Pump system

Abstract

The present application relates to a new improved long stroke pump system for wellbore hydraulic fracturing operations. The pump system comprises a power system, a driving system and a fracturing fluid pumping assembly. The fracturing fluid pumping assembly includes one or more pairs of hydraulic cylinders that are mechanically decoupled from each other but hydraulically coupled to each other.

Description

[0001] Cross-references to related applications

[0002] This application claims the benefit of U.S. Provisional Patent Application US63 / 533,829, filed August 21, 2023, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The embodiments of this disclosure generally relate to a pump system for wellbore hydraulic fracturing operations. Background Technology

[0004] Current high-pressure pump systems used for hydraulic fracturing in wells are subjected to harsh operating conditions, often leading to damage to pump system components, operational malfunctions, and shortened service life. This reduces reliability and increases maintenance costs. Therefore, a new and improved pump system is needed. Summary of the Invention

[0005] This paper describes a new and improved long-stroke pump system for wellbore hydraulic fracturing operations. The pump system includes a power system, a drive system, and a fracturing fluid pumping assembly. The fracturing fluid pumping assembly includes one or more pairs of hydraulic cylinders that are mechanically decoupled from each other but hydraulically coupled.

[0006] Each pair of hydraulic cylinders is mechanically decoupled because there is no direct mechanical connection or coupling that transfers energy from one hydraulic cylinder to another. During operation, the mechanical energy generated by one hydraulic cylinder is not transferred to the other. Each pair of hydraulic cylinders is hydraulically coupled because energy is transferred from one hydraulic cylinder to the other via operating hydraulic fluid. During operation, the hydraulic energy generated by one hydraulic cylinder is used to assist in actuating the other hydraulic cylinder. Furthermore, the hydraulic cylinders are sized to allow the plunger to retract from the corresponding spacer stub and / or fluid end piece for easy access for maintenance, repair, and / or replacement of the plunger, spacer stub, and / or any component of the plunger and / or spacer stub. Attached Figure Description

[0007] To provide a thorough understanding of the implementation of the features described above, the disclosure briefly outlined above will be described in more detail with reference to the embodiments, some of which are illustrated in the accompanying drawings. However, it should be noted that the drawings only show typical embodiments of the present disclosure and should not be considered as limiting the scope of the disclosure, as the disclosure may also cover other equally effective embodiments.

[0008] Figure 1 A long-stroke pump system for wellbore hydraulic fracturing operations is shown according to one or more embodiments.

[0009] Figure 2 An illustration is provided according to one or more embodiments. Figure 1 Another view of the long-stroke pump system.

[0010] Figure 3 An illustration is provided according to one or more embodiments. Figure 1 Another view of the long-stroke pump system.

[0011] Figure 4 An illustration is provided according to one or more embodiments. Figure 1 Another view of the long-stroke pump system.

[0012] Figure 5 An illustration is provided according to one or more embodiments. Figure 1 A top view of a long-stroke pump system.

[0013] Figure 6 An illustration is provided according to one or more embodiments. Figure 1 It is part of a long-stroke pump system.

[0014] Figure 7 An illustration is provided according to one or more embodiments. Figure 1 It is part of a long-stroke pump system.

[0015] Figure 8 An illustration is provided according to one or more embodiments. Figure 1 A cross-sectional view of a part of a long-stroke pump system.

[0016] Figure 9 An illustration is provided according to one or more embodiments. Figure 1 A cross-sectional view of a part of a long-stroke pump system.

[0017] Figure 10 An illustration is provided according to one or more embodiments. Figure 1 A cross-sectional view of a part of a long-stroke pump system.

[0018] Figure 11 An illustration is provided according to one or more embodiments. Figure 1 A cross-sectional view of a part of a long-stroke pump system.

[0019] Figure 12 An illustration is provided according to one or more embodiments. Figure 1 A cross-sectional view of a part of a long-stroke pump system.

[0020] Figure 13 A portion of a long-stroke pump system for wellbore hydraulic fracturing operations is shown according to one or more embodiments.

[0021] Figure 14 An illustration is provided according to one or more embodiments. Figure 13 It is part of a long-stroke pump system.

[0022] Figure 15A A portion of a long-stroke pump system according to one or more embodiments is schematically shown in a first operating position.

[0023] Figure 15B The illustration schematically shows the second operating position according to one or more embodiments. Figure 15A It is part of a long-stroke pump system.

[0024] For ease of understanding, the same reference numerals have been used where possible to refer to the same elements common in the various figures. It is contemplated that elements disclosed in one embodiment may be advantageously applied to other embodiments without specific description. Detailed Implementation

[0025] This disclosure contemplates that the use of terms such as “connection,” “linkage,” and / or “linkage” may include direct connections and / or indirect connections (such as connections made through other components). This disclosure also contemplates that the use of terms such as “connection,” “linkage,” and / or “linkage” may include, but is not limited to, joining, welding, interference fit, brazing, and / or fastening using fasteners (such as pins, rivets, screws, bolts, and / or nuts). This disclosure further contemplates that the use of terms such as “connection,” “linkage,” and / or “linkage” may include, but is not limited to, components integrally formed as a single entity. This disclosure further contemplates that the use of terms such as “connection,” “linkage,” and / or “linkage” may include operative connections, such as mechanical connections, electrical connections, and / or hydraulic (e.g., fluid) connections.

[0026] Figures 1 to 7 A long-stroke pump system 1000 for wellbore hydraulic fracturing operations is illustrated according to one or more embodiments. The long-stroke pump system 1000 includes a fluid reservoir 1010, a power system 1020, a drive system 1030, a fluid coupling device 1040, and a fracturing fluid pumping assembly 1050. In one or more embodiments, the drive system and / or the fluid coupling device 1040 constitutes part of the fracturing fluid pumping assembly 1050. The long-stroke pump system 1000 is supported on a trailer 1060, which allows the long-stroke pump system 1000 to be moved to and from one or more well sites.

[0027] A fluid reservoir 1010 contains operating fluid, which is pumped by a drive system 1030 to operate a fracturing fluid pumping assembly 1050. The drive system 1030 is powered by a power system 1020. The drive system 1030 may include one or more pumps 1031 and one or more pump manifolds 1032. The power system 1020 may include a motor 1021 and / or a turbine 1022. The motor 1021 of the power system 1020 may include a diesel engine, a gasoline engine, and / or an electric motor. The drive system 1030 is fluidly connected to the fracturing fluid pumping assembly 1050 via a fluid connection device 1040. The fluid connection device 1040 may include one or more fluid lines / valves 1041 and / or connecting manifolds 1043 arranged to supply operating fluid to and from the fracturing fluid pumping assembly 1050.

[0028] One or more hydraulic cylinders 1051 may be connected to a fluid end-piece assembly 1054 via one or more spacer frames 1052 and / or one or more spacer stubs 1053. The fluid end-piece assembly 1054 includes one or more fluid end-pieces 1055 in fluid communication with a discharge manifold 1056 (having an outlet 1059) and a suction manifold 1057 (having an inlet 1058). One or more plungers 1045 extend from one or more hydraulic cylinders 1051 to the fluid end-pieces 1055.

[0029] refer to Figures 1 to 7 The operating fluid is pumped to and pumped out of one or more hydraulic cylinders 1051 of the fracturing fluid pumping assembly 1050 via pump 1031 and pump manifold 1032 of the drive system 1030. The fluid connection device 1040 may also include a connection manifold 1043, which is in fluid communication with the pump manifold 1032 via one or more fluid lines / valve 1041 (such as hoses and / or check valves). The connection manifold 1043 is also in fluid communication with the hydraulic cylinders 1051 via one or more fluid lines / valve 1041 (such as hoses and / or check valves). Figures 1 to 5 Only a few pairs of fluid lines / valves 1041 are shown in the diagram, while... Figures 6 to 12 For clarity, it has been removed.

[0030] In one or more embodiments, the fluid line / valve 1041 may include: two inlet hoses for pumping operating fluid into a pair of hydraulic cylinders 1051 (via one or more hydraulic cylinder inlets 1071); two outlet hoses for returning fluid from the pair of hydraulic cylinders 1051 (via one or more hydraulic cylinder outlets 1072); and two pressure relief hoses for returning a portion of the operating fluid from the pair of hydraulic cylinders 1051 (via one or more hydraulic cylinder pressure relief ports 1073). Each hydraulic cylinder 1051 may include a sensor port 1074, in which a sensor may be supported to measure one or more operating parameters of the hydraulic cylinder 1051.

[0031] refer to Figures 8 to 12 Each hydraulic cylinder 1051 has a cylinder housing 1080 and a cylinder rod 1081 extending from the cylinder housing 1080. A piston 1082 is coupled to one end of the cylinder rod 1081 and disposed within the cylinder housing 1080. The piston 1082 is in sealing contact with the cylinder housing 1080, thereby forming fluid chambers 1083A (e.g., pump-side fluid chambers) and fluid chambers 1083B (e.g., plunger-side fluid chambers) on opposite sides of the piston 1082, to which operating fluid is supplied (e.g., pumped) and returned. Fluid lines / ports 1099 (e.g., ...) can be formed between each pair of hydraulic cylinders 1051. Figure 12 As shown), fluid communication is provided between sealed fluid chambers 1083B formed within the cylinder housing 1080 on one side of the piston 1082. A fluid line / port 1099 may be formed through the cylinder housing 1080, one or more flanged end connectors 1085 of the cylinder housing 1080, and / or a support frame 1086 disposed between the cylinder housings 1080.

[0032] The opposite ends of the cylinder rod 1081 are connected to (and / or at least partially disposed within) the plunger 1045 via a coupling 1087. The plunger 1045 extends in a sealing manner to one end of one of the spacer tubes 1053. The length (L1) of each cylinder housing 1080 is sized to allow the plunger 1045 to be fully retracted from the spacer tube 1053 via the cylinder rod 1081, thereby facilitating access for inspection, maintenance, and / or replacement of the plunger 1045 and / or the sealing assembly 1089 of the plunger 1045 and / or the spacer tube 1053.

[0033] The opposite ends of the spacer 1053 are connected to one of the fluid end pieces 1055 of the fluid end piece assembly 1054. An internal region of each spacer 1053 forms a fluid chamber 1094, which is in fluid communication with a fluid chamber 1096 formed in the fluid end piece 1055 connected to the spacer 1053. Each of the fluid end pieces 1055 is in fluid communication with an intake manifold 1057 and an exhaust manifold 1056 of the fluid end piece assembly 1054. Each of the fluid end pieces 1055 includes an intake valve assembly 1091 and an exhaust valve assembly 1092, which are configured to guide fracturing fluid into and out of the fluid chamber 1096 of the fluid end piece 1055 via the intake manifold 1057 and the exhaust manifold 1056.

[0034] like Figure 8 As indicated by reference arrow 1095, plunger 1045 (via rod 1081) repeatedly performs reciprocating strokes to draw fracturing fluid into and out of fluid end piece 1055. As plunger 1045 strokes away from fluid end piece 1055, fracturing fluid flows into fluid end piece 1055 through suction manifold 1057 and subsequently through suction valve assembly 1091. As plunger 1045 strokes toward fluid end piece 1055, fracturing fluid flows out of fluid end piece 1055 through discharge valve assembly 1092 and subsequently through discharge manifold 1056. Valve cover 1093 at least secures and seals discharge valve assembly 1092 within fluid end piece 1055.

[0035] Each of the spacer frames 1052 may include one or more struts 1098 and / or one or more strut housings 1097, which are connected at one end to a support frame 1086. The support frame 1086 and spacer frames 1052 may be used to support hydraulic cylinders 1051, cylinder rods 1081, plungers 1045, spacer stubs 1053, and / or fluid end pieces 1055 via one or more connectors (such as threaded connectors and / or flanged connectors). For example, each pair of hydraulic cylinders 1051 may be connected to a support frame 1086, such that three pairs of hydraulic cylinders 1051 would require three support frames 1086.

[0036] Figure 13 and Figure 14An embodiment of a fluid coupling device 1040 is shown, configured to supply operating fluid between the drive system 1030 and the hydraulic cylinders 1051 and to allow the operating fluid to return. Each pump 1031 and pump manifold 1032 is configured to supply operating fluid to a pair of hydraulic cylinders 1051 and to allow the operating fluid to return to a pair of hydraulic cylinders 1051. Thus, three pumps 1031 and three pump manifolds 1032 supply operating fluid to three pairs (i.e., six) of hydraulic cylinders 1051 and allow the operating fluid to return to three pairs of hydraulic cylinders 1051. The fluid coupling device 1040 has two inlet hoses 1046 for pumping operating fluid into each pair of hydraulic cylinders 1051 (e.g., via...). Figure 7 Hydraulic cylinder inlet 1071 (shown); two outlet hoses 1047 for allowing operating fluid to return from each pair of hydraulic cylinders 1051 (e.g., via... Figure 7 Hydraulic cylinder outlet 1072 shown); and two pressure relief hoses 1048, for also allowing a portion of the operating fluid to return from each pair of hydraulic cylinders 1051 (e.g., via such... Figure 7 The hydraulic cylinder pressure relief port 1073 is shown.

[0037] Figure 15A and Figure 15B A portion of a long-stroke pump system 2000 (such as a long-stroke pump system 1000) according to one or more embodiments is schematically shown in a first operating position and a second operating position. Specifically, Figure 15A and Figure 15B Hydraulic coupling between a pair of hydraulic cylinders 2001 and 2002 is shown. Hydraulic cylinders 2001 and 2002 are mechanically decoupled from each other but hydraulically coupled, as further described below.

[0038] refer to Figure 15A Hydraulic cylinder 2001 moves during the suction stroke, while hydraulic cylinder 2002 moves during the discharge stroke. Operating fluid from the fluid chamber 2003 (e.g., a pump-side fluid chamber) on the first side of the piston 2005 of hydraulic cylinder 2001 is pumped and / or expelled from hydraulic cylinder 2001 via pump 2015, flows through pump manifold 2006, and is directed to the fluid chamber 2007 (e.g., a pump-side fluid chamber) on the first side of the piston 2008 of hydraulic cylinder 2002. A portion or all of the operating fluid from fluid chamber 2003 may optionally be directed from pump manifold 2006 to a fluid reservoir (such as...). Figure 1 The fluid reservoir 1010 shown. A portion or all of the operating fluid pumped into the fluid chamber 2007 may optionally be drawn from the same or different fluid reservoirs (such as, e.g., via the pump manifold 2006). Figure 1The fluid reservoir 1010 shown is used for supply. Although only one fluid line from each hydraulic cylinder 2001 and 2002 to the pump manifold 2006 is shown schematically in the figure, any number of fluid lines (such as two, three, four, five, six or more) can actually be used to supply, return and / or release operating fluid from each hydraulic cylinder 2001 and 2002 through the pump manifold 2006.

[0039] The pressurized operating fluid pumped into fluid chamber 2007 causes piston 2008, rod 2009, and plunger 2010 to move in the direction toward fluid end member 2 during the discharge stroke. As piston 2008 moves in the direction toward fluid end member 2, the operating fluid in fluid chamber 2011 (e.g., plunger-side fluid chamber) located on the opposite second side of piston 2008 of hydraulic cylinder 2002 is pressurized and forced out of fluid chamber 2011. This pressurized operating fluid flows from fluid chamber 2011 into fluid chamber 2004 (e.g., plunger-side fluid chamber), causing piston 2005, rod 2012, and plunger 2013 of hydraulic cylinder 2001 to move in the direction toward pump 2015 and pump manifold 2006 during the suction stroke. The fluid conduit 2014 between fluid chamber 2004 and fluid chamber 2011 can be either an external fluid conduit between the cylinder shells of hydraulic cylinders 2001 and 2002, or an internal fluid conduit with ports through the cylinder shell, flanged end connectors, and / or support frame (e.g., ...). Figure 12 (As shown).

[0040] Hydraulic energy generated by the pressurized operating fluid in fluid chamber 2011 (when compressed by piston 2008 in hydraulic cylinder 2002) is supplied to fluid chamber 2004 via fluid line 2014 to assist in the movement of piston 2005, piston rod 2012, and subsequently plunger 2013 of hydraulic cylinder 2001. Hydraulic energy generated by the pressurized operating fluid in fluid chamber 2003 (when compressed by piston 2005 in hydraulic cylinder 2001) and / or by pressurized operating fluid pressurized by pump 2015 can be supplied to fluid chamber 2007 via pump manifold 2006 to assist in the movement of piston 2008, piston rod 2009, and subsequently plunger 2010 of hydraulic cylinder 2002. In this way, hydraulic cylinders 2001 and 2002 are mechanically decoupled from each other but hydraulically coupled.

[0041] A portion of the operating fluid from the fluid chamber 2011 may optionally be directed via the pressure relief line 2016 to the pump manifold 2006 and the fluid reservoir (such as...). Figure 1The fluid reservoir 1010 is shown. Although only one pressure relief line 2016 is schematically shown in the figure, any number of fluid lines can be used to release operating fluid from each hydraulic cylinder 2001, 2002 via the pump manifold 2006. Although the pressure relief line 2016 is schematically shown as being located outside the hydraulic cylinders 2001, 2002, the pressure relief line 2016 may have an opening inside the cylinder housing of the hydraulic cylinders 2001, 2002.

[0042] During the discharge stroke, fracturing fluid is pumped from the spacer 2017 and fluid end piece 2 via a discharge valve assembly and discharge manifold (such as discharge valve assembly 1092 and discharge manifold 1056 of the long-stroke pump system 1000). As the piston 2008 and rod 2009 (and consequently plunger 2010) of hydraulic cylinder 2002 move in the direction of the discharge stroke, the piston 2005 and rod 2012 (and consequently plunger 2013) of hydraulic cylinder 2001 move in the opposite direction toward pump 2015 and pump manifold 2006 during the suction stroke. During the suction stroke, fracturing fluid is pumped to the spacer 2018 and fluid end piece 1 via a suction valve assembly and suction manifold (such as suction valve assembly 1091 and suction manifold 1057 of the long-stroke pump system 1000).

[0043] refer to Figure 15B Operating fluid from fluid chamber 2007 of hydraulic cylinder 2002 is pumped and / or ejected from hydraulic cylinder 2002 via pump 2015, flows through pump manifold 2006, and is guided back to fluid chamber 2003 of hydraulic cylinder 2001. A portion or all of the operating fluid from fluid chamber 2007 may optionally be guided from pump manifold 2006 to a fluid reservoir (such as...). Figure 1 The fluid reservoir 1010 shown. A portion or all of the operating fluid pumped into the fluid chamber 2003 can optionally be drawn from the fluid reservoir (such as...) via the pump manifold 2006. Figure 1 The fluid reservoir 1010 shown is used for supply.

[0044] The pressurized operating fluid pumped into the fluid chamber 2003 of hydraulic cylinder 2001 causes piston 2005, piston rod 2012, and plunger 2013 to move toward fluid end member 1 during the discharge stroke. As piston 2005 moves toward fluid end member 1, the operating fluid in fluid chamber 2004 located on the opposite second side of piston 2005 in hydraulic cylinder 2001 is pressurized and forced out of fluid chamber 2004. This pressurized operating fluid flows from fluid chamber 2004 to fluid chamber 2011 of hydraulic cylinder 2002, which helps cause piston 2008, piston rod 2009, and plunger 2010 of hydraulic cylinder 2002 to move toward pump 2015 and pump manifold 2006 during the suction stroke.

[0045] Hydraulic energy generated by the pressurized operating fluid in fluid chamber 2004 (when compressed by piston 2005 in hydraulic cylinder 2001) is supplied to fluid chamber 2011 via fluid line 2014 to assist in the movement of piston 2008, piston rod 2009, and consequently plunger 2010 in hydraulic cylinder 2002. Hydraulic energy generated by the pressurized operating fluid in fluid chamber 2007 (when compressed by piston 2008 in hydraulic cylinder 2002) and / or by pressurized operating fluid pressurized by pump 2015 can be supplied to fluid chamber 2003 via pump manifold 2006 to assist in the movement of piston 2005, piston rod 2012, and consequently plunger 2013 in hydraulic cylinder 2001. In this way, hydraulic cylinders 2001 and 2002 are mechanically decoupled from each other but hydraulically coupled.

[0046] During the discharge stroke, fracturing fluid is discharged from the spacer 2018 and fluid end piece 1 via the discharge valve assembly and discharge manifold. As the piston 2005 and rod 2012 (and consequently plunger 2013) of hydraulic cylinder 2001 move in the direction of the discharge stroke, the piston 2008 and rod 2009 (and consequently plunger 2010) of hydraulic cylinder 2002 move in the opposite direction toward pump 2015 and pump manifold 2006 during the suction stroke. During the suction stroke, fracturing fluid is pumped to the spacer 2017 and fluid end piece 2 via the suction valve assembly and suction manifold. As described above, the operating fluid is repeatedly pumped to hydraulic cylinders 2001, 2002 and pump-out hydraulic cylinders 2001, 2002 to provide suction, pressurization, and discharge of fracturing fluid through fluid end pieces 1 and 2 to perform wellbore hydraulic fracturing operations.

[0047] Long-stroke pump systems 1000 and 2000 can be arranged such that the piston / rod / plunger moves at approximately 10 to 50 strokes per minute (e.g., 20 strokes per minute) for both suction and discharge strokes, in contrast to conventional pump systems which typically operate at over 150 strokes per minute. The longer and slower pump strokes of long-stroke pump systems 1000 and 2000 provide reduced wear on components and thus extended service life / maintenance intervals. Any one or more components of long-stroke pump systems 1000 and / or 2000 can be combined with any one or more other components of long-stroke pump systems 1000 and / or 2000.

[0048] In one or more embodiments, the fracturing fluid pumping assembly includes a first pair of hydraulic cylinders that are mechanically decoupled from each other but hydraulically coupled to each other. The fracturing fluid pumping assembly may also include a second pair of hydraulic cylinders that are mechanically decoupled from each other but hydraulically coupled to each other. The fracturing fluid pumping assembly may also include a third pair of hydraulic cylinders that are mechanically decoupled from each other but hydraulically coupled to each other. The fracturing fluid pumping assembly may include any number of pairs of hydraulic cylinders that are mechanically decoupled from each other but hydraulically coupled to each other.

[0049] In one or more embodiments, the fracturing fluid pumping assembly includes: a first pair of hydraulic cylinders, each of the hydraulic cylinders having a rod extending at least partially from the cylinder body of the first pair of hydraulic cylinders, wherein the first pair of hydraulic cylinders are mechanically decoupled from each other but hydraulically coupled to each other; a first pair of spacer tubes; a first spacer frame, the first spacer frame being coupled at one end to the first pair of hydraulic cylinders and at the opposite end to the first pair of spacer tubes; and a fluid end-piece assembly having a pair of fluid end-pieces coupled to the first pair of spacer tubes, wherein a plunger of each fluid end-piece is coupled to one of the rods of the first pair of hydraulic cylinders.

[0050] Each hydraulic cylinder includes a cylinder housing, a cylinder rod at least partially disposed within the cylinder housing, and a piston coupled to the cylinder rod and forming a fluid chamber within the cylinder housing. A first pair of hydraulic cylinders are hydraulically coupled to each other such that operating fluid is repeatedly pumped from the fluid chamber of one hydraulic cylinder to the fluid chamber of another hydraulic cylinder, and then back. As operating fluid is pumped out of one hydraulic cylinder, the cylinder rod of that cylinder extends further, at least partially, from the cylinder housing during the discharge stroke. As operating fluid is pumped into one hydraulic cylinder, the cylinder rod of that cylinder retracts at least partially into the cylinder housing during the suction stroke.

[0051] While the rod of one hydraulic cylinder moves in a first direction during the discharge stroke, the rod of another hydraulic cylinder moves in the opposite second direction during the suction stroke. Each plunger is at least partially disposed within a spacer tube that is connected to one of the fluid end pieces. The length of each cylinder housing is sized to allow each plunger to fully retract from each spacer tube. Each fluid end piece includes a suction valve assembly configured to introduce fluid into the fluid end piece and a discharge valve assembly configured to guide fluid out of the fluid end piece. Each fluid end piece is in fluid communication with both a suction manifold and a discharge manifold.

[0052] The fracturing fluid pumping assembly also includes a second pair of hydraulic cylinders that are mechanically decoupled from each other but hydraulically coupled. The fracturing fluid pumping assembly also includes a third pair of hydraulic cylinders that are mechanically decoupled from each other but hydraulically coupled.

[0053] In one or more embodiments, the pump system includes a power system, a drive system, and any of the embodiments of the fracturing fluid pumping assembly described herein. The drive system includes one or more pumps and one or more pump manifolds configured to direct operating fluid between pairs of hydraulically coupled hydraulic cylinders. The power system is configured to power the one or more pumps.

[0054] In one or more embodiments, the fracturing fluid pumping assembly includes: a first hydraulic cylinder, the first hydraulic cylinder including a first cylinder housing, a first cylinder rod at least partially disposed within the first cylinder housing, and a first piston connected to the first cylinder rod, the first piston forming a pump-side fluid chamber and a plunger-side fluid chamber within the first cylinder housing on opposite sides of the first piston; a second hydraulic cylinder, the second hydraulic cylinder including a second cylinder housing, a second cylinder rod at least partially disposed within the second cylinder housing, and a second piston connected to the second cylinder rod, the second piston forming a pump-side fluid chamber and a plunger-side fluid chamber within the second cylinder housing on opposite sides of the second piston; and a pump configured to pump operating fluid into the pump-side fluid chamber within the first cylinder housing and configured to pump operating fluid into the pump-side fluid chamber within the second cylinder housing, wherein the plunger-side fluid chamber of the first cylinder housing is in fluid communication with the plunger-side fluid chamber of the second cylinder housing.

[0055] A first piston rod is connected to a first plunger, which extends into a first fluid endpiece, and a second piston rod is connected to a second plunger, which extends into a second fluid endpiece. Operating fluid is supplied from the plunger-side fluid chamber of the first cylinder housing to the plunger-side fluid chamber of the second cylinder housing, causing the second piston, second piston rod, and second plunger to move during the suction stroke to draw fracturing fluid into the second fluid endpiece. Operating fluid is also supplied from the plunger-side fluid chamber of the second cylinder housing back to the plunger-side fluid chamber of the first cylinder housing, causing the first piston, first piston rod, and first plunger to move during the suction stroke to draw fracturing fluid into the first fluid endpiece. As the first piston, first piston rod, and first plunger move during the suction stroke, the second piston, second piston rod, and second plunger move during the discharge stroke to pump fracturing fluid out of the second fluid endpiece.

[0056] The benefits of the embodiments of the long-stroke pump system disclosed herein include increased efficiency, reduced costs, shorter operation time, reduced resource mobilization, and ease of design and operation.

[0057] It will be recognized by those skilled in the art that the foregoing embodiments are merely exemplary and not restrictive. All modifications, variations, enhancements, equivalents, and improvements that will be apparent to those skilled in the art upon reading this specification and examining the accompanying drawings are intended to be included within the scope of this disclosure. Therefore, the appended claims are intended to cover all such modifications, variations, enhancements, equivalents, and improvements. This disclosure also contemplates that one or more aspects of the embodiments described herein may be used in place of one or more other aspects described herein. The scope of protection of this disclosure is determined by the following claims.

Claims

1. A fracturing fluid pumping assembly, the fracturing fluid pumping assembly comprising: The first pair of hydraulic cylinders, each having a cylinder rod extending at least partially from the first pair of hydraulic cylinders, wherein the first pair of hydraulic cylinders are mechanically decoupled from each other but hydraulically coupled to each other; The first pair of spacer short tubes; A first spacer frame, which is connected at one end to the first pair of hydraulic cylinders and at the opposite end to the first pair of spacer stubs; and A fluid end-piece assembly having a pair of fluid end-pieces connected to a first pair of spaced short tubes, wherein the plunger of each fluid end-piece is connected to one of the cylinder rods of the first pair of hydraulic cylinders.

2. The fracturing fluid pumping assembly according to claim 1, wherein, Each hydraulic cylinder includes: a cylinder housing, wherein the cylinder rod is at least partially disposed within the cylinder housing; and a piston connected to the cylinder rod and forming a fluid chamber within the cylinder housing.

3. The fracturing fluid pumping assembly according to claim 2, wherein, The first pair of hydraulic cylinders are hydraulically coupled to each other, such that the operating fluid is repeatedly pumped from the fluid chamber of one hydraulic cylinder to the fluid chamber of the other hydraulic cylinder and then returns.

4. The fracturing fluid pumping assembly according to claim 3, wherein, As the operating fluid is pumped out of one of the hydraulic cylinders, the cylinder rod extends further, at least partially, from the cylinder housing during the discharge stroke.

5. The fracturing fluid pumping assembly according to claim 4, wherein, As the operating fluid is pumped into one of the hydraulic cylinders, the cylinder rod retracts at least partially into the cylinder housing during the suction stroke.

6. The fracturing fluid pumping assembly according to claim 5, wherein, While the rod of one hydraulic cylinder moves in a first direction during the discharge stroke, the rod of the other hydraulic cylinder moves in the opposite second direction during the suction stroke.

7. The fracturing fluid pumping assembly according to claim 6, wherein, Each plunger is at least partially disposed within a short spacer tube connected to one of the fluid end pieces.

8. The fracturing fluid pumping assembly according to claim 7, wherein, The length of each cylinder housing is sized to allow each plunger to retract completely from each spacer stub.

9. The fracturing fluid pumping assembly according to claim 7, wherein, Each fluid end piece includes: a suction valve assembly configured to direct operating fluid into the fluid end piece; and a discharge valve assembly configured to direct the operating fluid out of the fluid end piece.

10. The fracturing fluid pumping assembly according to claim 9, wherein, Each fluid end piece is in fluid communication with the suction manifold and the discharge manifold.

11. The fracturing fluid pumping assembly according to claim 1, wherein, The fracturing fluid pumping assembly also includes a second pair of hydraulic cylinders that are mechanically decoupled from each other but hydraulically coupled.

12. The fracturing fluid pumping assembly according to claim 11, wherein, The fracturing fluid pumping assembly also includes a third pair of hydraulic cylinders that are mechanically decoupled from each other but hydraulically coupled.

13. A pump system, the pump system comprising: Power system; Drive system; and The fracturing fluid pumping assembly according to claim 1.

14. The pump system according to claim 13, wherein, The drive system includes one or more pumps and one or more pump manifolds configured to guide operating fluid between pairs of hydraulically coupled hydraulic cylinders.

15. The pump system according to claim 14, wherein, The power system is configured to provide power to the one or more pumps.

16. A fracturing fluid pumping assembly, the fracturing fluid pumping assembly comprising: The first hydraulic cylinder includes a first cylinder housing, a first cylinder rod at least partially disposed within the first cylinder housing, and a first piston connected to the first cylinder rod. The first piston forms a pump-side fluid chamber and a plunger-side fluid chamber on the opposite side of the first piston within the first cylinder housing. The second hydraulic cylinder includes a second cylinder housing, a second cylinder rod at least partially disposed within the second cylinder housing, and a second piston connected to the second cylinder rod. The second piston forms a pump-side fluid chamber and a plunger-side fluid chamber on opposite sides of the second piston within the second cylinder housing. A pump configured to pump operating fluid to a pump-side fluid chamber within a first cylinder housing and configured to pump operating fluid to a pump-side fluid chamber within a second cylinder housing, wherein the plunger-side fluid chamber within the first cylinder housing and the plunger-side fluid chamber within the second cylinder housing are in fluid communication.

17. The fracturing fluid pumping assembly according to claim 16, wherein, The first cylinder rod is connected to a first plunger, the first plunger extending into a first fluid end piece, and wherein the second cylinder rod is connected to a second plunger, the second plunger extending into a second fluid end piece.

18. The fracturing fluid pumping assembly according to claim 17, wherein, Operating fluid is supplied from the plunger-side fluid chamber of the first cylinder housing to the plunger-side fluid chamber of the second cylinder housing, so that the second piston, the second cylinder rod, and the second plunger move during the suction stroke, thereby drawing fracturing fluid into the second fluid end piece.

19. The fracturing fluid pumping assembly according to claim 18, wherein, Operating fluid is supplied from the plunger-side fluid chamber of the second cylinder housing to the plunger-side fluid chamber of the first cylinder housing to move the first piston, the first cylinder rod, and the first plunger during the suction stroke, thereby drawing fracturing fluid into the first fluid end piece.

20. The fracturing fluid pumping assembly according to claim 19, wherein, As the first piston, the first cylinder rod, and the first plunger move during the suction stroke, the second piston, the second cylinder rod, and the second plunger move during the discharge stroke to pump fracturing fluid out of the second fluid end piece.

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