U.S. patent application number 16/269930 was filed with the patent office on 2019-06-06 for pump assembly including fluid cylinder and tapered valve seats.
The applicant listed for this patent is S.P.M. FLOW CONTROL, INC.. Invention is credited to Jacob A. Bayyouk, Tugrul Comlekci.
Application Number | 20190170138 16/269930 |
Document ID | / |
Family ID | 48903044 |
Filed Date | 2019-06-06 |
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United States Patent
Application |
20190170138 |
Kind Code |
A1 |
Bayyouk; Jacob A. ; et
al. |
June 6, 2019 |
PUMP ASSEMBLY INCLUDING FLUID CYLINDER AND TAPERED VALVE SEATS
Abstract
According to one aspect, a pump assembly includes a fluid
cylinder, the fluid cylinder including a fluid passage, the fluid
passage defining a tapered internal shoulder of the fluid cylinder,
the tapered internal shoulder defining a first angle. A valve
controls flow of fluid through the fluid passage. The valve
includes a valve seat, which is disposed in the fluid passage and
includes a tapered external shoulder, the tapered external shoulder
defining a second angle. In one embodiment, the first tapered
external shoulder engages the first tapered internal shoulder to
distribute and transfer loading.
Inventors: |
Bayyouk; Jacob A.;
(Richardson, TX) ; Comlekci; Tugrul; (Glasgow,
GB) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
S.P.M. FLOW CONTROL, INC. |
Fort Worth |
TX |
US |
|
|
Family ID: |
48903044 |
Appl. No.: |
16/269930 |
Filed: |
February 7, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15355609 |
Nov 18, 2016 |
10240597 |
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16269930 |
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29546567 |
Nov 24, 2015 |
D787029 |
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15355609 |
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29446059 |
Feb 20, 2013 |
D748228 |
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29546567 |
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13755217 |
Jan 31, 2013 |
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29446059 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B23P 15/00 20130101;
F04B 53/16 20130101; F04B 53/22 20130101; F16K 1/42 20130101; F04B
7/00 20130101; F04B 53/162 20130101; F04B 53/1087 20130101; F16K
15/063 20130101; F04B 53/10 20130101; F16K 1/36 20130101; Y10T
29/49236 20150115; B23P 6/00 20130101; F16K 25/00 20130101 |
International
Class: |
F04B 53/10 20060101
F04B053/10; F04B 53/16 20060101 F04B053/16; F16K 15/06 20060101
F16K015/06; F04B 53/22 20060101 F04B053/22; F16K 1/42 20060101
F16K001/42; F04B 7/00 20060101 F04B007/00; B23P 6/00 20060101
B23P006/00; F16K 1/36 20060101 F16K001/36; F16K 25/00 20060101
F16K025/00 |
Claims
1. A valve seat adapted to be disposed within a fluid cylinder of a
pump assembly, the valve seat comprising: a seat body defining an
axis, the seat body comprising an enlarged-diameter portion
defining a tapered external shoulder extending at a first acute
angle from the axis and a tapered surface extending at a second
acute angle from the axis; wherein the tapered external shoulder is
adapted to engage the fluid cylinder of the pump assembly; and
wherein the first and second acute angles are measured from the
axis in a same angular direction, the first acute angle being less
than the second acute angle; and a bore extending through the seat
body along the axis; wherein the tapered surface is adapted to be
reciprocably engaged by a valve member of the pump assembly.
2. The valve seat of claim 1, wherein the seat body further defines
a first outside surface having a first outside diameter.
3. The valve seat of claim 2, wherein the first outside surface is
adapted to engage the fluid cylinder of the valve seat.
4. The valve seat of claim 2, wherein the enlarged-diameter portion
further defines a second outside surface extending axially from the
tapered external shoulder, the second outside surface having a
second outside diameter that is greater than the first outside
diameter.
5. The valve seat of claim 4, wherein the tapered external shoulder
is axially disposed between the first outside surface and the
second outside surface.
6. The valve seat of claim 2, wherein the bore defines an inside
surface having an inside diameter that is less than the first
outside diameter.
7. The valve seat of claim 6, further comprising: an annular groove
formed in the first outside surface and having a groove diameter
that is less than the first outside diameter and greater than the
inside diameter; and a sealing element disposed within the annular
groove.
8. The valve seat of claim 2, wherein the first outside surface is
tapered at a third acute angle measured in the same angular
direction from the axis, the third acute angle being less than both
the first and second acute angles.
9. The valve seat of claim 2, further comprising an annular notch
formed in the seat body adjacent each of the first outside surface
and the tapered external shoulder.
10. The valve seat of claim 1, wherein the tapered external
shoulder defines a frusto-conical surface.
11. A pump assembly, comprising: a fluid cylinder; a valve seat
disposed within the fluid cylinder, the valve seat comprising: a
seat body defining an axis, the seat body comprising an
enlarged-diameter portion defining a tapered external shoulder
extending at a first acute angle from the axis and a tapered
surface extending at a second acute angle from the axis; wherein
the tapered external shoulder engages the fluid cylinder of the
pump assembly; and wherein the first and second acute angles are
measured from the axis in a same angular direction, the first acute
angle being less than the second acute angle; and a bore extending
through the seat body along the axis; and a valve member
reciprocable to sealingly engage the tapered surface.
12. The pump assembly of claim 11, wherein the seat body further
defines a first outside surface having a first outside
diameter.
13. The pump assembly of claim 12, wherein the first outside
surface engages the fluid cylinder of the pump assembly.
14. The pump assembly of claim 12, wherein the enlarged-diameter
portion further defines a second outside surface extending axially
from the tapered external shoulder, the second outside surface
having a second outside diameter that is greater than the first
outside diameter.
15. The pump assembly of claim 14, wherein the tapered external
shoulder is axially disposed between the first outside surface and
the second outside surface.
16. The pump assembly of claim 12, wherein the bore defines an
inside surface having an inside diameter that is less than the
first outside diameter.
17. The pump assembly of claim 16, further comprising: an annular
groove formed in the first outside surface and having a groove
diameter that is less than the first outside diameter and greater
than the inside diameter; and a sealing element disposed within the
annular groove.
18. The pump assembly of claim 12, wherein the first outside
surface is tapered at a third acute angle measured in the same
angular direction from the axis, the third acute angle being less
than both the first and second acute angles.
19. The pump assembly of claim 12, further comprising an annular
notch formed in the seat body adjacent each of the first outside
surface and the tapered external shoulder.
20. The pump assembly of claim 11, wherein the tapered external
shoulder defines a frusto-conical surface.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 15/355,609, filed Nov. 18, 2016, which is a
continuation of U.S. patent application Ser. No. 29/546,567, filed
Nov. 24, 2015, now U.S. Pat. No. D787,029, issued May 16, 2017,
which is a continuation of U.S. patent application Ser. No.
29/446,059, filed Feb. 20, 2013, now U.S. Pat. No. D748,228, issued
Jan. 26, 2016, which is a continuation of U.S. patent application
Ser. No. 13/755,217, filed Jan. 31, 2013; the entire disclosures of
U.S. patent application Ser. Nos. 15/355,609, 29/546,567,
29/446,059, and 13/755,217 are hereby incorporated herein by
reference.
TECHNICAL FIELD
[0002] This disclosure relates in general to pump assemblies and,
in particular, a reciprocating pump assembly including a fluid
cylinder and valve seats.
BACKGROUND OF THE DISCLOSURE
[0003] Reciprocating pump assemblies typically include fluid end
blocks or fluid cylinders and inlet and outlet valves disposed
therein. During operation, the inlet and outlet valves typically
experience high loads and frequencies. In some cases, valve seats
of the inlet and outlet valves, as well as portions of the fluid
cylinder engaged therewith, may be subjected to highly concentrated
cyclic loads and thus may fatigue to failure. Moreover, it is
sometimes difficult to remove valve seats from the fluid cylinder
for replacement, which difficulty may result in damage to the fluid
cylinder. Further, when replacing a worn valve seat or producing a
new pump assembly, an incorrect valve seat may unintentionally be
disposed in the fluid cylinder, which may hurt pump performance and
possibly damage the fluid cylinder or valve seat. In many cases,
this mix-up of parts is possible because differences between valve
seats may not be easily discernable upon visual inspection.
Therefore, what is needed is an apparatus or method that addresses
one or more of the foregoing issues, among others.
SUMMARY
[0004] In a first aspect, there is provided a pump assembly that
includes a fluid cylinder having a first axis, the fluid cylinder
includes a first fluid passage through which fluid is adapted to
flow along the first axis, the first fluid passage defining a first
tapered internal shoulder of the fluid cylinder, the first tapered
internal shoulder defining a first angle from the first axis; and a
first valve to control flow of fluid through the first fluid
passage, the first valve includes a first valve seat disposed in
the first fluid passage, the first valve seat having a second axis
that is aligned with the first axis, the first valve seat includes
a first tapered external shoulder, the first tapered external
shoulder defining a second angle from the second axis; wherein each
of the first and second angles ranges from about 10 degrees to
about 45 degrees measured from the first axis and the second axis
aligned therewith.
[0005] In an exemplary embodiment, the first tapered internal
shoulder and the first tapered external shoulder define first and
second frusto-conical surfaces, respectively; and wherein the first
tapered internal shoulder engages the first tapered external
shoulder to distribute and transfer loading between the first and
second frusto-conical surfaces.
[0006] In certain exemplary embodiments, the first and second
angles are equal.
[0007] In another exemplary embodiment, each of the first and
second angles is about 30 degrees measured from the first axis and
the second axis aligned therewith.
[0008] In certain exemplary embodiments, the fluid cylinder further
includes a pressure chamber in fluid communication with the first
fluid passage; a second fluid passage in fluid communication with
the pressure chamber and through which fluid is adapted to flow
along the first axis, the second fluid passage defining a second
tapered internal shoulder of the fluid cylinder, the second tapered
internal shoulder defining a third angle from the first axis; a
fluid inlet passage in fluid communication with the pressure
chamber via the first fluid passage; and a fluid outlet passage in
fluid communication with the pressure chamber via the second fluid
passage; wherein the pump assembly further includes a second valve
to control flow of the fluid through the second fluid passage, the
second valve includes a second valve seat disposed in the second
fluid passage, the second valve seat having a third axis that is
aligned with each of the first and second axes, the second valve
seat includes a second tapered external shoulder, the second
tapered external shoulder defining a fourth angle from the third
axis; and wherein each of the third and fourth angles ranges from
about 10 degrees to about 45 degrees measured from the first axis
and each of the second and third axes aligned therewith.
[0009] In another exemplary embodiment, the second tapered internal
shoulder and the second tapered external shoulder defines third and
fourth frusto-conical surfaces, respectively; and wherein the
second tapered internal shoulder engages the second tapered
external shoulder to distribute and transfer loading between the
third and fourth frusto-conical surfaces.
[0010] In yet another exemplary embodiment, the third and fourth
angles are equal.
[0011] In an exemplary embodiment, each of the third and fourth
angles is about 30 degrees measured from the first axis and each of
the second and third axes aligned therewith.
[0012] In another exemplary embodiment, the first valve seat
further includes a seat body, the seat body includes an
enlarged-diameter portion at one end thereof, the enlarged-diameter
portion includes the first tapered external shoulder and defining a
first cylindrical surface extending axially from the first
frusto-conical surface, the first cylindrical surface defining a
first outside diameter; a bore formed through the seat body, the
bore defining a second cylindrical surface, the second cylindrical
surface defining a first inside diameter; wherein the first fluid
passage includes an enlarged-diameter portion and a
reduced-diameter portion extending axially therefrom; wherein the
enlarged-diameter portion of the first fluid passage defines the
first tapered internal shoulder of the fluid cylinder; wherein the
reduced-diameter portion of the first fluid passage defines an
inside surface of the fluid cylinder and a second inside diameter;
wherein the enlarged-diameter portion of the seat body is disposed
in the enlarged-diameter portion of the first fluid passage;
wherein the seat body defines an outside surface that is engaged
with the inside surface of the fluid cylinder; and wherein the
outside surface defines a second outside diameter.
[0013] In yet another exemplary embodiment, at least one of the
inside surface of the fluid cylinder and the outside surface of the
seat body is tapered at a taper angle from the first axis and the
second axis aligned therewith, the taper angle ranging from greater
than 0 degrees to about 5 degrees measured from the first axis and
the second axis aligned therewith.
[0014] In an exemplary embodiment, the first valve seat further
includes an annular groove formed in the outside surface of the
seat body, the annular groove defining a groove diameter; and a
sealing element disposed in the annular groove and sealingly
engaging the inside surface of the fluid cylinder.
[0015] In another exemplary embodiment, each of the first and
second angles is about 30 degrees; wherein the first outside
diameter is about 5 inches; wherein the first inside diameter is
about 3 inches; wherein the second inside diameter is about 4.5
inches; wherein the groove diameter is about 4 inches; and wherein
the second outside diameter is about 4.5 inches.
[0016] In yet another exemplary embodiment, the fluid cylinder
further includes a pressure chamber in fluid communication with the
first fluid passage; and wherein the pump assembly further includes
a housing connected to the fluid cylinder, and a plunger rod
assembly extending out of the housing and into the pressure
chamber.
[0017] In a second aspect, a fluid cylinder for a pump assembly is
provided, the fluid cylinder having a fluid passage axis and
includes a first fluid passage through which fluid is adapted to
flow along the fluid passage axis, the first fluid passage defining
a first tapered internal shoulder of the fluid cylinder, the first
tapered internal shoulder defining a first angle from the fluid
passage axis, the first angle ranging from about 10 degrees to
about 45 degrees measured from the fluid passage axis; and a
pressure chamber in fluid communication with the first fluid
passage.
[0018] In certain exemplary embodiment, the first angle is about 30
degrees measured from the fluid passage axis.
[0019] In an exemplary embodiment, the fluid cylinder includes a
second fluid passage in fluid communication with the pressure
chamber and through which fluid is adapted to flow along the fluid
passage axis, the second fluid passage defining a second tapered
internal shoulder of the fluid cylinder, the second tapered
internal shoulder defining a second angle from the fluid passage
axis; and a fluid outlet passage in fluid communication with the
pressure chamber via the second fluid passage; wherein the second
angle ranges from about 10 degrees to about 45 degrees measured
from the fluid passage axis.
[0020] In another exemplary embodiment, the first and second angles
are equal.
[0021] In yet another exemplary embodiment, each of the first and
second angles is about 30 degrees measured from the fluid passage
axis.
[0022] In certain exemplary embodiments, the first fluid passage
includes an enlarged-diameter portion and a reduced-diameter
portion extending axially therefrom; wherein the enlarged-diameter
portion of the first fluid passage defines the first tapered
internal shoulder of the fluid cylinder; and wherein the
reduced-diameter portion of the first fluid passage defines an
inside surface of the fluid cylinder and an inside diameter.
[0023] In another exemplary embodiment, the inside surface is
tapered at a taper angle from the fluid passage axis, the taper
angle ranging from greater than 0 degrees to about 5 degrees
measured from the fluid passage axis.
[0024] In an exemplary embodiment, each of the first and second
angles is about 30 degrees; and wherein the inside diameter is
about 4.5 inches.
[0025] In a third aspect, there is provided a valve seat adapted to
be disposed within a fluid cylinder for a pump assembly, the valve
seat having a valve seat axis and includes a seat body, the seat
body includes an enlarged-diameter portion at one end thereof, the
enlarged-diameter portion includes a first tapered external
shoulder, the first tapered external shoulder defining a first
angle from the valve seat axis, and a frusto-conical surface
extending at the first angle from the valve seat axis, the first
angle ranging from about 10 degrees to about 45 degrees measured
from the valve seat axis, wherein the enlarged-diameter portion
defines a first cylindrical surface extending axially from the
frusto-conical surface, the first cylindrical surface defining a
first outside diameter, wherein the seat body defines an outside
surface, the outside surface defining a second outside diameter
that is less than the first outside diameter, and wherein the
frusto-conical surface is axially disposed between the outside
surface and the first cylindrical surface; and a bore formed
through the seat body and through which fluid flows along the valve
seat axis, the bore defining a second cylindrical surface, the
second cylindrical surface defining an inside diameter that is less
than the second outside diameter.
[0026] In an exemplary embodiment, the first angle is about 30
degrees measured from the valve seat axis.
[0027] In another exemplary embodiment, the outside surface of the
seat body is tapered at a second angle from the valve seat axis;
and wherein the second angle ranges from greater than 0 degrees to
about 5 degrees measured from the valve seat axis.
[0028] In yet another exemplary embodiment, the valve seat includes
an annular groove formed in the outside surface of the seat body,
the annular groove defining a groove diameter that is less than the
second outside diameter and greater than the inside diameter; and a
sealing element disposed in the annular groove.
[0029] In certain exemplary embodiments, the first angle is about
30 degrees measured from the valve seat axis; wherein the first
outside diameter is about 5 inches; wherein the inside diameter is
about 3 inches; wherein the groove diameter is about 4 inches; and
wherein the second outside diameter is about 4.5 inches.
[0030] In a fourth aspect, there is provided a valve seat adapted
to be disposed within a fluid cylinder for a pump assembly, the
valve seat having a valve seat axis and includes a seat body, the
seat body includes an enlarged-diameter portion at one end thereof,
the enlarged-diameter portion includes a first tapered external
shoulder, the first tapered external shoulder defining a first
angle from the valve seat axis, and a frusto-conical surface
extending at the first angle from the valve seat axis, wherein the
enlarged-diameter portion defines a first cylindrical surface
extending axially from the frusto-conical surface, the first
cylindrical surface defining a first outside diameter, wherein the
seat body defines an outside surface, the outside surface defining
a second outside diameter that is less than the first outside
diameter, wherein the outside surface of the seat body is tapered
at a second angle from the valve seat axis, and wherein the
frusto-conical surface is axially disposed between the outside
surface and the first cylindrical surface; and a bore formed
through the seat body and through which fluid flows along the valve
seat axis, the bore defining a second cylindrical surface, the
second cylindrical surface defining an inside diameter that is less
than the second outside diameter.
[0031] In an exemplary embodiment, the first angle ranges from
about 10 degrees to about 45 degrees measured from the valve seat
axis; and wherein the second angle ranges from greater than 0
degrees to about 5 degrees measured from the valve seat axis.
[0032] In another exemplary embodiment, the first angle is about 30
degrees measured from the valve seat axis; and wherein the second
angle ranges from greater than 0 degrees to about 5 degrees
measured from the valve seat axis.
[0033] In yet another exemplary embodiment, the valve seat includes
an annular groove formed in the outside surface of the seat body,
the annular groove defining a groove diameter that is less than the
second outside diameter and greater than the inside diameter; and a
sealing element disposed in the annular groove.
[0034] In an exemplary embodiment, the first angle is about 30
degrees measured from the valve seat axis; wherein the second angle
ranges from greater than 0 degrees to about 5 degrees measured from
the valve seat axis; wherein the first outside diameter is about 5
inches; wherein the inside diameter is about 3 inches; wherein the
groove diameter is about 4 inches; and wherein the second outside
diameter is about 4.5 inches.
[0035] In a fifth aspect, there is provided a method of producing a
first pump assembly based on a second pump assembly, the first and
second pump assemblies includes first and second fluid cylinders,
respectively, and first and second valve seats, respectively, the
first and second fluid cylinders includes first and second fluid
passages formed therein, respectively, in which the first and
second valve seats are adapted to be disposed, respectively, the
first and second fluid passages defining first and second inside
diameters, respectively, the first and second valve seats defining
first and second outside diameters, respectively, the method
includes producing the first fluid cylinder, includes sizing the
first inside diameter to be less than the second outside diameter
so that the second valve seat is not permitted to be disposed in
the first fluid passage; and producing the first valve seat,
includes sizing the first outside diameter so that: the first
outside diameter is less than the second inside diameter; and a
radial clearance would be defined between the first valve seat and
an inside surface of the second fluid cylinder defined by the
second fluid passage if the first valve seat were to be disposed in
the second fluid passage. As a result, operational incompatibility
between parts of the first and second pump assemblies is ensured
and a long-term mix-up between parts is avoided.
[0036] In an exemplary embodiment, the method includes disposing
the first valve seat in the first fluid passage.
[0037] In another exemplary embodiment, producing the first valve
seat includes forming an enlarged-diameter portion, the
enlarged-diameter portion includes a tapered external shoulder, the
tapered external shoulder defining a first angle, the
enlarged-diameter portion defining a cylindrical surface, the
cylindrical surface defining a third outside diameter that is
greater than the first outside diameter; wherein producing the
first fluid cylinder includes forming the first fluid passage so
that the first fluid passage defines a tapered internal shoulder,
the tapered internal shoulder defining a second angle.
[0038] In yet another exemplary embodiment, producing the first
valve seat further includes forming a bore through the first valve
seat, the bore defining a third inside diameter that is less than
the first outside diameter; forming an annular groove in the first
valve seat, the annular groove defining a groove diameter that is
less than the first outside diameter and greater than the third
inside diameter; and disposing a sealing element in the annular
groove.
[0039] In certain exemplary embodiments, the method includes
disposing the first valve seat in the first fluid passage of the
first cylinder so that: the tapered external shoulder engages the
tapered internal shoulder, and the sealing element sealingly
engages the fluid cylinder.
[0040] In other exemplary embodiments, each of the first and second
angles is about 30 degrees relative to an axis; wherein the third
outside diameter is about 5 inches; wherein the third inside
diameter is about 3 inches; wherein the first inside diameter is
about 4.5 inches; wherein the groove diameter is about 4 inches;
and wherein the first outside diameter is about 4.5 inches.
[0041] Other aspects, features, and advantages will become apparent
from the following detailed description when taken in conjunction
with the accompanying drawings, which are a part of this disclosure
and which illustrate, by way of example, principles of the
inventions disclosed.
DESCRIPTION OF FIGURES
[0042] The accompanying drawings facilitate an understanding of the
various embodiments.
[0043] FIG. 1 is an elevational view of a reciprocating pump
assembly according to an exemplary embodiment, the pump assembly
includes a fluid cylinder assembly.
[0044] FIG. 2 is a section view of the fluid cylinder assembly of
FIG. 1 according to an exemplary embodiment, the fluid cylinder
assembly including a fluid cylinder and inlet and outlet valves,
the inlet and outlet valves each including a valve seat.
[0045] FIG. 3 is an enlarged view of a portion of the section view
of FIG. 2, according to an exemplary embodiment.
[0046] FIG. 4 is a section view of respective portions of the valve
seat and the fluid cylinder, according to another exemplary
embodiment.
[0047] FIG. 5 is a section view of respective portions of the valve
seat and fluid cylinder, according to yet another exemplary
embodiment.
[0048] FIG. 6 is a section view of a valve according to another
exemplary embodiment, the valve including a valve seat.
[0049] FIG. 7 is a perspective view of the valve seat of FIG. 6,
according to an exemplary embodiment.
[0050] FIG. 8 is a sectional view of the valve seat of FIGS. 6 and
7, according to an exemplary embodiment.
[0051] FIG. 9 is a sectional view of the valve of FIG. 6 disposed
within the fluid cylinder of FIG. 2, according to an exemplary
embodiment.
[0052] FIG. 10 is a flow chart illustration of a method of
producing a new pump assembly based on a previously sold pump
assembly referred to as Legacy or the Legacy model, according to an
exemplary embodiment.
[0053] FIG. 11 is a sectional view of a valve seat, according to
another exemplary embodiment.
DETAILED DESCRIPTION
[0054] 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 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 or fluid cylinder
18, which is connected to the housing 16 via a plurality of stay
rods 20. The fluid cylinder 18 includes a fluid inlet passage 22
and a fluid outlet passage 24, which are spaced in a parallel
relation. A plurality of cover assemblies 26, one of which is shown
in FIG. 1, is connected to the fluid cylinder 18 opposite the stay
rods 20. A plurality of cover assemblies 28, one of which is shown
in FIG. 1, is connected to the fluid cylinder 18 opposite the fluid
inlet passage 22. A plunger rod assembly 30 extends out of the
housing 16 and into the fluid cylinder 18. In several exemplary
embodiments, the pump assembly 10 is freestanding on the ground, is
mounted to a trailer that can be towed between operational sites,
or is mounted to a skid.
[0055] In an exemplary embodiment, as illustrated in FIG. 2 with
continuing reference to FIG. 1, the plunger rod assembly 30
includes a plunger 32, which extends through a bore 34 formed in
the fluid cylinder 18, and into a pressure chamber 36 formed in the
fluid cylinder 18. In several exemplary embodiments, a plurality of
parallel-spaced bores may be formed in the fluid cylinder 18, with
one of the bores being the bore 34, a plurality of pressure
chambers may be formed in the fluid cylinder 18, with one of the
pressure chambers being the pressure chamber 36, and a plurality of
parallel-spaced plungers may extend through respective ones of the
bores and into respective ones of the pressure chambers, with one
of the plungers being the plunger 32. At least the bore 34, the
pressure chamber 36, and the plunger 32 together may be
characterized as a plunger throw. In several exemplary embodiments,
the reciprocating pump assembly 10 includes three plunger throws
(i.e., a triplex pump assembly), or includes four or more plunger
throws.
[0056] As shown in FIG. 2, the fluid cylinder 18 includes inlet and
outlet fluid passages 38 and 40 formed therein, which are generally
coaxial along a fluid passage axis 42. Under conditions to be
described below, fluid is adapted to flow through the inlet and
outlet fluid passages 38 and 40 and along the fluid passage axis
42. The fluid inlet passage 22 is in fluid communication with the
pressure chamber 36 via the inlet fluid passage 38. The pressure
chamber 36 is in fluid communication with the fluid outlet passage
24 via the outlet fluid passage 40. The fluid inlet passage 38
includes an enlarged-diameter portion 38a and a reduced-diameter
portion 38a extending downward therefrom. The enlarged-diameter
portion 38a defines a tapered internal shoulder 43 and thus a
frusto-conical surface 44 of the fluid cylinder 18. The
reduced-diameter portion 38a defines an inside surface 46 of the
fluid cylinder 18. Similarly, the fluid outlet passage 40 includes
an enlarged-diameter portion 40a and a reduced-diameter portion 40b
extending downward therefrom. The enlarged-diameter portion 40a
defines a tapered internal shoulder 48 and thus a frusto-conical
surface 50 of the fluid cylinder 18. The reduced-diameter portion
40b defines an inside surface 52 of the fluid cylinder 18.
[0057] An inlet valve 54 is disposed in the fluid passage 38, and
engages at least the frusto-conical surface 44 and the inside
surface 46. Similarly, an outlet valve 56 is disposed in the fluid
passage 40, and engages at least the frusto-conical surface 50 and
the inside surface 52. In an exemplary embodiment, each of valves
54 and 56 is a spring-loaded valve that is actuated by a
predetermined differential pressure thereacross.
[0058] A counterbore 58 is formed in the fluid cylinder 18, and is
generally coaxial with the fluid passage 42. The counterbore 58
defines an internal shoulder 58a and includes an internal threaded
connection 58a adjacent the internal shoulder 58a. A counterbore 60
is formed in the fluid cylinder 18, and is generally coaxial with
the bore 34 along an axis 62. The counterbore 60 defines an
internal shoulder 60a and includes an internal threaded connection
60b adjacent the internal shoulder 60a. In several exemplary
embodiments, the fluid cylinder 18 may include a plurality of
parallel-spaced counterbores, one of which may be the counterbore
58, with the quantity of counterbores equaling the quantity of
plunger throws included in the pump assembly 10. Similarly, in
several exemplary embodiments, the fluid cylinder 18 may include
another plurality of parallel-spaced counterbores, one of which may
be the counterbore 60, with the quantity of counterbores equaling
the quantity of plunger throws included in the pump assembly
10.
[0059] A plug 64 is disposed in the counterbore 58, engaging the
internal shoulder 58a and sealingly engaging an inside cylindrical
surface defined by the reduced-diameter portion of the counterbore
58. An external threaded connection 66a of a fastener 66 is
threadably engaged with the internal threaded connection 58a of the
counterbore 58 so that an end portion of the fastener 66 engages
the plug 64. As a result, the fastener 66 sets or holds the plug 64
in place against the internal shoulder 58a defined by the
counterbore 58, thereby maintaining the sealing engagement of the
plug 64 against the inside cylindrical surface defined by the
reduced-diameter portion of the counterbore 58. The cover assembly
28 shown in FIGS. 1 and 2 includes at least the plug 64 and the
fastener 66. In an exemplary embodiment, the cover assembly 28 may
be disconnected from the fluid cylinder 18 to provide access to,
for example, the counterbore 58, the pressure chamber 36, the
plunger 32, the fluid passage 40 or the outlet valve 56. The cover
assembly 28 may then be reconnected to the fluid cylinder 18 in
accordance with the foregoing. In several exemplary embodiments,
the pump assembly 10 may include a plurality of plugs, one of which
is the plug 64, and a plurality of fasteners, one of which is the
fastener 66, with the respective quantities of plugs and fasteners
equaling the quantity of plunger throws included in the pump
assembly 10.
[0060] A plug 68 is disposed in the counterbore 60, engaging the
internal shoulder 60a and sealingly engaging an inside cylindrical
surface defined by the reduced-diameter portion of the counterbore
60. In an exemplary embodiment, the plug 68 maybe characterized as
a suction cover. An external threaded connection 70a of a fastener
70 is threadably engaged with the internal threaded connection 60b
of the counterbore 60 so that an end portion of the fastener 70
engages the plug 68. As a result, the fastener 70 sets or holds the
plug 68 in place against the internal shoulder 60a defined by the
counterbore 60, thereby maintaining the sealing engagement of the
plug 68 against the inside cylindrical surface defined by the
reduced-diameter portion of the counterbore 60. The cover assembly
26 shown in FIGS. 1 and 2 includes at least the plug 68 and the
fastener 70. In an exemplary embodiment, the cover assembly 26 may
be disconnected from the fluid cylinder 18 to provide access to,
for example, the counterbore 60, the pressure chamber 36, the
plunger 32, the fluid passage 38, or the inlet valve 54. The cover
assembly 26 may then be reconnected to the fluid cylinder in
accordance with the foregoing. In several exemplary embodiments,
the pump assembly 10 may include a plurality of plugs, one of which
is the plug 68, and a plurality of fasteners, one of which is the
fastener 70, with the respective quantities of plugs and fasteners
equaling the quantity of plunger throws included in the pump
assembly 10.
[0061] A valve spring retainer 72 is disposed in the
enlarged-diameter portion 38a of the fluid passage 38. The valve
spring retainer 72 is connected to the end portion of the plug 68
opposite the fastener 70. In an exemplary embodiment, and as shown
in FIG. 2, the valve spring retainer 72 is connected to the plug 68
via a hub 74, which is generally coaxial with the axis 62.
[0062] In an exemplary embodiment, as illustrated in FIG. 3 with
continuing reference to FIGS. 1 and 2, the inlet valve 54 includes
a valve seat 76 and a valve member 78 engaged therewith. The valve
seat 76 includes a seat body 80 having an enlarged-diameter portion
82 at one end thereof. The enlarged-diameter portion 82 of the seat
body 80 is disposed in the enlarged-diameter portion 38a of the
fluid passage 38. A bore 83 is formed through the seat body 80. The
valve seat 76 has a valve seat axis 84, which is aligned with the
fluid passage axis 42 when the inlet valve 54 is disposed in the
fluid passage 38, as shown in FIG. 3. Under conditions to be
described below, fluid flows through the bore 83 and along the
valve seat axis 84. The bore 83 defines an inside surface 85 of the
seat body 80. An outside surface 86 of the seat body 80 contacts
the inside surface 46 defined by the fluid passage 38. A sealing
element, such as an o-ring 88, is disposed in an annular groove 90
formed in the outside surface 86. The o-ring 88 sealingly engages
the inside surface 46. The enlarged-diameter portion 82 includes a
tapered external shoulder 91 and thus defines a frusto-conical
surface 92, which extends angularly upward from the outside surface
86. The portion 82 further defines a cylindrical surface 94, which
extends axially upward from the extent of the frusto-conical
surface 92. The frusto-conical surface 92 is axially disposed
between the outside surface 86 and the cylindrical surface 94. The
portion 82 further defines a tapered surface 96, which extends
angularly upward from the inside surface 85. In an exemplary
embodiment, the tapered surface 96 extends at an angle from the
valve seat axis 84, which angle ranges from about 15 degrees to
about 45 degrees. The seat body 80 of the valve seat 76 is disposed
within the reduced-diameter portion 38a of the fluid passage 38 so
that the outside surface 86 of the seat body 80 engages the inside
surface 46 of the fluid cylinder 18. In an exemplary embodiment,
the seat body 80 forms an interference fit, or is press fit, in the
portion 38a of the fluid passage 38 so that the valve seat 76 is
prevented from being dislodged from the fluid passage 38.
[0063] The valve member 78 includes a central stem 98, from which a
valve body 100 extends radially outward. An outside annular cavity
102 is formed in the valve body 100. A seal 104 extends within the
cavity 102, and is adapted to sealingly engage the tapered surface
96 of the valve seat 76, under conditions to be described below. A
plurality of circumferentially-spaced legs 106 extend angularly
downward from the central stem 98, and slidably engage the inside
surface 85 of the seat body 80. In several exemplary embodiments,
the plurality of legs 106 may include two, three, four, five, or
greater than five, legs 106. A lower end portion of a spring 108 is
engaged with the top of the valve body 100 opposite the central
stem 98. The valve member 78 is movable, relative to the valve seat
76 and thus the fluid cylinder 18, between a closed position (shown
in FIG. 3) and an open position (not shown), under conditions to be
described below.
[0064] In an exemplary embodiment, the seal 104 is molded in place
in the valve body 100. In an exemplary embodiment, the seal 104 is
preformed and then attached to the valve body 100. In several
exemplary embodiments, the seal 104 is composed of one or more
materials such as, for example, a deformable thermoplastic
material, a urethane material, a fiber-reinforced material, carbon,
glass, cotton, wire fibers, cloth, and/or any combination thereof.
In an exemplary embodiment, the seal 104 is composed of a cloth
which is disposed in a thermoplastic material, and the cloth may
include carbon, glass, wire, cotton fibers, and/or any combination
thereof. In several exemplary embodiments, the seal 104 is composed
of at least a fiber-reinforced material, which can prevent or at
least reduce delamination. In an exemplary embodiment, the seal 104
has a hardness of 95 A durometer or greater, or a hardness of 69 D
durometer or greater. In several exemplary embodiments, the valve
body 100 is much harder and more rigid than the seal 104.
[0065] The outlet valve 56 is identical to the inlet valve 54 and
therefore will not be described in further detail. Features of the
outlet valve 56 that are identical to corresponding features of the
inlet valve 54 will be given the same reference numerals as that of
the inlet valve 54. The valve seat axis 84 of the outlet valve 56
is aligned with each of the fluid passage axis 42 and the valve
seat axis 84 of the inlet valve 54. The outlet valve 56 is disposed
in the fluid passage 40, and engages the fluid cylinder 18, in a
manner that is identical to the manner in which the inlet valve 54
is disposed in the fluid passage 38, and engages the fluid cylinder
18, with one exception. This one exception involves the spring 108
of the outlet valve 56; more particularly, the upper portion of the
spring 108 of the outlet valve 56 is compressed against the bottom
of the plug 64, rather than being compressed against a component
that corresponds to the valve spring retainer 72, against which the
upper portion of the spring 108 of the inlet valve 54 is
compressed.
[0066] In operation, in an exemplary embodiment, with continuing
reference to FIGS. 1-3, the plunger 32 reciprocates within the bore
34, reciprocating in and out of the pressure chamber 36. That is,
the plunger 32 moves back and forth horizontally, as viewed in FIG.
2, away from and towards the fluid passage 42. In an exemplary
embodiment, the engine or motor (not shown) drives the crankshaft
(not shown) enclosed within the housing 16, thereby causing the
plunger 32 to reciprocate within the bore 34 and thus in and out of
the pressure chamber 36.
[0067] As the plunger 32 reciprocates out of the pressure chamber
36, the inlet valve 54 is opened. More particularly, as the plunger
32 moves away from the fluid passage 42, the pressure inside the
pressure chamber 36 decreases, creating a differential pressure
across the inlet valve 54 and causing the valve member 78 to move
upward, as viewed in FIGS. 2 and 3, relative to the valve seat 76
and the fluid cylinder 18. As a result of the upward movement of
the valve member 78, the spring 108 is compressed between the valve
body 100 and the valve spring retainer 72, the seal 104 disengages
from the tapered surface 96, and the inlet valve 54 is thus placed
in its open position. Fluid in the fluid inlet passage 22 flows
along the fluid passage axis 42 and through the fluid passage 38
and the inlet valve 54, being drawn into the pressure chamber 36.
To flow through the inlet valve 54, the fluid flows through the
bore 83 of the valve seat 76 and along the valve seat axis 84.
During the fluid flow through the inlet valve 54 and into the
pressure chamber 36, the outlet valve 56 is in its closed position,
with the seal 104 of the valve member 78 of the outlet valve 56
engaging the tapered surface 96 of the valve seat 76 of the outlet
valve 56. Fluid continues to be drawn into the pressure chamber 36
until the plunger 32 is at the end of its stroke away from the
fluid passage 42. At this point, the differential pressure across
the inlet valve 54 is such that the spring 108 of the inlet valve
54 is not further compressed, or begins to decompress and extend,
forcing the valve member 78 of the inlet valve 54 to move downward,
as viewed in FIGS. 2 and 3, relative to the valve seat 76 and the
fluid cylinder 18. As a result, the inlet valve 54 is placed in, or
begins to be placed in, its closed position, with the seal 104
sealingly engaging, or at least moving towards, the tapered surface
96.
[0068] As the plunger 32 moves into the pressure chamber 36 and
thus towards the fluid passage 42, the pressure within the pressure
chamber 36 begins to increase. The pressure within the pressure
chamber 36 continues to increase until the differential pressure
across the outlet valve 56 exceeds a predetermined set point, at
which point the outlet valve 56 opens and permits fluid to flow out
of the pressure chamber 36, along the fluid passage axis 42 and
through the fluid passage 40 and the outlet valve 56, and into the
fluid outlet passage 24. As the plunger 32 reaches the end of its
stroke towards the fluid passage 42 (i.e., its discharge stroke),
the inlet valve 54 is in, or is placed in, its closed position,
with the seal 104 sealingly engaging the tapered surface 96.
[0069] The foregoing is repeated, with the reciprocating pump
assembly 10 pressurizing the fluid as the fluid flows from the
fluid inlet passage 22 and to the fluid outlet passage 24 via the
pressure chamber 36. In an exemplary embodiment, the pump assembly
10 is a single-acting reciprocating pump, with fluid being pumped
across only one side of the plunger 32.
[0070] In an exemplary embodiment, during the above-described
operation of the reciprocating pump assembly 10, the taper of each
of the surfaces 44 and 92 balances the loading forces applied
thereagainst. In an exemplary embodiment, the loading is
distributed across the surface 44 and 92, reducing stress
concentrations. In an exemplary embodiment, the stresses in the
valve seat 76, in the vicinity of the fillet interface between the
surfaces 86 and the 92, are balanced with the stresses in the fluid
cylinder 18, in the vicinity of the round interface between the
surfaces 46 and 44. As a result, these stresses are reduced. In an
exemplary embodiment, the taper of each of the surfaces 44 and 92
permits the outside diameter of the seat body 80 of the inlet valve
54 to be reduced, thereby also permitting a relative smaller
service port, as well relatively smaller cross-bore diameters
within the fluid cylinder 18. In an exemplary embodiment, the taper
of each of the surfaces 44 and 92 reduces the extraction force
necessary to remove the valve seat 76 from the fluid passage
38.
[0071] In an exemplary embodiment, as illustrated in FIG. 4 with
continuing reference to FIGS. 1-3, a taper angle 110 is defined by
the tapered external shoulder 91 and thus the frusto-conical
surface 92. A taper angle 112 is defined by the tapered internal
shoulder 43 and thus the frusto-conical surface 44. Each of the
taper angles 110 and 112 may be measured from the fluid passage
axis 42 and the valve seat axis 84 aligned therewith. In an
exemplary embodiment, the taper angles 110 and 112 are equal, and
range from about 10 degrees to about 45 degrees measured from the
fluid passage axis 42 and the valve seat axis 84 aligned therewith.
In an exemplary embodiment, the taper angles 110 and 112 range from
about 20 degrees to 40 degrees measured from the fluid passage axis
42 and the valve seat axis 84 aligned therewith. In an exemplary
embodiment, the taper angles 110 and 112 range from about 25 to 35
degrees measured from the fluid passage axis 42 and the valve seat
axis 84 aligned therewith. In an exemplary embodiment, the taper
angles 110 and 112 are equal, and each of the taper angles 110 and
112 is about 30 degrees measured from the fluid passage axis 42 and
the valve seat axis 84 aligned therewith. In an exemplary
embodiment, the taper angles 110 and 112 are not equal. As shown in
FIG. 4, a frusto-conical gap or region 114 may be defined between
the surfaces 44 and 92. Moreover, a radial clearance 116 is defined
between the outside cylindrical surface 94 of the valve seat 76 and
an inside surface 118 of the fluid cylinder 18, the surface 118
being defined by the enlarged-diameter portion 38a of the fluid
passage 38. In an exemplary embodiment, the region 114 may be
omitted and the surface 92 may abut the surface 44. In an exemplary
embodiment, material may be disposed in the region 114 to absorb,
transfer and/or distribute loads between the surfaces 44 and
92.
[0072] As shown in FIG. 4, at least the end portion of the body 80
opposite the enlarged-diameter portion 82 is tapered at a taper
angle 120 from the fluid passage axis 42 and the valve seat axis 84
aligned therewith. In an exemplary embodiment, the taper angle 120
ranges from about 0 degrees to about 5 degrees measured from the
fluid passage axis 42 and the valve seat axis 84 aligned therewith.
In an exemplary embodiment, the taper angle 120 ranges from about 1
degree to about 4 degrees measured from the fluid passage axis 42
and the valve seat axis 84 aligned therewith. In an exemplary
embodiment, the taper angle 120 ranges from about 1 degree to about
3 degrees measured from the fluid passage axis 42 and the valve
seat axis 84 aligned therewith. In an exemplary embodiment, the
taper angle 120 is about 2 degrees measured from the fluid passage
axis 42 and the valve seat axis 84 aligned therewith. In an
exemplary embodiment, the taper angle 120 is about 1.8 degrees
measured from the fluid passage axis 42 and the valve seat axis 84
aligned therewith. In an exemplary embodiment, instead of, or in
addition to the end portion of the body 80 opposite the
enlarged-diameter portion 82 being tapered, the inside surface 46
of the fluid cylinder 18 is tapered at the taper angle 120. In an
exemplary embodiment, an interference fit may be formed between the
body 80 and the inside surface 46, thereby holding the valve seat
76 in place in the fluid cylinder. In several exemplary
embodiments, instead of using an interference fit in the fluid
passage 38, a threaded connection, a threaded nut, and/or a
snap-fit mechanism may be used to hold the valve seat 76 in place
in the fluid cylinder 18.
[0073] In an exemplary embodiment, during operation of the pump
assembly 10 using the embodiment of the inlet valve 54 illustrated
in FIG. 4, the surfaces 92 and 44 provide load balancing, with
loading on the enlarged-diameter portion 82 of the valve seat 76
being distributed and transferred to the surface 44 of the fluid
cylinder 18, via either the pressing of the surface 92 against the
surface 44 or intermediate material(s) disposed therebetween.
[0074] In an exemplary embodiment, as illustrated in FIG. 5 with
continuing reference to FIGS. 1-4, a fillet surface 122 of the
fluid cylinder 18 is defined by the enlarged-diameter portion 38a
of the fluid passage 38. The fillet surface 122 extends between the
frusto-conical surface 44 and the inside surface 118. As shown in
FIG. 5, each of the frusto-conical surfaces 92 and 44 is tapered at
a taper angle 123, which may be measured from the fluid passage
axis 42 and the valve seat axis 84 aligned therewith. In an
exemplary embodiment, the taper angle 123 ranges from about 10
degrees to about 45 degrees measured from the fluid passage axis 42
and the valve seat axis 84 aligned therewith. In an exemplary
embodiment, the taper angle 123 ranges from about greater than 10
degrees to about 30 degrees measured from the fluid passage axis 42
and the valve seat axis 84 aligned therewith. In an exemplary
embodiment, the taper angle 123 ranges from about 12 degrees to
about 20 degrees measured from the fluid passage axis 42 and the
valve seat axis 84 aligned therewith. In an exemplary embodiment,
the taper angle 123 is about 14 degrees measured from the fluid
passage axis 42 and the valve seat axis 84 aligned therewith. In an
exemplary embodiment, the surface 92 and 44 may be tapered at
respective angles that are not equal. The surface 92 abuts the
surface 44. As shown in FIG. 5, the groove 90 and the o-ring 88 are
omitted in favor of an annular groove 124 and an o-ring 126,
respectively. The annular groove 124 is formed in the
frusto-conical surface 92, and the o-ring 126 is disposed in the
annular groove 124. The o-ring 126 sealingly engages the
frusto-conical surface 44.
[0075] In an exemplary embodiment, during operation of the pump
assembly 10 using the embodiment of the inlet valve 54 illustrated
in FIG. 5, loads applied to the valve seat 76 are distributed and
transferred to the fluid cylinder 18 via, at least in part, the
load balancing provided by the abutment of the surface 92 against
the surface 44.
[0076] In an exemplary embodiment, during operation of the pump
assembly 10 using any of the foregoing embodiments of the inlet
valve 54, downwardly directed axial loads along the fluid passage
42 are applied against the top of the valve body 100. This loading
is usually greatest as the plunger 32 moves towards the fluid
passage 42 and the outlet valve 56 opens and permits fluid to flow
out of the pressure chamber 36, through the fluid passage 40 and
the outlet valve 56, and into the fluid outlet passage 24. As the
plunger 32 reaches the end of its stroke towards the fluid passage
42 (its discharge stroke), the inlet valve 54 is in, or is placed
in, its closed position, and the loading applied to the top of the
valve body 100 is transferred to the seal 104 via the valve body
100. The loading is then transferred to the valve seat 76 via the
seal 104, and then is distributed and transferred to the tapered
internal shoulder 43 of the fluid cylinder 18 via either the
engagement of the surface 92 against the surface 44 or intermediate
material(s) disposed therebetween. The tapering of the surfaces 92
and 44 facilitates this distribution and transfer of the downwardly
directed axial loading to the fluid cylinder 18 in a balanced
manner, thereby reducing stress concentrations in the fluid
cylinder 18 and the valve seat 76.
[0077] In an exemplary embodiment, as illustrated in FIGS. 6-8 with
continuing reference to FIGS. 1-5, an inlet valve is generally
referred to by the reference numeral 128 and includes several parts
that are identical to corresponding parts of the inlet valve 54,
which identical parts are given the same reference numerals. The
inlet valve 128 includes a valve seat 129. The valve seat 129
includes several features that are identical to corresponding
features of the valve seat 76, which identical features are given
the same reference numerals. An annular notch 130 is formed in the
valve seat 128 at the intersection of the surfaces 86 and 92.
[0078] As shown in FIG. 8, a taper angle 132 is defined by the
external tapered shoulder 93 and thus the frusto-conical surface
94. The taper angle 132 may be measured from the valve seat axis
84. In an exemplary embodiment, the taper angle 132 is about 30
degrees measured from the valve seat axis 84. In an exemplary
embodiment, the taper angle 132 ranges from about 10 degrees to
about 45 degrees measured from the valve seat axis 84. In an
exemplary embodiment, the taper angle 132 ranges from about 20
degrees to about 40 degrees measured from the valve seat axis 84.
In an exemplary embodiment, the taper angle 132 ranges from about
25 to about 35 degrees measured from the valve seat axis 84. The
cylindrical surface 94 defined by the enlarged-diameter portion 82
of the valve seat 129 defines an outside diameter 134. In an
exemplary embodiment, the outside diameter 134 is about 5 inches.
In an exemplary embodiment, the outside diameter 134 is about 5.06
inches. The inside surface 85 of the seat body 80 defined by the
bore 83 formed therethrough defines an inside diameter 136. In an
exemplary embodiment, the inside diameter 136 ranges from about 3
inches to about 3.5 inches. In an exemplary embodiment, the inside
diameter 136 is about 3.27 inches. An annular surface 138 of the
seat body 80 is defined by the annular groove 90. A groove diameter
140 is defined by the annular surface 138. In an exemplary
embodiment, the groove diameter 140 ranges from about 4 inches to
about 4.5 inches. In an exemplary embodiment, the groove diameter
140 is about 4.292 inches. In an exemplary embodiment, an outside
diameter 142 is defined by the outside surface 86 of the seat body
80 at an axial location therealong adjacent the annular notch 130,
or at least in the vicinity of the intersection between the
surfaces 86 and 92. In an exemplary embodiment, the outside
diameter 142 ranges from about 4 inches to about 5 inches. In an
exemplary embodiment, the outside diameter 142 ranges from about
4.5 inches to about 5 inches. In an exemplary embodiment, the
outside diameter 142 ranges from about 4.5 inches to about 4.6
inches. In an exemplary embodiment, the outside diameter 142 is
about 4.565 inches. The outside surface 86 is tapered radially
inward beginning at the axial location of the outside diameter 142
and ending at the end of the body 80 opposite the enlarged-diameter
portion 82, thereby defining a taper angle 144 from the valve seat
axis 84. In an exemplary embodiment, the taper angle 144 ranges
from about 0 degrees to about 5 degrees measured from the valve
seat axis 84. In an exemplary embodiment, the taper angle 144
ranges from greater than 0 degrees to about 5 degrees measured from
the valve seat axis 84. In an exemplary embodiment, the taper angle
120 is about 2 degrees measured from the valve seat axis 84. In an
exemplary embodiment, the taper angle 144 is about 1.8 degrees
measured from the valve seat axis 84.
[0079] In an exemplary embodiment, as illustrated in FIG. 9 with
continuing reference to FIGS. 1-8, the inlet valve 54 is omitted
from the pump assembly 10 in favor of the inlet valve 128, which is
disposed in the fluid passage 38. The tapered external shoulder 91
of the valve seat 129 engages the tapered internal shoulder 43 of
the fluid cylinder 18. Thus, the frusto-conical surface 92 engages
the frusto-conical surface 44. In an exemplary embodiment, the
tapered internal shoulder 43 defines a taper angle from the fluid
passage axis 42 that is equal to the taper angle 132. In an
exemplary embodiment, the tapered internal shoulder 43 defines a
taper angle that is equal to the taper angle 132, and the taper
angle 132 ranges from about 10 degrees to about 45 degrees measured
from the valve seat axis 84. In an exemplary embodiment, the
tapered angle 132 ranges from about 20 degrees to 45 degrees
measured from the valve seat axis 84. In an exemplary embodiment,
the tapered angle 132 ranges from about 25 degrees to 35 degrees
measured from the valve seat axis 84. In an exemplary embodiment,
the tapered internal shoulder 43 defines a taper angle that is
equal to the taper angle 132, and the taper angle 132 is about 30
degrees measured from the valve seat axis 84. The o-ring 88
sealingly engages the inside surface 46 of the fluid cylinder 18.
The outside surface 86 of the body 80 of the valve seat 129 of the
inlet valve 128 engages the inside surface 46 of the fluid cylinder
18. In an exemplary embodiment, at least the reduced-diameter
portion 38a of the fluid passage 38 is tapered such that an inside
diameter 146 defined by the portion 38a decreases along the fluid
passage 42 in an axial direction away from the enlarged-diameter
portion 38a. In an exemplary embodiment, at an axial location
corresponding to the intersection between the surfaces 46 and 44,
the inside diameter 146 ranges from about 4 inches to about 5
inches. In an exemplary embodiment, at an axial location
corresponding to the intersection between the surfaces 46 and 44,
the inside diameter 146 ranges from about 4.5 inches to about 5
inches. In an exemplary embodiment, at an axial location
corresponding to the intersection between the surfaces 46 and 44,
the inside diameter 146 ranges from about 4.5 inches to about 4.6
inches. In an exemplary embodiment, at an axial location
corresponding to the intersection between the surfaces 46 and 44,
the inside diameter 146 is about 4.553 inches. In an exemplary
embodiment, an interference fit is formed between the outside
surface 86 and the inside surface 46, thereby preventing the valve
seat 129 from being dislodged from the fluid passage 38.
[0080] In an exemplary embodiment, the operation of the inlet valve
129 during the operation of the pump assembly 10 is identical to
the operation of the inlet valve 54. Therefore, the operation of
the inlet valve 129 during the operation of the pump assembly 10
will not be described in detail.
[0081] In an exemplary embodiment, the inlet valve 54 may be
omitted from the pump assembly 10 in favor of the inlet valve 128,
and the outlet valve 56 may be omitted from the pump assembly 10 in
favor of an outlet valve that is identical to the inlet valve 128.
In an exemplary embodiment, the operation of the pump assembly 10
using the inlet valve 128, and an outlet valve that is identical to
the inlet valve 128, is identical to the above-described operation
of the pump assembly 10 using the inlet valve 54 and the outlet
valve 56.
[0082] In several experimental exemplary embodiments, experimental
finite element analyses were conducted on an Experimental Baseline
Embodiment (simulating a previous pump assembly that may be
referred to as Legacy or the Legacy model) of a combination of the
valve seat 129 and the fluid cylinder 18, and also on three
Experimental Exemplary Embodiments of combinations of the valve
seat 129 and the fluid cylinder 18. Experimental stresses were
determined at three points in each of the Experimental Exemplary
Embodiments 1, 2 and 3, which points are shown in FIG. 9, namely
Point A, which is on the fluid cylinder 18 at about the
intersection between the surfaces 44 and 118; Point B, which is on
the valve seat 129 at about the nadir defined by the annular notch
130; and Point C, which is on the valve seat 129 at about the
intersection between the axially-extending surface of the fluid
cylinder 18 defined by the annular groove 90 and the lower
radially-extending surface of the fluid cylinder 18 defined by the
annular groove 90.
[0083] For the Experimental Baseline Embodiment, the taper angle
132 was 90 degrees, the inside diameter 136 was 3.27 inches, and
the outside diameter 134 was 5.06 inches. For Experimental
Exemplary Embodiments 1, 2 and 3, the taper angle 132 was 30
degrees, the inside diameter 136 was 3.27 inches, and the outside
diameter 134 was 5.06 inches. These values correspond to the
plunger 32 being a 4.5-inch plunger, that is, the plunger 32 having
an outside diameter of about 4.5 inches. Additional dimensions of
the Experimental Exemplary Embodiments are set forth in Table I
below (these values also correspond to the plunger 32 being a
4.5-inch plunger):
TABLE-US-00001 TABLE I Dimensions Experimental Experimental
Experimental Experimental Baseline Exemplary Exemplary Exemplary
Embodiment Embodiment 1 Embodiment 2 Embodiment 3 Inside diameter
4.641 4.641 4.596 4.553 146 (inches) Groove diameter 4.380 4.380
4.335 4.292 140 (inches) Outside diameter 4.653 4.653 4.608 4.565
142 (inches)
[0084] The stress response results of the experimental finite
element analyses, under a simulated condition corresponding to the
pressure chamber 36 being pressurized at 16,800 psi, are set forth
in Table II below:
TABLE-US-00002 TABLE II Stress Responses at 16,800 psi Experimental
Experimental Experimental Experimental Baseline Exemplary Exemplary
Exemplary Embodiment Embodiment 1 Embodiment 2 Embodiment 3
Von-mises stress - Point 58,632.6 41,860.4 41,754.2 41,658.5 A
(psi) Von-mises stress - Point 106,517 59,282.6 58,571.6 58,312.3 B
(psi) Von-mises stress - Point 52,330 81,584.5 81,849.1 81,216.9 C
(psi) 1st principal stress - Point 49,716.1 26,393.5 26,148.7
25,944.3 A (psi) 1st principal stress - Point 86,958.5 22,320.2
20,384.6 19,046.2 B (psi)
[0085] The stress response results of the experimental finite
element analyses, under a simulated condition corresponding to the
pressure chamber 36 being pressurized at 19,286 psi, are set forth
in Table III below:
TABLE-US-00003 TABLE III Stress Responses at 19,286 psi
Experimental Experimental Experimental Experimental Baseline
Exemplary Exemplary Exemplary Embodiment Embodiment 1 Embodiment 2
Embodiment 3 Von-mises stress - Point 69,340.0 47,815.8 47,697.2
47,591.5 A (psi) Von-mises stress - Point 123,150 77,791.6 76,387.5
75,565.0 B (psi) Von-mises stress - Point 50,763 76,511.0 77,434.2
77,433.5 C (psi) 1st principal stress - Point 59,885.5 29,796.5
29,546.8 29,340.3 A (psi) 1st principal stress - Point 110,138
42,530.0 39,977.6 38,101.2 B (psi)
[0086] As indicated in Tables II and III above, as the experimental
outside diameter 142 of the experimental valve seat 129 was
reduced, the experimental stress responses decreased. This was an
unexpected result. The decreases in experimental stress responses
for Points B and A on the Experimental Exemplary Embodiments of the
valve seat 129 were unexpected because it was expected that, as the
cross-sectional area of the valve seat 129 (corresponding to a
cross-section of the body 80 that is below the enlarged-diameter
portion 82 and is perpendicular to the valve seat axis 84)
decreased, the stress responses at Points B and A would increase.
Unexpected experimental results were achieved with the taper angle
132 being about 30 degrees, the outside diameter 134 being about 5
inches, the inside diameter 136 being about 3 inches, the groove
diameter being about 4 inches, and, unexpectedly, the outside
diameter 142 being less than 4.6 inches. Based on these unexpected
results, it was determined that a new pump assembly 10 could be
produced based on the pump assembly 10, with the diameters 146, 140
and 142 of the new pump assembly 10 being sufficiently less than
the diameters 146, 140 and 142 of the previous pump assembly 10 so
that the valve seat 129 of the new pump assembly 10 would not be
operationally compatible with the fluid cylinder 18 of the previous
pump assembly 10, and so that the valve seat 129 of the previous
pump assembly 10 would not be operationally compatible with the
fluid cylinder 18 of the new pump assembly 10, thereby preventing
any mix-up of parts between the new and previous pump assemblies
10. These goals of operational incompatibility and long-term mix-up
prevention could be achieved while unexpectedly improving the
stress responses of the new pump assembly 10.
[0087] In an exemplary embodiment, as illustrated in FIG. 10 with
continuing reference to FIGS. 1-9, a method of producing a new pump
assembly based on the previous pump assembly is generally referred
to by the reference numeral 150 and referred to herein as Legacy or
the Legacy model. The method 150 includes a step 152 at which a
replacement fluid cylinder is produced, the replacement fluid
cylinder including a replacement fluid passage formed therein, the
replacement fluid passage defining a replacement inside diameter.
The step 152 includes sizing the replacement inside diameter so
that a valve seat sized and shaped for the Legacy pump assembly is
not permitted to be disposed in the replacement fluid passage.
Since the Legacy valve seat is not permitted to be disposed in the
replacement fluid passage, the parts are operationally incompatible
and a mix-up of the parts is avoided. At step 154, a replacement
valve seat is produced, the replacement valve seat defining a
replacement outside diameter. The step 154 includes sizing the
replacement outside diameter so that the replacement outside
diameter is less than a Legacy inside diameter defined by a Legacy
fluid passage formed in a Legacy fluid cylinder of the Legacy model
pump assembly, and so that a radial clearance is defined between
the replacement valve seat and an inside surface of the Legacy
fluid cylinder defined by the Legacy fluid passage if the
replacement valve seat is disposed in the Legacy fluid passage. As
a result, if the replacement valve seat is disposed in the Legacy
fluid passage and the Legacy pump assembly is subsequently
operated, the Legacy pump assembly will not be able to hold
pressure and this pressure deficiency will be quickly and easily
detected, prompting troubleshooting and the detection of the
operational incompatibility, and mix-up, of the parts. Thus, a
long-term mix-up of the parts is avoided. At step 156, the
replacement valve seat is disposed in the replacement fluid passage
of the replacement fluid cylinder. In several exemplary
embodiments, the method 150 includes additional steps in which the
replacement pump assembly is assembled in accordance with the
foregoing description of the pump assembly 10. In several exemplary
embodiments, each of the replacement and Legacy fluid cylinders may
be identical to the fluid cylinder 18 as illustrated in FIG. 9, and
each of the replacement and Legacy valve seats may be identical to
the valve seat 129 as illustrated in FIGS. 8 and 9, with at least
two exceptions. First, the inside diameter 146 of the replacement
fluid cylinder is less than the outside diameter 142 of the Legacy
valve seat so that the Legacy valve seat is not permitted to be
disposed in the portion 38a of the fluid passage 38 of the
replacement fluid cylinder. Second, the outside diameter 142 of the
replacement valve seat is less than the inside diameter 146 of the
Legacy fluid cylinder so that a radial clearance is defined between
the surface 86 of the replacement valve seat and the inside surface
46 of the Legacy fluid cylinder.
[0088] In an exemplary embodiment, as illustrated in FIG. 11 with
continuing reference to FIGS. 1-10, a valve seat is generally
referred to by the reference numeral 160 and includes several
features that are identical to corresponding features of the valve
seat 129, which identical features are given the same reference
numerals. The annular notch 130 of the valve seat 129 is omitted in
favor of an annular channel 162. In an exemplary embodiment, the
taper angle 132 is about 30 degrees measured from the axis 84. In
an exemplary embodiment, the outside diameter 134 is about 4.5
inches. In an exemplary embodiment, the inside diameter 136 is
about 3 inches. In an exemplary embodiment, the groove diameter 140
is about 3.5 inches. In an exemplary embodiment, the outside
diameter 142 is about 3.5 inches. In an exemplary embodiment, the
taper angle 144 is about 1.8 degrees measured from the axis 84. In
an exemplary embodiment, the taper angle 132 ranges from about 10
degrees to about 45 degrees measured from the axis 84. In an
exemplary embodiment, the outside diameter 134 ranges from about 4
inches to about 5 inches. In an exemplary embodiment, the inside
diameter 136 ranges from about 2.5 inches to about 3.5 inches. In
an exemplary embodiment, the groove diameter 140 ranges from about
3 inches to about 4 inches. In an exemplary embodiment, the outside
diameter 142 ranges from about 3 inches to about 4 inches. In an
exemplary embodiment, the taper angle 144 ranges from greater than
0 degrees to about 5 degrees. In several exemplary embodiments, the
valve seat 129 may be used in one or more of the valves 54, 56 and
128.
[0089] In several exemplary embodiments, variations may be made to
the valve member 100, or the valve member 100 may be omitted in
favor of another valve member that does not include the plurality
of legs 106. In several exemplary embodiments, the valves 54, 56
and 128 may be configured to operate in the presence of highly
abrasive fluids, such as drilling mud, and at relatively high
pressures, such as at pressures of up to about 15,000 psi or
greater. In several exemplary embodiments, instead of, or in
addition to being used in reciprocating pumps, the valves 54, 56
and 128 or the components thereof, such as the valve seats 76, 129
and 160, may be used in other types of pumps and fluid systems.
Correspondingly, instead of, or in addition to being used in
reciprocating pumps, the fluid cylinder 18 or features thereof may
be used in other types of pumps and fluid systems.
[0090] 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.
[0091] 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.
[0092] 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.
[0093] 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.
* * * * *