 at point p1
at a shallow angle and crosses side s2 at point p2 at another
shallow angle. Circle C touches, but does not cross, side s3 at
point p3 near the midpoint of side s3.
[0298] Polygon P is defined by five line segments l1, l2, l3, l4,
and l5. Line segment 11 is a portion of side s1 adjoining side s4
and measuring about 0.279 inches in length. Line segment l2 is an
arc of circle C measuring about 1.374 inches in length. Line
segment l3 is a portion of side s2 adjoining side s3 measuring
about 0.125 inches in length. Line segment l3 and side s3 fully
coincide in terms of length and location as do line segment l4 and
side s4.
[0299] Rotating polygon P around central axis A provides valve
insert 7010 with its outer surfaces. One surface arising from the
rotation of line segment 7011 is a circular, inside wall 7012 that
extends vertically upward from the bottom of valve insert 7010 and
opens toward the interior of valve insert 7010. Similarly, the
rotation of line segment 7012 around axis A produces a convex, top
wall 7014 that projects, at first, upwardly and inwardly from the
top of inside wall 7012, then, projects upwardly and outwardly and,
finally, arches outwardly and downwardly from its crest. Also, the
rotation of line segment 7013 around axis A results in valve insert
7010 being provided with a round, wing wall 7016 that projects
horizontally outward from the outer periphery of top wall 7014.
Further, rotating line segment 7014 around axis A generates a
circular, outside wall 18 that projects downwardly from wing wall
7016 and parallels inside wall 7012. Finally, rotating line segment
1s around axis A produces a circular, bottom wall 7020 that slopes
downwardly and inwardly from the bottom of outside wall 7018 to
join the bottom of inside wall 7012.
[0300] Discharge valve 7022 includes a valve seat 7024 and a
reciprocating piston 7026. Piston 7026 has a head portion 7028 for
engaging valve seat 7024 and a hollow, stem portion 30 extending
upwardly from head portion 7028. A valve guide 7032 is positioned
above piston 7026 and has a guide rod 7034 that projects downwardly
into a longitudinal socket 7036 in stem portion 7030. A number of
radial apertures 7038 penetrate the bottom of stem portion 7030. A
compressed spring 7040 is disposed between the valve guide 7032 and
head portion 7028 to normally press head portion 7028 into
engagement with seat 7024. A valve retainer 7042 is screwed into a
pump (not shown) to retain valve 7022 therein.
[0301] Valve seat 7024 is a hollow cylinder with an inner wall
7044. Wall 7044 has a top part 7044t that slopes downwardly and
inwardly toward center of seat 7024. Wall 7044 also has a bottom
part 7044b that slopes upwardly and inwardly. Finally, wall 7044
has a substantially vertical, middle part 7044m that connects the
bottom of top part 7044t to the top of bottom part 7044b.
[0302] Valve seat 7024 has an outer wall 7046 that snugly engages
the pump within which valve 7022 is positioned. Outer wall 7046
slopes downwardly an inwardly at a shallow angle. A pair of
peripheral channels 7048, 7050 is provided around the middle of
wall 7046. Within each of channels 7048, 7050 is positioned an
o-ring seal 7052, 7054. Projecting from the top of outer wall 7046
is a peripheral flange 7056. The bottom of flange 7056 slopes
downwardly and inwardly toward outer wall 7046.
[0303] Head portion 7028 includes a bottom part 7028b and a rim
part 7028r that extends upwardly and outwardly from the periphery
of bottom part 7028b. Bottom part 7028b is conical with a rounded
bottom wall 7058 and a side wall 7060 that extends upwardly and
outwardly from bottom wall 7058. Rim part 7028r, however, has a
side wall 7062 that projects upwardly and outwardly from the top of
side wall 7060 so as to permit flush positioning of rim part 7028r
against top part 7044t of seat 7024. Rim part 7028r projects above
bottom part 7028b so as to define a circular recess 7064 in the top
of head portion 7028.
[0304] Stem portion 7030 extends upwardly from the center of recess
7064 within spring 7040. Stem portion 7030 is integrally formed
with head portion 7028 and has an exterior diameter that decreases
gradually from its bottom within recess 7064 to its top positioned
above rim part 7028r. The top of stem portion 7030 abuts valve
guide 7032. Socket 7036 extends downwardly through the center of
stem portion 7030 and into the center of rim part 7028r. The bottom
of stem portion 7030 has a peripheral, downwardly and outwardly
sloping ledge 7066. Piston 7026 has apertures 7038 that extend
outwardly from socket 7036.
[0305] Side wall 7062 of rim part 7028r is provided with a
peripheral recess 7068 that snugly receives a valve insert 7010,
serving as a principal, sealing element for valve 7022. Recess 7068
has a back edge 7070, remote from side wall 7062, which is
generally circular in cross section. The top wall 7014, flanked by
inside wall 7012 and wing wall 7016, correspond in terms of shape
to that of back edge 7070 so as to "snap fit" into recess 7068.
Insert 7010 is easy to press into head portion 7028 and has little
tendency to loosen over time.
[0306] Valve guide 7032 includes a circular plug 7072 having a
circular, vertical, side wall 7074 and a circumferential flange
7076 projecting outwardly from the top of side wall 7074. To
prevent fluid leaks around plug 7072, side wall 7074 is provided
with a pair of peripheral grooves 7078, 7080 beneath flange 7076
within which are positioned o-ring seals 7082, 7084.
[0307] Plug 7072 has a circular recess 7086 in the bottom thereof.
Recess 7086 is centered on the longitudinal axis of valve 7022. A
circular platform 7088 extends downwardly from the center of recess
partially toward the bottom of plug 7072.
[0308] A cylindrical, guide rod 7034 is integrally formed with plug
7072. Guide rod 7034 is smaller in diameter than platform 7088 and
extends downwardly from the center of platform 7088 so as to be
slidably received within socket 7036 of stem portion 7030.
[0309] Projecting from the top of plug 7072 is a cylindrical sleeve
7090 with an interiorly threaded socket 7092. Sleeve 7090 is used
in a conventional manner to lift valve guide 7032.
[0310] Valve retainer 7042 includes a circular cap 7094 having a
helically threaded side wall 7096 that permits retainer 7042 to be
screwed into a pump. To facilitate the turning of retainer 7042, a
polygonal pin 7098 of hexagonal cross section is affixed to, and
extends upwardly from, the top of cap 7094. A cylindrical cutout
7100 is provided in the bottom of cap 7094 to loosely receive
sleeve 7090. In use, the bottom of cap 7094 presses downwardly upon
the top of plug 7072.
[0311] After installing discharge valve 7022 in a pump, a plunger
(not shown) is reciprocated in a pumping chamber beneath valve seat
7024. As the plunger moves forward to drive pressurized fluid
through seat 7024, the compressive force of spring 7040 is overcome
and piston 7026 is elevated to the position shown in FIG. 7. With
head portion 7028 being disengaged from seat 7024, fluid flows past
seat 7024. A discharge port (not shown) in the pump conveys
pressurized fluid from valve 7022. When the plunger travels back to
its starting point, the fluid pressure is reduced within seat 7024
such that the compressive force of spring 7040 drives side wall
7062 and insert 7010 onto top part 7044t of seat 7024 thereby
preventing substantial volumes of fluid from traveling back from
valve 7022 into the pumping chamber of the pump. The process of
opening and closing valve 7022 is automatic and can be accomplished
many times a second.
[0312] Suction valve 7110 includes a valve seat and guide assembly
7112 for positioning in a pump (not shown) and a piston 7118 that
moves within assembly 7112. Piston 7118 has a head 7120 for
engaging the seat portion 7122 of assembly 7112 and a stem 7124
extending downwardly from head 7120 through the guide portion 7126
of assembly 7112. A valve keeper 7128 is fitted upon the bottom of
stem 7124 and is retained there by a split ring 7130. A compressed
spring 7132 is positioned between guide portion 7126 and keeper
7128 for normally retaining head 7120 in engagement with seat
portion 7122 to prevent fluid flow through valve 7110. A valve
retainer 7134 is screwed into the pump to retain the balance of
valve 7110 within the pump and provide for the attachment of valve
7110 to a fluid source.
[0313] Seat portion 7122 comprises an outer ring 7136 and an
outwardly projecting peripheral flange 7142 that is integrally
formed with outer ring 7136. Outer ring 7136 has an outer surface
7146 that slopes upwardly an inwardly at a shallow angle. A number
of peripheral channels 7148, 7150, and 7152 are provided around
outer surface 7146 at spaced-apart intervals. Within channels 7148,
7150 and 7152 are positioned o-ring seals 7154, 7156 and 7159,
respectively. Outer ring 7136 also has an inner surface 7158 that
is shaped to reduce turbulence in fluid moving through valve 7110.
Inner surface 7158 has a top part 15% that is beveled such that it
slopes downwardly and inwardly toward the center of seat portion
7122. Inner surface 7158 also has a bottom part 7158b that slopes
upwardly and inwardly. Connecting bottom part 7158b and top part
7158t together, inner surface 7158 has a medial part 7158m that
slopes upwardly and inwardly.
[0314] Peripheral flange 7142 extends outwardly from the bottom of
outer ring 7136. The top of flange 7142 snugly engages the pump
thereby ensuring a strong platform for assembly 7112. To ensure
against fluid leaks around valve 7110, the bottom of flange 7142 is
provided with a peripheral groove 7162 that receives an o-ring seal
7164 for engaging valve retainer 7134.
[0315] Guide portion 7126 includes an inner ring 7166 that slidably
receives stem 7124 of piston 7118. Inner ring 7166 has an interior
wall 7168 for engaging stem 7124 and an opposed exterior wall 7170.
Exterior wall 7170 has an upper part 7170u and a lower part 7170l
of smaller diameter and substantially equal height. A shoulder 7172
is provided at the junction of the upper and lower parts 7170u and
7170l that serves as an abutment for the top of spring 7132. Upper
part 7170u is positioned within seat portion 7122 adjacent flange
7142 and tapers upwardly and inwardly. Lower part 7170l projects
outwardly from the bottom of seat portion 7122.
[0316] Inner ring 7166 and outer ring 7136 are connected together
by three, vertically oriented fins (not shown). These fins radiate
outwardly from upper part 7170u of exterior wall 7170 of inner ring
7166 to join bottom part 7158b of outer ring 7136.
[0317] Head 7120 has a beveled, peripheral edge 7178 that is
adapted to snugly engage top part 7158t of seat portion 7122.
Extending around edge 7178 is a recess 7184 that is generally
circular in cross section and is further shaped to snugly receive
valve insert 7010 that serves as sealing element for valve 7110.
The top wall 7014, flanked by inside wall 7012 and wing wall 7016,
correspond in terms of shape to that of recess 7184 so as to "snap
fit" into recess 7184. Insert 7010 is easy to press into head
portion 7120 and has little tendency to loosen over time.
[0318] Stem 7124 has a spherical knob 7186 at its bottom end. The
diameter of knob 7186 is smaller than the diameter of stem 7124 to
easily fit through inner ring 7166.
[0319] Above knob 7186, stem 7124 is provided with a peripheral
groove 7188. Groove 7188 is shaped so as to positively grip a
correspondingly shaped split ring 7130 and keep split ring 7130
from springing outwards during use of valve 7110.
[0320] Valve keeper 7128 is fitted over the bottom of stem 7124 and
has a conical configuration. Keeper 7128 has an exterior diameter
that increases gradually from its top, where it has the same
diameter as exterior wall 7170l of inner ring 7166, to its bottom.
Extending outwardly from the bottom of keeper 7128 is a peripheral
rim 7190 that serves as an abutment for the bottom of the
spring.
[0321] A recess 7192 is provided in the bottom of keeper 7128 for
snugly receiving split ring 7130 that is fitted into groove 7188.
To ensure that split ring 7130 does not slide from recess 7192,
split ring 7130 is provided with a peripheral groove 7194 at its
midpoint into which is fitted an o-ring 7196.
[0322] Valve retainer 7134 is segmented, hollow, and cylindrical.
The upper segment 7134u of retainer 7134 is provided with external,
helical threads 7198 that screw tightly into a pump.
[0323] Valve retainer 7134 has a middle segment 7134m that is
joined to the bottom of upper segment 7134u. Middle segment 7134m
has a polygonal cross section with six, principal, external faces
7200 separated by six, secondary, external faces 7202 hexagonally
arranged. Faces 7200 can be gripped by a wrench for rotating valve
retainer 7134.
[0324] Valve retainer 7134 has a bottom segment 7134b that is
joined to the bottom of middle segment 7134m. Bottom segment 7134b
is circular in cross section and has a peripheral slot 7204 around
the middle thereof. Slot 7204 accommodates a coupling (not shown)
for the quick and easy connection of valve retainer 7134 to a fluid
source.
[0325] Valve retainer 7134 has a segmented passageway 7206 that
conveys fluid through segments 7134u, 7134m, and 7134b into
assembly 7112.
[0326] After the installation of suction valve 7110 in a pump, a
plunger (not shown) is reciprocated above head 7120. As the plunger
moves forward to drive fluid from a pumping chamber, the peripheral
edge 7178 of head 7120 and valve insert 7010 carried thereon are
snugly pressed under the influence of spring 7132 against top
surface 7158t of seat portion 7122 ensuring that no fluid leaks
through valve 7110. When the plunger travels back to its starting
point, a partial vacuum is created that lifts piston 7118 against
the compressive force of spring 7132 and draws fluid upwardly
through valve 7110. The process of opening and closing valve 7110
is entirely automatic and requires mere fractions of a second to
accomplish.
[0327] While valve insert 7010 has been described with a high
degree of particularity, it will be appreciated by those skilled in
the art that modifications can be made to it. Therefore, it is to
be understood that my invention is not limited solely to valve
insert 7010, but encompasses any and all valve insert embodiments
within the scope of the following claims.
[0328] The valve inserts described with respect to FIGS. 43-50 are
configured to reduce and correct the improper and laborious
maintenance of the pump system.
[0329] Recirculating Manifold
[0330] Referring now also to FIGS. 51-55 in the drawings, a
recirculating manifold is illustrated. Recirculating manifold 8030
is another embodiment of suction or supply manifold 28 described
previously. Manifold 8030 receives fluid through a connecting pipe
8032 and equally distributes the fluid through a number of feeders.
As seen in FIG. 51, manifold 8030 includes a total of three feeders
8034, 8036, 8038, each used to supply fluid to a suction valve in a
fluid end. Manifold 8030 includes a base plate 8057 configured to
couple manifold 8030 to a fluid end. Manifold 8030 is configured to
optimize the distribution of fluid flow through the three feeders
while avoiding dead spaces where fluid can accumulate and cause
cavitation, fatigue, and cracks.
[0331] Cavitation is caused when fluids that are being pumped
vaporize inside the pumps. Vaporized fluids return to liquid form
as pressure increases, which causes a vapor bubble collapse in the
fluids within and along the inner walls of the fluid ends. These
collapsing vapor bubbles produce localized shock waves that break
off small amounts of the fluid end's metal walls. These areas along
the fluid end walls that are damaged due to cavitation create
stress risers that form into fatigue cracks. This results in the
fluid ends failing to hold & maintain pump pressure due to
pressure leaks through the cracks that have formed in fluid ends.
This condition results in the destruction of the fluid ends which
are then replaced.
[0332] One of the primary causes of pump cavitation is insufficient
fluid charge flow into the suction side of the pump. This is
typically caused by inadequate suction manifold design. Suspended
particles, like sand in the fluid which has been added
intentionally as "propants", can collect & clog a supply
manifold, thereby restricting the inlet flow into the pump causing
pump cavitation. Manifold 8030 is configured to reduce or eliminate
pump cavitation due to inadequate and/or inconsistent charge flow
of the fluid. Furthermore, manifold 8030 is configured to reduce
and correct the improper operation of pump system 1.
[0333] Manifold 8030 includes feeders 8034, 8036, 8038 and
interconnects the feeders with pipes and elbows in such a way to
permit the fluid to smoothly return back on itself, creating a
constant, uninterrupted flow of fluid. As seen in FIG. 51, manifold
8030 is shaped in a "FIG. 8". It should be understood that other
shapes, designs, and configurations of manifold 8030 may be
utilized.
[0334] Manifold 8030 incorporates a series of pipes and elbows that
are in communication with each feeder collectively. Connecting pipe
8032 couples to a radius elbow 8042. Elbow 8042 includes an upper
port and a lower port. The upper port feeds a top reducer pipe
8040. The lower port feeds a bottom reducer 8044. Radius elbow
8042, top reducer 8040, and bottom reducer 8044 wrap around a
portion of feeder 8034.
[0335] Top reducer 8040 and bottom reducer 8044 extend past first
feeder 8034 toward second feeder 8036. Top reducer 8040 passes over
bottom reducer 8044, not in communication with each other. Bottom
reducer 8044 is in communication with second feeder 8036. Top
reducer 8040 couples to a short radius elbow 8046. Bottom reducer
8044 couples to a long radius elbow 8048. Elbows 8046, 8048 are
each in communication with third feeder 8038.
[0336] An important feature of manifold 8030 is the elimination of
dead space that leads to the collection of suspended particles.
Manifold 8030 is configured to remove dead space where suspended
particles like sand can build up and block a pipe. Manifold 8030
does this by removing any endings or terminations in the fluid
reservoir, by incorporating periodic bends or elbows in the
pipes.
[0337] In operation, fluid enters into manifold 8030 and is pulled
into the first feeder 8034, but because the volume of fluid
entering manifold 8030 is more than first feeder 8034 can handle,
the whole manifold becomes filled with fluid, and then the fluid
encounters the second feeder 8036 and third feeder 8038. Any fluid
that is not pulled in by the third feeder 8038 is then diverted
back towards the first pipe. In this way, flow always leads to a
pipe, and never leads to a dead space.
[0338] A second important feature of manifold 8030 is the reduced
area of top reducer 8040 and bottom reducer 8044 and the
orientation of angles L.sub.1 and L.sub.2. In particular with FIG.
54, a partial section view of top reducer 8040 is shown. Top
reducer 8040 has a feeder area 8043 defined by an axis 8041a, and a
bend area 8045 that extends away from first feeder 8034. Bend area
8045 has an axis 8041b offset from axis 8041a. Axis 8041b bends at
an angle L.sub.1 toward the side which first feeder 8034 is
located. Angle L.sub.1 can be any angle but it has been discovered
that an angle of 37 degrees has some advantages. The reduction in
area of top reducer 8040 occurs by partially collapsing the
exterior walls of reducer 8040 adjacent first feeder 8034 toward
axis 8041a, while the walls of reducer 8040 opposite first feeder
8034 remain unchanged in direction.
[0339] In particular with FIG. 55, a partial section view of bottom
reducer 8044 is shown. Bottom reducer 8044 has a feeder area 8047
defined by an axis 8050a, and a bend area 8049 that extends away
from first feeder 8034. Bend area 8045 has an axis 8050b offset
from axis 8050a. Axis 8050b bends at an angle L.sub.2 toward the
side which first feeder 8034 is located. Angle L.sub.2 can be any
angle but it has been discovered that an angle of 37 degrees has
some advantages. The reduction in area of bottom reducer 8044
occurs by partially collapsing the exterior walls of reducer 8040
opposite first feeder 8034 toward axis 8050a, while the walls of
reducer 8044 adjacent first feeder 8034 remain unchanged in
direction.
[0340] The reduced areas assist in overcoming head loss and
maintaining the flow of fluid through the pipes and elbows. It is
understood that any number of feeders may be used in manifold
8030.
[0341] The particular embodiments disclosed above are illustrative
only, as the application may be modified and practiced in different
but equivalent manners apparent to those skilled in the art having
the benefit of the teachings herein. It is therefore evident that
the particular embodiments disclosed above may be altered or
modified, and all such variations are considered within the scope
and spirit of the application. Accordingly, the protection sought
herein is as set forth in the description. It is apparent that an
application with significant advantages has been described and
illustrated. Although the present application is shown in a limited
number of forms, it is not limited to just these forms, but is
amenable to various changes and modifications without departing
from the spirit thereof.
[0342] Rock Screen Insert
[0343] Referring now also to FIGS. 56-59 in the drawings, a rock
screen insert 8001 is illustrated. Rock screen insert is located
within a suction valve 8003, 8005 to filter out large particulates
from the fluid received through the supply manifold, like manifold
8030. Rock screen insert 8001 holds a locking mechanism in place
and keeping rocks out of the fluid end. In doing so, rock screen
insert 8001 described with respect to FIGS. 56-59 are configured to
reduce or eliminate pump cavitation due to inadequate and/or
inconsistent charge flow of the fluid. Furthermore, rock screen
insert 8001 is configured to reduce and correct the improper
operation of pump system 1, partly by acting to secure a forward
valve guide for the suction valve 8003, 8005.
[0344] Fluid flowing from a supply manifold (not shown in FIGS.
56-59) often contain rocks and debris. Rocks that enter the pump
through the suction side pose a serious threat to the service life
of pump system 1. If rocks pass through with the fluid being
pumped, one of two things can happen. If the rocks are small
enough, they are crushed by the force of the valve and cause little
to no damage to the pump. However, large rocks can do significant
damage to the internal components of pump system 1, especially the
suction valve. These elements can work inside of the suction valve
and get stuck in between the valves and seats, thereby causing
damage to the fluid end and cause cavitation problems. Such
problems are not derived from inefficient supply manifolds but are
an inherent part of the type of fluid being supplied.
[0345] Insert 8001 is capable of operating within an assortment of
various types of suction valves. For example, FIG. 57 depicts a
dual guided suction valve 8005, similar in form and function to
that of valve 8230 in FIG. 70, utilizing rock screen insert 8001a.
Additionally a second type of suction valve, suction valve 8003 is
depicted in FIGS. 58 and 59 with insert 8001b. Suction valve 8003
is similar in form and function to that of other suction valve
assemblies described in the present application. It is understood
that other valves and configurations are possible. It is understood
that insert 8001 may be used on a variety of fluid ends, such as
any of those describe in this application or others within the
scope of the application.
[0346] Insert 8001 forms a barrier across the full inner diameter
of the suction valve. As seen in FIG. 56, insert 8001 is configured
to have apertures 8009 along a top surface 8011 that allows small
rocks to pass through, but catches any rocks too big to be crushed
by the valve. Apertures 8009 consist of an assortment of shapes and
sizes. Some apertures 8009 are elongated cylinders or circular. It
is understood that the orientation and design of apertures 8009 are
capable of being adjusted. These apertures filter out the rocks and
debris in the fluid. Any rocks caught by the rock screen are easily
removed from the pump during routine inspections of the fluid end.
It should be understood that other shapes, designs, and
configurations of the rock screen inserts may be utilized.
[0347] Insert 8001 may be located in any location within the
suction valve assembly prior to the valve 8007a, 8007b. Suction
Valve 8003 includes a spring retainer and valve stop 8015, valve
guide 8013, and valve 8007a. Furthermore, a valve guide 8017 and
valve stem 8019 are illustrated and serve to guide movement of
valve 8007a. As valve 8007a is actuated from the pressure
differential of the reciprocating plunger (not shown in FIGS.
56-59), valve 8007a presses against valve seat 8021. A suction nut
8023 is threadedly coupled to the fluid end 8002 and maintains a
manifold connection 8025 to couple to the supply manifold for
receiving fluid.
[0348] Suction valves 8003, 8005 are double guided, with front and
rear guides working together to ensure straight and consistent
movement of the valves. The rock screen insert 8001 helps maintain
the front guide so the valve has straighter travel and better
consistency. A locking mechanism is used for easy installation and
removal. The locking mechanism keeps the valve assembly in place
during pumping as well as ensures against premature valve failure
due to erosion and wear. This locking mechanism is made secure in
part due to the finished edges of the rock screen insert, which are
machined for this particular purpose.
[0349] Insert 8001 is designed to be as low maintenance as
possible. Collected rocks on top of the suction guides are removed
automatically when the valves & seats are changed simply
because the covers are removed during the standard valve and seat
change outs and operators will instinctively dump and knock them
off the covers before they re-install them back into the fluid
ends.
[0350] Packing Nut Assemblies
[0351] Referring now to FIGS. 60-67 in the drawings, individual
alternative embodiments of a packing nut are illustrated. The
packing nuts described herein are designed to eliminate the
problems caused by the need to manually set & adjust packing
nuts by providing automated control through pressure regulation and
monitoring.
[0352] Packing nuts described in FIGS. 60-67 are each configured to
reduce and correct the improper and laborious maintenance of the
pump system 1, and the improper operation of pump system 1. This is
done by accomplishing at lease three objectives: 1) properly
sealing the plunger chamber to create pressure; 2) adequately
lubricating the plunger to prolong the life of the packing nut and
plunger as they are in friction contact through the reciprocating
movement; and 3) sufficiently removing heat through the gradual
controlled leakage of lubrication through the packing nut.
[0353] Packing nut 8060 includes a body 8062, a bellows 8064 having
an internal wall 8064a and an outer wall 8064b, a nose ring 8066,
and a pressure port 8068. Body 8062 threadedly couples to the fluid
end. Body 8062 is threadedly coupled to the fluid end. The threads
may vary in size and count to permit retrofit applications on
existing pump systems. The plunger translates along an inner
surface 8070 of body 8062. Seals 8072 are provided to prevent
leakage between the plunger and body 8062.
[0354] Nose ring 8066 is freely coupled to body 8062 by bellows
8064. Internal wall 8064a and outer wall 8064b are affixed to nose
ring 8066 and body 8062 in a pressure holding connection which can
be either welded seam or a mechanical rolled seam design. An
annular volume is created between the walls 8064a and 8064b,
thereby creating a piston area that translates the nose ring
concentrically along an axis 8072 of body 8062 when hydraulic
pressure is applied through pressure port 8068. Nose ring 8066
applies a compression load to the packing element is attached to
the other end of the bellows in the same manner as described above.
Pressure port 8068 is configured to pressurize bellows 8064 as
needed. An existing lube system is used to provide pressurized lube
to packing nut 8060 through pressure port 8068.
[0355] Referring now also to FIGS. 62-64 in the drawings, a second
embodiment of a hydrostatic packing nut is illustrated. Packing nut
8074 is similar in purpose, form and function to that of packing
nut 8060 except as described herein. Packing nut 8074 uses
hydraulic forces to transmit an accurate compressive load that
serves to seal the plunger and fluid end bore. The actual
compressive forces can be directly read from a pressure gauge or
transducer as opposed to theoretical forces generated by screw type
only threaded packing nuts, which cannot be accurate due to
frictional losses that exist in the thread at any given time.
[0356] Packing nut 8074 is seen in FIG. 62. A cross section of
packing nut 8074 is illustrated in FIG. 63. Packing nut 8074 is
configured to allow for automated adjusting while pump system 1 is
in operation. Furthermore, packing nut 8074 is configured to allow
for safe and accurate adjustment of the packing set over the full
operating range of the fluid end.
[0357] The packing nut assembly 8074 includes an outer threaded
body 8076, an inner packing adjustment piston 8078, an outside
diameter hydraulic seal 8082, and an inside diameter hydraulic seal
8080. Body 8076 includes a pressure port 8084 that receives
variable pressure from an external source. Threaded body 8076,
along with the inner packing adjustment piston 8078, are coupled to
the fluid end in a threaded relationship. Hydraulic pressure is
regulated through pressure port 8084 and hydraulic fluid is
captured between the sealing elements 8080 and 8082. The annular
volume between sealing elements 8080 and 8082 creates a piston area
that causes linear movement of the adjustment piston 8078 when
hydraulic pressure is applied.
[0358] Outward movement of piston 8078 pre-loads the packing nut
8074 just as screwing the conventional packing nut inward on the
threads creates a preload. The advantage with packing nut 8074 is
the ability to set the packing load from a remote location through
the remote regulation of hydraulic pressure. Additionally, nut 8074
may include the use of a monitor 8086 to allow the advantage of
monitoring the operating load that the packing is experiencing via
feed back from the hydraulic pressure changes while the system is
in operation. Monitor 8086 is configured to provide an operator of
pump system 1 operational feedback concerning the condition of nut
8074.
[0359] End point adjustment for packing wear can be set by
adjusting the amount of travel left where the small diameter of the
packing adjustment piston 8078 passes under sealing element 8080.
When the travel allows the piston to go past the sealing element
8080 the hydraulic pressure is lost signaling that the packing
element has been compressed and worn to the end of its service
life.
[0360] Packing nut 8074 allows dynamic adjustment and pressure
monitoring throughout the entire operating range of the fluid end.
This allows the packing elements to run at their optimum
compression loads for any given pressure setting. Since the packing
elements are running neither in an under or over compressed state
the service life will increase.
[0361] Referring now also to FIGS. 65-67 in the drawings, a third
alternative hydrostatic packing nut 8088 is illustrated. Packing
nut 8088 is similar to that of nut 8074 and 8060 except that nut
8088 provides the same operating effects without additional moving
parts.
[0362] The packing nut 8088 is a one piece unit that uses two seals
8090 and 8092 to prevent the hydraulic pressure that is introduced
through a pressure port 8094 from escaping to atmosphere either
around the plunger or around the packing bore in the fluid end.
Being captured, the pressure is forced to react against the packing
assembly to produce axial and radial energizing pressure against
the packing nut 8088 causing sealing against the plunger and fluid
end packing bore.
[0363] Packing nut 8088 is in communication with a variable
pressure hydraulic source 8096 through port 8094. Packing nut 8088
may be in communication with a sensor 8098 to monitor the pressure
within nut 8088. An operator is able to regulate and monitor the
pressure of nut 8088. As with nut 8074, a loss of hydraulic
pressure may be experienced which would signal the end of nuts 8088
useful life.
[0364] Dual Guided Valves
[0365] Referring now also to FIGS. 68-75 in the drawings,
alternative embodiments of valve guides are illustrated. There are
six types of valve guides used on fluid ends 10, 410, 4012 as seen
in FIGS. 11-16. Fluid ends 10, 410 use guides that mate with stems
which are on the back sides of the valves. The suction valve stem
is part of the suction valve & the discharge stem is a separate
part from the discharge valve. Fluid end 4012 uses dual guided
valves that mate with stems which are on both sides of the valves.
Fluid end 4012 has more guide types because even though fluid end
4012 uses the same valves & seats for both the suction &
discharge sides, fluid end 4012 uses different guides on each of
the four stems, (two on suction & two on discharge).
[0366] FIG. 68 shows a discharge valve guide assembly 8200 for use
in a discharge valve of a fluid end similar to fluid end 4012.
Valve guide assembly 8200 includes a front discharge valve guide
8202, a valve 8204 with an upper guide stem 8206 and a lower guide
stem 8208, a spring 8210, a rear discharge valve guide 8212. Front
guide 8202 mates with lower guide stem 8208; on the front of the
discharge valve 8204, the front guide 8202 positions under seat
8214 & registers to align using the seat deck bores. Rear guide
8212 is mounted in the discharge cover 8216 which also serves as a
valve spring 8210 retainer & valve stop.
[0367] In particular with FIG. 69 a suction valve guide assembly
for use in a suction valve of a fluid end similar to fluid end 4012
is illustrated. Valve guide assembly 8230 includes a front suction
valve guide 8232, a valve 8234, a spring 8236, and a rear suction
valve guide 8238. Front guide 8232 is designed to deal with the
position of the valve which is beneath the plunger. Rear guide 8238
is also configured to be a spring 8236 retainer & valve 8234
stop while at the same time permitting fluid to flow around it.
[0368] Front guide 8232 of suction valve guide assembly 8230 is
configured to serve as a seat retainer & due to the limited
accessibility. Front guide 8232 also includes a locking mechanism
8240 to automatically lock & retain the seat of front guide
8232 when the valve was installed and automatically unlock the seat
of front guide 8232 when the valve were removed. The locking
mechanism 8240 is configured to permit the installation and removal
of valve 8234 with a single hand. Locking mechanism also includes a
shaft 8242, a set spring 8244, and a set screw 8246. It is
understood that other types of locking mechanisms may be used and
are contemplated herein.
[0369] As seen in FIG. 70, discharge valve guide assembly 8200 and
suction valve guide assembly 8230 are illustrated within a fluid
end. Suction valve front guide 8232 doubles as the seat retainer
using the locking mechanism 8240 which locks as the valve is
installed & unlocks as it is removed. The rear suction valve
guide 8238 uses a locating diameter in the fluid end to center the
guide in line with the suction bore. The rear guide 8238 also
functions as a spring retainer & valve stop. Plunger chamber
8248 is illustrated as running perpendicular to a line between the
valve assemblies 8200 and 8230. A packing side 8250 of plunger
chamber 8248 is configured to receive a packing nut similar to any
of those described in the application, in particular with FIGS.
60-67. Opposite packing side 8250 is a suction cover side 8252.
[0370] With respect to valve guides used in fluid ends 10, 410 as
described in FIGS. 11-14, FIG. 71 illustrates a discharge valve
guide 8270 as well as a discharge valve 8272 similar to piston 106
in FIG. 12D. Valve 8272 is shown with a valve insert 8274 similar
to insert 7010 in FIG. 43. Valve 8272 includes a hollow elongated
shaft 8276 located behind a head portion 8278 of valve 8272. The
hollow feature 8273 of shaft 8276 is configured to accept a stem
8280 protruding from valve guide 8270. Slots 8282 are formed in
shaft 8276 for sand evacuation. It is preferred for there to be a
total of four slots 8282 in shaft 8276 but more or less is
possible. Stem 8280 has a fluted tip for channeling the sand away
that may build up in between the stem 8280 and valve 8272.
[0371] Discharge valve guide 8270 is configured to also function as
the seal/cover for the discharge bore in the fluid end, in addition
to the valve spring retainer & the valve stop. Stem 8280 is
configured to rest within the hollow feature 8273 thereby
permitting translational movement of discharge valve 8270. As valve
8270 actuates the movement is controlled & regulated by the
guide stem 8280 which maintains the position of the valve 8270
centrally in line with the valve seat.
[0372] Referring now to FIGS. 72-76 a suction valve assembly for
use in fluid ends 10, 410 is illustrated. Suction valve guide
assembly 8290 includes at least a suction valve guide 8292 adjacent
a suction valve seat 8294, a suction valve 8296, and a locking
mechanism 8302. The valve spring has been omitted to show the guide
8292 more clearly in FIGS. 72-73. Suction valve 8296 is another
embodiment of associated portions of the suction valve 5010
described in FIGS. 38-40. Suction valve 8296 is similar in form and
function to suction valve 5010 except as noted herein. There are at
least two changes with the suction valve assembly of FIG. 38: 1)
changes to the valve itself; and 2) changes to the guide.
[0373] The changes made to the valve 5010 in FIGS. 38-40 affect the
valve keeper 5028, split ring 5030, O-ring 5096, knob 5086, and
stem 5024. These items corporately perform four functions as
follows, retain the valve spring, Retain the valve inside the valve
retainer or suction nut 8300, regulate the amount the valve can
open during actuation (also called valve stoke & valve stop),
and provide the ability to remove, change, service and assemble the
valve into the valve assembly & fluid end.
[0374] With respect to changes to the suction valve itself, suction
valve 8296 has lengthened stem 8298 by removing the valve keeper
5028 and stop groove 5088 seen in FIG. 38. Stem 8298 is partially
threaded adjacent the end opposite the valve head. A retainer
groove 8308 is located above threaded portion 8304 for engaged
contact with a spring retainer and valve stop 8015.
[0375] Suction valve 8296 includes a locking mechanism that
includes quick lock and release valve retainers designed to
eliminate the need for complicated locking mechanisms (including
roll and cotter pins) currently used to retain suction valves and
spring assemblies in fluid ends. The locking mechanism prevents the
threads from backing out/coming loose and is a portion of the one
piece threaded spring retainer/valve stop 8015. Spring retainer and
valve stop 8015 include a retainer 8302 and a valve stop 8305.
Retainer 8302 is threadedly fastened to stem 8298 along threaded
portion 8304. Valve stop 8305 includes a rotatable hook 8306 that
is selectively rotated such that the hook 8306 portion engages
groove 8308 to lock and secure valve 8296.
[0376] Suction valve 8296 is configured to permit installation and
removal of suction valve assembly 8290 with a single hand. The
spring retainer, valve retainer, valve removal knob & valve
stop groove located on the valve stem area, have been combined into
one assembled part, suction valve 8296.
[0377] The changes made and incorporated into this portion of valve
8296 and valve assembly 8290 do not change the way the valve 8296
functions mechanically with respect to valve 5010. Valve 8296 still
uses the same guide method, stroke distance, seal areas, spring
force, etc. These changes are made to simplify the design, reduce
costs, and provide better ease of assembly and maintenance, while
performing the same objectives & purposes of the original
design, seen in FIGS. 38-40.
[0378] With respect to the valve guide, valve guide 8292 is
positioned central to the seat 8294 locating on the counter bore
diameter on the back of the seat 8294. Valve guide 8292 includes a
filter insert similar in form and function to a rock screen insert
described in FIGS. 56-59. This filter is to prevent rocks &
other large debris from entering the fluid end which often times
would get stuck between the valve & valve guide which would
lead to jetting & damage to valves, seats, & fluid ends.
The stem 8298, in this embodiment, is part of the suction valve
8296 and passes through the guide 8292 up until the spring retainer
and valve stop 8015. FIG. 76 shows a completely assembled suction
valve assembly 8290 outside of a fluid end.
[0379] The valve assemblies described with respect to FIGS. 68-76
are configured to reduce and correct the improper and laborious
maintenance of the pump system.
[0380] Straight Seals and Peanut Shaped Intersections
[0381] Referring now also to FIGS. 77-79 in the drawings, an
alternative embodiment of the tapered seats in a fluid end is
illustrated. A high pressure straight seal 8320 is illustrated in
various figures throughout the application, namely FIG. 68 (#8214),
FIG. 69 (#8232), and FIG. 57 to name a few. Although the numerical
identifier for seal 8320 is different in FIGS. 77-80, it is
understood that prior Figures used in this application may be used
to assist in ascertaining the forms, functions, and any limitations
of seals 8320 described herein this section.
[0382] Seal 8320 include at least a straight seat 8322 and a
retainer 8324. Seal 8320 allows seats to be installed in fluid ends
without needing seat tapers, which were previously needed to insure
a metal to metal contact between the seats & seat tapers in
fluid ends so that the seats would have tight seals under pressure.
Where taper seats are exposed to high pressures, the taper seats
are pushed with such great force into the fluid ends that they
become stuck needing extreme force to remove them. Hardened taper
seats can act as wedges that damage the expensive fluid ends by
pushing & distorting the walls of the fluid end. This is also
compounded when fresh hardened taper seats are installed to
continue the distortion where the previous seats left off, in
effect sharpen the pile driver wedge & keep going.
[0383] Seals 8320 also can include a seal made using a combination
of urethanes that is proprietary blend. The seals have a greater
temperature & corrosive chemical exposure operating range &
they do not need the same special storage & handling
requirements that O-rings in tapered seats have. O-rings on taper
seats are low pressure seals & only allow the pump to build up
pressure & then the metal contact area on the tapers is
designed to take over as the pump reaches higher pressures pushing
the wedged metal sides of the seat & seat taper which is inside
the fluid end against each other.
[0384] Straight seals 8320 are high pressure seals which eliminate
the need for taper seat decks & taper seats by sealing at high
pressures in a straight bore within the fluid end, not a taper
wedge using metal to metal contact. This allows the fluid end to
remain undamaged, the seats to be installed & removed with
minimal force, faster valve & seat changes, longer valve &
seat life, & longer fluid end life. Seals 8320 may be used in
any fluid end such as those described in this application.
[0385] An additional feature and benefit of seals 8320 is the
inclusion of retainer 8324. Retainer 8324 is coaxial with seat 8322
and slides over an external surface of seat 8322. Retainer 8324
contacts a ledge within the valve assembly, thereby restricting
undesired translation of the valve 8326 and seat during promotion
of the plunger. Seals 8320 are rated to 50,000 psi with service
life spans up to 1500 hours in the frac applications. Current Frac
pressures peak at 15,000 psi.
[0386] Seals 8320 are configured to reduce stress concentrations
within the fluid end assembly by distributing forces generated
against the valves over a larger surface area as compared to taper
seats. Seal 8320 is configured to reduce metal fatigue in the fluid
end and increase ease of maintenance. Furthermore, seal 8320 is
configured to reduce and correct the improper and laborious
maintenance of the pump system.
[0387] FIG. 78 illustrates the seal 8320 used in fluid end 10, 410.
Fluid end 10, 410 has an alternative suction seat seal deck 8328
and an alternative discharge seat seal deck 8330. Suction seat
straight seal 8332 is configured to contact deck 8328 in the
suction valve. Suction seat straight seal 8334 is configured to
contact deck 8330 in the discharge valve. FIG. 79 illustrates a
suction seat seal deck 8336 and a discharge seat seal deck for use
in fluid end 4012.
[0388] Referring now also to FIGS. 80A and 80B in the drawings,
schematics of the vertical passage with sectional views showing the
shape of the passage from front, side & top views is
illustrated. Fluid ends 10, 410, 4012 (any all other fluid end
embodiments herein described) are modified to include selectively
tailored peanut shaped bores or cut outs at the intersections of
the suction valve, discharge valves, and plunger chamber. It is
understood that modified bores may be included in other locations
within pump system 1, for example in the recirculating
manifold.
[0389] The peanut shape redirects the stress forces that normally
build up around the main intersection into the stronger main core
area of the fluid end, similar to a detour for traffic, the stress
follows the peanut shape curves away from & around the
intersections instead of flowing & concentrating into them.
[0390] The Peanut shape intersection uses six separate
cylindrically shaped cut outs that are applied to a cylindrically
shaped bore intersection where two cylindrically shaped bores
intersect perpendicular & central to each other also called a
"tee" intersection, as seen in fluid end 4012. Four of the
cylindrically shaped cutouts are applied in the horizontal axis
& the other two are applied in the vertical axis. The
Horizontal axis appears to take the form similar to the shape of a
peanut when viewed in line with the horizontal axis. The vertical
axis appears to take the shape of an oval when viewed in line with
the vertical axis. The tee intersection where the bores &
cylindrically shaped cutouts meet takes a form that has features
from the combined bores & cylindrical cutouts.
[0391] As seen in FIG. 80, The two vertical cylindrical cut outs
8344 are formed from the bottom suction side 8340 (opposite
discharge side 8341) & stop when they reach the center line
8342 of the tee intersection 8350 where they end with spherically
shaped radiuses 8346, (not sharp corners) & do not continue
passed the intersection in the vertical passage. In the same manner
the four horizontal cutouts 8348 are formed from the suction cover
side & stop when they reach the center line of the tee
intersection 8350 where they end with spherically shaped radiuses
8346, (not sharp corners).
[0392] Software is used to detect weaknesses in the fluid ends and
optimize the size, depth, and types of bores or cut outs used to
reduce stress concentrations. It is understood that although peanut
shaped bores have been described with respect to a single
embodiment of a fluid end, any fluid ends contemplated within the
scope of this application are capable of using the peanut shape
bores or cut outs.
[0393] Combining Peanut shape intersections & straight seat
decks in the fluid end design used in pump system 1 strengthens the
fluid end which lengthens the service life of the fluid end by up
to 75%. Combining straight seat decks & peanut shape
intersections in the same fluid end increases the fluid end life by
eliminating the concentrated stress areas that form around the
intersections & seat decks in fluid ends that use taper seat
decks along with standard cylindrical intersections. Combining
Peanut shape intersections & straight seat decks in the fluid
end design together increases life expectancy beyond that expected
with the use of either one individually.
[0394] It should be noted that the individual components and parts
of the pump system described herein are individually configured to
improves pump efficiencies and service life; but when combined into
one pump system, the components and parts of the pump system
described herein work together to produce the highest efficiencies
and longest service life.
[0395] The present application provides significant advantages,
including: (1) reduced pump cavitation due to inadequate and/or
inconsistent charge flow; (2) reduced cracking and failure die to
metal fatigue in the pump system fluid ends; (3) reduce and correct
the improper and laborious maintenance of the pump system; and (4)
reduce and correct the improper operation of the pump system.
[0396] While the preferred embodiment has been described with
reference to an illustrative embodiment, this description is not
intended to be construed in a limiting sense. Various modifications
and other embodiments of the application will be apparent to
persons skilled in the art upon reference to the description.
[0397] The particular embodiments disclosed above are illustrative
only, as the application may be modified and practiced in different
but equivalent manners apparent to those skilled in the art having
the benefit of the teachings herein. It is therefore evident that
the particular embodiments disclosed above may be altered or
modified, and all such variations are considered within the scope
and spirit of the application. Accordingly, the protection sought
herein is as set forth in the description. It is apparent that an
application with significant advantages has been described and
illustrated. Although the present application is shown in a limited
number of forms, it is not limited to just these forms, but is
amenable to various changes and modifications without departing
from the spirit thereof.
* * * * *