U.S. patent application number 15/330212 was filed with the patent office on 2018-03-01 for pump housing with multiple discharge valves.
The applicant listed for this patent is George H. Blume. Invention is credited to George H. Blume.
Application Number | 20180058444 15/330212 |
Document ID | / |
Family ID | 61242024 |
Filed Date | 2018-03-01 |
United States Patent
Application |
20180058444 |
Kind Code |
A1 |
Blume; George H. |
March 1, 2018 |
Pump housing with multiple discharge valves
Abstract
A plunger pump fluid end housing assembly comprising: a fluid
end housing, multiple plungers a single suction valve and seat
corresponding with each said plunger, and one or more discharge
valves and seats corresponding with each said plunger; wherein axes
of said suction valve and seat are parallel with said plunger, the
axes of said discharge valves and seats are substantially parallel
to each other and perpendicular to the said plunger axis, and the
suction manifold is positioned to feed the fluid chamber opposite
the power end of the fluid end.
Inventors: |
Blume; George H.; (Austin,
TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Blume; George H. |
Austin |
TX |
US |
|
|
Family ID: |
61242024 |
Appl. No.: |
15/330212 |
Filed: |
August 23, 2016 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F04B 53/1087 20130101;
F04B 53/16 20130101; F04B 53/02 20130101; F04B 1/0448 20130101;
F04B 1/124 20130101; F04B 53/147 20130101; F04B 53/146 20130101;
F04B 53/164 20130101; F04B 1/0461 20130101; F04B 1/16 20130101 |
International
Class: |
F04B 53/10 20060101
F04B053/10; F04B 1/12 20060101 F04B001/12; F04B 1/16 20060101
F04B001/16; F04B 53/16 20060101 F04B053/16 |
Claims
1. A plunger pump fluid end housing with multiple fluid chambers
arranged in a longitudinal plane and each fluid chamber comprising:
a suction bore; a plunger bore; a plurality of discharge bores;
wherein the axis of said suction bore and the axis of said plunger
bore are parallel, and wherein the axis of each individual
discharge bore in said plurality of discharge bores is parallel to
the axes of the other individual discharge bores in said plurality
of discharge bores and also is substantially perpendicular to said
suction bore axis.
2. A plunger pump fluid end housing of claim 1 wherein each fluid
chamber contains two discharge bores.
3. A plunger pump fluid end housing of claim 1 wherein the axis of
said plunger bore is substantially collinear with the axis of said
suction bore.
4. A plunger pump fluid end housing of claim 1 wherein the area of
either discharge port in said discharge bore equals approximately
half the area of the suction port in said suction bore.
5. A plunger pump fluid end housing of claim 1 wherein the axes of
the said individual discharge bores within said plurality of
discharge bores are substantially collinear.
6. A plunger pump fluid end housing of claim 1 wherein the suction
manifold ports of said housing are positioned on the fluid end
housing opposite to the power end of the plunger pump.
7. A plunger pump fluid end housing assembly comprising: a fluid
end housing; a plurality of plungers; a single suction valve and
seat corresponding to each individual plunger in said plurality of
plungers; a plurality of discharge valves and seats corresponding
to each individual plunger in said plurality of plungers; wherein
the axis of each said suction valve and seat is parallel to each of
said individual plungers in said plurality of plungers; and wherein
the axes of each of the individual discharge valves in said
plurality of discharge valves and seats is parallel and
substantially perpendicular to the respective axis of each of the
said individual plungers, suction valves, and suction seats.
8. A plunger pump fluid end housing of claim 7, wherein each fluid
chamber contains two discharge valves and two discharge seats.
9. A plunger pump fluid end housing assembly of claim 8, wherein
each axis of said individual plungers is substantially collinear
with the corresponding axis each of said individual suction valves
and corresponding individual valve seats.
10. A plunger pump fluid end housing assembly of claim 7, wherein
the flow area of either discharge seat of said assembly equals
approximately half the flow area of said suction seat in said
housing.
11. A plunger pump fluid end housing of claim 7, wherein the axes
of said multiple discharge valves and seats are substantially
collinear.
12. A plunger pump fluid end housing of claim 7, wherein the
suction manifold of said housing assembly is positioned opposite to
the power end of the plunger pump.
Description
FIELD OF THE INVENTION
[0001] The invention relates generally to high-pressure plunger
pumps used, for example, in oil field operations. More
particularly, the invention relates to an internal bore
configuration that improves flow, improves cylinder filling, and
incorporates structural features for stress-relief in high-pressure
plunger pumps.
BACKGROUND
[0002] Engineers typically design high-pressure oil field plunger
pumps in two sections; the (proximal) power section and the
(distal) fluid section. The power section usually comprises a
crankshaft, reduction gears, bearings, connecting rods, crossheads,
crosshead extension rods, etc. Commonly used fluid sections usually
comprise a plunger pump fluid end housing with multiple fluid
chambers, each chamber having a suction valve in a suction bore, a
discharge valve in a discharge bore, an access bore, and a plunger
in a plunger bore, plus high-pressure seals, retainers, etc. FIG. 1
is a cross-sectional schematic view of a typical fluid end housing
fluid chamber showing its connection to a power section by stay
rods. A plurality of fluid chambers similar to that illustrated in
FIG. 1 may be combined, as suggested in the Triplex fluid section
housing schematically illustrated in FIG. 2.
[0003] Valve terminology varies according to the industry (e.g.,
pipeline or oil field service) in which the valve is used. In some
applications, the term "valve" means just the moving element or
valve body. In the present application, however, the term "valve"
includes other components in addition to the valve body (e.g.,
various valve guides to control the motion of the valve body, the
valve seat, and/or one or more valve springs that tend to hold the
valve closed, with the valve body reversibly sealed against the
valve seat).
[0004] Each individual bore in a plunger pump fluid end housing is
subject to fatigue due to alternating high and low pressures that
occur with each stroke of the plunger cycle. Conventional fluid end
housings, also referred to as cross-bore blocks, typically fail due
to fatigue cracks in one of the areas defined by the intersecting
suction, plunger, access and discharge bores as schematically
illustrated in FIG. 3A.
[0005] To reduce the likelihood of fatigue cracking in the
high-pressure plunger pump fluid end housings described above, a
Y-block housing design has been proposed. The Y-block design, which
is schematically illustrated in FIG. 4, reduces stress
concentrations in a plunger pump housing such as that shown in FIG.
3A by increasing the angles of bore intersections above 90.degree..
In the illustrated example of FIG. 4, the bore intersection angles
are approximately 120.degree.. A more complete cross-sectional view
of a Y-block plunger pump fluid end housing is schematically
illustrated in FIG. 5.
[0006] Both cross-bore blocks and Y-blocks have several major
disadvantages when used to pump heavy slurry fluids as typically
utilized in oilfield fracturing service. A first disadvantage is
related to the feeding of the plunger bore cavity on the suction
stroke of the pump. Upon passing through the suction valve, the
fluid must make a 90 degree turn in a cross-bore housing, or a 60
degree turn in a Y-block housing, into the plunger bore as
illustrated in FIG. 6. This change in the direction of the heavy
fluid robs the fluid of kinetic energy, hereafter referred to as
fluid energy.
[0007] Fluid energy is normally added to the fluid by small
supercharging pumps upstream from the plunger pump. Fluid energy is
necessary to overcome fluid inertia and ensure complete filling of
the inner pump cavity or volume on the suction stroke. If the fluid
could possibly enter the housing inner cavity or volume in a linear
or straight path, less fluid energy would be lost.
[0008] The second disadvantage of cross-bore blocks and Y-blocks
relates to the large intersecting curved areas where the various
bores intersect. Because the suction bore above the suction valve
is almost as large as the plunger bore, the intersection area of
the suction bore with the plunger bore is particularly large as
illustrated in FIGS. 3A and 3B. While the intersection of the
suction bore and the plunger bore is notably large, the
intersection of the discharge bore and the plunger bore is almost
as large.
[0009] As shown in FIGS. 7a and 7B, the intersecting cylindrical
sections result in intersection curves that focus or concentrate
the stresses generated by the internal pump pressures into a very
small area. This small area is located at the bore intersection
near the plane formed by the axis of the plunger and suction or
discharge bore cylinders at the finite point of the intersection of
the two cylinders. Because the intersection curve changes slope
through three-dimensional space, this intersection cannot be easily
chamfered or filleted by conventional machining techniques that
would mitigate these stresses to a smaller extent. Indeed, complex
computer finite element stress analysis calculations indicate that
chamfering or filleting the corner intersection has minimal effect
on reducing the stresses at this corner intersection.
[0010] The amount of stress at the intersecting bores of
conventional fluid end housings is defined by the magnitude of the
"Bore Intersection Pitch" as illustrated in FIGS. 3A, 3B, and 4.
Any geometry that reduces the "Bore Intersection Pitch" will reduce
the stress concentrations in the fluid end and increase the life of
the fluid end by mitigating cyclic fatigue failure. Y-Block fluid,
such as those illustrated in FIG. 4, end housing designs do reduce
this pitch, but the reduction is insufficient to prevent cyclic
fatigue failure of the fluid end housing when subjected to high
pressure and long pumping cycles.
SUMMARY OF THE INVENTION
[0011] The fluid end housing of the present invention comprises
multiple fluid chambers with each chamber having a suction bore
that is aligned with the plunger bore, commonly referred to as an
"in-line configuration," i.e., the bores are aligned. As such, the
axis of the suction bore is substantially co-linear with the
plunger bore. The configuration of the suction bore of the present
invention eliminates the loss of fluid energy present in fluid end
housings of the prior art in which the suction fluid flow must
undergo a right angle turn to fill the plunger bore or inner cavity
of the housing.
[0012] The fluid chamber of the housing of the present invention
also comprises multiple discharge valves and seats. In one
embodiment, two discharge valves and seats are included in the
assembly. In this embodiment, each valve is approximately half the
size of the suction valve such that the combined flow capacity of
the two discharge valves approximately equals the flow capacity of
the single suction valve. In this embodiment, the bores of said
discharge valves are arranged opposite of each other and
perpendicular to the plunger bore centerline. In this embodiment of
the invention, the discharge ports connecting the plunger chamber
with the discharge valves and seats are less than half the size of
the plunger bore; thus the intersection area of the discharge bore
with the plunger bore is significantly smaller than the
intersection area of the suction bore with the plunger bore of
conventional housings of the prior art. Because the plunger bore of
the present invention is many times larger than the discharge bore,
the bore intersection pitch and the convergence of stress is
markedly reduced. Accordingly, in the embodiments of the present
invention, the peak stress at the bore intersection is less than
20% of the stress of conventional housings of the prior art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a cross-sectional schematic view of a typical
prior art plunger pump fluid section showing its connection to a
power section by stay rods.
[0014] FIG. 2 schematically illustrates a conventional prior art
Triplex plunger pump fluid section housing.
[0015] FIG. 3A is a cross-sectional schematic view of suction,
plunger, access and discharge bores of a conventional prior art
plunger pump housing intersecting at right angles and showing areas
of elevated stress and the "Bore Intersection Pitch."
[0016] FIG. 3B schematically illustrates the sectional view labeled
B-B in FIG. 3A.
[0017] FIG. 4 is a cross-sectional schematic view of suction,
plunger and discharge bores of a prior art Y-block plunger pump
housing intersecting at obtuse angles showing areas of elevated
stress and the "Bore Intersection Pitch."
[0018] FIG. 5 is a cross-sectional schematic view similar to that
in FIG. 4, including internal plunger pump components of a prior
art Y-block fluid section.
[0019] FIG. 6 schematically illustrates a cross-section of a prior
art right-angular plunger pump with valves, plunger, and a suction
valve spring retainer showing the flow around the suction valve and
the turn of the fluid into the plunger bore.
[0020] FIG. 7A schematically illustrates a three dimensional
cross-section of one cylinder of a prior art right-angular plunger
pump.
[0021] FIG. 7B schematically illustrates the enlarged sectional
view labeled B-B in FIG. 7A highlighting the convergence of the
stress at the intersection bores.
[0022] FIG. 8 schematically illustrates a cross-section of the
fluid end housing assembly of the present invention showing its
connection to a power section by stay rods.
[0023] FIG. 9A schematically illustrates a cross-section of the
fluid end housing assembly of the present invention including
detailed cross sections of the components of the assembly.
[0024] FIG. 9B schematically illustrates the sectional view labeled
B-B in FIG. 9A.
[0025] FIG. 9C schematically illustrates the enlarged section
labeled C-C in FIG. 9B.
[0026] FIG. 10A schematically illustrates a cross-section of the
fluid end housing of the present invention
[0027] FIG. 10B schematically illustrates the sectional view
labeled B-B in FIG. 10A.
[0028] FIG. 10C schematically illustrates the sectional view
labeled C-C in FIG. 10B.
[0029] FIG. 11A schematically illustrates an orthogonal view of the
suction valve spring retainer/plunger spacer.
[0030] FIG. 11B schematically illustrates an end view of the
suction valve spring retainer/plunger spacer.
[0031] FIG. 11C schematically illustrates the section view labeled
C-C of the suction valve spring retainer/plunger spacer of FIG.
11B.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0032] FIG. 8 schematically illustrates a cross-section of an
embodiment of the fluid end housing assembly 100 of the present
invention showing its connection to a power section by stay rods.
As opposed to fluid end housing of the prior art as illustrated in
FIG. 1, fluid end housing 1 of the present invention is configured
with the suction manifold 5 mounted in a position on the fluid end
housing opposite the power end of the pump.
[0033] The housing 1 of the present invention features multiple
fluid chambers 2 with each chamber 2 containing multiple bores. The
plunger 310 may be of a two-piece design as illustrated in FIG. 8
with a plunger pressure end 311 and a plunger clamp end 312. A
two-piece plunger facilitates easier maintenance by field
mechanics. Alternately a one-piece plunger, not shown, could be
utilized. However a one-piece plunger would require removal of the
fluid end housing assembly 100 from the power end assembly for
routine maintenance on components of assembly 100.
[0034] FIG. 9A schematically illustrates a cross-section of the
fluid end housing assembly 100 of the present invention showing the
major internal components of the assembly 100 including a fluid end
housing 1 featuring multiple fluid chambers 2 with each chamber
containing multiple internal bores 10, 20, 30, and 40. Major
internal components of the assembly 100 arranged in the plunger
bore 30 of housing 1 include the plunger 311, plunger packing 361,
plunger packing gland nut 351, and suction valve spring
retainer/plunger spacer 330. The suction bore 10, opposite to the
plunger bore 30, contains the suction seat 112, suction valve 114,
suction valve spring 115, suction valve guide 328 and suction valve
spring retainer 326. Suction valve guide 328 and suction valve
spring retainer 326 are integral to the suction valve spring
retainer/plunger spacer 330. The centerlines of the suction bore
10, suction seat 112, suction valve 114, suction valve spring 115,
the plunger bore 30, plunger 311, plunger packing 361, and the
plunger packing gland nut 351 are all substantially co-linear. The
co-linear arrangement of the plunger bore 30 and the suction bore
10 eliminates the concentration of stresses at the intersection
these two bores typical of fluid end housings of the prior art as
shown in FIGS. 3A, 3B, 4, 7A, and 7B.
[0035] FIG. 9A schematically further illustrates the components in
the upper and lower discharge bores 20 and 40, respectively. Upper
discharge bore 20 and lower discharge bore 40 connect with upper
discharge manifold 28 and lower discharge bore 48, respectively,
which are joined externally to the fluid end housing assembly 100
and the fluid end housing 1. Upper discharge bore 20 contains an
upper discharge seat 212, upper discharge valve 214, upper
discharge valve spring 215, upper discharge cover 216, and upper
discharge cover retainer 217. Lower discharge bore 40 contains a
lower discharge seat 412, lower discharge valve 414, lower
discharge valve spring 415, lower discharge cover 416, and lower
discharge cover retainer 417.
[0036] FIG. 9B schematically Section B-B of FIG. 9A. FIG. 9C
illustrates enlarged Section C-C of FIG. 9B. Suction valve guide
328 and suction valve spring retainer 326 are integral to the
suction valve spring retainer/plunger spacer 330. Shoulder 337 and
cylindrical surface 332 of flange 333 on suction valve spring
retainer/plunger spacer 330 mates with shoulder 37 and plunger
packing bore 32 of housing 1, respectively. Central section 335 of
suction valve spring retainer/plunger spacer 330 connects flange
333 with suction valve spring retainer 326. Central plunger chamber
34 positions central section 335 of suction valve spring
retainer/plunger spacer 330. Plunger 311 reciprocates back and
forth through the plunger packing 361 and inner surface 331 of
suction valve spring retainer/plunger spacer 330. The centerlines
of the suction bore 10, suction seat 112, suction valve 114,
suction valve spring 115, plunger bore 30, plunger 311, plunger
packing 361, and plunger packing gland nut 351 are all
substantially co-linear.
[0037] FIG. 10A is an illustration of the fluid end housing 1
showing plunger bore 30, suction bore 10, upper discharge bore 20,
and lower discharge bore 40 without the various other internal
components shown in FIGS. 8 and 9A-C. Plunger bore 30 contains a
packing bore 32 for holding plunger packing 361 and outer surface
332 of flange 333 of suction valve spring retainer/plunger spacer
330. Packing bore 30 also contains a plunger packing gland nut bore
35 for positioning of the plunger packing gland nut 351. Packing
bore 32 is separated from the central plunger chamber 34 by a
packing shoulder 37 which mates with a shoulder 337 on suction
valve spring retainer/plunger spacer 330 as shown in FIGS. 11B and
11C. Plunger packing bore 32 also mates with the cylindrical
section 332 of the flange 333 of suction valve spring
retainer/plunger spacer 330 as illustrated in FIGS. 9 and 11B.
Central section 335 of suction valve spring retainer/plunger spacer
330 is co-linear with central plunger chamber 34 of plunger bore
30.
[0038] Suction bore 10 as illustrated in FIG. 10A contains a
suction seat bore 12 that captures suction seat 112 and a suction
valve bore 14 in which suction valve 114 controls fluid flow.
Suction valve bore 14 also holds suction valve spring 115, suction
valve spring retainer 326, and upper suction valve guide 328.
Immediately adjacent to the suction seat bore 12 is suction port 11
that connects the suction seat 112 and suction valve 114 with the
suction manifold 5 as illustrated in FIG. 8.
[0039] FIG. 10B schematically illustrates Section B-B of FIG. 10A.
FIG. 10C illustrates Section C-C of FIG. 10B. Upper discharge bore
20 of fluid end housing 1 contains a discharge seat bore 22 that
captures the discharge seat 212 as shown in FIG. 9A. Immediately
adjacent to the discharge seat bore 22 is upper discharge port 21
that connects the upper discharge seat 212 and upper discharge
valve 214 with plunger chamber 34 at the bore intersection 25.
Upper discharge bore 20 of fluid end housing 1 also contains an
upper discharge cover bore 26 and an upper discharge cover retainer
bore 27 that mate with upper discharge cover 216 and upper
discharge cover retainer 217, respectively. Upper discharge valve
bore 24 allows fluid passage from upper discharge seat 212 around
upper discharge valve 214 and into upper discharge manifold 28 as
illustrated in FIGS. 9A and 10A.
[0040] Lower discharge bore 40 of fluid end housing 1 contains a
lower discharge seat bore 42 that captures the lower discharge seat
412 as shown in FIG. 9A. Immediately adjacent to the lower
discharge seat bore 42 is lower discharge port 41 that connects the
lower discharge seat 412 and lower discharge valve 414 with plunger
chamber 34 at the bore intersection 45. Lower discharge bore 40 of
fluid end housing 1 also contains a lower discharge cover bore 46
and a lower discharge cover retainer bore 47 that mate with lower
discharge cover 416 and lower discharge cover retainer 417,
respectively. Lower discharge valve bore 44 allows fluid passage
from lower discharge seat 412 around lower discharge valve 414 and
into lower discharge manifold 48 as illustrated in FIGS. 9A and
10A. Upper discharge manifold 28 and lower discharge manifold 48
connect externally to the fluid end housing 1.
[0041] FIGS. 11A, 11B, and 11C schematically illustrate the suction
valve spring retainer/plunger spacer 330. FIG. 11A illustrates an
end orthogonal view of the suction valve spring retainer/plunger
spacer 330. FIG. 11B schematically illustrates an end view of the
suction valve spring retainer/plunger spacer 330. FIG. 11C
schematically illustrates the section view labeled C-C of the
suction valve spring retainer/plunger spacer 330 of FIG. 11B.
Suction valve spring retainer/plunger spacer 330 is constructed
with a flange 333, a central section 335, a suction valve spring
retainer 326 and a suction valve guide 328. Flange section 333 has
a substantially cylindrical outside surface 332 and a shoulder 337
that mate with packing bore 32 and shoulder 37 of fluid end housing
1, respectively, as shown in FIGS. 9B and 9C.
[0042] Central section 335 has a substantially cylindrically inside
surface 331 that it shares with flange 333. The diameter of
cylindrical inner surface 331 is slightly greater than diameter of
plunger 311 to allow plunger 311 to reciprocate freely within the
suction valve spring retainer/plunger spacer 330. Exterior surface
334 of central section 335 of the suction valve spring
retainer/plunger spacer 330 mates with plunger chamber 34 of fluid
end housing 1.
[0043] Central section 335 has two opposing ports 320 and 340 that
align with ports 21 and 41 in fluid end housing 1. The spring
retainer section 326 is designed for the purpose of positioning and
retaining the suction valve spring 115. Spring retainer section 326
connects with central section 335 via webs 395, 396, 397, and 398.
Ports 314, 315, 316, and 317 allow passage for pumped fluid from
the suction valve 114 to the interior of central section 335 of the
suction valve spring retainer/plunger spacer 330.
* * * * *