U.S. patent application number 16/165042 was filed with the patent office on 2019-02-14 for fluid liner wear indicator for suction manifold of reciprocating pump assembly.
The applicant listed for this patent is S.P.M. FLOW CONTROL, INC.. Invention is credited to Charles Ben Shuck.
Application Number | 20190049052 16/165042 |
Document ID | / |
Family ID | 57586660 |
Filed Date | 2019-02-14 |
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United States Patent
Application |
20190049052 |
Kind Code |
A1 |
Shuck; Charles Ben |
February 14, 2019 |
FLUID LINER WEAR INDICATOR FOR SUCTION MANIFOLD OF RECIPROCATING
PUMP ASSEMBLY
Abstract
A manifold through which a fluid is adapted to flow. The
manifold includes an elongated member at least partially defining a
fluid chamber through which the fluid is adapted to flow, a
longitudinal axis, and an interior surface; a fluid liner disposed
within the fluid chamber and adapted to dynamically respond to
pressure fluctuations within the fluid chamber as the fluid flows
therethrough; and a wear indicator positioned radially between the
interior surface of the elongated member and the longitudinal axis.
The fluid liner is subject to wear and/or erosion due to the flow
of the fluid therethrough and/or the dynamic response of the fluid
liner to the pressure fluctuations within the fluid chamber. The
wear indicator is adapted to indicate the degree to which the fluid
liner has been subjected to the wear and/or erosion.
Inventors: |
Shuck; Charles Ben; (Azle,
TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
S.P.M. FLOW CONTROL, INC. |
Fort Worth |
TX |
US |
|
|
Family ID: |
57586660 |
Appl. No.: |
16/165042 |
Filed: |
October 19, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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15188037 |
Jun 21, 2016 |
10113679 |
|
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16165042 |
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62183141 |
Jun 22, 2015 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F16L 41/026 20130101;
F16L 41/03 20130101; F16L 57/06 20130101; E21B 43/26 20130101; F16L
55/041 20130101; F04B 51/00 20130101; F04B 15/02 20130101; F04B
53/14 20130101; F04B 47/00 20130101; Y10T 137/8158 20150401; F16L
55/0332 20130101; F04B 19/22 20130101; F04B 53/16 20130101; F16L
2201/30 20130101 |
International
Class: |
F16L 41/02 20060101
F16L041/02; F04B 51/00 20060101 F04B051/00; F04B 47/00 20060101
F04B047/00; F04B 15/02 20060101 F04B015/02; F04B 53/16 20060101
F04B053/16; E21B 43/26 20060101 E21B043/26; F16L 55/033 20060101
F16L055/033; F16L 41/03 20060101 F16L041/03; F16L 57/06 20060101
F16L057/06; F04B 53/14 20060101 F04B053/14; F04B 19/22 20060101
F04B019/22; F16L 55/04 20060101 F16L055/04 |
Claims
1. A manifold through which a fluid is adapted to flow, the
manifold comprising: an elongated member at least partially
defining a fluid chamber through which the fluid is adapted to
flow, a longitudinal axis, and an interior surface, the elongated
member comprising: one or more inlets via which the fluid flows
into the fluid chamber; and one or more outlets via which the fluid
flows out of the fluid chamber; a fluid liner disposed within the
fluid chamber and adapted to dynamically respond to pressure
fluctuations within the fluid chamber as the fluid flows
therethrough, the fluid liner being subject to wear and/or erosion
due to the flow of the fluid therethrough and the dynamic response
of the fluid liner to the pressure fluctuations, the fluid liner
having a first erosion rate; and a wear body embedded in the fluid
liner and positioned radially between the interior surface of the
elongated member and the longitudinal axis; wherein the wear body
has a second erosion rate that is less than the first erosion rate
of the fluid liner; wherein, as the fluid liner wears and/or
erodes, the wear body protrudes from the fluid liner to an
increasing degree to indicate the degree to which the fluid liner
has been subjected to the wear and/or erosion.
2. The manifold of claim 1, wherein the wear body extends
circumferentially about the longitudinal axis of the elongated
member.
3. The manifold of claim 2, wherein the wear body comprises an
annular ring extending circumferentially about the longitudinal
axis of the elongated member.
4. The manifold of claim 1, wherein the wear body forms a
three-dimensional shape that does not extend circumferentially
about the longitudinal axis of the elongated member.
5. The manifold of claim 1, wherein the wear body comprises a
plurality of separate body segments, at least respective portions
of the body segments of the wear body being embedded in the fluid
liner.
6. The manifold of claim 5, wherein the body segments have
different shapes relative to one another.
7. The manifold of claim 5, wherein at least one of the body
segments forms a three-dimensional shape that does not extend
circumferentially about the longitudinal axis of the elongated
member.
8. The manifold of claim 5, wherein the body segments are
graduated, or stepped, with respect to one another.
9. The manifold of claim 1, wherein the manifold further comprises
a plug, at least a portion of which is embedded in the fluid liner
and positioned radially between the interior surface of the
elongated member and the longitudinal axis; and wherein the wear
body is the portion of the plug that is embedded in the fluid liner
and positioned radially between the interior surface of the
elongated member and the longitudinal axis.
10. The manifold of claim 9, wherein the elongated member comprises
a port; and wherein the plug extends through the port and into the
fluid chamber.
11. The manifold of claim 1, wherein the wear body is in contact
with the interior surface of the elongated member.
12. The manifold of claim 1, wherein at least a portion of the
fluid liner extends between the wear body and the interior surface
of the elongated member so that the wear body does not contact the
interior surface of the elongated member.
13. The manifold of claim 1, wherein, before the fluid liner has
been subjected to the wear and/or erosion, the fluid liner covers
the wear body so that at least a portion of the fluid liner extends
between the wear body and the longitudinal axis of the elongated
member.
14. The manifold of claim 1, wherein the wear body is formed of a
first material and the fluid liner is formed of a second material
that is different from the first material.
15. A suction manifold adapted to be connected to a fluid end block
of a reciprocating pump assembly, the suction manifold comprising:
a fluid chamber through which fluid is adapted to flow; a fluid
liner disposed within the fluid chamber, the fluid liner being
subject to wear and/or erosion, the fluid liner having a first
erosion rate; and a wear body embedded in the fluid liner; wherein
the wear body has a second erosion rate that is less than the first
erosion rate of the fluid liner; wherein, as the fluid liner wears
and/or erodes, the wear body protrudes from the fluid liner to an
increasing degree to indicate the degree to which the fluid liner
has been subjected to the wear and/or erosion.
16. The suction manifold of claim 15, further comprising: an
elongated member at least partially defining the fluid chamber; and
a discharge tube extending from the elongated member, the discharge
tube defining a fluid passage.
17. The suction manifold of claim 16, further comprising: a valve
lift stem extending from the discharge tube; and a bull plug
assembly connected to the valve lift stem.
18. A suction manifold adapted to be connected to a fluid end block
of a reciprocating pump assembly, the suction manifold comprising:
a fluid chamber through which fluid is adapted to flow; a fluid
liner disposed within the fluid chamber, the fluid liner being
subject to wear and/or erosion; and a wear groove formed in the
fluid liner and devoid of any component of the manifold; wherein
the wear groove is adapted to indicate the degree to which the
fluid liner has been subjected to the wear and/or erosion.
19. The suction manifold of claim 18, further comprising: an
elongated member at least partially defining the fluid chamber; and
a discharge tube extending from the elongated member, the discharge
tube defining a fluid passage.
20. The suction manifold of claim 19, further comprising: a valve
lift stem extending from the discharge tube; and a bull plug
assembly connected to the valve lift stem.
21. The suction manifold of claim 18, wherein the wear groove
defines a depth; and wherein, as the fluid liner wears and/or
erodes, the depth of the wear groove diminishes to indicate the
degree to which the fluid liner has been subjected to the wear
and/or erosion.
22. The suction manifold of claim 18, wherein, as the fluid liner
wears and/or erodes, an emergence of the wear groove indicates the
degree to which the fluid liner has been subjected to the wear
and/or erosion.
23. The suction manifold of claim 18, wherein the wear groove is
one of a plurality of wear grooves formed in the fluid liner;
wherein the wear grooves are graduated, or stepped, with respect to
one another; and wherein, as the fluid liner wears and/or erodes,
either a progressive emergence, or a progressive disappearance, of
the wear grooves indicates the degree to which the fluid liner has
been subjected to the wear and/or erosion.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser.
No. 15/188,037, filed Jun. 21, 2016, which claims the benefit of
the filing date of, and priority to, U.S. Application No.
62/183,141, filed Jun. 22, 2015, the entire disclosures of which
are hereby incorporated herein by reference.
TECHNICAL FIELD
[0002] The present disclosure relates generally to a reciprocating
pump and, more specifically, to enhancing the performance,
reliability, and/or capacity of the reciprocating pump by equipping
a fluid liner of the suction manifold of the reciprocating pump
with a wear indicator according to the present disclosure.
BACKGROUND OF THE DISCLOSURE
[0003] Various pumps are used in connection with oilfield
operations such as, for example, cementing, acidizing, or
fracturing of a subterranean wellbore. During such operations,
these pumps are often subject to short and frequent duty cycles,
and are required to deliver a fluid or slurry to the wellbore at
pressures up to 20,000 psi. An exemplary pump for oilfield
operations is a reciprocating pump. A manifold may supply a fluid
to the reciprocating pump, and may distribute the fluid to
different pressure chambers within a fluid end portion of the
reciprocating pump. A fluid liner may be disposed within the
manifold and adapted to dynamically respond to pressure
fluctuations within the manifold as the fluid flows therethrough.
The fluid liner is subject to wear and/or erosion due to the flow
of the fluid therethrough and/or the dynamic response of the fluid
liner to the pressure fluctuations within the manifold as the fluid
flows therethrough. Therefore, what is needed is an apparatus,
manifold, or method that addresses one or more of the foregoing
issues, among other issues.
SUMMARY
[0004] In a first aspect, there is provided a manifold through
which a fluid is adapted to flow, the manifold including an
elongated member at least partially defining a fluid chamber
through which the fluid is adapted to flow, a longitudinal axis,
and an interior surface, the elongated member including one or more
inlets via which the fluid flows into the fluid chamber; and one or
more outlets via which the fluid flows out of the fluid chamber; a
fluid liner disposed within the fluid chamber and adapted to
dynamically respond to pressure fluctuations within the fluid
chamber as the fluid flows therethrough; and a wear indicator, at
least a portion of which is embedded in the fluid liner and
positioned radially between the interior surface of the elongated
member and the longitudinal axis; wherein the fluid liner is
subject to wear and/or erosion due to the flow of the fluid
therethrough and/or the dynamic response of the fluid liner to the
pressure fluctuations within the fluid chamber as the fluid flows
therethrough; and wherein the wear indicator is adapted to indicate
the degree to which the fluid liner has been subjected to the wear
and/or erosion.
[0005] In an exemplary embodiment, the wear indicator includes a
plurality of separate segments that are graduated, or stepped, with
respect to one another; and wherein at least a portion of each of
the respective segments is embedded in the fluid liner.
[0006] In another exemplary embodiment, the wear indicator forms an
annular ring defining a cross section and extending
circumferentially about the longitudinal axis of the elongated
member.
[0007] In yet another exemplary embodiment, the wear indicator is
in contact with the interior surface of the elongated member.
[0008] In certain exemplary embodiments, at least a portion of the
fluid liner extends between the wear indicator and the interior
surface of the elongated member so that the wear indicator does not
contact the interior surface of the elongated member.
[0009] In an exemplary embodiment, the fluid liner covers the wear
indicator so that at least a portion of the fluid liner extends
between the wear indicator and the longitudinal axis of the
elongated member, thereby preventing the fluid that flows through
the fluid chamber from contacting the wear indicator.
[0010] In another exemplary embodiment, the fluid liner does not
cover at least a portion of the wear indicator, thereby allowing
the fluid that flows through the fluid chamber to contact the wear
indicator.
[0011] In yet another exemplary embodiment, the wear indicator is
formed of a first material and the fluid liner is formed of a
second material that is different from the first material; and,
when the fluid flows through the fluid chamber, the first material
erodes at a first rate and the second material erodes at a second
rate.
[0012] In certain exemplary embodiments, the first rate is greater
than or equal to the second rate.
[0013] In an exemplary embodiment, the first rate is less than the
second rate.
[0014] In a second aspect, there is provided a reciprocating pump
assembly, the fluid end portion including: a fluid end block, the
fluid end block including a pressure chamber, a plunger adapted to
reciprocate within the pressure chamber, and a discharge manifold
in fluid communication with the pressure chamber; and a suction
manifold through which a fluid is adapted to flow, wherein the
suction manifold is connected to the fluid end block, and wherein
the suction manifold includes an elongated member at least
partially defining a fluid chamber through which the fluid is
adapted to flow, a longitudinal axis, and an interior surface, the
elongated member including an inlet via which the fluid flows into
the fluid chamber, and an outlet via which the fluid flows out of
the fluid chamber, the outlet being in fluid communication with the
pressure chamber; a fluid liner disposed within the fluid chamber
and adapted to dynamically respond to pressure fluctuations within
the fluid chamber as the fluid flows therethrough; and a wear
indicator, at least a portion of which is embedded in the fluid
liner and positioned radially between the interior surface of the
elongated member and the longitudinal axis; wherein the fluid liner
is subject to wear and/or erosion due to the flow of the fluid
therethrough and/or the dynamic response of the fluid liner to the
pressure fluctuations within the fluid chamber as the fluid flows
therethrough; and wherein the wear indicator is adapted to indicate
the degree to which the fluid liner has been subjected to the wear
and/or erosion.
[0015] In an exemplary embodiment, the wear indicator includes a
plurality of separate segments that are graduated, or stepped, with
respect to one another; and wherein at least a portion of each of
the respective segments is embedded in the fluid liner.
[0016] In another exemplary embodiment, the wear indicator forms an
annular ring defining a cross section and extending
circumferentially about the longitudinal axis of the elongated
member.
[0017] In yet another exemplary embodiment, the wear indicator is
in contact with the interior surface of the elongated member.
[0018] In certain exemplary embodiments, at least a portion of the
fluid liner extends between the wear indicator and the interior
surface of the elongated member so that the wear indicator does not
contact the interior surface of the elongated member.
[0019] In an exemplary embodiment, the fluid liner covers the wear
indicator so that at least a portion of the fluid liner extends
between the wear indicator and the longitudinal axis of the
elongated member, thereby preventing the fluid that flows through
the fluid chamber from contacting the wear indicator.
[0020] In another exemplary embodiment, the fluid liner does not
cover at least a portion of the wear indicator, thereby allowing
the fluid that flows through the fluid chamber to contact the wear
indicator.
[0021] In yet another exemplary embodiment, the wear indicator is
formed of a first material and the fluid liner is formed of a
second material that is different from the first material; and,
when the fluid flows through the fluid chamber, the first material
erodes at a first rate and the second material erodes at a second
rate.
[0022] In certain exemplary embodiments, the first rate is greater
than or equal to the second rate.
[0023] In an exemplary embodiment, the first rate is less than the
second rate.
[0024] In a third aspect, there is provided a manifold through
which a fluid is adapted to flow, the manifold including an
elongated member at least partially defining a fluid chamber
through which the fluid is adapted to flow, a longitudinal axis,
and an interior surface, the elongated member including: one or
more inlets via which the fluid flows into the fluid chamber; and
one or more outlets via which the fluid flows out of the fluid
chamber; a fluid liner disposed within the fluid chamber and
adapted to dynamically respond to pressure fluctuations within the
fluid chamber as the fluid flows therethrough; and a wear indicator
positioned radially between the interior surface of the elongated
member and the longitudinal axis, the wear indicator including at
least one of: a wear body embedded in the fluid liner; and a wear
groove formed in the fluid liner; wherein the fluid liner is
subject to wear and/or erosion due to the flow of the fluid
therethrough and/or the dynamic response of the fluid liner to the
pressure fluctuations within the fluid chamber as the fluid flows
therethrough; and wherein the wear indicator is adapted to indicate
the degree to which the fluid liner has been subjected to the wear
and/or erosion.
[0025] In an exemplary embodiment, the wear indicator includes the
wear body, the wear body including a plurality of separate body
segments that are graduated, or stepped, with respect to one
another, at least respective portions of the body segments of the
wear body being embedded in the fluid liner.
[0026] In another exemplary embodiment, the wear indicator includes
the wear body, the wear body forming an annular ring extending
circumferentially about the longitudinal axis of the elongated
member.
[0027] In yet another exemplary embodiment, the wear indicator
includes the wear body, the wear body being in contact with the
interior surface of the elongated member.
[0028] In certain exemplary embodiments, the wear indicator
includes the wear body, at least a portion of the fluid liner
extending between the wear body and the interior surface of the
elongated member so that the wear body does not contact the
interior surface of the elongated member.
[0029] In an exemplary embodiment, the wear indicator includes the
wear body, the fluid liner covering the wear body so that at least
a portion of the fluid liner extends between the wear body and the
longitudinal axis of the elongated member, thereby initially
preventing the fluid that flows through the fluid chamber from
contacting the wear body.
[0030] In another exemplary embodiment, the wear indicator includes
the wear body, the wear body being formed of a first material and
the fluid liner being formed of a second material that is different
from the first material; and, when the fluid flows through the
fluid chamber, the first material erodes at a first rate and the
second material erodes at a second rate.
[0031] In yet another exemplary embodiment, the wear indicator
includes the wear groove, the wear groove including a plurality of
separate groove segments that are graduated, or stepped, with
respect to one another.
[0032] In certain exemplary embodiment, the wear indicator includes
the wear groove, the wear groove forming an annular groove
extending circumferentially about the longitudinal axis of the
elongated member.
[0033] In an exemplary embodiment, the wear indicator includes the
wear groove, the wear groove being formed in the interior of the
fluid liner.
[0034] In a fourth aspect, there is provided a fluid end portion
for a reciprocating pump assembly, the fluid end portion including
a fluid end block, including: a pressure chamber; a plunger adapted
to reciprocate within the pressure chamber; and a discharge
manifold in fluid communication with the pressure chamber; and a
suction manifold through which a fluid is adapted to flow, the
suction manifold being connected to the fluid end block and
including: an elongated member at least partially defining a fluid
chamber through which the fluid is adapted to flow, a longitudinal
axis, and an interior surface, the elongated member including: an
inlet via which the fluid flows into the fluid chamber; and an
outlet via which the fluid flows out of the fluid chamber, the
outlet being in fluid communication with the pressure chamber; a
fluid liner disposed within the fluid chamber and adapted to
dynamically respond to pressure fluctuations within the fluid
chamber as the fluid flows therethrough; and a wear indicator
positioned radially between the interior surface of the elongated
member and the longitudinal axis, the wear indicator including at
least one of: a wear body embedded in the fluid liner; and a wear
groove formed in the fluid liner; wherein the fluid liner is
subject to wear and/or erosion due to the flow of the fluid
therethrough and/or the dynamic response of the fluid liner to the
pressure fluctuations within the fluid chamber as the fluid flows
therethrough; and wherein the wear indicator is adapted to indicate
the degree to which the fluid liner has been subjected to the wear
and/or erosion.
[0035] In an exemplary embodiment, the wear indicator includes the
wear body, the wear body including a plurality of separate body
segments that are graduated, or stepped, with respect to one
another, at least respective portions of the body segments of the
wear body being embedded in the fluid liner.
[0036] In another exemplary embodiment, the wear indicator includes
the wear body, the wear body forming an annular ring extending
circumferentially about the longitudinal axis of the elongated
member.
[0037] In yet another exemplary embodiment, the wear indicator
includes the wear body, the wear body being in contact with the
interior surface of the elongated member.
[0038] In certain exemplary embodiments, the wear indicator
includes the wear body, at least a portion of the fluid liner
extending between the wear body and the interior surface of the
elongated member so that the wear body does not contact the
interior surface of the elongated member.
[0039] In an exemplary embodiment, the wear indicator includes the
wear body, the fluid liner covering the wear body so that at least
a portion of the fluid liner extends between the wear body and the
longitudinal axis of the elongated member, thereby preventing the
fluid that flows through the fluid chamber from contacting the wear
body.
[0040] In another exemplary embodiment, the wear indicator includes
the wear body, the wear body being formed of a first material and
the fluid liner being formed of a second material that is different
from the first material; and, when the fluid flows through the
fluid chamber, the first material erodes at a first rate and the
second material erodes at a second rate.
[0041] In yet another exemplary embodiment, the wear indicator
includes the wear groove, the wear groove including a plurality of
separate groove segments that are graduated, or stepped, with
respect to one another.
[0042] In certain exemplary embodiments, the wear indicator
includes the wear groove, the wear groove forming an annular groove
extending circumferentially about the longitudinal axis of the
elongated member.
[0043] In an exemplary embodiment, the wear indicator includes the
wear groove, the wear groove being formed in the interior of the
fluid liner.
BRIEF DESCRIPTION OF THE DRAWINGS
[0044] Various embodiments of the present disclosure will be
understood more fully from the detailed description given below and
from the accompanying drawings of various embodiments of the
disclosure. In the drawings, like reference numbers may indicate
identical or functionally similar elements.
[0045] FIG. 1 is an elevational view of a reciprocating pump
assembly including a power end portion and a fluid end portion, the
fluid end portion including a manifold, according to an exemplary
embodiment.
[0046] FIG. 2 is a perspective view of the manifold of FIG. 1,
according to an exemplary embodiment.
[0047] FIG. 3 is an elevational side view of the manifold of FIG.
2, according to an exemplary embodiment.
[0048] FIG. 4 is an elevational end view of the manifold of FIGS. 2
and 3, according to an exemplary embodiment.
[0049] FIG. 5 is a cross-sectional side view of the manifold of
FIGS. 2-4, the manifold including a fluid liner, according to an
exemplary embodiment.
[0050] FIG. 6 is a cross-sectional end view of the manifold of FIG.
5, the manifold including a fluid liner, according to an exemplary
embodiment.
[0051] FIG. 7A is a detailed view of an exemplary embodiment of a
portion of the manifold of FIG. 5, the manifold including the fluid
liner and a wear indicator, according to an exemplary
embodiment.
[0052] FIG. 7B is a detailed view of another exemplary embodiment
of a portion of the manifold of FIG. 5, the manifold including the
fluid liner and a wear indicator, according to an exemplary
embodiment.
[0053] FIG. 7C is a detailed view of yet another exemplary
embodiment of a portion of the manifold of FIG. 5, the manifold
including the fluid liner and a wear indicator, according to an
exemplary embodiment.
[0054] FIG. 7D is a detailed view of still yet another exemplary
embodiment of a portion of the manifold of FIG. 5, the manifold
including the fluid liner and a wear indicator, according to an
exemplary embodiment.
[0055] FIG. 8A is a detailed view of an exemplary embodiment of a
portion of the manifold of FIG. 5, the manifold including the fluid
liner and a wear indicator, according to an exemplary
embodiment.
[0056] FIG. 8B is a detailed view of another exemplary embodiment
of a portion of the manifold of FIG. 5, the manifold including the
fluid liner and a wear indicator, according to an exemplary
embodiment.
[0057] FIG. 8C is a detailed view of yet another exemplary
embodiment of a portion of the manifold of FIG. 5, the manifold
including the fluid liner and a wear indicator, according to an
exemplary embodiment.
DETAILED DESCRIPTION
[0058] In an exemplary embodiment, as illustrated in FIG. 1, a
reciprocating pump assembly is generally referred to by the
reference numeral 10 and includes a power end portion 12 and a
fluid end portion 14 operably coupled thereto. The power end
portion 12 includes a crankshaft housing 16 in which a crankshaft
(not shown) is disposed, the crankshaft being operably coupled to
an engine or motor (not shown), which is adapted to drive the
crankshaft. The fluid end portion 14 includes a fluid end block 18,
which is connected to the crankshaft housing 16 via a plurality of
stay rods 20, two of which are shown in FIG. 1. An inlet such as,
for example, a suction manifold 22 is connected to the fluid end
block 18 and includes an interior passage 24 and a mounting plate
26. The structure of the suction manifold 22 will be discussed in
further detail below. The fluid end block 18 also includes a
discharge manifold 28 that defines an interior passage 29, which is
spaced in a parallel relation from the interior passage 24 of the
suction manifold 22. The fluid end block 18 includes a plurality of
pressure chambers (not shown) formed therein so that each pressure
chamber is in fluid communication with each of the interior passage
24 of the suction manifold 22 and the interior passage 29 of the
discharge manifold 28. The fluid end portion 14 further includes a
plurality of plungers 30 that are received by, and extend within,
the respective pressure chambers. The plungers 30 and their
respective pressure chambers are arranged transversely across the
fluid end portion 14. Further, each plunger 30 is adapted to
reciprocate within the corresponding pressure chamber during
operation of the reciprocating pump assembly 10. The mounting plate
26 of the suction manifold 22 mates against a bottom surface 32 of
the fluid end block 18.
[0059] A stationary crosshead housing 34 is connected to the
crankshaft housing 16. In several exemplary embodiments, the
stationary crosshead housing 34 is part of the crankshaft housing
16. A plurality of pony rods 36 extend out of the stationary
crosshead housing 34. Respective ones of the plungers 30 are
connected to the pony rods 36, respectively. One of the pony rods
36, and the corresponding plunger 30 connected thereto, are shown
in FIG. 1. A plurality of sleeves 38 (four shown in FIG. 1) extend
between the stationary crosshead housing 34 and the fluid end block
18. The stay rods 20 extend from at least the crankshaft housing
16, through the stationary crosshead housing 34, through respective
ones of the sleeves 38, and through respective bores (not shown)
formed in the fluid end block 18. The stay rods 20 include
respective threaded ends, which are threadably engaged with
respective nuts 40 to connect the fluid end block 18 to the
crankshaft housing 16.
[0060] The fluid end block 18 further includes a plurality of
integrally formed bosses 42 (one shown in FIG. 1) which protrude
towards the crankshaft housing 16. A nose plate, or an alignment
plate 44, is engaged with a surface 46 of the fluid end block 18.
The surface 46 is defined by an integrally formed web 48 of the
fluid end block 18, from which the bosses 42 protrude. The sleeves
38 extend through the alignment plate 44 and engage the fluid end
block 18.
[0061] In several exemplary embodiments, each of the bosses 42 may
be characterized as, or may be a part of, a packing gland. Since
the bosses 42 are integrally formed with the fluid end block 18,
each of the bosses 42 may be characterized as, or may be a part of,
an integrated packing gland. In an exemplary embodiment, instead of
being integrally formed with the fluid end block 18, each of the
bosses 42 may be connected to the fluid end block 18 using
fasteners such as, for example, bolts. In an exemplary embodiment,
instead of being integrally formed with the fluid end block 18, the
bosses 42 and the web 48 may be connected to the fluid end block 18
using fasteners such as, for example, bolts.
[0062] In several exemplary embodiments, the combination of at
least each pressure chamber and the corresponding plunger 30 may be
characterized as a plunger throw. The reciprocating pump assembly
10 may be a triplex pump with the fluid end portion 14 having a set
of three plunger throws, each including respective ones of the
pressure chambers and the plungers 30. Although the reciprocating
pump assembly 10 could be a triplex pump, as described above, the
reciprocating pump assembly 10 may alternatively include any number
of plunger throws such as, for example, one plunger throw, two
plunger throws (duplex pump), four plunger throws (quadriplex
pump), five plunger throws (quintuplex pump), or more.
[0063] During operation, in several exemplary embodiments, the
power end portion 12 is adapted to cause the plungers 30, one of
which is shown in FIG. 1, to reciprocate in and out of the pressure
chambers, respectively, thereby causing fluid to be: sucked into
one or more of the pressure chambers via the interior passage 24 of
the suction manifold 22; pressurized in the one or more of the
pressure chambers; and discharged out of the fluid end block 18 via
the interior passage 29 of the discharge manifold 28. In several
exemplary embodiments, the reciprocating pump assembly 10 is used
in connection with various oilfield operations such as, for
example, cementing, acidizing, or fracturing of a subterranean
wellbore. During such operations, these reciprocating pumps are
often subject to short and frequent duty cycles, and are required
to deliver a fluid or slurry to the wellbore at pressures up to
20,000 psi. In an exemplary embodiment, the reciprocating pump
assembly is configured to conduct cementing and/or acidizing
operations within an oil and gas well. In an exemplary embodiment,
the reciprocating pump assembly 10 is a mud pump, or a hydraulic
fracturing pump, which is configured to hydraulically fracture (or
"frac") an oil and gas well. In an exemplary embodiment, the
reciprocating pump assembly 10 is a pump suitable for performing
high pressure fracturing operations, and may be used to obtain
pressures of about 20,000 psi or more. In an exemplary embodiment,
the reciprocating pump assembly 10 is a pump suitable for
performing high pressure fracturing operations, and may be used to
obtain pressures of less than about 20,000 psi.
[0064] In an exemplary embodiment, as illustrated in FIGS. 2-4 with
continuing reference to FIG. 1, the suction manifold 22 of the
fluid end portion 14 includes a generally cylindrical elongated
manifold member 50. The elongated manifold member 50 includes
opposing end portions 50a and 50b. A longitudinal axis 52 is
defined by the elongated manifold member 50. Axially-spaced
discharge tubes 54a, 54b, and 54c extend upwardly from the
elongated manifold member 50 in a direction that is perpendicular
to the longitudinal axis 52. The tubes 54a, 54b, and 54c define
fluid passages 56a, 56b, and 56c, respectively (FIG. 2). Further,
the tubes 54a, 54b, and 54c extend to the mounting plate 26, which
mates against the bottom surface 32 of the fluid end block 18 and
may be connected to respective fluid inlet members, or inlet valve
housings, of the fluid end block 18. An end plate 58 is connected
to the elongated manifold member 50 at the end portion 50a, and an
end cap 60 is connected to the elongated manifold member 50 at the
end portion 50b. A connector 62 extends from the end plate 58, and
is adapted to be connected to a fluid conduit. A cleanout stem 64
extends from the end cap 60 and along the longitudinal axis 52.
Valve lift stems 66a, 66b, and 66c extend from the tubes 54a, 54b,
and 54c, respectively. Respective bull plug assemblies 68 are
connected to each of the cleanout stem 64 and the valve lift stems
66a, 66b, and 66c.
[0065] In an exemplary embodiment, as illustrated in FIGS. 5 and 6,
the elongated manifold member 50 defines a cylindrical inside
surface 70, and at least partially defines a fluid chamber 72. The
elongated manifold member 50 includes a fluid inlet 74 at one axial
end portion thereof. The tubes 54a, 54b, and 54c define cylindrical
inside surfaces 76a, 76b, and 76c, respectively. A single,
continuous fluid liner 78 is disposed within the fluid chamber 72.
In an exemplary embodiment, the fluid liner 78 is bonded to the
cylindrical inside surface 70 of the elongated manifold member 50.
The fluid liner 78 may also be bonded to the cylindrical inside
surfaces 76a, 76b, and 76c of the respective tubes 54a, 54b, and
54c. The fluid liner 78 is adapted to dynamically respond to
pressure fluctuations within the fluid chamber 72 during fluid flow
therethrough while the bond between the fluid liner 78 and the
cylindrical inside surface 70 and/or the bond between the fluid
liner 78 and the inside surfaces 76a, 76b, and 76c is maintained.
The portion of the fluid liner 78 permanently bonded to the inside
surface 70 is cylindrical in shape, corresponding to the
cylindrical shape of the inside surface 70. The respective portions
of the fluid liner 78 bonded to the inside surfaces 76a, 76b, and
76c are cylindrical in shape, corresponding to the respective
cylindrical shapes of the inside surfaces 76a, 76b, and 76c. As a
result, the fluid liner 78 defines radially-extending fluid
passages 80a, 80b, and 80c that are coaxial with the tubes 54a,
54b, and 54c, respectively. When the mounting plate 26 mates
against the bottom surface 32 of the fluid end block 18, and is
thus connected to the respective inlet valve housings of the fluid
end block 18, the fluid chamber 72 is in fluid communication with
the respective inlet valve housings via the fluid passages 80a,
80b, and 80c. The fluid passages 80a, 80b and 80c are axially
spaced from each other so that respective portions of the fluid
liner 78 extend axially between the fluid passages 80a and 80b, and
between the fluid passages 80b and 80c.
[0066] The fluid liner 78 may be formed of a resilient material
that includes, for example, a foaming nitrile rubber type material
(also known as Buna-N, Perbunan or Nitrile Butadiene Rubber (NBR)
and provided under trades names such as Nipol.RTM., Krynac.RTM.,
and Europrene.RTM.). The fluid liner 78 may be formed of a
resilient material that includes, for example, nitrile rubber foam
that includes at least one of a nitrile rubber, a conductive carbon
black, and a plasticizer, or any combination of the foregoing. The
fluid liner 78 may be formed of a resilient material that includes
additional foam materials and/or non-foam materials including, but
not limited to, ethylene propylene diene monomer (EPDM) rubber. The
fluid liner 78 may be formed of a resilient material that includes
cells filled with an inert gas such as, but not limited to,
nitrogen.
[0067] In operation, with continuing reference to FIGS. 1-6, the
operation of the reciprocating pump assembly 10, to which the
mounting plate 26 is connected, causes fluid to be sucked or drawn
into the suction manifold 22 from a fluid source. In addition to,
or instead of, the fluid being drawn into the suction manifold by
the operation of the reciprocating pump assembly 10, an inlet valve
may be opened, allowing pressurized fluid to flow into the suction
manifold 22 from the fluid source. More particularly, the fluid
flows from the fluid source, through the fluid inlet 74, and into
the fluid chamber 72. The fluid flows through the fluid chamber 72,
and out of the fluid chamber 72 via one or more of the
radially-extending fluid passages 80a, 80b and 80c. The fluid then
flows out of the discharge tubes 54a, 54b, and 54c, and into the
respective inlet valve housings of the fluid end block 18 of the
reciprocating pump assembly 10. The fluid is subsequently drawn
into the respective pressure chambers of the fluid end block 18,
which are in fluid communication with the inlet valve housings. The
fluid is pressurized in the pressure chambers, via the plungers 30,
and discharged into the discharge manifold 28 via respective outlet
valve housings that are in fluid communication with the pressure
chambers.
[0068] During the above-described operation of the suction manifold
22, and thus during the flow of fluid through the suction manifold
22, pressure fluctuations occur within the fluid chamber 72 due to,
for example, sudden fluid velocity changes, sudden fluid
acceleration changes, acceleration-induced parameters, pressure
pulses, the respective operations of valves disposed in the inlet
valve housings, the pressurization of the fluid in the pressure
chambers, the respective operations of valves disposed in the
outlet valve housings, operational variations of the fluid source,
or any combination of the foregoing. The fluid liner 78 dynamically
responds to the pressure fluctuations within the fluid chamber 72
by, for example, flexing and/or undergoing compression in one or
more portions thereof, while maintaining the permanent bond between
the fluid liner 78 and inside surfaces 76a, 76b, and 76c. As a
result, the fluid liner 78 changes the inlet fluid volume capacity
of the reciprocating pump assembly in response to the pressure
fluctuations within the fluid chamber 72, while maintaining the
permanent bond between the fluid liner 78 and the inside surfaces
76a, 76b, and 76c. By dynamically responding to the pressure
fluctuations within the fluid chamber 72, the fluid liner 78
operates to stabilize fluid velocities in the fluid chamber 72 and
the radially-extending fluid passages 80a, 80b, and 80c. The fluid
liner 78 dynamically responds to the pressure fluctuations within
the fluid chamber 72 by, for example, dampening pulsations within
the fluid chamber 72 resulting from fluid flow therethrough,
absorbing water-hammering effects within the suction manifold 22,
reducing or attenuating vibration within the suction manifold 22,
and/or decreasing shock waves within the suction manifold 22. The
fluid liner 78 can store kinetic energy generated by the motion of
the fluid therethrough by local compression of the fluid liner 78.
The kinetic energy can be released from the fluid liner 78, which
assists the fluid acceleration into the pressure chambers of the
fluid end block 18. This storing and discharging of kinetic energy
increases the efficiency of the reciprocating pump assembly and
reduces fluid cavitation by attenuating the pulsations and
acoustical pressure waves created by accelerating and decelerating
of the pumped fluid.
[0069] During the above-described operation of the suction manifold
22, the fluid may contain slurry, mud, drilling fluid, water, other
types of liquids, and/or any combination thereof. The fluid may
contain entrained solid particulates such as, for example,
proppant, soil, mined ore particulates, tailings, etc. The fluid
liner 78 operates to concentrate any entrained solid particulates
in the fluid flow in the center of the elongated manifold member
50, and the center of each of the fluid passages 80a, 80b, and 80c,
thereby reducing the quantity of entrained solid particulates that
undesirably collect or accumulate in the suction manifold 22 and
thus do not flow into the pressure chambers of the fluid end block
18.
[0070] In an exemplary embodiment, as illustrated in FIGS. 7A-7D
with continuing reference to FIGS. 1-6, the suction manifold 22
includes a wear indicator formed in the fluid liner 78. In several
exemplary embodiments, the wear indicator includes a wear body 82,
at least a portion of which is embedded within the fluid liner 78.
The wear body 82 is positioned radially between the cylindrical
inside surface 70 of the elongated manifold member 50 and the
longitudinal axis 52. In several exemplary embodiments, the wear
body 82 forms an annular ring extending about a circumference of
the fluid chamber 72, as shown in FIG. 7A. The shape of a
cross-section of the annular wear body 82 may form any one of a
number of shapes such as, for example, a circular shape, a
triangular shape, a rectangular shape, a polygonal shape, another
planar shape, or any combination thereof. Alternatively, in several
exemplary embodiments, the wear body 82 may form a
three-dimensional shape that does not extend circumferentially
about the fluid chamber 72. Examples of such shapes are shown in
FIG. 7B, and may include any one of a number of shapes such as, for
example, a spherical shape, a prismatic shape, a pyramid shape, a
cubic shape, a cylindrical shape, a conical shape, another
three-dimensional shape, or any combination thereof. In several
exemplary embodiments, as shown in FIG. 7C, the suction manifold 22
includes a wear indicator, the wear indicator including multiple
wear bodies 82 (i.e., separate body segments). The multiple wear
bodies 82 may have different sizes and/or shapes relative to one
another. For example, the multiple wear bodies 82 may be graduated,
or stepped, with respect to one another, as shown in FIG. 7C. In
several exemplary embodiments, the wear body 82 forms a portion of
a plug 84 that is threaded into the interior chamber 72 and the
fluid liner 78 through a threaded port 86 in the elongated manifold
member 50, as shown in FIG. 7D.
[0071] In several exemplary embodiments, one or more of the wear
bodies 82 are in contact with the inside surface 70 of the
elongated manifold member 50, as shown in FIGS. 7A-7D. However, in
several exemplary embodiments, one or more of the wear bodies 82
are not in contact with the inside surface 70. In several exemplary
embodiments, the fluid liner 78 covers one or more of the wear
bodies 82, preventing any fluid that flows through the fluid
chamber 72 of the suction manifold 22 from contacting the one or
more wear bodies 82. As a result, the wear bodies 82 covered by the
fluid liner 78 are not initially exposed to the fluid flowing
through the suction manifold 22. However, in several exemplary
embodiments, at least respective portions of one or more of the
wear bodies 82 are not covered by the fluid liner 78, and are thus
exposed to the fluid flowing through fluid chamber 72 of the
suction manifold 22.
[0072] In several exemplary embodiments, one or more of the wear
bodies 82 are formed of a material having an erosion rate greater
than or equal to an erosion rate of the fluid liner 78. In several
exemplary embodiments, one or more of the wear bodies 82 are formed
of a material having an erosion rate less than the erosion rate of
the fluid liner 78. In several exemplary embodiments, one or more
of the wear bodies 82 are formed of a resilient material that
includes, for example, a foaming nitrile rubber type material (also
known as Buna-N, Perbunan or Nitrile Butadiene Rubber (NBR) and
provided under trades names such as Nipol.RTM., Krynac.RTM., and
Europrene.RTM.). In several exemplary embodiments, one or more of
the wear bodies 82 is formed of a resilient material that includes,
for example, nitrile rubber foam that includes at least one of a
nitrile rubber, a conductive carbon black, and a plasticizer, or
any combination of the foregoing. In several exemplary embodiments,
one or more of the wear bodies 82 is formed of a resilient material
that includes additional foam materials and/or non-foam materials
including, but not limited to, ethylene propylene diene monomer
(EPDM) rubber. In several exemplary embodiments, one or more of the
wear bodies 82 are formed of a resilient material that includes
cells filled with an inert gas such as, but not limited to,
nitrogen. In several exemplary embodiments, one or more of the wear
bodies 82 are formed of another material such as, for example, a
metal material, a plastic material, a ceramic material, other
materials, and/or any combination thereof.
[0073] During the above-described operation of the suction manifold
22, the fluid liner 78 is subject to wear and/or erosion from the
entrained solid particulates and the pressure fluctuations of the
fluid within the fluid chamber 72. As the fluid liner 78 erodes,
the wear bodies 82 emerge from the eroding fluid liner 78 and
become (or remain) exposed to the fluid flowing through the fluid
chamber 72 of the suction manifold 22. Thereafter, in those
embodiments where one or more of the wear bodies 82 have an erosion
rate greater than or equal to the erosion rate of the fluid liner
78, the one or more wear bodies 82 erode at a rate substantially
equal to the erosion rate of the fluid liner 78. However, in those
embodiments where one or more of the wear bodies 82 have an erosion
rate less than the erosion rate of the fluid liner 78, the one or
more wear bodies 82 protrude progressively from the fluid liner 78
as the fluid liner 78 continues to erode. As material erodes from
the fluid liner 78, the capability of the fluid liner 78 to
dynamically respond to pressure fluctuations within the fluid
chamber 72 deteriorates. To ensure peak performance, the fluid
liner 78 must be replaced after a predetermined amount of material
has been worn or eroded from the fluid liner 78. In order to
determine whether the predetermined amount of material has eroded
from the fluid liner 78, the wear bodies 82 may be visually
inspected by removing the end plate 58 from the end portion 50a of
the elongated manifold member 50 and/or by removing the cleanout
stem 64 from the end cap 60 of the elongated manifold member 50. In
those embodiments where one or more of the wear bodies 82 are in
contact with the inside surface 70, the emergence of the one or
more wear bodies 82 as the fluid liner 78 erodes may indicate that
the fluid liner 78 needs replacement. Alternatively, in those
embodiments where one or more of the wear bodies 82 are not in
contact with the inside surface 70, the disappearance of the one or
more wear bodies 82, i.e., the complete erosion of the wear bodies
82, may indicate that the fluid liner 78 needs replacement. In
those embodiments where the suction manifold 22 includes multiple
wear bodies 82 (i.e., separate body segments) that are graduated,
or stepped, with respect to one another (shown in FIG. 7C), the
progressive emergence (or disappearance) of the respective wear
bodies 82 may indicate differing amounts of erosion from the fluid
liner 78, thus indicating the remaining useful life of the fluid
liner 78. Alternatively, in those embodiments where the plug 84 is
employed (shown in FIG. 7D), the plug 84 itself, including the wear
body 82, may be inspected upon removal of the plug 84 from the
threaded port 86.
[0074] In another exemplary embodiment, as illustrated in FIGS.
8A-8C with continuing reference to FIGS. 1-6 and 7A-7D, instead of,
or in addition to, the wear body 82, the suction manifold 22
includes another wear indicator, such as, for example, a wear
groove 88 formed in the fluid liner 78. The wear groove 88 is
positioned radially between the cylindrical inside surface 70 of
the elongated manifold member 50 and the longitudinal axis 52. In
several exemplary embodiments, the wear groove 88 forms a
three-dimensional shape that does not extend circumferentially
about the fluid chamber 72, as shown in FIG. 8A. Examples of such
shapes may include, but are not limited to, a spherical shape, a
prismatic shape, a pyramid shape, a cubic shape, a cylindrical
shape, a conical shape, another three-dimensional shape, or any
combination thereof. In several exemplary embodiments, the wear
groove 88 forms an annular groove extending about a circumference
of the fluid chamber 72, as shown in FIG. 8B. The shape of a
cross-section of the annular wear groove 88 may form any one of a
number of shapes such as, for example, a circular shape, a
triangular shape, a rectangular shape, a polygonal shape, another
planar shape, or any combination thereof. In several exemplary
embodiments, as shown in FIG. 8C, the suction manifold 22 includes
a wear groove, the wear groove including multiple wear grooves 88
(i.e., separate groove segments). The multiple wear grooves 88 may
form a pattern in the interior of the fluid liner 78. Additionally,
the multiple wear grooves 88 may have different sizes, shapes, and
or depths relative to one another. For example, the respective
depths of the multiple wear grooves 88 may be graduated, or
stepped, with respect to one another, as shown in FIG. 8C.
[0075] In several exemplary embodiments, one or more of the wear
grooves 88 are formed in the interior of the fluid liner 78, as
shown in FIGS. 8A-8C. As a result, at least respective portions of
the one or more wear grooves 88 are not covered by the fluid liner
78 and are thus exposed to the fluid flowing through fluid chamber
72 of the suction manifold 22. However, in several exemplary
embodiments, one or more of the wear grooves are not formed in the
interior of the fluid liner 78 so that the fluid liner 78 covers at
least respective portions of one or more of the wear grooves 88. As
a result, the fluid liner 78 initially prevents any fluid that
flows through the fluid chamber 72 of the suction manifold 22 from
contacting the one or more wear grooves 88.
[0076] As discussed, during the above-described operation of the
suction manifold 22, the fluid liner 78 is subject to wear and/or
erosion from the entrained solid particulates and the pressure
fluctuations of the fluid within the fluid chamber 72. As the fluid
liner 78 erodes, the respective depths of the wear grooves 88
gradually diminish until one or more of the wear grooves disappears
entirely. As material erodes from the fluid liner 78, the
capability of the fluid liner 78 to dynamically respond to pressure
fluctuations within the fluid chamber 72 deteriorates. To ensure
peak performance, the fluid liner 78 must be replaced after a
predetermined amount of material has been worn or eroded from the
fluid liner 78. In order to determine whether the predetermined
amount of material has eroded from the fluid liner 78, the wear
grooves 88 may be visually inspected by removing the end plate 58
from the end portion 50a of the elongated manifold member 50 and/or
by removing the cleanout stem 64 from the end cap 60 of the
elongated manifold member 50. In those embodiments where one or
more of the wear grooves 88 are formed in the interior of the fluid
liner 78, the degree to which the respective depths of the one or
more wear grooves 88 has diminished (or the complete disappearance
of one or more of the wear grooves 88), may indicate that the fluid
liner 78 needs replacement. Alternatively, in those embodiments
where one or more of the wear grooves 88 are not formed in the
interior of the fluid liner 78, the emergence of the one or more
wear grooves 88 as the fluid liner 78 erodes may indicate that the
fluid liner 78 needs replacement. Finally, in those embodiments
where the suction manifold 22 includes grooves 88 that are
graduated, or stepped, with respect to one another (shown in FIG.
8C), the progressive emergence (or disappearance) of the respective
wear grooves 88 may indicate differing amounts of erosion from the
fluid liner 78, thus indicating the remaining useful life of the
fluid liner 78.
[0077] In the foregoing description of certain embodiments,
specific terminology has been resorted to for the sake of clarity.
However, the disclosure is not intended to be limited to the
specific terms so selected, and it is to be understood that each
specific term includes other technical equivalents which operate in
a similar manner to accomplish a similar technical purpose. Terms
such as "left" and right", "front" and "rear", "above" and "below"
and the like are used as words of convenience to provide reference
points and are not to be construed as limiting terms.
[0078] In this specification, the word "comprising" is to be
understood in its "open" sense, that is, in the sense of
"including", and thus not limited to its "closed" sense, that is
the sense of "consisting only of". A corresponding meaning is to be
attributed to the corresponding words "comprise", "comprised" and
"comprises" where they appear.
[0079] In addition, the foregoing describes only some embodiments
of the invention(s), and alterations, modifications, additions
and/or changes can be made thereto without departing from the scope
and spirit of the disclosed embodiments, the embodiments being
illustrative and not restrictive.
[0080] Furthermore, invention(s) have described in connection with
what are presently considered to be the most practical and
preferred embodiments, it is to be understood that the invention is
not to be limited to the disclosed embodiments, but on the
contrary, is intended to cover various modifications and equivalent
arrangements included within the spirit and scope of the
invention(s). Also, the various embodiments described above may be
implemented in conjunction with other embodiments, e.g., aspects of
one embodiment may be combined with aspects of another embodiment
to realize yet other embodiments. Further, each independent feature
or component of any given assembly may constitute an additional
embodiment.
* * * * *