Fluid ends and valve assemblies for high power pumps and related systems and methods

Abstract

Fluid ends, valve assemblies, and related systems and methods may include a fixed sleeve configured to be positioned in a valve bore defined by a fluid end block. The fixed sleeve may define a sleeve recess, and a discharge member may be positioned in the sleeve recess. The discharge member may define a valve seat. The discharge member may be positioned to reciprocate relative to the sleeve recess between a closed discharge position and an open discharge position. The valve assembly further may include a suction member positioned to reciprocate relative to the discharge member between a closed suction position when contacting the valve seat and an open suction position when spaced from the valve seat. The suction member and the discharge member may be positioned to control flow of fluid into and from the fluid end block, thereby to enhance control of fluid flow through the fluid end block.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to, and the benefit of U.S. Provisional Application No. 63 / 779,486, filed Mar. 28, 2025, titled “FLUID ENDS AND VALVE ASSEMBLIES FOR HIGH POWER PUMPS AND RELATED SYSTEMS AND METHODS,” the disclosure of which is incorporated herein by reference in its entirety.TECHNICAL FIELD

[0002] The present disclosure relates to fluid ends, valve assemblies, and related systems and methods and, more particularly, to fluid ends and valve assemblies for high-power pumps, and related systems and methods.BACKGROUND

[0003] Pumps may be used to transfer fluid having a first pressure from one location to another location at a second pressure greater than the first pressure. Pumps often include valves to control the flow of fluid into, through, and from a pump chamber of the pump. For example, a reciprocating plunger pump may include a first one-way valve or check-valve to allow fluid to be drawn into the pump and a second one-way valve or check-valve to permit the discharge of the fluid drawn into the pump while the first valve is closed. For example, the first valve may open to allow fluid to be drawn into the pump while the second valve is closed, and thereafter the first valve may close while the second valve is open while a plunger in the pump increases the pressure of the fluid in the pump chamber and forces the fluid through the second valve to pump the fluid.

[0004] An example of a high-power pump may be used, for example, to pump fracturing fluid at high pressures and high flow rates during a hydraulic fracturing operation. For example, a hydraulic fracturing operation involves pumping a fracturing fluid at high flow rates and high pressures sufficient to fracture a reservoir formation to allow hydrocarbons to more easily flow from the formation toward a wellbore for production. Such high flow rates and high pressures may result in significant wear to components associated with the fluid flow, such as the pumps used to pump the fracturing fluid. In addition, the fracturing fluid may contain substances, for example, proppants and fluids, having abrasive and corrosive characteristics, and thus, components associated with the fracturing operation may exhibit high wear rates or high failure rates. As a result, components associated with pumps, such as fluid ends and associated valves, may be particularly susceptible high wear rates and failures, thereby requiring replacement. For example, it is common to replace valves relatively frequently during the service life of a high-power pump, which may result in relatively high maintenance and service costs over the service life of the high-power pump.

[0005] For at least these reasons, Applicant has recognized that it may be desirable to provide fluid ends and valve assemblies for high-power pumps, and related systems and methods, resulting in relatively increased efficiencies associated with the reliability of the fluid ends and associated valve assemblies. At least some examples described herein may address one or more of the above-noted potential issues, as well as possibly others.SUMMARY

[0006] As referenced above, it may be desirable to provide fluid ends and valve assemblies for high-power pumps, and related systems and methods, resulting in relatively increased efficiencies associated with the reliability of fluid ends and valve assemblies of high-power pumps, such as, for example, fluid ends and valve assemblies used in the oil and gas industry, where the operating conditions and fluids may present a particularly harsh environment. In some embodiments, the fluid ends and valve assemblies presented herein may have a relatively enhanced reliability, resulting in less frequent service and replacement. For example, in some embodiments, a fluid end may include a fluid end block having a plunger bore positioned to receive a packing assembly and a reciprocating plunger, and the plunger bore may be axially aligned with a valve bore that receives a valve assembly that acts as both a suction valve and a discharge valve. In some embodiments, the valve assembly may include a discharge member positioned to open and close a discharge port of the fluid end, and a face of the discharge member may provide a valve seat for a suction member positioned to open and close a suction port of the fluid end. In some embodiments, the fluid ends and valve assemblies may reduce or prevent fatigue failures of fluid end blocks, which may thereby mitigate the need to use stainless steel construction, instead allowing the use of relatively more efficient carbon steel. In some embodiments, the fluid ends and valve assemblies may facilitate access to internal components of the fluid end from a side of the fluid opposite an associated power end, which may be less ergonomically challenging for a service technician, thereby improving efficiencies associated with assembly and service of the fluid end.

[0007] According to some embodiments, a valve assembly to enhance control of fluid flow through a fluid end block of a high-power pump may include a fixed sleeve having a sleeve body configured to be positioned at least partially in a valve bore. The valve bore may be at least partially defined by a fluid end block. The sleeve body may be annular and may at least partially define a sleeve recess. The valve assembly further may include a discharge member at least partially positioned in the sleeve recess. The discharge member may have a discharge member body at least partially defining a valve seat. The discharge member body may be positioned to reciprocate relative to the sleeve recess between a closed discharge position and an open discharge position. The valve assembly also may include a suction member having a suction member body positioned to reciprocate relative to the discharge member between a closed suction position when contacting the valve seat and an open suction position when spaced from the valve seat. The discharge member may be positioned to: (a) prevent flow of fluid to a discharge port in the fluid end block when the discharge member is in the closed discharge position, and (b) allow fluid to flow to the discharge port in the fluid end block when the discharge member is in the open discharge position, and the suction member may be positioned to: (a) prevent fluid from being drawn through the suction port when the suction member is in closed suction position, and (b) allow fluid to be drawn through the suction port when the suction member is in the open suction position, thereby to enhance control of fluid flow through the fluid end block.

[0008] According to some embodiments, a valve assembly to enhance control of fluid flow through a fluid end block of a high-power pump may include a fixed sleeve having a sleeve body configured to be positioned at least partially in a valve bore at least partially defined by a fluid end block. The sleeve body may be annular and may at least partially define a discharge member seat and a suction member seat. The valve assembly further may include a discharge member associated with the sleeve body. The discharge member may include a discharge member body at least partially defining a discharge surface. The discharge member body may be positioned to reciprocate relative to the sleeve body between a closed discharge position when the discharge surface contacts the discharge member seat and an open discharge position when the discharge surface is spaced from the discharge member seat. The valve assembly also may include a suction member having a suction member body positioned to reciprocate relative to the sleeve body between a closed suction position when contacting the suction member seat and an open suction position when the suction member body is spaced from the suction member seat. The discharge member body and the suction member body may be positioned to move in opposite longitudinal directions when the discharge member body moves to the closed discharge position and the suction member body moves to the closed suction position. The discharge member may be positioned to: (a) prevent flow of fluid to a discharge port in the fluid end block when the discharge member is in the closed discharge position, and (b) allow fluid to flow to the discharge port in the fluid end block when the discharge member is in the open discharge position, and the suction member may be positioned to: (a) prevent flow of fluid from a suction port in the fluid end block when the suction member is in the closed suction position, and (b) allow fluid to be drawn through the suction port when the suction member is in the open suction position, thereby to enhance control of fluid flow through the fluid end block.

[0009] According to some embodiments, a fluid end may include a fluid end block at least partially defining a valve bore, a suction port, and a discharge port. The fluid end further may include a valve assembly at least partially positioned in the valve bore, thereby to enhance control of fluid flow through the fluid end block. The valve assembly may include a fixed sleeve having a sleeve body at least partially positioned in the valve bore. The sleeve body may be annular and may at least partially define a sleeve recess. The valve assembly further may include a discharge member at least partially positioned in the sleeve recess. The discharge member may have a discharge member body at least partially defining a valve seat. The discharge member body may be positioned to reciprocate relative to the sleeve recess between a closed discharge position and an open discharge position. The valve assembly also may include a suction member having a suction member body positioned to reciprocate relative to the discharge member between a closed suction position when contacting the valve seat and an open suction position when spaced from the valve seat. The discharge member may be positioned to: (a) prevent flow of fluid to the discharge port in the fluid end block when the discharge member is in the closed discharge position, and (b) allow fluid to flow to the discharge port in the fluid end block when the discharge member is in the open discharge position, and the suction member may be positioned to: (a) prevent fluid from being drawn through the suction port when the suction member is in the closed suction position, and (b) allow fluid to be drawn through the suction port when the suction member is in the open suction position, thereby to enhance control of fluid flow through the fluid end block.

[0010] According to some embodiments, a fluid end may include a fluid end block at least partially defining a valve bore, a suction port, and a discharge port. The fluid end further may include a valve assembly at least partially positioned in the valve bore, thereby to enhance control of fluid flow through the fluid end block. The valve assembly may include a fixed sleeve having a sleeve body configured to be positioned at least partially in the valve bore. The sleeve body may be annular and may at least partially define a discharge member seat and a suction member seat. The valve assembly further may include a discharge member associated with the sleeve body. The discharge member may have a discharge member body at least partially defining a discharge surface. The discharge member body may be positioned to reciprocate relative to the sleeve body between a closed discharge position when the discharge surface contacts the discharge member seat and an open discharge position when the discharge surface is spaced from the discharge member seat. The valve assembly also may include a suction member having a suction member body positioned to reciprocate relative to the sleeve body between a closed suction position when contacting the suction member seat and an open suction position when the suction member body is spaced from the suction member seat. The discharge member body and the suction member body may be positioned to move in opposite longitudinal directions when the discharge member body moves to the closed discharge position and the suction member body moves to the closed suction position. The discharge member may be positioned to: (a) prevent flow of fluid to a discharge port in the fluid end block when the discharge member is in the closed discharge position, and (b) allow fluid to flow to the discharge port in the fluid end block when the discharge member is in the open discharge position, and the suction member may be positioned to: (a) prevent flow of fluid from a suction port in the fluid end block when the suction member is in the closed suction position, and (b) allow fluid to be drawn through the suction port when the suction member is in the open suction position, thereby to enhance control of fluid flow through the fluid end block.

[0011] According to some embodiments, a fluid end for a high-power pump may include a valve assembly according to any of the valve assemblies described herein. According to some embodiments, a high-power pump may include a fluid end according to any of the fluid ends described herein.

[0012] According to some embodiments, a method to enhance control of fluid flow through a fluid end of a high-power pump may include positioning a valve assembly in a valve bore in a fluid end block of the fluid end, the valve bore having a longitudinal valve axis extending in a first direction substantially parallel to a longitudinal axis of a plunger bore. The valve assembly may include a suction member and a discharge member. The suction member and the discharge member may be positioned to reciprocate relative to the valve bore in a direction substantially parallel to the first direction. The discharge member may at least partially define a valve seat, and the suction member may be positioned to reciprocate relative to the discharge member between a closed suction position when the suction member contacts the valve seat and an open suction position when the suction member is spaced from the valve seat, thereby to enhance control of fluid flow through the fluid end.

[0013] According to some embodiments, a method to enhance control of fluid flow through a fluid end of a high-power pump may include positioning a valve assembly in a valve bore in a fluid end block of the fluid end, the valve bore having a longitudinal valve axis extending in a first direction substantially parallel to a longitudinal axis of a plunger bore. The valve assembly may include a fixed sleeve at least partially defining a suction member seat and a discharge member seat. The valve assembly further may include a suction member positioned to reciprocate relative to the valve bore between: (a) a closed suction position when the suction member contacts the suction member seat and (b) an open suction position when the suction member is spaced from the suction member seat. The valve assembly also may include a discharge member positioned to reciprocate relative to the valve bore between: (a) a closed discharge position when the discharge member contacts the discharge member seat and (b) an open discharge position when the discharge member is spaced from the discharge member seat, thereby to enhance control of fluid flow through the fluid end.

[0014] According to some embodiments, a method to enhance connection between a fluid end and a power end of a high-power pump may include passing each of a plurality of stay rods through one of a plurality of stay rod bores passing substantially through a fluid end block from a power end side of the fluid end block to a side of the fluid end block opposite the power end side. The method also may include connecting a first end of each of the plurality of stay rods to the fluid end block, and connecting a second end of each of the plurality of stay rods to the power end, thereby to enhance connection of the fluid end to the power end.

[0015] According to some embodiments, a method to enhance assembly of a valve assembly in a fluid end of a high-power pump may include inserting a discharge member into a valve bore in a first side of a fluid end block of the fluid end, the valve bore having a longitudinal valve axis extending in a first direction substantially parallel to a plunger bore of the fluid end block. The discharge member may at least partially define a valve seat. The method also may include inserting a suction member into the valve bore and positioning the suction member relative to the discharge member, such that the suction member reciprocates relative to the discharge member between a closed suction position when the suction member contacts the valve seat and an open suction position when the suction member is spaced from the valve seat, thereby to enhance control of fluid flow through the fluid end.

[0016] Still other aspects and advantages of these exemplary embodiments and other embodiments, are discussed in detail herein. Moreover, it is to be understood that both the foregoing information and the following detailed description provide merely illustrative examples of various aspects and embodiments and are intended to provide an overview or framework for understanding the nature and character of the claimed aspects and embodiments. Accordingly, these and other objects, along with advantages and features of the present disclosure, will become apparent through reference to the following description and the accompanying drawings. Furthermore, it is to be understood that the features of the various embodiments described herein are not mutually exclusive and may exist in various combinations and permutations.BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The accompanying drawings, which are included to provide a further understanding of the embodiments of the present disclosure, are incorporated in and constitute a part of this specification, illustrate embodiments of the present disclosure, and together with the detailed description, serve to explain principles of the embodiments discussed herein. No attempt is made to show structural details of this disclosure in more detail than may be necessary for a fundamental understanding of the embodiments discussed herein and the various ways in which they may be practiced. According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate embodiments of the disclosure.

[0018] FIG. 1 is a schematic perspective section view of an example pump, including an example fluid end, according to embodiments of the disclosure.

[0019] FIG. 2A is a schematic detailed side section view of the example valve assembly shown in FIG. 2A, according to embodiments of the disclosure.

[0020] FIG. 2B is a schematic side section view of the example valve assembly shown in FIG. 2A, according to embodiments of the disclosure.

[0021] FIG. 2C is a schematic side section view of the example fluid end and valve assembly shown in FIG. 2A, with an example plunger moving toward a bottom dead center position during an example suction stroke, according to embodiments of the disclosure.

[0022] FIG. 2D is a schematic side section view of the example fluid end and valve assembly shown in FIG. 2A, with the example plunger reaching the bottom dead center position, according to embodiments of the disclosure.

[0023] FIG. 2E is a schematic detailed side section view the example valve assembly shown in FIG. 2D, with an example suction member in an example open position, according to embodiments of the disclosure.

[0024] FIG. 2F is a schematic side section view of the example fluid end and valve assembly shown in FIG. 2A, with the example plunger moving from the bottom dead center position toward a top dead center position during an example discharge stroke, according to embodiments of the disclosure.

[0025] FIG. 2G is a schematic side section view of the example fluid end and valve assembly shown in FIG. 2A, with the example plunger reaching the top dead center position, according to embodiments of the disclosure.

[0026] FIG. 2H is a schematic detailed side section view the example valve assembly shown in FIG. 2G, with an example discharge member in an example open position, according to embodiments of the disclosure.

[0027] FIG. 2I is a schematic side section view of the example fluid end and valve assembly shown in FIG. 2A, with the example plunger moving from the top dead center position toward the bottom dead center position during an example suction stroke, according to embodiments of the disclosure.

[0028] FIG. 3 is a schematic partial side section view of an example fluid end and example stay rods for connecting the fluid end to a power end, according to embodiments of the disclosure.

[0029] FIG. 4A is a schematic side section view of another example fluid end and another example valve assembly, with an example plunger moving toward a bottom dead center position during an example suction stroke, with an example suction member in an open position and an example discharge member in a closed position, according to embodiments of the disclosure.

[0030] FIG. 4B is a schematic side section view of the example fluid end and valve assembly shown in FIG. 4A, with the plunger moving from the bottom dead center position toward the top dead center position during an example discharge stroke, with the discharge member in an open position and the suction member in a closed position, according to embodiments of the disclosure.

[0031] FIG. 5A is a schematic side section view of another example valve assembly and an example plunger, with an example suction member closed and an example discharge member closed, according to embodiments of the disclosure.

[0032] FIG. 5B is a schematic side section view of the example valve assembly shown in FIG. 5A, with the example plunger moving away from a top dead center position toward a bottom dead center position during an example suction stroke, according to embodiments of the disclosure.

[0033] FIG. 5C is a schematic side section view of the example valve assembly shown in FIG. 5A, with the example plunger moving further toward the bottom dead center position during an example suction stroke, with an example suction member in an open position and an example discharge member in a closed position, according to embodiments of the disclosure.

[0034] FIG. 5D is a schematic side section view of the example valve assembly shown in FIG. 5A, with the example plunger reaching the bottom dead center position, with the example suction member in the open position and the example discharge member in the closed position, according to embodiments of the disclosure.

[0035] FIG. 5E is a schematic side section view of the example valve assembly shown in FIG. 5A, with the example plunger moving away from the bottom dead center position toward the top dead center position during an example discharge stroke, with an example suction member returning to the closed position while the example discharge member remains in the closed position, according to embodiments of the disclosure.

[0036] FIG. 5F is a schematic side section view of the example valve assembly shown in FIG. 5A, with the example plunger continuing to move toward the top dead center position during an example discharge stroke, with the example suction member remaining in the closed position and the example discharge member moving to the open position, according to embodiments of the disclosure.

[0037] FIG. 6 is a schematic side view diagram showing an example method to enhance control of fluid flow through a fluid end of a high-power pump consistent with the example fluid end shown in FIGS. 2A-2I, according to embodiments of the disclosure.

[0038] FIG. 7 is a schematic side view diagram showing an example method to enhance control of fluid flow through a fluid end of a high-power pump consistent with the example fluid end shown in FIGS. 4A and 4B, according to embodiments of the disclosure.

[0039] FIG. 8 is a schematic side view diagram showing an example method to enhance control of fluid flow through a fluid end of a high-power pump consistent with the example valve assembly shown in FIGS. 5A-5F, according to embodiments of the disclosure.

[0040] FIG. 9 is a schematic side view diagram showing an example method of enhancing connection between a fluid end and a power end consistent with the example fluid end and example stay rods shown in FIG. 3, according to embodiments of the disclosure.DETAILED DESCRIPTION

[0041] The drawings include like numerals to indicate like parts throughout the several views, the following description is provided as an enabling teaching of exemplary embodiments, and those skilled in the relevant art will recognize that many changes may be made to the embodiments described. It also will be apparent that some of the desired benefits of the embodiments described may be obtained by selecting some of the features of the embodiments without utilizing other features. Accordingly, those skilled in the art will recognize that many modifications and adaptations to the embodiments described are possible and may even be desirable in certain circumstances. Thus, the following description is provided as illustrative of the principles of the embodiments and not in limitation thereof.

[0042] The phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. As used herein, the term “plurality” refers to two or more items or components. The terms “comprising,”“including,”“carrying,”“having,”“containing,” and “involving,” whether in the written description or the claims and the like, are open-ended terms, in particular, to mean “including but not limited to,” unless otherwise stated. Thus, the use of such terms is meant to encompass the items listed thereafter, and equivalents thereof, as well as additional items. The transitional phrases “consisting of” and “consisting essentially of,” are closed or semi-closed transitional phrases, respectively, with respect to any claims. Use of ordinal terms such as “first,”“second,”“third,” and the like in the claims to modify a claim element does not by itself connote any priority, precedence, or order of one claim element over another or the temporal order in which acts of a method are performed, but are used merely as labels to distinguish one claim element having a certain name from another element having a same name (but for use of the ordinal term) to distinguish claim elements.

[0043] The present disclosure is generally directed fluid ends, valve assemblies, and related systems and methods and, more particularly, to fluid ends and valve assemblies for high-power pumps, and related systems and methods, such as, for example, fluid ends and valve assemblies used in the oil and gas industry, where the operating conditions and fluids may present a particularly harsh environment. Applicant has recognized that fluid ends and valve assemblies may have a number drawbacks. For example, because in many fluid end blocks the bores that receive the valves intersect the respective bores in which the plunger reciprocates, the intersection of the bores are high-stress, failure-prone areas of the fluid end block due to the high cycle rate pumping common in high-power pumps, for example, such as hydraulic fracturing pumps that may pump at 15,000 psi and from 1 to 3 Hz. In such pumps, for example, the material around the intersections of the bores may be subject to impact from sand, rocks, and debris during normal operation. Due to such impacts, such pumps generally have forged stainless steel fluid end blocks rather than carbon steel fluid end blocks in order to reduce wear and failure rates, leading to manufacturing inefficiencies. In addition, Applicant has also recognized that servicing the valves of such pumps, a relatively common occurrence, may generally require accessing vertical valve bores via respective covers, while servicing packing assemblies of such pumps, also a relatively common occurrence, may generally require accessing horizontal plunger bores via different respective covers, resulting in servicing inefficiencies. Moreover, separate suction valve seats and discharge valve seats may often be press-fitted into tapered portions of the respective vertical bores, and thus, in order to install and remove the respective suction and discharge valve seats from the respective bores, hydraulic cylinders may be required to exert sufficient installation and extraction forces, typically greater than twenty tons, on the respective valve seats, resulting in installation and servicing inefficiencies. Servicing packing assemblies may be performed from a side of the fluid end adjacent the associated power end, which may require that service personnel lean over the fluid end to remove large packing nuts that retain a packing assembly, which may be ergonomically challenging for service personnel and inefficient. For some high-power pumps, a typical fluid end may weigh from 3,000 to 7,000 pounds, and may be attached from the fluid end side to the power end by as many as ten to twenty stay rods, which may often be tightened to specific preload torques to prevent fastener fatigue, resulting in such an operation being ergonomically challenging and inefficient for service personnel.

[0044] In some embodiments, the fluid ends and valve assemblies presented herein may have a relatively enhanced reliability, resulting in less frequent service and replacement. For example, in some embodiments, a fluid end may include a fluid end block having a plunger bore positioned to receive a packing assembly and a reciprocating plunger, and the plunger bore may be axially aligned with a valve bore that receives a valve assembly that, in at least some embodiments, acts as both a suction valve and a discharge valve. In some embodiments, the valve assembly may include a discharge member positioned to open and close a discharge port of the fluid end, and a face of the discharge member may provide a valve seat for a suction member positioned to open and close a suction port of the fluid end. In some embodiments, the fluid ends and valve assemblies may reduce or prevent fatigue failures of fluid end blocks, which may thereby mitigate the need to use stainless steel construction, instead allowing the use of relatively more efficient carbon steel. In some embodiments, the fluid ends and valve assemblies may facilitate access to internal components of the fluid end from a side of the fluid opposite the associated power end, which may be less ergonomically challenging for service personnel, thereby improving efficiencies associated with assembly and service of the fluid end.

[0045] For example, FIG. 1 is a schematic perspective section view of an example pump 10, including an example fluid end 12, and a schematic depiction of an example power end 14, according to embodiments of the disclosure. The pump 10 may be any high-power pump, high-pressure pump, reciprocating pump, and / or high-flow rate pump suitable for pumping solids, semi-solids, slurries, liquids, fluids, or combinations thereof. In some embodiments, the pump 10 may be, for example, a hydraulic fracturing pump for pumping hydraulic fracturing fluid. Although embodiments of the pump 10 are described herein as being a “hydraulic fracturing pump” for pumping hydraulic fracturing fluid for the purpose of discussion, the pump 10 may be any other type of pump, such as, for example, any type of high-power pump, high-pressure pump, reciprocating pump, and / or high-flow rate pump suitable for pumping solids, semi-solids, slurries, liquids, fluids, or combinations thereof. In some embodiments, the pump 10 may be, for example, a hydraulic fracturing pump for pumping solids, semi-solids, slurries, liquids, fluids, or combinations thereof, such as hydraulic fracturing fluid.

[0046] For example, a reciprocating plunger pump may be used to pump a fracturing fluid at high flow rates and high pressures sufficient to fracture a reservoir formation to allow hydrocarbons to more easily flow from the formation toward a wellbore for production. A hydraulic fracturing operation may include as many as six or more hydraulic fracturing units, and each of the hydraulic fracturing units may include a prime mover, such as an electric motor or internal combustion engine, either directly connected, or connected via a transmission, to the reciprocating plunger pump to supply power to drive the reciprocating plunger pump to pump the fracturing fluid into the formation to stimulate production of the well. For example, typical flow rates for a hydraulic fracturing operation may range from about 1,500 to about 4,000 gallons per minute, and typical pressures may range from about 7,500 to about 15,000 pounds per square inch. Although many examples discussed in this disclosure are explained in relation to hydraulic fracturing pumps, such as reciprocating plunger pumps for pumping fracturing fluid and related methods, other flow control-related and / or pumping-related operations, components, and methods are contemplated.

[0047] As shown in FIG. 1, the example pump 10 may be a reciprocating plunger pump and may include the fluid end 12 and the power end 14. The power end 14 may include, for example, a housing 16 for power transmission components 18, such as a crankshaft, bearings supporting the crankshaft in the housing, crossheads, reduction gears, pony rods, connecting rods, and / or plungers connected to the pony rods or connecting rods. A prime mover, such as an electric motor and / or an internal combustion engine, may be connected to the power transmission components 18, thereby to drive the power transmission components 18 during operation of the pump 10.

[0048] As shown in FIG. 1, for example, the fluid end 12 may include a fluid end block 20 including one or more plunger bores 22 in each of which a packing assembly 24 is received and respective plungers 26 reciprocate, one or more chambers 28 receiving fluid, one or more suction ports 30 for drawing fluid into the one or more chambers 28, and one or more discharge ports 32 for discharging fluid from the one or more chambers 28 at a higher pressure. For example, as each plunger 26, moved via operation of the power transmission components 18 of the power end 14, at least partially retracts into a respective plunger bore 22, fluid is drawn from a fluid source 34, for example, through a suction manifold, into the chamber 28 of the fluid end 12 via the suction port 30 in the fluid end block 20, while a suction member 36 is open and a discharge member 38 is closed. As each plunger 26 reverses direction and moves back toward the chamber 28, moved via operation of the power transmission components 18, pressurized fluid 40 (e.g., fluid at a higher pressure than fluid received from the fluid source 34) is discharged from the fluid end 12 via the discharge port 32 in the fluid end block 20 while the discharge member 38 is open and the suction member 36 is closed, for example, as described herein. In some embodiments, the pump 10 may further include a discharge manifold having a discharge passage, and the discharge member 38, when open, may allow the pressurized fluid 40 to be discharged from the pump 10 via the discharge manifold and discharge passage for downstream use, for example, as part of a hydraulic fracturing operation or other operation. In some embodiments, the suction member 36 and the discharge member 38 may be part of a common valve assembly 42, for example, as described herein. The suction member 36 and / or the discharge member 38 may act as one-way valves or check-valves, allowing fluid to flow only in a single direction, either into the chamber 28 of the fluid end block 20 via the suction member 36, or from the chamber 28 of the fluid end block 20 via the discharge member 38. In this example manner, the fluid end 12 draws fluid from the fluid source 34 into the fluid end block 20 at a first pressure and discharges the fluid from the fluid end 12 at a higher pressure. In some pump embodiments, the fluid end 12 may include multiple (e.g., two, three, four, or five) sets of suction ports, plunger bores, packing assemblies, plungers, and / or discharge ports to pump fluid at high pressures and / or high flow rates.

[0049] As shown in FIG. 1, according to some embodiments, the fluid end 12 may include an access port 44 providing access to one or more of the chambers 28, for example, for use during assembly and / or maintenance of the fluid end 12. Each of the one or more access ports 44 may be selectively closed via a respective spacer 45 and / or a respective cover 46 received in the access port 44. In some embodiments, the access port 44 may be defined in the fluid end block 20 by a circular aperture having an interior face having a substantially cylindrical configuration, for example, as shown in FIG. 1. In some embodiments, the spacer 45 and / or the cover 46 may have a substantially circular cross-section and may have a substantially cylindrical configuration sized and shaped to fit within the interior face of the access port 44, for example, as shown in FIG. 1. In some embodiments, the spacer 45 and / or the cover 46 may be sized and shaped to fit snugly (e.g., in a substantially sealed manner) within the access port 44. In some embodiments, a retainer assembly 48 may be used to secure the spacer 45 and / or the cover 46 within the access port 44. As shown, in some embodiments, the retainer assembly 48 may include an outer housing 50 configured to be secured to an exterior surface of the fluid end block 20 adjacent the access port 44, for example, via one or more fasteners 52 (e.g., studs and nuts), as shown. The outer housing 50 may define a receiver aperture 54 provided with internal threads. The retainer assembly 48 further may include a retainer 56, which may include a substantially cylindrical body having external threads configured to threadedly engage the internal threads of the outer housing 50. In some embodiments, the retainer 56 may be threaded into the outer housing 50 and into contact with an exterior end of the cover 46, thereby to secure the spacer 45 and / or the cover 46 in the access port 44.

[0050] As shown in FIG. 1, in some embodiments, the fluid end 12 may include an annular pressure ring 58, and an annular connection ring 60 may be connected to the fluid end block 20 via fasteners 62 (e.g., studs and bolts), thereby to secure the pressure ring 58 to the fluid end block 20. The pressure ring 58 and the connection ring 60 may each include a bore through which the plunger 26 reciprocates. One or more of the bores of the pressure ring 58 or the connection ring 60 may define an annular space around the plunger 26 in which the packing assembly 24 is received to seal the annular space around the plunger 26. In some embodiments, the packing assembly 24 may include one or more of a junk ring, a header ring, one or more pressure rings, a lube seal, an adaptor ring, or a lantern ring. As shown, in some embodiments, a packing nut 64 connects, via a threaded interface, to the connection ring 60, and axially anchors the packing assembly 24 in the annular space around the plunger 26. In some embodiments, the packing nut 64 may be immediately adjacent (e.g., in contact with) the lantern ring. The packing nut 64 may axially compress the packing assembly 24, depending on the extent to which the packing nut 64 is threaded into the connection ring via the threaded interface with the connection ring 60.

[0051] The plunger bore 22 and the packing assembly 24 may be substantially cylindrical, with the plunger bore 22 having a substantially circular cross-section and the packing assembly 24 having a substantially cylindrical outer surface received in the plunger bore 22. The packing assembly 24 may be configured to at least partially receive therein the plunger 26 as the plunger 26 reciprocates, thereby to draw fluid into the chamber 28 at a first pressure via the suction port 30 during movement of the plunger 26 in a first direction, and discharge the fluid from the chamber 28 at a second pressure greater than the first pressure via the discharge port 32 during movement of the plunger 26 in a second direction opposite the first direction.

[0052] FIGS. 2A, 2B, 2C, 2D, 2E, 2F, 2G, 2H, and 2I are schematic side section views of an example fluid end 12, including an example valve assembly 42, according to embodiments of the disclosure. In some embodiments, the valve assembly 42 may enhance control of fluid flow through the fluid end block 20. For example, the valve assembly 42, in some embodiments, may include a fixed sleeve 66 having a sleeve body positioned at least partially in a valve bore 68 at least partially defined by the fluid end block 20. The sleeve body may be substantially annular and may at least partially define a sleeve recess 70. The valve assembly 42 further may include a discharge member 38 at least partially received in the sleeve recess 70. In some embodiments, the sleeve recess 70 may at least partially define an inward facing cylindrical sleeve surface. The discharge member 38 may have a discharge member body at least partially defining a valve seat 74, and the discharge member body may be positioned to reciprocate relative to the sleeve recess 70, between a closed discharge position and an open discharge position, as described herein. The valve assembly 42, in some embodiments, may also include a suction member 36 having a suction member body positioned to reciprocate relative to the discharge member 38, between a closed suction position when contacting the valve seat 74 and an open suction position when spaced from the valve seat 74. In some embodiments, the discharge member 38 may positioned to: (a) prevent flow of fluid to the discharge port 32 in the fluid end block 20 when the discharge member 38 is in the closed discharge position, and (b) allow fluid to flow to the discharge port 32 in the fluid end block 20 when the discharge member 38 is in the open discharge position, as described herein. The suction member 36 may be positioned to: (a) prevent fluid from being drawn through the suction port 30 when the suction member 36 is in closed suction position, and (b) allow fluid to be drawn through the suction port 30 when the suction member 36 is in the open suction position, as described herein.

[0053] As shown in FIGS. 2A-2I, in some embodiments, the discharge member body may at least partially define a discharge member passage 78, and the suction member 36 may be at least partially positioned in the discharge member passage 78, for example, when the suction member 36 is in the closed suction position, for example, as shown in FIGS. 2A and 2B. For example, the discharge member body may at least partially define a discharge member head 80 and a discharge member stem 82 connected to the discharge member head 80. In some embodiments, the discharge member stem 82 may be at least partially positioned in the sleeve recess 70. The discharge member stem 82 and / or the sleeve recess 70 may be configured to facilitate reciprocation of the discharge member stem 82 in a direction substantially parallel to a longitudinal axis of the discharge member stem 82 relative to the sleeve recess 70, during movement of the discharge member 38 between the closed discharge position and the open discharge position. In some embodiments, the discharge member head 80 may at least partially define the valve seat 74, which may be at least partially concave, for example, as shown in FIGS. 2A-2I. For example, the valve seat 74 may present a radially inward facing frustoconical surface, and the discharge member passage 78 may pass longitudinally through the radially narrower end of the frustoconical surface.

[0054] As shown in FIGS. 2A and 2B, in some embodiments, the sleeve body of the fixed sleeve 66 may at least partially define one or more sleeve passages 84 positioned to provide fluid flow from the suction port 30 to the sleeve recess 70. The valve assembly 42, in some embodiments, may further include a discharge spring 86 biasing the discharge member 38 toward the closed discharge position, and the sleeve body of the fixed sleeve 66 may at least partially define a discharge spring recess 88 in which a first end of the discharge spring 86 is positioned, with a second end of the discharge spring 86 engaging the discharge member 38. As shown, the discharge spring 86 may include a coil spring, such as a conical-shaped coil spring, although springs of other types and / or shapes are contemplated.

[0055] As shown in FIGS. 2A-2I, in some embodiments, the discharge member body may include a guide 90 positioned in the discharge member passage 78, and the suction member body may include a suction member stem 92 at least partially received in the guide 90. The suction member stem 92 may be positioned to reciprocate relative to the guide 90 when the suction member 36 reciprocates between the closed suction position and the open suction position, for example, as described herein. The sleeve body of the fixed sleeve 66 may at least partially define a discharge spring recess 96 in which a first end of the discharge spring 86 is positioned, with a second end of the discharge spring 86 engaging, for example, the guide 90. In some embodiments, the valve assembly 42 further may include a suction spring 96 biasing the suction member 36 toward the closed suction position. The suction member stem 92 may at least partially define a suction spring boss 98 engaging a first end of the suction spring 96, with a second end of the suction spring 96 engaging the guide 90 of the discharge member body. As shown, the suction spring 96 may include a coil spring, although springs of other types and / or shapes are contemplated.

[0056] As shown in FIGS. 2A-2I, some embodiments of the valve assembly 42 also may include a discharge seat 100 configured to be at least partially received in the valve bore 68. The discharge seat 100 may at least partially define a discharge strike face 102 positioned to be contacted by the discharge member 38 when the discharge member 38 is in the closed discharge position, for example, as shown in FIGS. 2A and 2B. In some embodiments, the discharge member 38 may be positioned to move along a discharge axis of motion when reciprocating between the closed discharge position and the open discharge position. For example, in some embodiments, the discharge strike face 102 may lie in a plane substantially perpendicular to the discharge axis of motion. In some embodiments, the discharge strike face 102 may lie in a plane oblique relative to the discharge axis of motion.

[0057] As shown in FIGS. 2A-2I, the suction member body further may include a suction member head 104, and the suction member stem 92 may be connected to the suction member head 104. For example, the suction member stem 92 may be connected to the suction member head 104 via a threaded connection, an adhesive connection, a welded connection, and / or a connection formed via integral formation of the suction member stem 92 and the suction member head 104. For example, the suction member stem 92 may include a shoulder screw, for example, as shown in FIGS. 2A and 2B. The suction member head 104, in some embodiments, may present a suction closing surface 106, and the suction closing surface 106 may be at least partially convex and positioned to cooperatively engage the valve seat 74 of the discharge member head 80 when in the closed suction position. For example, the discharge member head 80 may at least partially define the valve seat 74, which may be at least partially concave, for example, and the valve seat 74 may present a radially inward facing frustoconical surface. In some embodiments, the suction closing surface 106 may be substantially complimentary to the frustoconical surface of the valve seat 74, thereby to close the discharge member passage 78 when the suction member 36 is in the closed suction position and open the discharge member passage 78 when the suction member 36 is in the open suction position.

[0058] In some embodiments, the discharge member 38 may further include a discharge seal 108 positioned to contact the discharge seat 100 when the discharge member 38 is in the closed discharge position, for example, as shown in FIGS. 2A and 2B. The discharge seal 108 may include an O-ring seal, although other seal types capable of providing a fluid seal between the discharge member head 80 and the discharge strike face 102 are contemplated. In some embodiments, the suction member 36 further may include a suction seal 110 positioned to contact the valve seat 74 when the suction member 36 is in the closed suction position, for example, as shown in FIGS. 2A and 2B. For example, the suction member head 104 may at least partially define a suction seal recess 112, and the suction seal 110 may be at least partially received in the suction seal recess 112, such that the suction seal 110 contacts the valve seat 74 at least partially defined by the discharge member 38 (e.g., the discharge member head 80) when the suction member 36 is in the closed suction position. The suction seal recess 112 and the suction seal 110 may be substantially annular.

[0059] As shown in FIGS. 2A-2I, in some embodiments, the fixed sleeve 66 may include a sleeve seal 114 positioned to provide a sliding fluid seal between the fixed sleeve 66 and the discharge member 38. In some embodiments, the sleeve seal 114 may include an O-ring seal, although other seal types capable of providing a fluid seal between the fixed sleeve 66 and the discharge member 38 are contemplated.

[0060] In some embodiments, as shown in FIGS. 2A-2I, the discharge member head 80 of the discharge member body may at least partially define a discharge closing surface 116, and the discharge closing surface 116 may at least partially define a discharge seal recess 118. The discharge seal 108 may be positioned in the discharge seal recess 118. In some embodiments, the discharge seal recess 118 and the discharge seal 108 may be substantially annular.

[0061] As explained with respect to FIGS. 2A-2I, in some embodiments, during operation of the pump 10, the suction member 36 may be in the closed suction position when the discharge member 38 is in the open discharge position, and the discharge member 38 may be in the closed discharge position when the suction member 36 is in the open suction position.

[0062] As described herein, in a least some embodiments, the fluid end 12 may include a fluid end block 20 having plunger bores 22 configured to receive respective packing assemblies 24 and respective reciprocating plungers 26, with each of the plunger bores 22 being axially aligned with (e.g., substantially parallel to) a respective valve bore 68 in which a respective valve assembly 42 is positioned, and with the valve assembly 42 operating as both a suction valve and a discharge valve. For example, as shown in FIG. 2A, in some embodiments, a plunger axis AP of the plunger bore 22 and a valve axis AV of the valve bore 68 may be substantially coaxial. In some embodiments, as shown in FIGS. 2A and 2B, the valve assembly 42 may include a valve seat (e.g., the discharge seat 100) for the discharge member 38, and the suction member 36 may use an axial face of the discharge member 38 as a valve seat (e.g., the valve seat 74). As shown in FIG. 2A, both the discharge member 38 and the suction member 36 are in respective closed conditions, with the suction member 36 being closed against the valve seat 74 provided by the discharge member 38 via the suction spring 96, and the discharge member 38 being closed against the discharge seat 100 via the discharge spring 86.

[0063] Applicant has recognized that, for at least some embodiments described herein, the plunger bore 22 and the valve bore 68 may be substantially axially aligned (e.g., substantially parallel to), resulting in elimination of an intersection between the valve bores and the respective plunger bores, thereby reducing or substantially eliminating cross-bore stress from the fluid end block 20. As a result, the stress associated with the fluid end block 20 may be reduced, which may permit the use of relatively more efficient carbon steel instead of relatively less efficient stainless steel. In some embodiments, the fluid end block 20 may comprise, or be formed of, carbon steel, which may be optionally coated and / or heat-treated to further protect the fluid end block 20. In some embodiments, the valve bore 68 may facilitate access to internal components in the fluid end 12 from the front of the fluid end 12, rather than from the opposite side of the fluid end, which is adjacent the power end 14. For example, in some embodiments, the valve assembly 42, including discharge member 38 and the suction member 36, may be removed from the front of the fluid end block 20. In some embodiments, it also may be possible to access, service, and / or remove the packing assembly 24 from the front of the fluid end block 20, which may be more ergonomically efficient for service personnel.

[0064] FIGS. 2C-2I show an example sequence of a plunger 26 traveling from top dead center (TDC) to bottom dead center (BDC) and back to TDC, with the example suction member 36 opening while the discharge member 38 is closed, the suction member 36 closing with the discharge member 38 opening, and both the suction member 36 and the discharge member closed when the plunger 26 begins to travel back toward BDC. As shown in FIG. 2C, the plunger 26 is traveling back toward BDC, as shown by arrow A. The suction created by the plunger 26 pulls the suction member 36 off the valve seat 74, overcoming the closing force provided by the suction spring 96. The discharge member 38 remains closed, with the discharge spring 86 holding the discharge member 38 against the discharge seat 100. With the suction member 36 open and the discharge member 38 closed, fluid is drawn into the suction port 30, through the discharge member passage 78 in the discharge member 38, and into the chamber 28 and plunger bore 22.

[0065] As shown in FIG. 2D, as the plunger 26 reaches BDC, with the suction member 36 remaining open and the discharge member 38 remaining closed, fluid continues to be drawn into the chamber 28 and plunger bore 22. FIG. 2E shows a close-up of the suction member 36 being open and the discharge member 38 remaining closed, with the discharge seat 100 modified relative to the discharge seat 100 shown in FIG. 2D. For example, in some embodiments, the discharge seat 100 may have a discharge strike face 102 that lies in a plane substantially perpendicular to the valve axis AV, for example, as shown in FIG. 2D, and in some embodiments, the discharge seat 100 may have a discharge strike face 102 that lies in a plane oblique relative to the valve axis AV, for example, as shown in FIG. 2E.

[0066] As shown in FIG. 2F, in some embodiments, as the plunger 26 changes direction after reaching BDC, as shown by arrow B, and travels toward TDC, the pressure of fluid being compressed in the plunger bore 22 and the chamber 28 by the plunger 26 drives the suction member 36 closed against the valve seat 74 provided by the discharge member 38, overcoming the force of the suction spring 96. The discharge member 38 also opens, the force of the discharge spring 86 being overcome by the pressure of the fluid. With the suction member 36 closed and the discharge member 38 open, fluid (e.g., the pressurized fluid 40 shown in FIG. 1), flows past the discharge member 38 and through the discharge port 32, as shown, and to a discharge manifold of the fluid end 12.

[0067] As shown in FIGS. 2G and 2H, in some embodiments, as the plunger 26 reaches TDC, the discharge member 38 remains open, the suction member 36 remains closed, and fluid continues to flow past the discharge member 38 and through the discharge port 32.

[0068] As shown in FIG. 2I, in some embodiments, as the plunger 26 reverses direction, as shown by arrow A, the suction created by the plunger 26 initially closes the discharge member 38, the discharge spring 86 overcoming the pressure in the chamber 28 and the plunger bore 22 and closing against the discharge seat 100, with the suction member 36 remaining closed until the suction force caused by the plunger 26 traveling toward BDC becomes sufficient to overcome the suction spring 96 force. Referring back to FIG. 2C, to repeat a pumping cycle, as the plunger 26 continues to travel toward BDC, the suction force overcomes the suction spring 96 force, and the suction member 36 opens, allowing fluid to be drawn into the suction port 30, through the discharge member passage 78, past the suction member 36, and into the chamber 28 and plunger bore 22.

[0069] FIG. 3 is a schematic partial side section view of an example fluid end 12 and example stay rods 120 for connecting the fluid end 12 to a power end 14, according to embodiments of the disclosure. In some embodiments, omission of relatively large vertical bores for each of the suction valves and discharge valves in a pump may provide the ability for the stay rods 120 connecting the fluid end 12 to the power end 14 to pass substantially completely through the fluid end block 20, for example, as shown in FIG. 3. For example, for pumps that include a suction valve bore receiving a suction valve and a discharge valve bore receiving a discharge valve, both of which bores are oriented perpendicular to the plunger bore, Applicant has recognized that the valve bores result in significantly reducing the material of the fluid end block available for facilitating connection to the power end. This may result in using studs mounted in, and extending from, the back side of the fluid (e.g., the side facing the power end). This may often render it difficult for service personnel to connect the fluid end to the power end, requiring access between the fluid end and the power end for assembling and correctly torquing fasteners that connect the fluid end to the power end.

[0070] As shown in FIG. 3, in some embodiments, omission of each of the bores for the respective suction valves and discharge valves in the fluid end block 20 may provide sufficient space and material of the fluid end block 20 for the stay rods 120 connecting the fluid end 12 to the power end 14 to pass through the fluid end block 20. This may result in relatively easier assembly of the fluid end 12 to the power end 14 for service personnel, providing service personnel with access from the front side of the fluid end 12 rather than the opposite power end side when assembling and torquing the stay rods 120. In addition, in some embodiments, the relatively longer stay rods 120 may inherently be more fatigue-resistant with correct preloading as compared to, for example, relatively shorter studs mounted in, and extending from, the back side of the fluid end.

[0071] As shown in FIG. 3, in some embodiments, the fluid end block 20 may include a plurality of stay rod bores 122 having respective longitudinal axes aligned with (e.g., substantially parallel to) the plunger axis AP of the plunger bore 22 and / or the valve axis AV of the valve bore 68. A first end of the stay rod bores 22, accessible from the front side of the fluid end block 20, may each include rod counter bores 124 dimensioned to receive one or more rod fasteners 126 (e.g., retainers and / or nuts) for securing a first end of each of the stay rods 120 to the fluid end block 20. In some embodiments, rod spacers 128 having respective rod passages 130 therethrough may be provided to space the power end 14 from the fluid end 12 and / or to secure the power end 14 to the fluid end 12. For example, as shown in FIG. 3, a first end of each of the rod spacers 128 may contact the power end side of the fluid end block 20 and extend toward the power end 14. A respective one of the stay rods 120 may pass through a respective rod passage 130 and substantially through the fluid end block 20 toward the front side of the fluid end block 20, opposite the power end 14, for securement by the one or more rod fasteners 126, which may be accessed from the front side of the fluid end 12. A second end (opposite the first end) of each of the stay rods 120 may be connected to the power end 14. For example, the second end of each of the stay rods 120 may include external threads for engaging internal threads of the power end 14, thereby to secure the second end of the respective stay rod 120 to the power end 14. In some embodiments, for example, as shown, the rod fasteners 126 may be tightened (e.g., torqued) from the front side of the fluid end 12 to place each of the stay rods 120 in tension, thereby to render the stay rods 120 relatively more fatigue-resistant. Further, in some embodiments, with the stay rods 120 being relatively longer than studs that extend from the back side of the fluid end 12 (e.g., the power end side), the stay rods 120 further may be inherently relatively more fatigue-resistant due to their relatively increased length.

[0072] FIG. 4A is a schematic side section view of another example fluid end 12 and another example valve assembly 42, with an example plunger 26 moving toward BDC during an example suction stroke, with an example suction member 36 in the open position and an example discharge member 38 in the closed position, according to embodiments of the disclosure. FIG. 4B is a schematic side section view of the example fluid end 12 and valve assembly 42 shown in FIG. 4A, with the plunger 26 moving from BDC toward TDC during an example discharge stroke, with the discharge member 38 in the open position and the suction member 36 in the closed position, according to embodiments of the disclosure.

[0073] As shown in FIG. 4A, in some embodiments, the sleeve body of the fixed sleeve 66 may at least partially define an exterior sleeve surface 132 and an interior sleeve surface 134. As shown, the exterior sleeve surface 132 and / or the interior sleeve surface 134 may be substantially cylindrical and extend longitudinally between a sleeve end cap 136 and a plunger opening 138 positioned to at least partially receive the plunger 126 or, in some embodiments, a piston. In some embodiments, the sleeve body of the fixed sleeve 66 may at least partially define a sleeve suction opening 140 positioned to allow fluid to be drawn through the suction port 30 when the suction member 36 is in the open suction position, for example, as shown in FIG. 4A, during a suction stroke of the plunger 26. The sleeve body of the fixed sleeve 66 further may at least partially define a sleeve discharge opening 142 positioned to allow fluid to flow to the discharge port 32 when the discharge member 38 is in the open discharge position, for example, as shown in FIG. 4B, during a discharge stroke of the plunger 26. The sleeve suction opening 140 may be positioned between the sleeve discharge opening 142 and the plunger opening 138, and / or the sleeve discharge opening 142 may be positioned between the sleeve end cap 136 and the sleeve suction opening 140. In some embodiments, the sleeve suction opening 140 and / or the sleeve discharge opening 142 may include two or more openings spaced circumferentially around the sleeve body of the fixed sleeve 66.

[0074] In some embodiments, as shown in FIGS. 4A and 4B, the discharge member body of the discharge member 38 may at least partially define an exterior discharge surface 144 and an interior discharge surface 146. The exterior discharge surface 144 and / or the interior discharge surface 146 may be substantially cylindrical and extend longitudinally between a discharge end cap 148 and a discharge member opening 150 positioned to at least partially receive the suction member 36. The discharge member body of the discharge member 38 may at least partially define a discharge member suction opening 152 positioned to allow fluid to be drawn through the suction port 30 and the sleeve suction opening 140 when the discharge member 38 is in the closed discharge position and the suction member 36 is in the open suction position. For example, as shown in FIG. 4A, the sleeve suction opening 140 and the discharge member suction opening 152, during the suction stroke, may be substantially longitudinally aligned, such that fluid may be drawn through the suction port 30 as the plunger 26 moves from TDC toward BDC. The discharge member body of the discharge member 38 further may at least partially define a discharge member discharge opening 154 positioned to allow fluid to flow to the discharge port 32 when the discharge member 38 is in the open discharge position and the suction member 36 is in the closed suction position. For example, as shown in FIG. 4B, the sleeve discharge opening 142 and the discharge member discharge opening 154, during the discharge stroke, may be substantially longitudinally aligned, such that fluid may be forced under pressure through the discharge port 32 as the plunger 26 moves from BDC toward TDC. In some embodiments, the discharge member suction opening 152 and / or the discharge member discharge opening 154 may include two or more openings spaced circumferentially around the discharge member body of the discharge member 38.

[0075] As shown in FIGS. 4A and 4B, in some embodiments, the suction member body of the suction member 36 may at least partially define an exterior suction surface 156 and an interior suction surface 158. The exterior suction surface 156 and / or the interior suction surface 158 may be substantially cylindrical and extend longitudinally between a first suction member end 160 and a second suction member end 162 positioned to at least partially receive the plunger 26 or, in some embodiments, a piston. The suction member body of the suction member 36 further may at least partially define a suction member suction opening 164 positioned to allow fluid to be drawn through the suction port 30, the sleeve suction opening 140, and / or the discharge member suction opening 152, for example, when the suction member 36 is in the open suction position and the discharge member 38 is in the closed discharge position, for example, as shown in FIG. 4A, during the suction stroke of the plunger 26. The suction member body of the suction member 36 also may at least partially define a suction member discharge opening 166 at the first suction member end 160 positioned to allow fluid to flow out the discharge member discharge opening 154 and the discharge port 32 under pressure when the discharge member 38 is in the open discharge position and the suction member 36 is in the closed suction position. The suction member suction opening 164 may be positioned between the first suction member end 160 and the second suction member end 162. In some embodiments, the suction member suction opening 164 may include two or more openings spaced circumferentially around the suction member body of the suction member 36.

[0076] As shown in FIGS. 4A and 4B, in some embodiments, the discharge member 38 may be at least partially positioned in the fixed sleeve 66, the suction member 36 may be at least partially positioned in the discharge member 38, and / or the suction member 36 may be positioned to at least partially receive the plunger 26, or, in some embodiments, a piston. In some embodiments, the discharge member suction opening 152 and the suction member suction opening 164 may be substantially longitudinally aligned when the discharge member 38 is in the closed discharge position and the suction member 36 is in the open suction position, thereby to allow fluid to be drawn through the suction port 30 in the fluid end block 20, for example, as shown in FIG. 4A. The sleeve discharge opening 142, the discharge member discharge opening 154, and the suction member discharge opening 166 may be substantially longitudinally aligned when the discharge member 38 is in the open discharge position and the suction member 36 is in the closed suction position, thereby to allow fluid to flow to the discharge port 32 in the fluid end block 20, for example, as shown in FIG. 4B.

[0077] As shown in FIGS. 4A and 4B, in some embodiments, the valve assembly 42 further may include a discharge cap seal 168 positioned to provide a fluid seal between a radially outer surface of the discharge end cap 148 and a radially inner surface of the sleeve body of the fixed sleeve 66 when the discharge member 38 is in the closed discharge position, for example, as shown in FIG. 4A. The valve assembly 42 further may include a valve seat seal 170 positioned adjacent the discharge member opening 150 to provide a fluid seal between the discharge member 38 and the suction member 36 when the discharge member 38 is in the open discharge position and the suction member 36 is in the closed suction position, for example, as shown in FIG. 4B. In some embodiments, the valve assembly 42 further may include a suction member seal 172 positioned to provide a fluid seal between the exterior suction surface 156 and the interior sleeve surface 134 of the sleeve body of the fixed sleeve 66.

[0078] As shown in FIGS. 4A and 4B, in some embodiments, the exterior sleeve surface 132 of the fixed sleeve 66 may include an exterior sleeve shoulder 176 positioned to contact an interior surface 178 of the valve bore 68 of the fluid end block 20. The exterior sleeve shoulder 176 may serve to longitudinally position the fixed sleeve 66 relative to the valve bore 68, while enabling the valve assembly 42, or at least portions thereof, to be removed via the access port 44, upon removal of the cover 46 from the access port 44 (see, e.g., FIG. 1).

[0079] As shown in FIGS. 4A and 4B, in some embodiments, the valve assembly 42 further may include a suction member spring 180 positioned to bias the suction member 36 in the closed suction position. For example, the interior sleeve surface 134 of the fixed sleeve 66 may include a spring retaining shoulder 182 positioned to contact a first end of the suction member spring 180, and a second end of the suction member spring 180 may be positioned to contact the second suction member end 162 of the suction member body of the suction member 36. As shown, the suction member spring 180 may include a coil spring, although springs of other types and / or shapes are contemplated.

[0080] In some embodiments, as shown in FIGS. 4A and 4B, the interior sleeve surface 134 of the sleeve body of the fixed sleeve 66 may include a sleeve shoulder 184, the exterior discharge surface 144 of the discharge body of the discharge member 38 may include a discharge body shoulder 186, and the sleeve shoulder 184 and the discharge body shoulder 186: (a) may be positioned to contact one another when the discharge member 38 is in the closed discharge position, for example, as shown in FIG. 4A, and (b) may be spaced from one another when the discharge member 38 is in the open discharge position, for example, as shown in FIG. 4B.

[0081] In some embodiments, the exterior suction surface 156 of the suction body of the suction member 36 may include a suction body shoulder 188, and the suction body shoulder 188 and the valve seat 74 of the discharge body: (a) may be positioned to contact one another when the suction member 36 is in the closed suction position, for example, as shown in FIG. 4B, and (b) may be spaced from one another when the suction member 36 is in the open suction position, for example, as shown in FIG. 4A.

[0082] In some embodiments, as shown in FIGS. 4A and 4B, the discharge body of the discharge member 38 and the suction body of the suction member 36 may be at least partially positioned within the sleeve body of the fixed sleeve 66. The suction body of the suction member 36 may be at least partially positioned within the discharge body of the discharge member 38.

[0083] In some embodiments, the sleeve body of the fixed sleeve 66 may be positioned to be fixed longitudinally relative to the valve bore 68 at least partially defined by the fluid end block 20. The discharge body of the discharge member 38 may be positioned to move longitudinally relative to the sleeve body of the fixed sleeve 66. The suction body of the suction member 36 may be positioned to move longitudinally relative to the sleeve body of the fixed sleeve 66, and / or the discharge body of the discharge member 38 may be positioned to move longitudinally relative to the suction body of the suction member 36, for example, as shown in FIGS. 4A and 4B.

[0084] As shown in FIGS. 4A and 4B, in some embodiments, the valve assembly 42 further may include one or more bore seals 190 positioned to be located between the exterior sleeve surface 132 of the sleeve body of the fixed sleeve 66 and the valve bore 68 at least partially defined by the fluid end block 20. The bore seal(s) 190 may be positioned to provide a fluid seal between the exterior sleeve surface 132 and the valve bore 68. The valve assembly 42 also may include a discharge seal 192 between the interior sleeve surface 134 of the sleeve body of the fixed sleeve 66 and the exterior discharge surface 144 of the discharge body of the discharge member 38. The discharge seal 192 may be positioned to provide a fluid seal between the interior sleeve surface 134 and the exterior discharge surface 144. The valve assembly 42 further may include a suction seal 194 between the interior discharge surface 146 of the discharge body of the discharge member 38 and the exterior suction surface 156 of the suction body of the suction member 36. The suction seal 194 may be positioned to provide a fluid seal between the interior discharge surface 146 and the exterior suction surface 156. The valve assembly 42 also may include a suction-to-sleeve seal 196 (e.g., a suction member seal 172) between the interior sleeve surface 134 of the sleeve body of the fixed sleeve 66 and the exterior suction surface 156 of the suction body of the suction member 36. The suction-to-sleeve seal may be positioned to provide a fluid seal between the interior sleeve surface 134 and the exterior suction surface 156. In some embodiments, the discharge seal 192, the suction seal 194, and or the suction-to-sleeve seal 196 provide(s) a sliding fluid seal.

[0085] As shown in FIGS. 4A and 4B, for example, in some embodiments, as the plunger 26 travels toward BDC during the suction stroke, as shown by the arrow A, the suction force pulls both the discharge member 38 and the suction member 36 toward the plunger 26, such that the discharge member suction opening 152 and the suction member suction opening 164 are axially or longitudinally aligned with the sleeve suction opening 140 of the fixed sleeve and the suction port 30, overcoming the force of the suction member spring 180, thereby to uncover the suction port 30, and allow fluid to be drawn through the suction port 30 and into the plunger bore 22 and chamber 28, for example, as shown in FIG. 4A. The discharge member 76, for example, the discharge end cap 148, in the position shown in FIG. 4A, prevents flow through the discharge port 32. As shown in FIG. 4B, for example, as the plunger 26 reverses direction and moves back toward TDC during the discharge stroke, in the absence of the suction force, the spring force provided by the suction member spring 180 and fluid pressure in the plunger bore 22 and chamber 28 push the discharge member 38 and the suction member 36 away from the plunger 26, covering the sleeve suction opening 140 of the fixed sleeve 66 with a portion of the suction member 36, thereby to close suction opening 140. Longitudinal movement of the discharge member 38 results in the discharge end cap 148 allowing fluid flow from the plunger bore 22 and chamber 28 to the discharge port 32, for example, as shown in FIG. 4B.

[0086] FIG. 5A is a schematic side section view of another example valve assembly 42 and an example plunger 26, with an example suction member 36 closed and an example discharge member 38 closed, according to embodiments of the disclosure. FIG. 5B is a schematic side section view of the valve assembly 42 shown in FIG. 5A, with the plunger 26 moving away from the TDC center position toward the BDC position during an example suction stroke, according to embodiments of the disclosure. FIG. 5C is a schematic side section view of the valve assembly 42 shown in FIG. 5A, with the plunger 26 moving further toward the BDC position during an example suction stroke, with the suction member 36 in an open position and the discharge member 38 in the closed position, according to embodiments of the disclosure. FIG. 5D is a schematic side section view of the valve assembly 42 shown in FIG. 5A, with the plunger 26 reaching the BDC position, the suction member 36 in the open position, and the discharge member 38 in the closed position, according to embodiments of the disclosure. FIG. 5E is a schematic side section view of the valve assembly 42 shown in FIG. 5A, with the plunger 26 moving away from the BDC position toward the TDC position during a discharge stroke, with the example suction member 36 returning to the closed position while the discharge member 38 remains in the closed position, according to embodiments of the disclosure. FIG. 5F is a schematic side section view of the valve assembly 42 shown in FIG. 5A, with the plunger 26 continuing to move toward the TDC position during the discharge stroke, the suction member 36 remaining in the closed position, and the discharge member 38 moving to the open position, according to embodiments of the disclosure.

[0087] As shown in FIGS. 5A-5F, in some embodiments, the valve assembly 42 may enhance control of fluid flow through a fluid end block 20 of a high-power pump 10 (see, e.g., FIG. 1) and may include a fixed sleeve 66 having a sleeve body configured to be positioned at least partially in the valve bore 68 (see, e.g., FIG. 2A) at least partially defined by a fluid end block 20. The sleeve body of the fixed sleeve 66 may be substantially annular and may at least partially define a discharge member seat 198 and a suction member seat 200. The valve assembly 42 further may include a discharge member 38 associated with the sleeve body of the fixed sleeve 66. The discharge member 38 may have a discharge member body at least partially defining a discharge surface 202. The discharge member body may be positioned to reciprocate relative to the sleeve body of the fixed sleeve 66 between a closed discharge position when the discharge surface 202 contacts the discharge member seat 198 (see, e.g., FIGS. 5A-5E) and an open discharge position when the discharge surface 202 is spaced from the discharge member seat 198 (see, e.g., FIG. 5F). The valve assembly 42 also may include a suction member 36 having a suction member body positioned to reciprocate relative to the sleeve body of the fixed sleeve 66 between a closed suction position when contacting the suction member seat 200 (see e.g., FIG. 5B) and an open suction position when the suction member body is spaced from the suction member seat 200 (see, e.g., FIG. 5C). In some embodiments, when the suction member 36 is in the open suction position, the first suction member end 160 is spaced from the suction member seat 200. The discharge member body of the discharge member 38 and the suction member body of the suction member 36 may be positioned to move in opposite longitudinal directions when the discharge member body moves to the closed discharge position and the suction member body moves to the closed suction position. In some embodiments, the discharge member 38 may be positioned to: (a) prevent flow of fluid to the discharge port 32 (see, e.g., FIGS. 1, 2A-2I, 4A, and 4B) in the fluid end block 20 when the discharge member 38 is in the closed discharge position, and (b) allow fluid to flow to the discharge port 32 in the fluid end block 20 when the discharge member 38 is in the open discharge position. In some embodiments, the suction member 36 may be positioned to: (a) prevent flow of fluid from the suction port 30 (see, e.g., FIGS. 1, 2A-2I, 4A, and 4B) into the chamber 28 in the fluid end block 20 when the suction member 36 is in the closed suction position, and (b) allow fluid to be drawn through the suction port 30 into the chamber 28 when the suction member 36 is in the open suction position.

[0088] In some embodiments, for example, as shown in FIGS. 5A-5F, the discharge member seat 198 and the suction member seat 200 may face in substantially opposite longitudinal directions. The valve assembly 42 further may include a discharge spring 204 biasing the discharge member 38 toward the closed discharge position and / or a suction spring 206 biasing the suction member 36 toward the closed suction position, for example, as shown in FIG. 5A. As shown, the discharge spring 204 and / or the suction spring 206 may include a coil spring, although springs of other types and / or shapes are contemplated.

[0089] In some embodiments, the sleeve body of the fixed sleeve 66 may at least partially define an exterior sleeve surface 132 and an interior sleeve surface 134. In some embodiments, the exterior sleeve surface 132 and the interior sleeve surface 134 may be substantially cylindrical and may extend longitudinally between the discharge member seat 198 and a plunger opening 138 positioned to at least partially receive the plunger 26 or a piston. The suction member body of the suction member 36 may at least partially define an exterior suction surface 156 and an interior suction surface 158. In some embodiments, the exterior suction surface 156 and the interior suction surface 158 may be substantially cylindrical and may extend longitudinally between a first suction member end 160 and a second suction member end 162 positioned to at least partially receive the plunger 26 or a piston. As shown in FIGS. 5A-5F, in some embodiments, the sleeve body of the fixed sleeve 66 may at least partially define a sleeve suction opening 140 positioned between the discharge member seat 198 and the plunger opening 138. As shown, in some embodiments, the exterior suction surface 156 of the suction member body may include an exterior suction portion 208 having a first outer diameter at the first suction member end 160 and an exterior shoulder portion 210 having a second outer diameter at the second suction member end 162, with the second outer diameter being greater than the first outer diameter. The difference between the first outer diameter and the second outer diameter may at least partially define a suction recess 212 (e.g., an annular recess) providing a flow passage, thereby to allow fluid to be drawn into the valve assembly 42 when the suction member 36 is in the open suction position (see, e.g., FIGS. 5C and 5D).

[0090] In some embodiments, as shown in FIGS. 5A-5F, the valve assembly 42 may further include the suction-to-sleeve seal 196 between the interior sleeve surface 134 and the exterior suction surface 156. The suction-to-sleeve seal 196 may provide a sliding fluid seal between the interior sleeve surface 134 and the exterior suction surface 156. The valve assembly 42 also may include a suction closing seal 214 at the first suction member end 160 of the suction member body and positioned to contact the suction member seat 200 of the sleeve body when the suction member 36 is in the closed suction position, for example, as shown in FIGS. 5A and 5B. In some embodiments, the suction closing seal 214 may include an O-ring seal, although other seal types are contemplated.

[0091] As shown in FIGS. 5A-5F, in some embodiments, the discharge member body of the discharge member 38 may include a discharge member head 80 and a discharge member stem 82 connected to the discharge member head 80. The discharge member head 80 may at least partially define the discharge surface 202, and the discharge surface 202 may face a direction generally opposite a direction in which the discharge member stem 82 extends. In some embodiments, the discharge member head 80 may at least partially define a spring contacting surface 216 opposite the discharge surface 202, and the discharge spring 204 may have a first end contacting the spring contacting surface 216 of the discharge member head 80, thereby to bias the discharge member 38 in the closed discharge position.

[0092] As shown in FIGS. 5A-5F, the discharge member 38 may be positioned to reciprocate along a longitudinal axis L, and the discharge member seat 198 may extend in a seat direction substantially perpendicular to the longitudinal axis or obliquely relative to the longitudinal axis L, for example, as shown.. For example, the discharge member head 80 may at least partially define the discharge surface 202, and the discharge surface 202 may be positioned to contact the discharge member seat 198 when the discharge member 38 is in the closed discharge position. In some embodiments, the discharge surface 202 may extend in a direction substantially parallel to (or slightly offset from parallel to) the seat direction of the discharge member seat 198.

[0093] In some embodiments, the sleeve body of the fixed sleeve 66 may at least partially define a sleeve body recess 218, and the suction member body of the suction member 36 may be at least partially positioned in the sleeve body recess 218. The suction member body may be positioned to reciprocate longitudinally in the sleeve body recess 218 between the open suction position and the closed suction position. In some embodiments, the suction member 36 may be in the closed suction position when the discharge member 38 is in the open discharge position, for example, as shown in FIG. 5F, thereby to allow fluid to flow from the chamber 28 to the discharge port 32 in the fluid end block 20 during a discharge stroke of the plunger 26. In some embodiments, the suction member 36 may be in the open suction position when the discharge member 38 is in the closed discharge position, for example, as shown in FIGS. 5C and 5D, thereby to allow fluid to be drawn through the suction port 30 into the chamber 28 during a suction stroke of the plunger 26.

[0094] As shown in FIGS. 5A-5F, in some embodiments, the suction member body of the suction member 36 may at least partially define a fluid chamber 220, and when the plunger 26 or a piston associated with the valve assembly 42 moves from the TDC longitudinal position toward the BDC longitudinal position, (a) a pressure drop in the fluid chamber 220 may at least partially cause the suction member body to move away from the suction member seat 200 (FIG. 5C), overcoming a suction spring force of the suction spring 206 acting on the suction member body and drawing fluid through the suction port 28 into the fluid chamber 220, and / or (b) a pressure drop in the fluid chamber 220 may at least partially cause the discharge member body to contact the discharge member seat 198. In some embodiments, the fluid chamber 220 may be at least partially coextensive with the chamber 28.

[0095] As shown in FIGS. 5A-5F, in some embodiments, when the plunger 26 or a piston associated with the valve assembly 42 moves from the TDC longitudinal position toward the BDC longitudinal position, pressure in an intake system of the high-power pump 10 acts against the exterior suction shoulder 210 of the exterior suction surface 156, thereby to at least partially cause the suction member body to move away from the suction member seat 200, overcoming a suction spring force of the suction spring 206 acting on the suction member body, and drawing fluid through the suction port 30 into the fluid chamber 220, for example, as shown in FIG. 5C. In some embodiments, when the plunger 26 or a piston associated with the valve assembly 42 moves from the TDC longitudinal position toward the BDC longitudinal position, pressure in a discharge system of the high-power pump 10 (see, e.g., FIG. 1) may act against the discharge member body of the discharge member 38, thereby to at least partially cause the discharge member body to contact the discharge member seat 198, for example, as shown in FIGS. 5B and 5C.

[0096] In some embodiments, when the plunger 26 or a piston associated with the valve assembly 42 reaches the BDC longitudinal position, (a) a pressure balance in the fluid chamber 220 may at least partially cause the suction member body to move toward the suction member seat 200, and / or (b) a pressure balance in the fluid chamber 220 may at least partially cause the discharge member body to contact the discharge member seat 198, for example, as shown in FIG. 5D.

[0097] In some embodiments, when the plunger 26 or a piston associated with the valve assembly 42 moves from the BDC longitudinal position toward the TDC longitudinal position: (a) a suction spring force of the suction spring 206 acting on the suction member body of the suction member 36 may at least partially cause the suction member body to move toward the suction member seat 200, thereby to prevent the drawing of fluid through the suction port 30 into the fluid chamber 220, and / or (b) a pressure increase in the fluid chamber 220 may at least partially cause the discharge member body of the discharge member 38 to move away from the discharge member seat 198, overcoming: (i) a discharge spring force of the discharge spring 204 acting on the discharge member body and allowing fluid in the fluid chamber 220 to pass through the discharge port 32, and / or (ii) pressure in a discharge system of the high-power pump 10 acting against the discharge member body, thereby to at least partially hold the discharge member body against the discharge member seat 198.

[0098] In some embodiments, as shown in FIGS. 5A-5F, when the plunger 26 or a piston associated with the valve assembly 42 reaches the TDC longitudinal position: (a) a pressure balance in the fluid chamber 220 may at least partially cause the suction member body of the suction member 36 to contact the suction member seat 200, thereby to prevent drawing fluid through the suction port 30 into the fluid chamber 220; (b) a suction spring force of the suction spring 206 acting on the suction member body may at least partially cause the suction member body to contact the suction member seat 200, thereby to prevent drawing of fluid through the suction port 32 into the fluid chamber 220; (c) a pressure balance in the fluid chamber 220 may at least partially cause the discharge member body to contact the discharge member seat 198, thereby to prevent fluid in the fluid chamber 200 from passing through the discharge port 32; and / or (d) a discharge spring force of the discharge spring 204 acting on the discharge member body may at least partially cause the discharge member body to contact the discharge member seat 198, thereby to prevent fluid in the fluid chamber 220 from passing through the discharge port 32.

[0099] With the plunger at BDC, as shown in FIG. 5A, the discharge member 38 is closed, with the discharge spring 204 holding the discharge member 38 against the fixed sleeve 66, which serves as a valve seat for the discharge member 38. In some embodiments, the diameter D of the valve assembly 42 may be sufficiently large to facilitate service and removal of the packing assembly (not shown in FIGS. 5A-5F) from the fluid end block (see, e.g., FIG. 2A).

[0100] As shown in FIG. 5B, in some embodiments, as the plunger 26 begins to move from TDC toward BDC, suction pressure begins to pull the suction member 36 toward the plunger 26 in direction A, with the discharge member 38 in the closed discharge position, held in the closed discharge position via the discharge spring 204 and discharge pressure in discharge passages, for example, of a discharge manifold. Until the force provided by the suction spring 206 is overcome by the suction pressure, the suction member 36 continues to close off the suction port 30.

[0101] As shown in FIG. 5C, in some embodiments, the plunger 26 is at an intermediate stroke point and continuing to move toward BDC. During the movement, the suction pressure becomes sufficient to overcome the force of the suction spring 206, allowing the suction member 36 to move toward the plunger 26 and open the suction port 30. As the suction port 30 opens, fluid is drawn into the chamber 28 (and / or the plunger bore 22) via the suction port 30 and suction created by the plunger 26 during the suction stroke.

[0102] As shown in FIG. 5D, as the plunger 26 reaches BDC, the suction port 30 remains open, with the suction member 36 compressing the suction spring 206, and fluid continues to be drawn into the chamber 28 (and / or the plunger bore 22).

[0103] FIG. 5E shows the plunger 26 reversing direction from the suction stroke to the discharge stroke, and moving from BDC toward TDC. The pressure balances in the plunger bore 22, and the suction member 36 moves in direction B, closing off the suction port 30 and preventing fluid flow through the suction port 30.

[0104] As shown in FIG. 5F, as the plunger 26 continues to move toward TDC during the discharge stroke, pressure in the plunger bore 22 builds and overcomes the force of the discharge spring 204 and the discharge pressure in the system, forcing the discharge member 38 away from the discharge member seat 198 provided by the fixed sleeve 66. The suction member 36 continues to close the suction port 30, the suction spring 206 holding the suction member 36 in a position to close off the suction port 30, thereby completing a pumping cycle.

[0105] Several example methods are described below, according to embodiments of the disclosure. The order in which the method steps are described is not intended to be construed as a limitation, and any number of the described method steps may be combined in any order and / or in parallel to implement the methods.

[0106] FIG. 6, FIG. 7, and FIG. 8 are a schematic side view diagrams showing example methods to enhance control of fluid flow through a fluid end 12 of a high-power pump 10 consistent with the example fluid ends 12 and / or valve assemblies 42 shown respectively in FIGS. 2A-2I, FIGS. 4A and 4B, and FIGS. 5A-5F, according to embodiments of the disclosure. According to some embodiments, a method to enhance control of fluid flow through a fluid end 12 of a high-power pump 10 may include positioning a valve assembly 42 in a valve bore 68 in a fluid end block 20 of the fluid end 12. The valve bore 68 may have a longitudinal valve axis AV extending in a first direction substantially parallel to a longitudinal plunger axis AP of a plunger bore 22. The valve assembly 42 may include a suction member 36 and a discharge member 38. The suction member 36 and the discharge member 38 may be positioned to reciprocate relative to the valve bore 68 in a direction substantially parallel to the first direction. The discharge member 38 may at least partially define a valve seat 74, and the suction member 36 may be positioned to reciprocate relative to the discharge member 38 between a closed suction position when the suction member 36 contacts the valve seat 74 and an open suction position when the suction member 36 is spaced from the valve seat 74, thereby to enhance control of fluid flow through the fluid end 12, for example, as described herein. In some embodiments of the method, the longitudinal valve axis AV may be substantially colinear relative to the longitudinal plunger axis AP.

[0107] In some embodiments of the method, the method further may include accessing the valve bore 68 from a first side of the fluid end block 20. The first side of the fluid end block 20 may be generally opposite a second side of the fluid end block 20 in which the plunger bore 22 is positioned. In some embodiments, the positioning of the valve assembly 42 in the valve bore 68 may include positioning a fixed sleeve 66 in the valve bore 68, and positioning the discharge member 38 in the fixed sleeve 66. The positioning of the valve assembly 42 further may include positioning the suction member 36 relative to the discharge member 38, and positioning the fixed sleeve 66, the discharge member 38, and the suction member 36 in the valve bore 68. For example, in some embodiments, the positioning of the valve assembly 42 in the valve bore 38 may include connecting the suction member 36 to the discharge member 38, positioning the discharge member 38 in the fixed sleeve 66, and inserting the fixed sleeve 66, the discharge member 38, and the suction member 36 into the valve bore 68.

[0108] In some embodiments of the method, the method further may include positioning a discharge spring 86 between the fixed sleeve 66 and the discharge member 38 to bias the discharge member 38 in a closed discharge position, for example, as described herein. In some embodiments, the method also may include positioning a suction spring 96 between the discharge member 38 and the suction member 36 to bias the suction member 36 in the closed suction position, for example, as described herein.

[0109] In some embodiments of the method, the method further may include inserting a discharge seat 100 into the valve bore 68. The discharge seat 100 may be positioned such that the discharge member 38: (a) prevents flow of fluid to a discharge port 32 in the fluid end block 20 when the discharge member 38 contacts the discharge seat 100, and (b) allows fluid to flow to the discharge port 32 in the fluid end block 20 when the discharge member 38 is spaced from the discharge seat 100, for example, as described herein.

[0110] According to some embodiments, a method to enhance control of fluid flow through a fluid end 12 of a high-power pump 10 may include positioning a valve assembly 42 in a valve bore 68 in a fluid end block 20 of the fluid end 12. The valve bore 68 may have a longitudinal valve axis AV extending in a first direction substantially parallel to a longitudinal plunger axis AP of a plunger bore 22. The valve assembly 42 may include a fixed sleeve 66 at least partially defining a suction member seat 200 and a discharge member seat 198, for example, as shown in FIGS. 5A-5F. The valve assembly 42 further may include a suction member 36 positioned to reciprocate relative to the valve bore 68 between: (a) a closed suction position when the suction member 36 contacts the suction member seat 200 and (b) an open suction position when the suction member 36 is spaced from the suction member seat 200. The valve assembly 42 also may include a discharge member 38 positioned to reciprocate relative to the valve bore 68 between: (a) a closed discharge position when the discharge member 38 contacts the discharge member seat 198 and (b) an open discharge position when the discharge member 38 is spaced from the discharge member seat 198, thereby to enhance control of fluid flow through the fluid end 12. In some embodiments of the method, the discharge member seat 198 and the section member seat 200 may face in opposite directions, the discharge member 38 and the suction member 36 may open via movement in opposite directions, and / or the discharge member 38 and the suction member 36 may close via movement in opposite directions, for example, as described herein.

[0111] FIG. 9 is a schematic side view diagram showing an example method of enhancing connection between a fluid end 12 and a power end 14 consistent with the example fluid end 12 and example stay rods 120 shown in FIG. 3, according to embodiments of the disclosure. According to some embodiments, a method to enhance connection between a fluid end 12 and a power end 14 of a high-power pump 10 may include passing each of a plurality of stay rods 120 through one of a plurality of stay rod bores 122 passing substantially through a fluid end block 20 from a power end side of the fluid end block 20 to a side of the fluid end block 20 opposite the power end side. The method also may include connecting a first end of each of the plurality of stay rods 120 to the fluid end block 20, and connecting a second end of each of the plurality of stay rods 120 to the power end 14, thereby to enhance connection of the fluid end 12 to the power end 14, for example, as described herein with respect to FIG. 3. In some embodiments of the method to enhance connection, the method further may include disconnecting each of the first ends of the plurality of stay rods 120 from the fluid end block 20, and separating the fluid end 12 from the power end 14, for example, during disassembly of the fluid end 12 from the power end 14.

[0112] According to some embodiments, a method to enhance assembly of a valve assembly 42 in a fluid end 12 of a high-power pump 10 may include inserting a discharge member 38 into a valve bore 68 in a fluid end block 20 of the fluid end 12, for example, in a manner consistent with FIGS. 6-8. The valve bore 68 may have a longitudinal valve axis AV extending in a first direction substantially parallel to a longitudinal plunger axis AP of a plunger bore 22. The method further may include positioning the discharge member 38 relative to the valve bore 68. The discharge member 38 may at least partially define a valve seat 74. The method also may include inserting a suction member 36 into the valve bore 68 and positioning the suction member 36 relative to the discharge member 38, such that the suction member 36 reciprocates relative to the discharge member 38 between a closed suction position when the suction member 36 contacts the valve seat 74 and an open suction position when the suction member 36 is spaced from the valve seat 74, thereby to enhance control of fluid flow through the fluid end 12, for example, as described herein.

[0113] In some embodiments of the method to enhance assembly, the method further may include inserting a discharge seat 100 into the valve bore 68 and positioning the discharge seat 100 relative to the valve bore 68, such that discharge member 38 reciprocates relative to the discharge seat 100 between a closed discharge position when the discharge member 38 contacts the discharge seat 100 and an open discharge position when the discharge member 38 is spaced from the discharge seat 100, thereby to enhance control of fluid flow through the fluid end 12. In some embodiments of the method to enhance assembly, the method also may include inserting a fixed sleeve 66 into the valve bore 68 and positioning the fixed sleeve 66 relative to the valve bore 68, such that the discharge member 38 and / or the suction member 36 is / are positioned in the fixed sleeve 66, thereby to reciprocate relative to the fixed sleeve 66. In some embodiments of the method to enhance assembly, the inserting of the fixed sleeve 66 into the valve bore 68 may include connecting the suction member 36 to the discharge member 38, positioning the discharge member 38 in the fixed sleeve 66, and inserting the fixed sleeve 66, the discharge member 38, and the suction member 36 into the valve bore 68. In some embodiments of the method to enhance assembly, the method also may include positioning a packing assembly 24 in the plunger bore 22 in a second side of the fluid end block 20. The second side may be generally opposite the first side, and the plunger bore 22 may have a longitudinal plunger axis AP extending substantially parallel to the first direction, for example, as described herein.

[0114] Having now described some illustrative embodiments of the disclosure, it should be apparent to those skilled in the art that the foregoing is merely illustrative and not limiting, having been presented by way of example only. Numerous modifications and other embodiments are within the scope of one of ordinary skill in the art and are contemplated as falling within the scope of the disclosure. In particular, although many of the examples presented herein involve specific combinations of method acts or system elements, it should be understood that those acts and those elements may be combined in other ways to accomplish the same objectives. Those skilled in the art should appreciate that the parameters and configurations described herein are exemplary and that actual parameters and / or configurations will depend on the specific application in which the systems, methods, and / or aspects or techniques of the disclosure are used. Those skilled in the art should also recognize or be able to ascertain, using no more than routine experimentation, equivalents to the specific embodiments of the disclosure. It is, therefore, to be understood that the embodiments described herein are presented by way of example only and that, within the scope of any appended claims and equivalents thereto, the disclosure may be practiced other than as specifically described.

[0115] This application claims priority to, and the benefit of U.S. Provisional Application No. 63 / 779,486, filed Mar. 28, 2025, titled “FLUID ENDS AND VALVE ASSEMBLIES FOR HIGH POWER PUMPS AND RELATED SYSTEMS AND METHODS,” the disclosure of which is incorporated herein by reference in its entirety.

[0116] Furthermore, the scope of the present disclosure shall be construed to cover various modifications, combinations, additions, alterations, etc., above and to the above-described embodiments, which shall be considered to be within the scope of this disclosure. Accordingly, various features and characteristics as discussed herein may be selectively interchanged and applied to other illustrated and non-illustrated embodiment, and numerous variations, modifications, and additions further may be made thereto without departing from the spirit and scope of the present disclosure as set forth in the appended claims.

Examples

Embodiment Construction

[0041]The drawings include like numerals to indicate like parts throughout the several views, the following description is provided as an enabling teaching of exemplary embodiments, and those skilled in the relevant art will recognize that many changes may be made to the embodiments described. It also will be apparent that some of the desired benefits of the embodiments described may be obtained by selecting some of the features of the embodiments without utilizing other features. Accordingly, those skilled in the art will recognize that many modifications and adaptations to the embodiments described are possible and may even be desirable in certain circumstances. Thus, the following description is provided as illustrative of the principles of the embodiments and not in limitation thereof.

[0042]The phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. As used herein, the term “plurality” refers to two or more items or compo...

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to, and the benefit of U.S. Provisional Application No. 63 / 779,486, filed Mar. 28, 2025, titled “FLUID ENDS AND VALVE ASSEMBLIES FOR HIGH POWER PUMPS AND RELATED SYSTEMS AND METHODS,” the disclosure of which is incorporated herein by reference in its entirety.TECHNICAL FIELD

[0002] The present disclosure relates to fluid ends, valve assemblies, and related systems and methods and, more particularly, to fluid ends and valve assemblies for high-power pumps, and related systems and methods.BACKGROUND

[0003] Pumps may be used to transfer fluid having a first pressure from one location to another location at a second pressure greater than the first pressure. Pumps often include valves to control the flow of fluid into, through, and from a pump chamber of the pump. For example, a reciprocating plunger pump may include a first one-way valve or check-valve to allow fluid to be drawn into the pump and a second one-way valve or check-valve to permit the discharge of the fluid drawn into the pump while the first valve is closed. For example, the first valve may open to allow fluid to be drawn into the pump while the second valve is closed, and thereafter the first valve may close while the second valve is open while a plunger in the pump increases the pressure of the fluid in the pump chamber and forces the fluid through the second valve to pump the fluid.

[0004] An example of a high-power pump may be used, for example, to pump fracturing fluid at high pressures and high flow rates during a hydraulic fracturing operation. For example, a hydraulic fracturing operation involves pumping a fracturing fluid at high flow rates and high pressures sufficient to fracture a reservoir formation to allow hydrocarbons to more easily flow from the formation toward a wellbore for production. Such high flow rates and high pressures may result in significant wear to components associated with the fluid flow, such as the pumps used to pump the fracturing fluid. In addition, the fracturing fluid may contain substances, for example, proppants and fluids, having abrasive and corrosive characteristics, and thus, components associated with the fracturing operation may exhibit high wear rates or high failure rates. As a result, components associated with pumps, such as fluid ends and associated valves, may be particularly susceptible high wear rates and failures, thereby requiring replacement. For example, it is common to replace valves relatively frequently during the service life of a high-power pump, which may result in relatively high maintenance and service costs over the service life of the high-power pump.

[0005] For at least these reasons, Applicant has recognized that it may be desirable to provide fluid ends and valve assemblies for high-power pumps, and related systems and methods, resulting in relatively increased efficiencies associated with the reliability of the fluid ends and associated valve assemblies. At least some examples described herein may address one or more of the above-noted potential issues, as well as possibly others.SUMMARY

[0006] As referenced above, it may be desirable to provide fluid ends and valve assemblies for high-power pumps, and related systems and methods, resulting in relatively increased efficiencies associated with the reliability of fluid ends and valve assemblies of high-power pumps, such as, for example, fluid ends and valve assemblies used in the oil and gas industry, where the operating conditions and fluids may present a particularly harsh environment. In some embodiments, the fluid ends and valve assemblies presented herein may have a relatively enhanced reliability, resulting in less frequent service and replacement. For example, in some embodiments, a fluid end may include a fluid end block having a plunger bore positioned to receive a packing assembly and a reciprocating plunger, and the plunger bore may be axially aligned with a valve bore that receives a valve assembly that acts as both a suction valve and a discharge valve. In some embodiments, the valve assembly may include a discharge member positioned to open and close a discharge port of the fluid end, and a face of the discharge member may provide a valve seat for a suction member positioned to open and close a suction port of the fluid end. In some embodiments, the fluid ends and valve assemblies may reduce or prevent fatigue failures of fluid end blocks, which may thereby mitigate the need to use stainless steel construction, instead allowing the use of relatively more efficient carbon steel. In some embodiments, the fluid ends and valve assemblies may facilitate access to internal components of the fluid end from a side of the fluid opposite an associated power end, which may be less ergonomically challenging for a service technician, thereby improving efficiencies associated with assembly and service of the fluid end.

[0007] According to some embodiments, a valve assembly to enhance control of fluid flow through a fluid end block of a high-power pump may include a fixed sleeve having a sleeve body configured to be positioned at least partially in a valve bore. The valve bore may be at least partially defined by a fluid end block. The sleeve body may be annular and may at least partially define a sleeve recess. The valve assembly further may include a discharge member at least partially positioned in the sleeve recess. The discharge member may have a discharge member body at least partially defining a valve seat. The discharge member body may be positioned to reciprocate relative to the sleeve recess between a closed discharge position and an open discharge position. The valve assembly also may include a suction member having a suction member body positioned to reciprocate relative to the discharge member between a closed suction position when contacting the valve seat and an open suction position when spaced from the valve seat. The discharge member may be positioned to: (a) prevent flow of fluid to a discharge port in the fluid end block when the discharge member is in the closed discharge position, and (b) allow fluid to flow to the discharge port in the fluid end block when the discharge member is in the open discharge position, and the suction member may be positioned to: (a) prevent fluid from being drawn through the suction port when the suction member is in closed suction position, and (b) allow fluid to be drawn through the suction port when the suction member is in the open suction position, thereby to enhance control of fluid flow through the fluid end block.

[0008] According to some embodiments, a valve assembly to enhance control of fluid flow through a fluid end block of a high-power pump may include a fixed sleeve having a sleeve body configured to be positioned at least partially in a valve bore at least partially defined by a fluid end block. The sleeve body may be annular and may at least partially define a discharge member seat and a suction member seat. The valve assembly further may include a discharge member associated with the sleeve body. The discharge member may include a discharge member body at least partially defining a discharge surface. The discharge member body may be positioned to reciprocate relative to the sleeve body between a closed discharge position when the discharge surface contacts the discharge member seat and an open discharge position when the discharge surface is spaced from the discharge member seat. The valve assembly also may include a suction member having a suction member body positioned to reciprocate relative to the sleeve body between a closed suction position when contacting the suction member seat and an open suction position when the suction member body is spaced from the suction member seat. The discharge member body and the suction member body may be positioned to move in opposite longitudinal directions when the discharge member body moves to the closed discharge position and the suction member body moves to the closed suction position. The discharge member may be positioned to: (a) prevent flow of fluid to a discharge port in the fluid end block when the discharge member is in the closed discharge position, and (b) allow fluid to flow to the discharge port in the fluid end block when the discharge member is in the open discharge position, and the suction member may be positioned to: (a) prevent flow of fluid from a suction port in the fluid end block when the suction member is in the closed suction position, and (b) allow fluid to be drawn through the suction port when the suction member is in the open suction position, thereby to enhance control of fluid flow through the fluid end block.

[0009] According to some embodiments, a fluid end may include a fluid end block at least partially defining a valve bore, a suction port, and a discharge port. The fluid end further may include a valve assembly at least partially positioned in the valve bore, thereby to enhance control of fluid flow through the fluid end block. The valve assembly may include a fixed sleeve having a sleeve body at least partially positioned in the valve bore. The sleeve body may be annular and may at least partially define a sleeve recess. The valve assembly further may include a discharge member at least partially positioned in the sleeve recess. The discharge member may have a discharge member body at least partially defining a valve seat. The discharge member body may be positioned to reciprocate relative to the sleeve recess between a closed discharge position and an open discharge position. The valve assembly also may include a suction member having a suction member body positioned to reciprocate relative to the discharge member between a closed suction position when contacting the valve seat and an open suction position when spaced from the valve seat. The discharge member may be positioned to: (a) prevent flow of fluid to the discharge port in the fluid end block when the discharge member is in the closed discharge position, and (b) allow fluid to flow to the discharge port in the fluid end block when the discharge member is in the open discharge position, and the suction member may be positioned to: (a) prevent fluid from being drawn through the suction port when the suction member is in the closed suction position, and (b) allow fluid to be drawn through the suction port when the suction member is in the open suction position, thereby to enhance control of fluid flow through the fluid end block.

[0010] According to some embodiments, a fluid end may include a fluid end block at least partially defining a valve bore, a suction port, and a discharge port. The fluid end further may include a valve assembly at least partially positioned in the valve bore, thereby to enhance control of fluid flow through the fluid end block. The valve assembly may include a fixed sleeve having a sleeve body configured to be positioned at least partially in the valve bore. The sleeve body may be annular and may at least partially define a discharge member seat and a suction member seat. The valve assembly further may include a discharge member associated with the sleeve body. The discharge member may have a discharge member body at least partially defining a discharge surface. The discharge member body may be positioned to reciprocate relative to the sleeve body between a closed discharge position when the discharge surface contacts the discharge member seat and an open discharge position when the discharge surface is spaced from the discharge member seat. The valve assembly also may include a suction member having a suction member body positioned to reciprocate relative to the sleeve body between a closed suction position when contacting the suction member seat and an open suction position when the suction member body is spaced from the suction member seat. The discharge member body and the suction member body may be positioned to move in opposite longitudinal directions when the discharge member body moves to the closed discharge position and the suction member body moves to the closed suction position. The discharge member may be positioned to: (a) prevent flow of fluid to a discharge port in the fluid end block when the discharge member is in the closed discharge position, and (b) allow fluid to flow to the discharge port in the fluid end block when the discharge member is in the open discharge position, and the suction member may be positioned to: (a) prevent flow of fluid from a suction port in the fluid end block when the suction member is in the closed suction position, and (b) allow fluid to be drawn through the suction port when the suction member is in the open suction position, thereby to enhance control of fluid flow through the fluid end block.

[0011] According to some embodiments, a fluid end for a high-power pump may include a valve assembly according to any of the valve assemblies described herein. According to some embodiments, a high-power pump may include a fluid end according to any of the fluid ends described herein.

[0012] According to some embodiments, a method to enhance control of fluid flow through a fluid end of a high-power pump may include positioning a valve assembly in a valve bore in a fluid end block of the fluid end, the valve bore having a longitudinal valve axis extending in a first direction substantially parallel to a longitudinal axis of a plunger bore. The valve assembly may include a suction member and a discharge member. The suction member and the discharge member may be positioned to reciprocate relative to the valve bore in a direction substantially parallel to the first direction. The discharge member may at least partially define a valve seat, and the suction member may be positioned to reciprocate relative to the discharge member between a closed suction position when the suction member contacts the valve seat and an open suction position when the suction member is spaced from the valve seat, thereby to enhance control of fluid flow through the fluid end.

[0013] According to some embodiments, a method to enhance control of fluid flow through a fluid end of a high-power pump may include positioning a valve assembly in a valve bore in a fluid end block of the fluid end, the valve bore having a longitudinal valve axis extending in a first direction substantially parallel to a longitudinal axis of a plunger bore. The valve assembly may include a fixed sleeve at least partially defining a suction member seat and a discharge member seat. The valve assembly further may include a suction member positioned to reciprocate relative to the valve bore between: (a) a closed suction position when the suction member contacts the suction member seat and (b) an open suction position when the suction member is spaced from the suction member seat. The valve assembly also may include a discharge member positioned to reciprocate relative to the valve bore between: (a) a closed discharge position when the discharge member contacts the discharge member seat and (b) an open discharge position when the discharge member is spaced from the discharge member seat, thereby to enhance control of fluid flow through the fluid end.

[0014] According to some embodiments, a method to enhance connection between a fluid end and a power end of a high-power pump may include passing each of a plurality of stay rods through one of a plurality of stay rod bores passing substantially through a fluid end block from a power end side of the fluid end block to a side of the fluid end block opposite the power end side. The method also may include connecting a first end of each of the plurality of stay rods to the fluid end block, and connecting a second end of each of the plurality of stay rods to the power end, thereby to enhance connection of the fluid end to the power end.

[0015] According to some embodiments, a method to enhance assembly of a valve assembly in a fluid end of a high-power pump may include inserting a discharge member into a valve bore in a first side of a fluid end block of the fluid end, the valve bore having a longitudinal valve axis extending in a first direction substantially parallel to a plunger bore of the fluid end block. The discharge member may at least partially define a valve seat. The method also may include inserting a suction member into the valve bore and positioning the suction member relative to the discharge member, such that the suction member reciprocates relative to the discharge member between a closed suction position when the suction member contacts the valve seat and an open suction position when the suction member is spaced from the valve seat, thereby to enhance control of fluid flow through the fluid end.

[0016] Still other aspects and advantages of these exemplary embodiments and other embodiments, are discussed in detail herein. Moreover, it is to be understood that both the foregoing information and the following detailed description provide merely illustrative examples of various aspects and embodiments and are intended to provide an overview or framework for understanding the nature and character of the claimed aspects and embodiments. Accordingly, these and other objects, along with advantages and features of the present disclosure, will become apparent through reference to the following description and the accompanying drawings. Furthermore, it is to be understood that the features of the various embodiments described herein are not mutually exclusive and may exist in various combinations and permutations.BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The accompanying drawings, which are included to provide a further understanding of the embodiments of the present disclosure, are incorporated in and constitute a part of this specification, illustrate embodiments of the present disclosure, and together with the detailed description, serve to explain principles of the embodiments discussed herein. No attempt is made to show structural details of this disclosure in more detail than may be necessary for a fundamental understanding of the embodiments discussed herein and the various ways in which they may be practiced. According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate embodiments of the disclosure.

[0018] FIG. 1 is a schematic perspective section view of an example pump, including an example fluid end, according to embodiments of the disclosure.

[0019] FIG. 2A is a schematic detailed side section view of the example valve assembly shown in FIG. 2A, according to embodiments of the disclosure.

[0020] FIG. 2B is a schematic side section view of the example valve assembly shown in FIG. 2A, according to embodiments of the disclosure.

[0021] FIG. 2C is a schematic side section view of the example fluid end and valve assembly shown in FIG. 2A, with an example plunger moving toward a bottom dead center position during an example suction stroke, according to embodiments of the disclosure.

[0022] FIG. 2D is a schematic side section view of the example fluid end and valve assembly shown in FIG. 2A, with the example plunger reaching the bottom dead center position, according to embodiments of the disclosure.

[0023] FIG. 2E is a schematic detailed side section view the example valve assembly shown in FIG. 2D, with an example suction member in an example open position, according to embodiments of the disclosure.

[0024] FIG. 2F is a schematic side section view of the example fluid end and valve assembly shown in FIG. 2A, with the example plunger moving from the bottom dead center position toward a top dead center position during an example discharge stroke, according to embodiments of the disclosure.

[0025] FIG. 2G is a schematic side section view of the example fluid end and valve assembly shown in FIG. 2A, with the example plunger reaching the top dead center position, according to embodiments of the disclosure.

[0026] FIG. 2H is a schematic detailed side section view the example valve assembly shown in FIG. 2G, with an example discharge member in an example open position, according to embodiments of the disclosure.

[0027] FIG. 2I is a schematic side section view of the example fluid end and valve assembly shown in FIG. 2A, with the example plunger moving from the top dead center position toward the bottom dead center position during an example suction stroke, according to embodiments of the disclosure.

[0028] FIG. 3 is a schematic partial side section view of an example fluid end and example stay rods for connecting the fluid end to a power end, according to embodiments of the disclosure.

[0029] FIG. 4A is a schematic side section view of another example fluid end and another example valve assembly, with an example plunger moving toward a bottom dead center position during an example suction stroke, with an example suction member in an open position and an example discharge member in a closed position, according to embodiments of the disclosure.

[0030] FIG. 4B is a schematic side section view of the example fluid end and valve assembly shown in FIG. 4A, with the plunger moving from the bottom dead center position toward the top dead center position during an example discharge stroke, with the discharge member in an open position and the suction member in a closed position, according to embodiments of the disclosure.

[0031] FIG. 5A is a schematic side section view of another example valve assembly and an example plunger, with an example suction member closed and an example discharge member closed, according to embodiments of the disclosure.

[0032] FIG. 5B is a schematic side section view of the example valve assembly shown in FIG. 5A, with the example plunger moving away from a top dead center position toward a bottom dead center position during an example suction stroke, according to embodiments of the disclosure.

[0033] FIG. 5C is a schematic side section view of the example valve assembly shown in FIG. 5A, with the example plunger moving further toward the bottom dead center position during an example suction stroke, with an example suction member in an open position and an example discharge member in a closed position, according to embodiments of the disclosure.

[0034] FIG. 5D is a schematic side section view of the example valve assembly shown in FIG. 5A, with the example plunger reaching the bottom dead center position, with the example suction member in the open position and the example discharge member in the closed position, according to embodiments of the disclosure.

[0035] FIG. 5E is a schematic side section view of the example valve assembly shown in FIG. 5A, with the example plunger moving away from the bottom dead center position toward the top dead center position during an example discharge stroke, with an example suction member returning to the closed position while the example discharge member remains in the closed position, according to embodiments of the disclosure.

[0036] FIG. 5F is a schematic side section view of the example valve assembly shown in FIG. 5A, with the example plunger continuing to move toward the top dead center position during an example discharge stroke, with the example suction member remaining in the closed position and the example discharge member moving to the open position, according to embodiments of the disclosure.

[0037] FIG. 6 is a schematic side view diagram showing an example method to enhance control of fluid flow through a fluid end of a high-power pump consistent with the example fluid end shown in FIGS. 2A-2I, according to embodiments of the disclosure.

[0038] FIG. 7 is a schematic side view diagram showing an example method to enhance control of fluid flow through a fluid end of a high-power pump consistent with the example fluid end shown in FIGS. 4A and 4B, according to embodiments of the disclosure.

[0039] FIG. 8 is a schematic side view diagram showing an example method to enhance control of fluid flow through a fluid end of a high-power pump consistent with the example valve assembly shown in FIGS. 5A-5F, according to embodiments of the disclosure.

[0040] FIG. 9 is a schematic side view diagram showing an example method of enhancing connection between a fluid end and a power end consistent with the example fluid end and example stay rods shown in FIG. 3, according to embodiments of the disclosure.DETAILED DESCRIPTION

[0041] The drawings include like numerals to indicate like parts throughout the several views, the following description is provided as an enabling teaching of exemplary embodiments, and those skilled in the relevant art will recognize that many changes may be made to the embodiments described. It also will be apparent that some of the desired benefits of the embodiments described may be obtained by selecting some of the features of the embodiments without utilizing other features. Accordingly, those skilled in the art will recognize that many modifications and adaptations to the embodiments described are possible and may even be desirable in certain circumstances. Thus, the following description is provided as illustrative of the principles of the embodiments and not in limitation thereof.

[0042] The phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. As used herein, the term “plurality” refers to two or more items or components. The terms “comprising,”“including,”“carrying,”“having,”“containing,” and “involving,” whether in the written description or the claims and the like, are open-ended terms, in particular, to mean “including but not limited to,” unless otherwise stated. Thus, the use of such terms is meant to encompass the items listed thereafter, and equivalents thereof, as well as additional items. The transitional phrases “consisting of” and “consisting essentially of,” are closed or semi-closed transitional phrases, respectively, with respect to any claims. Use of ordinal terms such as “first,”“second,”“third,” and the like in the claims to modify a claim element does not by itself connote any priority, precedence, or order of one claim element over another or the temporal order in which acts of a method are performed, but are used merely as labels to distinguish one claim element having a certain name from another element having a same name (but for use of the ordinal term) to distinguish claim elements.

[0043] The present disclosure is generally directed fluid ends, valve assemblies, and related systems and methods and, more particularly, to fluid ends and valve assemblies for high-power pumps, and related systems and methods, such as, for example, fluid ends and valve assemblies used in the oil and gas industry, where the operating conditions and fluids may present a particularly harsh environment. Applicant has recognized that fluid ends and valve assemblies may have a number drawbacks. For example, because in many fluid end blocks the bores that receive the valves intersect the respective bores in which the plunger reciprocates, the intersection of the bores are high-stress, failure-prone areas of the fluid end block due to the high cycle rate pumping common in high-power pumps, for example, such as hydraulic fracturing pumps that may pump at 15,000 psi and from 1 to 3 Hz. In such pumps, for example, the material around the intersections of the bores may be subject to impact from sand, rocks, and debris during normal operation. Due to such impacts, such pumps generally have forged stainless steel fluid end blocks rather than carbon steel fluid end blocks in order to reduce wear and failure rates, leading to manufacturing inefficiencies. In addition, Applicant has also recognized that servicing the valves of such pumps, a relatively common occurrence, may generally require accessing vertical valve bores via respective covers, while servicing packing assemblies of such pumps, also a relatively common occurrence, may generally require accessing horizontal plunger bores via different respective covers, resulting in servicing inefficiencies. Moreover, separate suction valve seats and discharge valve seats may often be press-fitted into tapered portions of the respective vertical bores, and thus, in order to install and remove the respective suction and discharge valve seats from the respective bores, hydraulic cylinders may be required to exert sufficient installation and extraction forces, typically greater than twenty tons, on the respective valve seats, resulting in installation and servicing inefficiencies. Servicing packing assemblies may be performed from a side of the fluid end adjacent the associated power end, which may require that service personnel lean over the fluid end to remove large packing nuts that retain a packing assembly, which may be ergonomically challenging for service personnel and inefficient. For some high-power pumps, a typical fluid end may weigh from 3,000 to 7,000 pounds, and may be attached from the fluid end side to the power end by as many as ten to twenty stay rods, which may often be tightened to specific preload torques to prevent fastener fatigue, resulting in such an operation being ergonomically challenging and inefficient for service personnel.

[0044] In some embodiments, the fluid ends and valve assemblies presented herein may have a relatively enhanced reliability, resulting in less frequent service and replacement. For example, in some embodiments, a fluid end may include a fluid end block having a plunger bore positioned to receive a packing assembly and a reciprocating plunger, and the plunger bore may be axially aligned with a valve bore that receives a valve assembly that, in at least some embodiments, acts as both a suction valve and a discharge valve. In some embodiments, the valve assembly may include a discharge member positioned to open and close a discharge port of the fluid end, and a face of the discharge member may provide a valve seat for a suction member positioned to open and close a suction port of the fluid end. In some embodiments, the fluid ends and valve assemblies may reduce or prevent fatigue failures of fluid end blocks, which may thereby mitigate the need to use stainless steel construction, instead allowing the use of relatively more efficient carbon steel. In some embodiments, the fluid ends and valve assemblies may facilitate access to internal components of the fluid end from a side of the fluid opposite the associated power end, which may be less ergonomically challenging for service personnel, thereby improving efficiencies associated with assembly and service of the fluid end.

[0045] For example, FIG. 1 is a schematic perspective section view of an example pump 10, including an example fluid end 12, and a schematic depiction of an example power end 14, according to embodiments of the disclosure. The pump 10 may be any high-power pump, high-pressure pump, reciprocating pump, and / or high-flow rate pump suitable for pumping solids, semi-solids, slurries, liquids, fluids, or combinations thereof. In some embodiments, the pump 10 may be, for example, a hydraulic fracturing pump for pumping hydraulic fracturing fluid. Although embodiments of the pump 10 are described herein as being a “hydraulic fracturing pump” for pumping hydraulic fracturing fluid for the purpose of discussion, the pump 10 may be any other type of pump, such as, for example, any type of high-power pump, high-pressure pump, reciprocating pump, and / or high-flow rate pump suitable for pumping solids, semi-solids, slurries, liquids, fluids, or combinations thereof. In some embodiments, the pump 10 may be, for example, a hydraulic fracturing pump for pumping solids, semi-solids, slurries, liquids, fluids, or combinations thereof, such as hydraulic fracturing fluid.

[0046] For example, a reciprocating plunger pump may be used to pump a fracturing fluid at high flow rates and high pressures sufficient to fracture a reservoir formation to allow hydrocarbons to more easily flow from the formation toward a wellbore for production. A hydraulic fracturing operation may include as many as six or more hydraulic fracturing units, and each of the hydraulic fracturing units may include a prime mover, such as an electric motor or internal combustion engine, either directly connected, or connected via a transmission, to the reciprocating plunger pump to supply power to drive the reciprocating plunger pump to pump the fracturing fluid into the formation to stimulate production of the well. For example, typical flow rates for a hydraulic fracturing operation may range from about 1,500 to about 4,000 gallons per minute, and typical pressures may range from about 7,500 to about 15,000 pounds per square inch. Although many examples discussed in this disclosure are explained in relation to hydraulic fracturing pumps, such as reciprocating plunger pumps for pumping fracturing fluid and related methods, other flow control-related and / or pumping-related operations, components, and methods are contemplated.

[0047] As shown in FIG. 1, the example pump 10 may be a reciprocating plunger pump and may include the fluid end 12 and the power end 14. The power end 14 may include, for example, a housing 16 for power transmission components 18, such as a crankshaft, bearings supporting the crankshaft in the housing, crossheads, reduction gears, pony rods, connecting rods, and / or plungers connected to the pony rods or connecting rods. A prime mover, such as an electric motor and / or an internal combustion engine, may be connected to the power transmission components 18, thereby to drive the power transmission components 18 during operation of the pump 10.

[0048] As shown in FIG. 1, for example, the fluid end 12 may include a fluid end block 20 including one or more plunger bores 22 in each of which a packing assembly 24 is received and respective plungers 26 reciprocate, one or more chambers 28 receiving fluid, one or more suction ports 30 for drawing fluid into the one or more chambers 28, and one or more discharge ports 32 for discharging fluid from the one or more chambers 28 at a higher pressure. For example, as each plunger 26, moved via operation of the power transmission components 18 of the power end 14, at least partially retracts into a respective plunger bore 22, fluid is drawn from a fluid source 34, for example, through a suction manifold, into the chamber 28 of the fluid end 12 via the suction port 30 in the fluid end block 20, while a suction member 36 is open and a discharge member 38 is closed. As each plunger 26 reverses direction and moves back toward the chamber 28, moved via operation of the power transmission components 18, pressurized fluid 40 (e.g., fluid at a higher pressure than fluid received from the fluid source 34) is discharged from the fluid end 12 via the discharge port 32 in the fluid end block 20 while the discharge member 38 is open and the suction member 36 is closed, for example, as described herein. In some embodiments, the pump 10 may further include a discharge manifold having a discharge passage, and the discharge member 38, when open, may allow the pressurized fluid 40 to be discharged from the pump 10 via the discharge manifold and discharge passage for downstream use, for example, as part of a hydraulic fracturing operation or other operation. In some embodiments, the suction member 36 and the discharge member 38 may be part of a common valve assembly 42, for example, as described herein. The suction member 36 and / or the discharge member 38 may act as one-way valves or check-valves, allowing fluid to flow only in a single direction, either into the chamber 28 of the fluid end block 20 via the suction member 36, or from the chamber 28 of the fluid end block 20 via the discharge member 38. In this example manner, the fluid end 12 draws fluid from the fluid source 34 into the fluid end block 20 at a first pressure and discharges the fluid from the fluid end 12 at a higher pressure. In some pump embodiments, the fluid end 12 may include multiple (e.g., two, three, four, or five) sets of suction ports, plunger bores, packing assemblies, plungers, and / or discharge ports to pump fluid at high pressures and / or high flow rates.

[0049] As shown in FIG. 1, according to some embodiments, the fluid end 12 may include an access port 44 providing access to one or more of the chambers 28, for example, for use during assembly and / or maintenance of the fluid end 12. Each of the one or more access ports 44 may be selectively closed via a respective spacer 45 and / or a respective cover 46 received in the access port 44. In some embodiments, the access port 44 may be defined in the fluid end block 20 by a circular aperture having an interior face having a substantially cylindrical configuration, for example, as shown in FIG. 1. In some embodiments, the spacer 45 and / or the cover 46 may have a substantially circular cross-section and may have a substantially cylindrical configuration sized and shaped to fit within the interior face of the access port 44, for example, as shown in FIG. 1. In some embodiments, the spacer 45 and / or the cover 46 may be sized and shaped to fit snugly (e.g., in a substantially sealed manner) within the access port 44. In some embodiments, a retainer assembly 48 may be used to secure the spacer 45 and / or the cover 46 within the access port 44. As shown, in some embodiments, the retainer assembly 48 may include an outer housing 50 configured to be secured to an exterior surface of the fluid end block 20 adjacent the access port 44, for example, via one or more fasteners 52 (e.g., studs and nuts), as shown. The outer housing 50 may define a receiver aperture 54 provided with internal threads. The retainer assembly 48 further may include a retainer 56, which may include a substantially cylindrical body having external threads configured to threadedly engage the internal threads of the outer housing 50. In some embodiments, the retainer 56 may be threaded into the outer housing 50 and into contact with an exterior end of the cover 46, thereby to secure the spacer 45 and / or the cover 46 in the access port 44.

[0050] As shown in FIG. 1, in some embodiments, the fluid end 12 may include an annular pressure ring 58, and an annular connection ring 60 may be connected to the fluid end block 20 via fasteners 62 (e.g., studs and bolts), thereby to secure the pressure ring 58 to the fluid end block 20. The pressure ring 58 and the connection ring 60 may each include a bore through which the plunger 26 reciprocates. One or more of the bores of the pressure ring 58 or the connection ring 60 may define an annular space around the plunger 26 in which the packing assembly 24 is received to seal the annular space around the plunger 26. In some embodiments, the packing assembly 24 may include one or more of a junk ring, a header ring, one or more pressure rings, a lube seal, an adaptor ring, or a lantern ring. As shown, in some embodiments, a packing nut 64 connects, via a threaded interface, to the connection ring 60, and axially anchors the packing assembly 24 in the annular space around the plunger 26. In some embodiments, the packing nut 64 may be immediately adjacent (e.g., in contact with) the lantern ring. The packing nut 64 may axially compress the packing assembly 24, depending on the extent to which the packing nut 64 is threaded into the connection ring via the threaded interface with the connection ring 60.

[0051] The plunger bore 22 and the packing assembly 24 may be substantially cylindrical, with the plunger bore 22 having a substantially circular cross-section and the packing assembly 24 having a substantially cylindrical outer surface received in the plunger bore 22. The packing assembly 24 may be configured to at least partially receive therein the plunger 26 as the plunger 26 reciprocates, thereby to draw fluid into the chamber 28 at a first pressure via the suction port 30 during movement of the plunger 26 in a first direction, and discharge the fluid from the chamber 28 at a second pressure greater than the first pressure via the discharge port 32 during movement of the plunger 26 in a second direction opposite the first direction.

[0052] FIGS. 2A, 2B, 2C, 2D, 2E, 2F, 2G, 2H, and 2I are schematic side section views of an example fluid end 12, including an example valve assembly 42, according to embodiments of the disclosure. In some embodiments, the valve assembly 42 may enhance control of fluid flow through the fluid end block 20. For example, the valve assembly 42, in some embodiments, may include a fixed sleeve 66 having a sleeve body positioned at least partially in a valve bore 68 at least partially defined by the fluid end block 20. The sleeve body may be substantially annular and may at least partially define a sleeve recess 70. The valve assembly 42 further may include a discharge member 38 at least partially received in the sleeve recess 70. In some embodiments, the sleeve recess 70 may at least partially define an inward facing cylindrical sleeve surface. The discharge member 38 may have a discharge member body at least partially defining a valve seat 74, and the discharge member body may be positioned to reciprocate relative to the sleeve recess 70, between a closed discharge position and an open discharge position, as described herein. The valve assembly 42, in some embodiments, may also include a suction member 36 having a suction member body positioned to reciprocate relative to the discharge member 38, between a closed suction position when contacting the valve seat 74 and an open suction position when spaced from the valve seat 74. In some embodiments, the discharge member 38 may positioned to: (a) prevent flow of fluid to the discharge port 32 in the fluid end block 20 when the discharge member 38 is in the closed discharge position, and (b) allow fluid to flow to the discharge port 32 in the fluid end block 20 when the discharge member 38 is in the open discharge position, as described herein. The suction member 36 may be positioned to: (a) prevent fluid from being drawn through the suction port 30 when the suction member 36 is in closed suction position, and (b) allow fluid to be drawn through the suction port 30 when the suction member 36 is in the open suction position, as described herein.

[0053] As shown in FIGS. 2A-2I, in some embodiments, the discharge member body may at least partially define a discharge member passage 78, and the suction member 36 may be at least partially positioned in the discharge member passage 78, for example, when the suction member 36 is in the closed suction position, for example, as shown in FIGS. 2A and 2B. For example, the discharge member body may at least partially define a discharge member head 80 and a discharge member stem 82 connected to the discharge member head 80. In some embodiments, the discharge member stem 82 may be at least partially positioned in the sleeve recess 70. The discharge member stem 82 and / or the sleeve recess 70 may be configured to facilitate reciprocation of the discharge member stem 82 in a direction substantially parallel to a longitudinal axis of the discharge member stem 82 relative to the sleeve recess 70, during movement of the discharge member 38 between the closed discharge position and the open discharge position. In some embodiments, the discharge member head 80 may at least partially define the valve seat 74, which may be at least partially concave, for example, as shown in FIGS. 2A-2I. For example, the valve seat 74 may present a radially inward facing frustoconical surface, and the discharge member passage 78 may pass longitudinally through the radially narrower end of the frustoconical surface.

[0054] As shown in FIGS. 2A and 2B, in some embodiments, the sleeve body of the fixed sleeve 66 may at least partially define one or more sleeve passages 84 positioned to provide fluid flow from the suction port 30 to the sleeve recess 70. The valve assembly 42, in some embodiments, may further include a discharge spring 86 biasing the discharge member 38 toward the closed discharge position, and the sleeve body of the fixed sleeve 66 may at least partially define a discharge spring recess 88 in which a first end of the discharge spring 86 is positioned, with a second end of the discharge spring 86 engaging the discharge member 38. As shown, the discharge spring 86 may include a coil spring, such as a conical-shaped coil spring, although springs of other types and / or shapes are contemplated.

[0055] As shown in FIGS. 2A-2I, in some embodiments, the discharge member body may include a guide 90 positioned in the discharge member passage 78, and the suction member body may include a suction member stem 92 at least partially received in the guide 90. The suction member stem 92 may be positioned to reciprocate relative to the guide 90 when the suction member 36 reciprocates between the closed suction position and the open suction position, for example, as described herein. The sleeve body of the fixed sleeve 66 may at least partially define a discharge spring recess 96 in which a first end of the discharge spring 86 is positioned, with a second end of the discharge spring 86 engaging, for example, the guide 90. In some embodiments, the valve assembly 42 further may include a suction spring 96 biasing the suction member 36 toward the closed suction position. The suction member stem 92 may at least partially define a suction spring boss 98 engaging a first end of the suction spring 96, with a second end of the suction spring 96 engaging the guide 90 of the discharge member body. As shown, the suction spring 96 may include a coil spring, although springs of other types and / or shapes are contemplated.

[0056] As shown in FIGS. 2A-2I, some embodiments of the valve assembly 42 also may include a discharge seat 100 configured to be at least partially received in the valve bore 68. The discharge seat 100 may at least partially define a discharge strike face 102 positioned to be contacted by the discharge member 38 when the discharge member 38 is in the closed discharge position, for example, as shown in FIGS. 2A and 2B. In some embodiments, the discharge member 38 may be positioned to move along a discharge axis of motion when reciprocating between the closed discharge position and the open discharge position. For example, in some embodiments, the discharge strike face 102 may lie in a plane substantially perpendicular to the discharge axis of motion. In some embodiments, the discharge strike face 102 may lie in a plane oblique relative to the discharge axis of motion.

[0057] As shown in FIGS. 2A-2I, the suction member body further may include a suction member head 104, and the suction member stem 92 may be connected to the suction member head 104. For example, the suction member stem 92 may be connected to the suction member head 104 via a threaded connection, an adhesive connection, a welded connection, and / or a connection formed via integral formation of the suction member stem 92 and the suction member head 104. For example, the suction member stem 92 may include a shoulder screw, for example, as shown in FIGS. 2A and 2B. The suction member head 104, in some embodiments, may present a suction closing surface 106, and the suction closing surface 106 may be at least partially convex and positioned to cooperatively engage the valve seat 74 of the discharge member head 80 when in the closed suction position. For example, the discharge member head 80 may at least partially define the valve seat 74, which may be at least partially concave, for example, and the valve seat 74 may present a radially inward facing frustoconical surface. In some embodiments, the suction closing surface 106 may be substantially complimentary to the frustoconical surface of the valve seat 74, thereby to close the discharge member passage 78 when the suction member 36 is in the closed suction position and open the discharge member passage 78 when the suction member 36 is in the open suction position.

[0058] In some embodiments, the discharge member 38 may further include a discharge seal 108 positioned to contact the discharge seat 100 when the discharge member 38 is in the closed discharge position, for example, as shown in FIGS. 2A and 2B. The discharge seal 108 may include an O-ring seal, although other seal types capable of providing a fluid seal between the discharge member head 80 and the discharge strike face 102 are contemplated. In some embodiments, the suction member 36 further may include a suction seal 110 positioned to contact the valve seat 74 when the suction member 36 is in the closed suction position, for example, as shown in FIGS. 2A and 2B. For example, the suction member head 104 may at least partially define a suction seal recess 112, and the suction seal 110 may be at least partially received in the suction seal recess 112, such that the suction seal 110 contacts the valve seat 74 at least partially defined by the discharge member 38 (e.g., the discharge member head 80) when the suction member 36 is in the closed suction position. The suction seal recess 112 and the suction seal 110 may be substantially annular.

[0059] As shown in FIGS. 2A-2I, in some embodiments, the fixed sleeve 66 may include a sleeve seal 114 positioned to provide a sliding fluid seal between the fixed sleeve 66 and the discharge member 38. In some embodiments, the sleeve seal 114 may include an O-ring seal, although other seal types capable of providing a fluid seal between the fixed sleeve 66 and the discharge member 38 are contemplated.

[0060] In some embodiments, as shown in FIGS. 2A-2I, the discharge member head 80 of the discharge member body may at least partially define a discharge closing surface 116, and the discharge closing surface 116 may at least partially define a discharge seal recess 118. The discharge seal 108 may be positioned in the discharge seal recess 118. In some embodiments, the discharge seal recess 118 and the discharge seal 108 may be substantially annular.

[0061] As explained with respect to FIGS. 2A-2I, in some embodiments, during operation of the pump 10, the suction member 36 may be in the closed suction position when the discharge member 38 is in the open discharge position, and the discharge member 38 may be in the closed discharge position when the suction member 36 is in the open suction position.

[0062] As described herein, in a least some embodiments, the fluid end 12 may include a fluid end block 20 having plunger bores 22 configured to receive respective packing assemblies 24 and respective reciprocating plungers 26, with each of the plunger bores 22 being axially aligned with (e.g., substantially parallel to) a respective valve bore 68 in which a respective valve assembly 42 is positioned, and with the valve assembly 42 operating as both a suction valve and a discharge valve. For example, as shown in FIG. 2A, in some embodiments, a plunger axis AP of the plunger bore 22 and a valve axis AV of the valve bore 68 may be substantially coaxial. In some embodiments, as shown in FIGS. 2A and 2B, the valve assembly 42 may include a valve seat (e.g., the discharge seat 100) for the discharge member 38, and the suction member 36 may use an axial face of the discharge member 38 as a valve seat (e.g., the valve seat 74). As shown in FIG. 2A, both the discharge member 38 and the suction member 36 are in respective closed conditions, with the suction member 36 being closed against the valve seat 74 provided by the discharge member 38 via the suction spring 96, and the discharge member 38 being closed against the discharge seat 100 via the discharge spring 86.

[0063] Applicant has recognized that, for at least some embodiments described herein, the plunger bore 22 and the valve bore 68 may be substantially axially aligned (e.g., substantially parallel to), resulting in elimination of an intersection between the valve bores and the respective plunger bores, thereby reducing or substantially eliminating cross-bore stress from the fluid end block 20. As a result, the stress associated with the fluid end block 20 may be reduced, which may permit the use of relatively more efficient carbon steel instead of relatively less efficient stainless steel. In some embodiments, the fluid end block 20 may comprise, or be formed of, carbon steel, which may be optionally coated and / or heat-treated to further protect the fluid end block 20. In some embodiments, the valve bore 68 may facilitate access to internal components in the fluid end 12 from the front of the fluid end 12, rather than from the opposite side of the fluid end, which is adjacent the power end 14. For example, in some embodiments, the valve assembly 42, including discharge member 38 and the suction member 36, may be removed from the front of the fluid end block 20. In some embodiments, it also may be possible to access, service, and / or remove the packing assembly 24 from the front of the fluid end block 20, which may be more ergonomically efficient for service personnel.

[0064] FIGS. 2C-2I show an example sequence of a plunger 26 traveling from top dead center (TDC) to bottom dead center (BDC) and back to TDC, with the example suction member 36 opening while the discharge member 38 is closed, the suction member 36 closing with the discharge member 38 opening, and both the suction member 36 and the discharge member closed when the plunger 26 begins to travel back toward BDC. As shown in FIG. 2C, the plunger 26 is traveling back toward BDC, as shown by arrow A. The suction created by the plunger 26 pulls the suction member 36 off the valve seat 74, overcoming the closing force provided by the suction spring 96. The discharge member 38 remains closed, with the discharge spring 86 holding the discharge member 38 against the discharge seat 100. With the suction member 36 open and the discharge member 38 closed, fluid is drawn into the suction port 30, through the discharge member passage 78 in the discharge member 38, and into the chamber 28 and plunger bore 22.

[0065] As shown in FIG. 2D, as the plunger 26 reaches BDC, with the suction member 36 remaining open and the discharge member 38 remaining closed, fluid continues to be drawn into the chamber 28 and plunger bore 22. FIG. 2E shows a close-up of the suction member 36 being open and the discharge member 38 remaining closed, with the discharge seat 100 modified relative to the discharge seat 100 shown in FIG. 2D. For example, in some embodiments, the discharge seat 100 may have a discharge strike face 102 that lies in a plane substantially perpendicular to the valve axis AV, for example, as shown in FIG. 2D, and in some embodiments, the discharge seat 100 may have a discharge strike face 102 that lies in a plane oblique relative to the valve axis AV, for example, as shown in FIG. 2E.

[0066] As shown in FIG. 2F, in some embodiments, as the plunger 26 changes direction after reaching BDC, as shown by arrow B, and travels toward TDC, the pressure of fluid being compressed in the plunger bore 22 and the chamber 28 by the plunger 26 drives the suction member 36 closed against the valve seat 74 provided by the discharge member 38, overcoming the force of the suction spring 96. The discharge member 38 also opens, the force of the discharge spring 86 being overcome by the pressure of the fluid. With the suction member 36 closed and the discharge member 38 open, fluid (e.g., the pressurized fluid 40 shown in FIG. 1), flows past the discharge member 38 and through the discharge port 32, as shown, and to a discharge manifold of the fluid end 12.

[0067] As shown in FIGS. 2G and 2H, in some embodiments, as the plunger 26 reaches TDC, the discharge member 38 remains open, the suction member 36 remains closed, and fluid continues to flow past the discharge member 38 and through the discharge port 32.

[0068] As shown in FIG. 2I, in some embodiments, as the plunger 26 reverses direction, as shown by arrow A, the suction created by the plunger 26 initially closes the discharge member 38, the discharge spring 86 overcoming the pressure in the chamber 28 and the plunger bore 22 and closing against the discharge seat 100, with the suction member 36 remaining closed until the suction force caused by the plunger 26 traveling toward BDC becomes sufficient to overcome the suction spring 96 force. Referring back to FIG. 2C, to repeat a pumping cycle, as the plunger 26 continues to travel toward BDC, the suction force overcomes the suction spring 96 force, and the suction member 36 opens, allowing fluid to be drawn into the suction port 30, through the discharge member passage 78, past the suction member 36, and into the chamber 28 and plunger bore 22.

[0069] FIG. 3 is a schematic partial side section view of an example fluid end 12 and example stay rods 120 for connecting the fluid end 12 to a power end 14, according to embodiments of the disclosure. In some embodiments, omission of relatively large vertical bores for each of the suction valves and discharge valves in a pump may provide the ability for the stay rods 120 connecting the fluid end 12 to the power end 14 to pass substantially completely through the fluid end block 20, for example, as shown in FIG. 3. For example, for pumps that include a suction valve bore receiving a suction valve and a discharge valve bore receiving a discharge valve, both of which bores are oriented perpendicular to the plunger bore, Applicant has recognized that the valve bores result in significantly reducing the material of the fluid end block available for facilitating connection to the power end. This may result in using studs mounted in, and extending from, the back side of the fluid (e.g., the side facing the power end). This may often render it difficult for service personnel to connect the fluid end to the power end, requiring access between the fluid end and the power end for assembling and correctly torquing fasteners that connect the fluid end to the power end.

[0070] As shown in FIG. 3, in some embodiments, omission of each of the bores for the respective suction valves and discharge valves in the fluid end block 20 may provide sufficient space and material of the fluid end block 20 for the stay rods 120 connecting the fluid end 12 to the power end 14 to pass through the fluid end block 20. This may result in relatively easier assembly of the fluid end 12 to the power end 14 for service personnel, providing service personnel with access from the front side of the fluid end 12 rather than the opposite power end side when assembling and torquing the stay rods 120. In addition, in some embodiments, the relatively longer stay rods 120 may inherently be more fatigue-resistant with correct preloading as compared to, for example, relatively shorter studs mounted in, and extending from, the back side of the fluid end.

[0071] As shown in FIG. 3, in some embodiments, the fluid end block 20 may include a plurality of stay rod bores 122 having respective longitudinal axes aligned with (e.g., substantially parallel to) the plunger axis AP of the plunger bore 22 and / or the valve axis AV of the valve bore 68. A first end of the stay rod bores 22, accessible from the front side of the fluid end block 20, may each include rod counter bores 124 dimensioned to receive one or more rod fasteners 126 (e.g., retainers and / or nuts) for securing a first end of each of the stay rods 120 to the fluid end block 20. In some embodiments, rod spacers 128 having respective rod passages 130 therethrough may be provided to space the power end 14 from the fluid end 12 and / or to secure the power end 14 to the fluid end 12. For example, as shown in FIG. 3, a first end of each of the rod spacers 128 may contact the power end side of the fluid end block 20 and extend toward the power end 14. A respective one of the stay rods 120 may pass through a respective rod passage 130 and substantially through the fluid end block 20 toward the front side of the fluid end block 20, opposite the power end 14, for securement by the one or more rod fasteners 126, which may be accessed from the front side of the fluid end 12. A second end (opposite the first end) of each of the stay rods 120 may be connected to the power end 14. For example, the second end of each of the stay rods 120 may include external threads for engaging internal threads of the power end 14, thereby to secure the second end of the respective stay rod 120 to the power end 14. In some embodiments, for example, as shown, the rod fasteners 126 may be tightened (e.g., torqued) from the front side of the fluid end 12 to place each of the stay rods 120 in tension, thereby to render the stay rods 120 relatively more fatigue-resistant. Further, in some embodiments, with the stay rods 120 being relatively longer than studs that extend from the back side of the fluid end 12 (e.g., the power end side), the stay rods 120 further may be inherently relatively more fatigue-resistant due to their relatively increased length.

[0072] FIG. 4A is a schematic side section view of another example fluid end 12 and another example valve assembly 42, with an example plunger 26 moving toward BDC during an example suction stroke, with an example suction member 36 in the open position and an example discharge member 38 in the closed position, according to embodiments of the disclosure. FIG. 4B is a schematic side section view of the example fluid end 12 and valve assembly 42 shown in FIG. 4A, with the plunger 26 moving from BDC toward TDC during an example discharge stroke, with the discharge member 38 in the open position and the suction member 36 in the closed position, according to embodiments of the disclosure.

[0073] As shown in FIG. 4A, in some embodiments, the sleeve body of the fixed sleeve 66 may at least partially define an exterior sleeve surface 132 and an interior sleeve surface 134. As shown, the exterior sleeve surface 132 and / or the interior sleeve surface 134 may be substantially cylindrical and extend longitudinally between a sleeve end cap 136 and a plunger opening 138 positioned to at least partially receive the plunger 126 or, in some embodiments, a piston. In some embodiments, the sleeve body of the fixed sleeve 66 may at least partially define a sleeve suction opening 140 positioned to allow fluid to be drawn through the suction port 30 when the suction member 36 is in the open suction position, for example, as shown in FIG. 4A, during a suction stroke of the plunger 26. The sleeve body of the fixed sleeve 66 further may at least partially define a sleeve discharge opening 142 positioned to allow fluid to flow to the discharge port 32 when the discharge member 38 is in the open discharge position, for example, as shown in FIG. 4B, during a discharge stroke of the plunger 26. The sleeve suction opening 140 may be positioned between the sleeve discharge opening 142 and the plunger opening 138, and / or the sleeve discharge opening 142 may be positioned between the sleeve end cap 136 and the sleeve suction opening 140. In some embodiments, the sleeve suction opening 140 and / or the sleeve discharge opening 142 may include two or more openings spaced circumferentially around the sleeve body of the fixed sleeve 66.

[0074] In some embodiments, as shown in FIGS. 4A and 4B, the discharge member body of the discharge member 38 may at least partially define an exterior discharge surface 144 and an interior discharge surface 146. The exterior discharge surface 144 and / or the interior discharge surface 146 may be substantially cylindrical and extend longitudinally between a discharge end cap 148 and a discharge member opening 150 positioned to at least partially receive the suction member 36. The discharge member body of the discharge member 38 may at least partially define a discharge member suction opening 152 positioned to allow fluid to be drawn through the suction port 30 and the sleeve suction opening 140 when the discharge member 38 is in the closed discharge position and the suction member 36 is in the open suction position. For example, as shown in FIG. 4A, the sleeve suction opening 140 and the discharge member suction opening 152, during the suction stroke, may be substantially longitudinally aligned, such that fluid may be drawn through the suction port 30 as the plunger 26 moves from TDC toward BDC. The discharge member body of the discharge member 38 further may at least partially define a discharge member discharge opening 154 positioned to allow fluid to flow to the discharge port 32 when the discharge member 38 is in the open discharge position and the suction member 36 is in the closed suction position. For example, as shown in FIG. 4B, the sleeve discharge opening 142 and the discharge member discharge opening 154, during the discharge stroke, may be substantially longitudinally aligned, such that fluid may be forced under pressure through the discharge port 32 as the plunger 26 moves from BDC toward TDC. In some embodiments, the discharge member suction opening 152 and / or the discharge member discharge opening 154 may include two or more openings spaced circumferentially around the discharge member body of the discharge member 38.

[0075] As shown in FIGS. 4A and 4B, in some embodiments, the suction member body of the suction member 36 may at least partially define an exterior suction surface 156 and an interior suction surface 158. The exterior suction surface 156 and / or the interior suction surface 158 may be substantially cylindrical and extend longitudinally between a first suction member end 160 and a second suction member end 162 positioned to at least partially receive the plunger 26 or, in some embodiments, a piston. The suction member body of the suction member 36 further may at least partially define a suction member suction opening 164 positioned to allow fluid to be drawn through the suction port 30, the sleeve suction opening 140, and / or the discharge member suction opening 152, for example, when the suction member 36 is in the open suction position and the discharge member 38 is in the closed discharge position, for example, as shown in FIG. 4A, during the suction stroke of the plunger 26. The suction member body of the suction member 36 also may at least partially define a suction member discharge opening 166 at the first suction member end 160 positioned to allow fluid to flow out the discharge member discharge opening 154 and the discharge port 32 under pressure when the discharge member 38 is in the open discharge position and the suction member 36 is in the closed suction position. The suction member suction opening 164 may be positioned between the first suction member end 160 and the second suction member end 162. In some embodiments, the suction member suction opening 164 may include two or more openings spaced circumferentially around the suction member body of the suction member 36.

[0076] As shown in FIGS. 4A and 4B, in some embodiments, the discharge member 38 may be at least partially positioned in the fixed sleeve 66, the suction member 36 may be at least partially positioned in the discharge member 38, and / or the suction member 36 may be positioned to at least partially receive the plunger 26, or, in some embodiments, a piston. In some embodiments, the discharge member suction opening 152 and the suction member suction opening 164 may be substantially longitudinally aligned when the discharge member 38 is in the closed discharge position and the suction member 36 is in the open suction position, thereby to allow fluid to be drawn through the suction port 30 in the fluid end block 20, for example, as shown in FIG. 4A. The sleeve discharge opening 142, the discharge member discharge opening 154, and the suction member discharge opening 166 may be substantially longitudinally aligned when the discharge member 38 is in the open discharge position and the suction member 36 is in the closed suction position, thereby to allow fluid to flow to the discharge port 32 in the fluid end block 20, for example, as shown in FIG. 4B.

[0077] As shown in FIGS. 4A and 4B, in some embodiments, the valve assembly 42 further may include a discharge cap seal 168 positioned to provide a fluid seal between a radially outer surface of the discharge end cap 148 and a radially inner surface of the sleeve body of the fixed sleeve 66 when the discharge member 38 is in the closed discharge position, for example, as shown in FIG. 4A. The valve assembly 42 further may include a valve seat seal 170 positioned adjacent the discharge member opening 150 to provide a fluid seal between the discharge member 38 and the suction member 36 when the discharge member 38 is in the open discharge position and the suction member 36 is in the closed suction position, for example, as shown in FIG. 4B. In some embodiments, the valve assembly 42 further may include a suction member seal 172 positioned to provide a fluid seal between the exterior suction surface 156 and the interior sleeve surface 134 of the sleeve body of the fixed sleeve 66.

[0078] As shown in FIGS. 4A and 4B, in some embodiments, the exterior sleeve surface 132 of the fixed sleeve 66 may include an exterior sleeve shoulder 176 positioned to contact an interior surface 178 of the valve bore 68 of the fluid end block 20. The exterior sleeve shoulder 176 may serve to longitudinally position the fixed sleeve 66 relative to the valve bore 68, while enabling the valve assembly 42, or at least portions thereof, to be removed via the access port 44, upon removal of the cover 46 from the access port 44 (see, e.g., FIG. 1).

[0079] As shown in FIGS. 4A and 4B, in some embodiments, the valve assembly 42 further may include a suction member spring 180 positioned to bias the suction member 36 in the closed suction position. For example, the interior sleeve surface 134 of the fixed sleeve 66 may include a spring retaining shoulder 182 positioned to contact a first end of the suction member spring 180, and a second end of the suction member spring 180 may be positioned to contact the second suction member end 162 of the suction member body of the suction member 36. As shown, the suction member spring 180 may include a coil spring, although springs of other types and / or shapes are contemplated.

[0080] In some embodiments, as shown in FIGS. 4A and 4B, the interior sleeve surface 134 of the sleeve body of the fixed sleeve 66 may include a sleeve shoulder 184, the exterior discharge surface 144 of the discharge body of the discharge member 38 may include a discharge body shoulder 186, and the sleeve shoulder 184 and the discharge body shoulder 186: (a) may be positioned to contact one another when the discharge member 38 is in the closed discharge position, for example, as shown in FIG. 4A, and (b) may be spaced from one another when the discharge member 38 is in the open discharge position, for example, as shown in FIG. 4B.

[0081] In some embodiments, the exterior suction surface 156 of the suction body of the suction member 36 may include a suction body shoulder 188, and the suction body shoulder 188 and the valve seat 74 of the discharge body: (a) may be positioned to contact one another when the suction member 36 is in the closed suction position, for example, as shown in FIG. 4B, and (b) may be spaced from one another when the suction member 36 is in the open suction position, for example, as shown in FIG. 4A.

[0082] In some embodiments, as shown in FIGS. 4A and 4B, the discharge body of the discharge member 38 and the suction body of the suction member 36 may be at least partially positioned within the sleeve body of the fixed sleeve 66. The suction body of the suction member 36 may be at least partially positioned within the discharge body of the discharge member 38.

[0083] In some embodiments, the sleeve body of the fixed sleeve 66 may be positioned to be fixed longitudinally relative to the valve bore 68 at least partially defined by the fluid end block 20. The discharge body of the discharge member 38 may be positioned to move longitudinally relative to the sleeve body of the fixed sleeve 66. The suction body of the suction member 36 may be positioned to move longitudinally relative to the sleeve body of the fixed sleeve 66, and / or the discharge body of the discharge member 38 may be positioned to move longitudinally relative to the suction body of the suction member 36, for example, as shown in FIGS. 4A and 4B.

[0084] As shown in FIGS. 4A and 4B, in some embodiments, the valve assembly 42 further may include one or more bore seals 190 positioned to be located between the exterior sleeve surface 132 of the sleeve body of the fixed sleeve 66 and the valve bore 68 at least partially defined by the fluid end block 20. The bore seal(s) 190 may be positioned to provide a fluid seal between the exterior sleeve surface 132 and the valve bore 68. The valve assembly 42 also may include a discharge seal 192 between the interior sleeve surface 134 of the sleeve body of the fixed sleeve 66 and the exterior discharge surface 144 of the discharge body of the discharge member 38. The discharge seal 192 may be positioned to provide a fluid seal between the interior sleeve surface 134 and the exterior discharge surface 144. The valve assembly 42 further may include a suction seal 194 between the interior discharge surface 146 of the discharge body of the discharge member 38 and the exterior suction surface 156 of the suction body of the suction member 36. The suction seal 194 may be positioned to provide a fluid seal between the interior discharge surface 146 and the exterior suction surface 156. The valve assembly 42 also may include a suction-to-sleeve seal 196 (e.g., a suction member seal 172) between the interior sleeve surface 134 of the sleeve body of the fixed sleeve 66 and the exterior suction surface 156 of the suction body of the suction member 36. The suction-to-sleeve seal may be positioned to provide a fluid seal between the interior sleeve surface 134 and the exterior suction surface 156. In some embodiments, the discharge seal 192, the suction seal 194, and or the suction-to-sleeve seal 196 provide(s) a sliding fluid seal.

[0085] As shown in FIGS. 4A and 4B, for example, in some embodiments, as the plunger 26 travels toward BDC during the suction stroke, as shown by the arrow A, the suction force pulls both the discharge member 38 and the suction member 36 toward the plunger 26, such that the discharge member suction opening 152 and the suction member suction opening 164 are axially or longitudinally aligned with the sleeve suction opening 140 of the fixed sleeve and the suction port 30, overcoming the force of the suction member spring 180, thereby to uncover the suction port 30, and allow fluid to be drawn through the suction port 30 and into the plunger bore 22 and chamber 28, for example, as shown in FIG. 4A. The discharge member 76, for example, the discharge end cap 148, in the position shown in FIG. 4A, prevents flow through the discharge port 32. As shown in FIG. 4B, for example, as the plunger 26 reverses direction and moves back toward TDC during the discharge stroke, in the absence of the suction force, the spring force provided by the suction member spring 180 and fluid pressure in the plunger bore 22 and chamber 28 push the discharge member 38 and the suction member 36 away from the plunger 26, covering the sleeve suction opening 140 of the fixed sleeve 66 with a portion of the suction member 36, thereby to close suction opening 140. Longitudinal movement of the discharge member 38 results in the discharge end cap 148 allowing fluid flow from the plunger bore 22 and chamber 28 to the discharge port 32, for example, as shown in FIG. 4B.

[0086] FIG. 5A is a schematic side section view of another example valve assembly 42 and an example plunger 26, with an example suction member 36 closed and an example discharge member 38 closed, according to embodiments of the disclosure. FIG. 5B is a schematic side section view of the valve assembly 42 shown in FIG. 5A, with the plunger 26 moving away from the TDC center position toward the BDC position during an example suction stroke, according to embodiments of the disclosure. FIG. 5C is a schematic side section view of the valve assembly 42 shown in FIG. 5A, with the plunger 26 moving further toward the BDC position during an example suction stroke, with the suction member 36 in an open position and the discharge member 38 in the closed position, according to embodiments of the disclosure. FIG. 5D is a schematic side section view of the valve assembly 42 shown in FIG. 5A, with the plunger 26 reaching the BDC position, the suction member 36 in the open position, and the discharge member 38 in the closed position, according to embodiments of the disclosure. FIG. 5E is a schematic side section view of the valve assembly 42 shown in FIG. 5A, with the plunger 26 moving away from the BDC position toward the TDC position during a discharge stroke, with the example suction member 36 returning to the closed position while the discharge member 38 remains in the closed position, according to embodiments of the disclosure. FIG. 5F is a schematic side section view of the valve assembly 42 shown in FIG. 5A, with the plunger 26 continuing to move toward the TDC position during the discharge stroke, the suction member 36 remaining in the closed position, and the discharge member 38 moving to the open position, according to embodiments of the disclosure.

[0087] As shown in FIGS. 5A-5F, in some embodiments, the valve assembly 42 may enhance control of fluid flow through a fluid end block 20 of a high-power pump 10 (see, e.g., FIG. 1) and may include a fixed sleeve 66 having a sleeve body configured to be positioned at least partially in the valve bore 68 (see, e.g., FIG. 2A) at least partially defined by a fluid end block 20. The sleeve body of the fixed sleeve 66 may be substantially annular and may at least partially define a discharge member seat 198 and a suction member seat 200. The valve assembly 42 further may include a discharge member 38 associated with the sleeve body of the fixed sleeve 66. The discharge member 38 may have a discharge member body at least partially defining a discharge surface 202. The discharge member body may be positioned to reciprocate relative to the sleeve body of the fixed sleeve 66 between a closed discharge position when the discharge surface 202 contacts the discharge member seat 198 (see, e.g., FIGS. 5A-5E) and an open discharge position when the discharge surface 202 is spaced from the discharge member seat 198 (see, e.g., FIG. 5F). The valve assembly 42 also may include a suction member 36 having a suction member body positioned to reciprocate relative to the sleeve body of the fixed sleeve 66 between a closed suction position when contacting the suction member seat 200 (see e.g., FIG. 5B) and an open suction position when the suction member body is spaced from the suction member seat 200 (see, e.g., FIG. 5C). In some embodiments, when the suction member 36 is in the open suction position, the first suction member end 160 is spaced from the suction member seat 200. The discharge member body of the discharge member 38 and the suction member body of the suction member 36 may be positioned to move in opposite longitudinal directions when the discharge member body moves to the closed discharge position and the suction member body moves to the closed suction position. In some embodiments, the discharge member 38 may be positioned to: (a) prevent flow of fluid to the discharge port 32 (see, e.g., FIGS. 1, 2A-2I, 4A, and 4B) in the fluid end block 20 when the discharge member 38 is in the closed discharge position, and (b) allow fluid to flow to the discharge port 32 in the fluid end block 20 when the discharge member 38 is in the open discharge position. In some embodiments, the suction member 36 may be positioned to: (a) prevent flow of fluid from the suction port 30 (see, e.g., FIGS. 1, 2A-2I, 4A, and 4B) into the chamber 28 in the fluid end block 20 when the suction member 36 is in the closed suction position, and (b) allow fluid to be drawn through the suction port 30 into the chamber 28 when the suction member 36 is in the open suction position.

[0088] In some embodiments, for example, as shown in FIGS. 5A-5F, the discharge member seat 198 and the suction member seat 200 may face in substantially opposite longitudinal directions. The valve assembly 42 further may include a discharge spring 204 biasing the discharge member 38 toward the closed discharge position and / or a suction spring 206 biasing the suction member 36 toward the closed suction position, for example, as shown in FIG. 5A. As shown, the discharge spring 204 and / or the suction spring 206 may include a coil spring, although springs of other types and / or shapes are contemplated.

[0089] In some embodiments, the sleeve body of the fixed sleeve 66 may at least partially define an exterior sleeve surface 132 and an interior sleeve surface 134. In some embodiments, the exterior sleeve surface 132 and the interior sleeve surface 134 may be substantially cylindrical and may extend longitudinally between the discharge member seat 198 and a plunger opening 138 positioned to at least partially receive the plunger 26 or a piston. The suction member body of the suction member 36 may at least partially define an exterior suction surface 156 and an interior suction surface 158. In some embodiments, the exterior suction surface 156 and the interior suction surface 158 may be substantially cylindrical and may extend longitudinally between a first suction member end 160 and a second suction member end 162 positioned to at least partially receive the plunger 26 or a piston. As shown in FIGS. 5A-5F, in some embodiments, the sleeve body of the fixed sleeve 66 may at least partially define a sleeve suction opening 140 positioned between the discharge member seat 198 and the plunger opening 138. As shown, in some embodiments, the exterior suction surface 156 of the suction member body may include an exterior suction portion 208 having a first outer diameter at the first suction member end 160 and an exterior shoulder portion 210 having a second outer diameter at the second suction member end 162, with the second outer diameter being greater than the first outer diameter. The difference between the first outer diameter and the second outer diameter may at least partially define a suction recess 212 (e.g., an annular recess) providing a flow passage, thereby to allow fluid to be drawn into the valve assembly 42 when the suction member 36 is in the open suction position (see, e.g., FIGS. 5C and 5D).

[0090] In some embodiments, as shown in FIGS. 5A-5F, the valve assembly 42 may further include the suction-to-sleeve seal 196 between the interior sleeve surface 134 and the exterior suction surface 156. The suction-to-sleeve seal 196 may provide a sliding fluid seal between the interior sleeve surface 134 and the exterior suction surface 156. The valve assembly 42 also may include a suction closing seal 214 at the first suction member end 160 of the suction member body and positioned to contact the suction member seat 200 of the sleeve body when the suction member 36 is in the closed suction position, for example, as shown in FIGS. 5A and 5B. In some embodiments, the suction closing seal 214 may include an O-ring seal, although other seal types are contemplated.

[0091] As shown in FIGS. 5A-5F, in some embodiments, the discharge member body of the discharge member 38 may include a discharge member head 80 and a discharge member stem 82 connected to the discharge member head 80. The discharge member head 80 may at least partially define the discharge surface 202, and the discharge surface 202 may face a direction generally opposite a direction in which the discharge member stem 82 extends. In some embodiments, the discharge member head 80 may at least partially define a spring contacting surface 216 opposite the discharge surface 202, and the discharge spring 204 may have a first end contacting the spring contacting surface 216 of the discharge member head 80, thereby to bias the discharge member 38 in the closed discharge position.

[0092] As shown in FIGS. 5A-5F, the discharge member 38 may be positioned to reciprocate along a longitudinal axis L, and the discharge member seat 198 may extend in a seat direction substantially perpendicular to the longitudinal axis or obliquely relative to the longitudinal axis L, for example, as shown.. For example, the discharge member head 80 may at least partially define the discharge surface 202, and the discharge surface 202 may be positioned to contact the discharge member seat 198 when the discharge member 38 is in the closed discharge position. In some embodiments, the discharge surface 202 may extend in a direction substantially parallel to (or slightly offset from parallel to) the seat direction of the discharge member seat 198.

[0093] In some embodiments, the sleeve body of the fixed sleeve 66 may at least partially define a sleeve body recess 218, and the suction member body of the suction member 36 may be at least partially positioned in the sleeve body recess 218. The suction member body may be positioned to reciprocate longitudinally in the sleeve body recess 218 between the open suction position and the closed suction position. In some embodiments, the suction member 36 may be in the closed suction position when the discharge member 38 is in the open discharge position, for example, as shown in FIG. 5F, thereby to allow fluid to flow from the chamber 28 to the discharge port 32 in the fluid end block 20 during a discharge stroke of the plunger 26. In some embodiments, the suction member 36 may be in the open suction position when the discharge member 38 is in the closed discharge position, for example, as shown in FIGS. 5C and 5D, thereby to allow fluid to be drawn through the suction port 30 into the chamber 28 during a suction stroke of the plunger 26.

[0094] As shown in FIGS. 5A-5F, in some embodiments, the suction member body of the suction member 36 may at least partially define a fluid chamber 220, and when the plunger 26 or a piston associated with the valve assembly 42 moves from the TDC longitudinal position toward the BDC longitudinal position, (a) a pressure drop in the fluid chamber 220 may at least partially cause the suction member body to move away from the suction member seat 200 (FIG. 5C), overcoming a suction spring force of the suction spring 206 acting on the suction member body and drawing fluid through the suction port 28 into the fluid chamber 220, and / or (b) a pressure drop in the fluid chamber 220 may at least partially cause the discharge member body to contact the discharge member seat 198. In some embodiments, the fluid chamber 220 may be at least partially coextensive with the chamber 28.

[0095] As shown in FIGS. 5A-5F, in some embodiments, when the plunger 26 or a piston associated with the valve assembly 42 moves from the TDC longitudinal position toward the BDC longitudinal position, pressure in an intake system of the high-power pump 10 acts against the exterior suction shoulder 210 of the exterior suction surface 156, thereby to at least partially cause the suction member body to move away from the suction member seat 200, overcoming a suction spring force of the suction spring 206 acting on the suction member body, and drawing fluid through the suction port 30 into the fluid chamber 220, for example, as shown in FIG. 5C. In some embodiments, when the plunger 26 or a piston associated with the valve assembly 42 moves from the TDC longitudinal position toward the BDC longitudinal position, pressure in a discharge system of the high-power pump 10 (see, e.g., FIG. 1) may act against the discharge member body of the discharge member 38, thereby to at least partially cause the discharge member body to contact the discharge member seat 198, for example, as shown in FIGS. 5B and 5C.

[0096] In some embodiments, when the plunger 26 or a piston associated with the valve assembly 42 reaches the BDC longitudinal position, (a) a pressure balance in the fluid chamber 220 may at least partially cause the suction member body to move toward the suction member seat 200, and / or (b) a pressure balance in the fluid chamber 220 may at least partially cause the discharge member body to contact the discharge member seat 198, for example, as shown in FIG. 5D.

[0097] In some embodiments, when the plunger 26 or a piston associated with the valve assembly 42 moves from the BDC longitudinal position toward the TDC longitudinal position: (a) a suction spring force of the suction spring 206 acting on the suction member body of the suction member 36 may at least partially cause the suction member body to move toward the suction member seat 200, thereby to prevent the drawing of fluid through the suction port 30 into the fluid chamber 220, and / or (b) a pressure increase in the fluid chamber 220 may at least partially cause the discharge member body of the discharge member 38 to move away from the discharge member seat 198, overcoming: (i) a discharge spring force of the discharge spring 204 acting on the discharge member body and allowing fluid in the fluid chamber 220 to pass through the discharge port 32, and / or (ii) pressure in a discharge system of the high-power pump 10 acting against the discharge member body, thereby to at least partially hold the discharge member body against the discharge member seat 198.

[0098] In some embodiments, as shown in FIGS. 5A-5F, when the plunger 26 or a piston associated with the valve assembly 42 reaches the TDC longitudinal position: (a) a pressure balance in the fluid chamber 220 may at least partially cause the suction member body of the suction member 36 to contact the suction member seat 200, thereby to prevent drawing fluid through the suction port 30 into the fluid chamber 220; (b) a suction spring force of the suction spring 206 acting on the suction member body may at least partially cause the suction member body to contact the suction member seat 200, thereby to prevent drawing of fluid through the suction port 32 into the fluid chamber 220; (c) a pressure balance in the fluid chamber 220 may at least partially cause the discharge member body to contact the discharge member seat 198, thereby to prevent fluid in the fluid chamber 200 from passing through the discharge port 32; and / or (d) a discharge spring force of the discharge spring 204 acting on the discharge member body may at least partially cause the discharge member body to contact the discharge member seat 198, thereby to prevent fluid in the fluid chamber 220 from passing through the discharge port 32.

[0099] With the plunger at BDC, as shown in FIG. 5A, the discharge member 38 is closed, with the discharge spring 204 holding the discharge member 38 against the fixed sleeve 66, which serves as a valve seat for the discharge member 38. In some embodiments, the diameter D of the valve assembly 42 may be sufficiently large to facilitate service and removal of the packing assembly (not shown in FIGS. 5A-5F) from the fluid end block (see, e.g., FIG. 2A).

[0100] As shown in FIG. 5B, in some embodiments, as the plunger 26 begins to move from TDC toward BDC, suction pressure begins to pull the suction member 36 toward the plunger 26 in direction A, with the discharge member 38 in the closed discharge position, held in the closed discharge position via the discharge spring 204 and discharge pressure in discharge passages, for example, of a discharge manifold. Until the force provided by the suction spring 206 is overcome by the suction pressure, the suction member 36 continues to close off the suction port 30.

[0101] As shown in FIG. 5C, in some embodiments, the plunger 26 is at an intermediate stroke point and continuing to move toward BDC. During the movement, the suction pressure becomes sufficient to overcome the force of the suction spring 206, allowing the suction member 36 to move toward the plunger 26 and open the suction port 30. As the suction port 30 opens, fluid is drawn into the chamber 28 (and / or the plunger bore 22) via the suction port 30 and suction created by the plunger 26 during the suction stroke.

[0102] As shown in FIG. 5D, as the plunger 26 reaches BDC, the suction port 30 remains open, with the suction member 36 compressing the suction spring 206, and fluid continues to be drawn into the chamber 28 (and / or the plunger bore 22).

[0103] FIG. 5E shows the plunger 26 reversing direction from the suction stroke to the discharge stroke, and moving from BDC toward TDC. The pressure balances in the plunger bore 22, and the suction member 36 moves in direction B, closing off the suction port 30 and preventing fluid flow through the suction port 30.

[0104] As shown in FIG. 5F, as the plunger 26 continues to move toward TDC during the discharge stroke, pressure in the plunger bore 22 builds and overcomes the force of the discharge spring 204 and the discharge pressure in the system, forcing the discharge member 38 away from the discharge member seat 198 provided by the fixed sleeve 66. The suction member 36 continues to close the suction port 30, the suction spring 206 holding the suction member 36 in a position to close off the suction port 30, thereby completing a pumping cycle.

[0105] Several example methods are described below, according to embodiments of the disclosure. The order in which the method steps are described is not intended to be construed as a limitation, and any number of the described method steps may be combined in any order and / or in parallel to implement the methods.

[0106] FIG. 6, FIG. 7, and FIG. 8 are a schematic side view diagrams showing example methods to enhance control of fluid flow through a fluid end 12 of a high-power pump 10 consistent with the example fluid ends 12 and / or valve assemblies 42 shown respectively in FIGS. 2A-2I, FIGS. 4A and 4B, and FIGS. 5A-5F, according to embodiments of the disclosure. According to some embodiments, a method to enhance control of fluid flow through a fluid end 12 of a high-power pump 10 may include positioning a valve assembly 42 in a valve bore 68 in a fluid end block 20 of the fluid end 12. The valve bore 68 may have a longitudinal valve axis AV extending in a first direction substantially parallel to a longitudinal plunger axis AP of a plunger bore 22. The valve assembly 42 may include a suction member 36 and a discharge member 38. The suction member 36 and the discharge member 38 may be positioned to reciprocate relative to the valve bore 68 in a direction substantially parallel to the first direction. The discharge member 38 may at least partially define a valve seat 74, and the suction member 36 may be positioned to reciprocate relative to the discharge member 38 between a closed suction position when the suction member 36 contacts the valve seat 74 and an open suction position when the suction member 36 is spaced from the valve seat 74, thereby to enhance control of fluid flow through the fluid end 12, for example, as described herein. In some embodiments of the method, the longitudinal valve axis AV may be substantially colinear relative to the longitudinal plunger axis AP.

[0107] In some embodiments of the method, the method further may include accessing the valve bore 68 from a first side of the fluid end block 20. The first side of the fluid end block 20 may be generally opposite a second side of the fluid end block 20 in which the plunger bore 22 is positioned. In some embodiments, the positioning of the valve assembly 42 in the valve bore 68 may include positioning a fixed sleeve 66 in the valve bore 68, and positioning the discharge member 38 in the fixed sleeve 66. The positioning of the valve assembly 42 further may include positioning the suction member 36 relative to the discharge member 38, and positioning the fixed sleeve 66, the discharge member 38, and the suction member 36 in the valve bore 68. For example, in some embodiments, the positioning of the valve assembly 42 in the valve bore 38 may include connecting the suction member 36 to the discharge member 38, positioning the discharge member 38 in the fixed sleeve 66, and inserting the fixed sleeve 66, the discharge member 38, and the suction member 36 into the valve bore 68.

[0108] In some embodiments of the method, the method further may include positioning a discharge spring 86 between the fixed sleeve 66 and the discharge member 38 to bias the discharge member 38 in a closed discharge position, for example, as described herein. In some embodiments, the method also may include positioning a suction spring 96 between the discharge member 38 and the suction member 36 to bias the suction member 36 in the closed suction position, for example, as described herein.

[0109] In some embodiments of the method, the method further may include inserting a discharge seat 100 into the valve bore 68. The discharge seat 100 may be positioned such that the discharge member 38: (a) prevents flow of fluid to a discharge port 32 in the fluid end block 20 when the discharge member 38 contacts the discharge seat 100, and (b) allows fluid to flow to the discharge port 32 in the fluid end block 20 when the discharge member 38 is spaced from the discharge seat 100, for example, as described herein.

[0110] According to some embodiments, a method to enhance control of fluid flow through a fluid end 12 of a high-power pump 10 may include positioning a valve assembly 42 in a valve bore 68 in a fluid end block 20 of the fluid end 12. The valve bore 68 may have a longitudinal valve axis AV extending in a first direction substantially parallel to a longitudinal plunger axis AP of a plunger bore 22. The valve assembly 42 may include a fixed sleeve 66 at least partially defining a suction member seat 200 and a discharge member seat 198, for example, as shown in FIGS. 5A-5F. The valve assembly 42 further may include a suction member 36 positioned to reciprocate relative to the valve bore 68 between: (a) a closed suction position when the suction member 36 contacts the suction member seat 200 and (b) an open suction position when the suction member 36 is spaced from the suction member seat 200. The valve assembly 42 also may include a discharge member 38 positioned to reciprocate relative to the valve bore 68 between: (a) a closed discharge position when the discharge member 38 contacts the discharge member seat 198 and (b) an open discharge position when the discharge member 38 is spaced from the discharge member seat 198, thereby to enhance control of fluid flow through the fluid end 12. In some embodiments of the method, the discharge member seat 198 and the section member seat 200 may face in opposite directions, the discharge member 38 and the suction member 36 may open via movement in opposite directions, and / or the discharge member 38 and the suction member 36 may close via movement in opposite directions, for example, as described herein.

[0111] FIG. 9 is a schematic side view diagram showing an example method of enhancing connection between a fluid end 12 and a power end 14 consistent with the example fluid end 12 and example stay rods 120 shown in FIG. 3, according to embodiments of the disclosure. According to some embodiments, a method to enhance connection between a fluid end 12 and a power end 14 of a high-power pump 10 may include passing each of a plurality of stay rods 120 through one of a plurality of stay rod bores 122 passing substantially through a fluid end block 20 from a power end side of the fluid end block 20 to a side of the fluid end block 20 opposite the power end side. The method also may include connecting a first end of each of the plurality of stay rods 120 to the fluid end block 20, and connecting a second end of each of the plurality of stay rods 120 to the power end 14, thereby to enhance connection of the fluid end 12 to the power end 14, for example, as described herein with respect to FIG. 3. In some embodiments of the method to enhance connection, the method further may include disconnecting each of the first ends of the plurality of stay rods 120 from the fluid end block 20, and separating the fluid end 12 from the power end 14, for example, during disassembly of the fluid end 12 from the power end 14.

[0112] According to some embodiments, a method to enhance assembly of a valve assembly 42 in a fluid end 12 of a high-power pump 10 may include inserting a discharge member 38 into a valve bore 68 in a fluid end block 20 of the fluid end 12, for example, in a manner consistent with FIGS. 6-8. The valve bore 68 may have a longitudinal valve axis AV extending in a first direction substantially parallel to a longitudinal plunger axis AP of a plunger bore 22. The method further may include positioning the discharge member 38 relative to the valve bore 68. The discharge member 38 may at least partially define a valve seat 74. The method also may include inserting a suction member 36 into the valve bore 68 and positioning the suction member 36 relative to the discharge member 38, such that the suction member 36 reciprocates relative to the discharge member 38 between a closed suction position when the suction member 36 contacts the valve seat 74 and an open suction position when the suction member 36 is spaced from the valve seat 74, thereby to enhance control of fluid flow through the fluid end 12, for example, as described herein.

[0113] In some embodiments of the method to enhance assembly, the method further may include inserting a discharge seat 100 into the valve bore 68 and positioning the discharge seat 100 relative to the valve bore 68, such that discharge member 38 reciprocates relative to the discharge seat 100 between a closed discharge position when the discharge member 38 contacts the discharge seat 100 and an open discharge position when the discharge member 38 is spaced from the discharge seat 100, thereby to enhance control of fluid flow through the fluid end 12. In some embodiments of the method to enhance assembly, the method also may include inserting a fixed sleeve 66 into the valve bore 68 and positioning the fixed sleeve 66 relative to the valve bore 68, such that the discharge member 38 and / or the suction member 36 is / are positioned in the fixed sleeve 66, thereby to reciprocate relative to the fixed sleeve 66. In some embodiments of the method to enhance assembly, the inserting of the fixed sleeve 66 into the valve bore 68 may include connecting the suction member 36 to the discharge member 38, positioning the discharge member 38 in the fixed sleeve 66, and inserting the fixed sleeve 66, the discharge member 38, and the suction member 36 into the valve bore 68. In some embodiments of the method to enhance assembly, the method also may include positioning a packing assembly 24 in the plunger bore 22 in a second side of the fluid end block 20. The second side may be generally opposite the first side, and the plunger bore 22 may have a longitudinal plunger axis AP extending substantially parallel to the first direction, for example, as described herein.

[0114] Having now described some illustrative embodiments of the disclosure, it should be apparent to those skilled in the art that the foregoing is merely illustrative and not limiting, having been presented by way of example only. Numerous modifications and other embodiments are within the scope of one of ordinary skill in the art and are contemplated as falling within the scope of the disclosure. In particular, although many of the examples presented herein involve specific combinations of method acts or system elements, it should be understood that those acts and those elements may be combined in other ways to accomplish the same objectives. Those skilled in the art should appreciate that the parameters and configurations described herein are exemplary and that actual parameters and / or configurations will depend on the specific application in which the systems, methods, and / or aspects or techniques of the disclosure are used. Those skilled in the art should also recognize or be able to ascertain, using no more than routine experimentation, equivalents to the specific embodiments of the disclosure. It is, therefore, to be understood that the embodiments described herein are presented by way of example only and that, within the scope of any appended claims and equivalents thereto, the disclosure may be practiced other than as specifically described.

[0115] This application claims priority to, and the benefit of U.S. Provisional Application No. 63 / 779,486, filed Mar. 28, 2025, titled “FLUID ENDS AND VALVE ASSEMBLIES FOR HIGH POWER PUMPS AND RELATED SYSTEMS AND METHODS,” the disclosure of which is incorporated herein by reference in its entirety.

[0116] Furthermore, the scope of the present disclosure shall be construed to cover various modifications, combinations, additions, alterations, etc., above and to the above-described embodiments, which shall be considered to be within the scope of this disclosure. Accordingly, various features and characteristics as discussed herein may be selectively interchanged and applied to other illustrated and non-illustrated embodiment, and numerous variations, modifications, and additions further may be made thereto without departing from the spirit and scope of the present disclosure as set forth in the appended claims.

Examples

Embodiment Construction

[0041]The drawings include like numerals to indicate like parts throughout the several views, the following description is provided as an enabling teaching of exemplary embodiments, and those skilled in the relevant art will recognize that many changes may be made to the embodiments described. It also will be apparent that some of the desired benefits of the embodiments described may be obtained by selecting some of the features of the embodiments without utilizing other features. Accordingly, those skilled in the art will recognize that many modifications and adaptations to the embodiments described are possible and may even be desirable in certain circumstances. Thus, the following description is provided as illustrative of the principles of the embodiments and not in limitation thereof.

[0042]The phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. As used herein, the term “plurality” refers to two or more items or compo...

Claims

1. A fluid end comprising:a fluid end block at least partially defining a valve bore, a suction port, and a discharge port; anda valve assembly at least partially positioned in the valve bore, thereby to enhance control of fluid flow through the fluid end block, the valve assembly comprising:a fixed sleeve having a sleeve body at least partially positioned in the valve bore, the sleeve body having a substantially annular shape and at least partially defining a sleeve recess;a discharge member at least partially positioned in the sleeve recess, the discharge member having a discharge member body at least partially defining a valve seat, the discharge member body positioned to reciprocate relative to the sleeve recess between a closed discharge position and an open discharge position; anda suction member having a suction member body positioned to reciprocate relative to the discharge member between a closed suction position when contacting the valve seat and an open suction position when spaced from the valve seat,the discharge member positioned to: (a) prevent flow of fluid to the discharge port in the fluid end block when the discharge member is in the closed discharge position, and (b) allow fluid to flow to the discharge port in the fluid end block when the discharge member is in the open discharge position, andthe suction member positioned to: (a) prevent fluid from being drawn through the suction port when the suction member is in the closed suction position, and (b) allow fluid to be drawn through the suction port when the suction member is in the open suction position, thereby to enhance control of fluid flow through the fluid end block.

2. The fluid end of claim 1, wherein:the valve bore is positioned in the fluid end block to at least partially receive one of a plunger or a piston reciprocating along a valve bore axis,the discharge member and the suction member are positioned to reciprocate along a common valve assembly axis, andthe valve bore axis and the valve assembly axis are substantially parallel relative to one another.

3. The fluid end of claim 2, wherein the valve bore axis and the valve assembly axis are substantially colinear relative to one another.

4. The fluid end of claim 1, wherein the discharge member body at least partially defines a discharge member passage, and wherein the suction member is at least partially positioned in the discharge member passage.

5. The fluid end of claim 1, wherein the discharge member body at least partially defines a discharge member head and a discharge member stem connected to the discharge member head, the discharge member stem at least partially positioned in the sleeve recess.

6. The fluid end of claim 1, wherein the valve assembly further comprises a discharge spring biasing the discharge member toward the closed discharge position, wherein the sleeve body at least partially defines a discharge spring recess to receive a first end of the discharge spring, and wherein a second end of the discharge spring engages the discharge member.

7. The fluid end of claim 1, wherein the discharge member body comprises a guide positioned in the discharge member passage, wherein the suction member body comprises a suction member stem at least partially positioned in the guide, and wherein the suction member stem is positioned to reciprocate relative to the guide when the suction member reciprocates between the closed suction position and the open suction position.

8. The fluid end of claim 7, wherein the valve assembly further comprises a discharge spring biasing the discharge member toward the closed discharge position, wherein the sleeve body at least partially defines a discharge spring recess receiving a first end of the discharge spring, and wherein a second end of the discharge spring engages the guide.

9. The fluid end of claim 7, wherein the valve assembly further comprises a suction spring biasing the suction member toward the closed suction position, wherein the suction member stem at least defines a suction spring boss engaging a first end of the suction spring, and wherein a second end of the suction spring engages the guide of the discharge member body.

10. The fluid end of claim 1, further comprising a discharge seat at least partially positioned in the valve bore, the discharge seat at least partially defining a discharge strike face positioned to be contacted by the discharge member when the discharge member is in the closed discharge position.

11. The fluid end of claim 1, wherein the suction member body comprises a suction member stem and a suction member head, wherein the suction member stem is connected to the suction member head.

12. The fluid end of claim 1, wherein the discharge member body comprises a discharge member head, wherein the discharge member head at least partially defines the valve seat, and wherein the valve seat is at least partially concave.

13. The fluid end of claim 12, wherein the suction member body comprises a suction member head, wherein the suction member head having a suction closing surface, and wherein the suction closing surface is at least partially convex and positioned to cooperatively engage the valve seat of the discharge member head when in the closed suction position.

14. The fluid end of claim 13, wherein the suction closing surface at least partially defines a suction seal recess, and wherein the suction member further comprises a suction seal positioned in the suction seal recess.

15. The fluid end of claim 1, wherein the sleeve body at least partially defines an exterior sleeve surface and an interior sleeve surface, wherein the exterior sleeve surface and the interior sleeve surface are substantially cylindrical and extend longitudinally between a sleeve end cap, and wherein a plunger opening is positioned to at least partially receive one of a plunger or a piston.

16. The fluid end of claim 15, wherein the sleeve body at least partially defines:a sleeve discharge opening positioned to allow fluid to flow to the discharge port when the discharge member is in the open discharge position, anda sleeve suction opening positioned to allow fluid to be drawn through the suction port when the suction member is in the open suction position.

17. The fluid end of claim 16, wherein the sleeve discharge opening is positioned between the sleeve end cap and the sleeve suction opening, and wherein the sleeve suction opening is positioned between the sleeve discharge opening and the plunger opening.

18. The fluid end of claim 15, wherein the discharge member body at least partially defines an exterior discharge surface and an interior discharge surface, the exterior discharge surface and the interior discharge surface being substantially cylindrical and extending longitudinally between a discharge end cap and a discharge member opening positioned to at least partially receive the suction member.

19. The fluid end of claim 18, wherein the discharge member body at least partially defines:a discharge member discharge opening positioned to allow fluid to flow to the discharge port when the discharge member is in the open discharge position and the suction member is in the closed suction position, anda discharge member suction opening positioned to allow fluid to be drawn through the suction port when the discharge member is in the closed discharge position and the suction member is in the open suction position.

20. The fluid end of claim 18, further comprising a discharge cap seal positioned to provide a fluid seal between a radially outer surface of the discharge end cap and a radially inner surface of the sleeve body when the discharge member is in the closed discharge position.

21. A fluid end comprising:a fluid end block at least partially defining a valve bore, a suction port, and a discharge port; anda valve assembly at least partially positioned in the valve bore, thereby to enhance control of fluid flow through the fluid end block, the valve assembly comprising:a fixed sleeve having a sleeve body positioned at least partially in a valve bore at least partially defined by a fluid end block, the sleeve body having a substantially annular shape and at least partially defining a discharge member seat and a suction member seat;a discharge member associated with the sleeve body, the discharge member having a discharge member body at least partially defining a discharge surface, the discharge member body positioned to reciprocate relative to the sleeve body between a closed discharge position when the discharge surface contacts the discharge member seat and an open discharge position when the discharge surface is spaced from the discharge member seat; anda suction member having a suction member body positioned to reciprocate relative to the sleeve body between a closed suction position when contacting the suction member seat and an open suction position when the suction member body is spaced from the suction member seat,the discharge member body and the suction member body positioned to move in opposite longitudinal directions when the discharge member body moves to the closed discharge position and the suction member body moves to the closed suction position,the discharge member positioned to: (a) prevent flow of fluid to a discharge port in the fluid end block when the discharge member is in the closed discharge position, and (b) allow fluid to flow to the discharge port in the fluid end block when the discharge member is in the open discharge position, andthe suction member positioned to: (a) prevent flow of fluid from a suction port in the fluid end block when the suction member is in the closed suction position, and (b) allow fluid to be drawn through the suction port when the suction member is in the open suction position, thereby to enhance control of fluid flow through the fluid end block.

22. The fluid end of claim 21, wherein:the valve bore is positioned in the fluid end block to at least partially receive one of a plunger or a piston reciprocating along a valve bore axis,the discharge member and the suction member are positioned to reciprocate along a common valve assembly axis, andthe valve bore axis and the valve assembly axis are substantially parallel relative to one another.

23. The fluid end of claim 22, wherein the valve bore axis and the valve assembly axis are substantially colinear relative to one another.

24. The fluid end of claim 21, wherein the discharge member seat and the suction member seat face in substantially opposite longitudinal directions.

25. The fluid end of claim 21, further comprising one or more of:a discharge spring biasing the discharge member toward the closed discharge position, ora suction spring biasing the suction member toward the closed suction position.

26. The fluid end of claim 21, wherein:the sleeve body at least partially defines a sleeve body recess,the suction member body is at least partially positioned in the sleeve body recess, andthe suction member body is positioned to reciprocate longitudinally in the sleeve body recess between the open suction position and the closed suction position.

27. The fluid end of claim 21, wherein:the sleeve body at least partially defines an exterior sleeve surface and an interior sleeve surface, the exterior sleeve surface and the interior sleeve surface having a substantially cylindrical shape and extending longitudinally between the discharge member seat and a plunger opening positioned to at least partially receive one of a plunger or a piston, andthe suction member body at least partially defines an exterior suction surface and an interior suction surface, the exterior suction surface and the interior suction surface having a substantially cylindrical shape and extending longitudinally between a first suction member end and a second suction member end positioned to at least partially receive one of a plunger or a piston.

28. The fluid end of claim 27, wherein the sleeve body at least partially defines a suction opening positioned between the discharge member seat and the plunger opening.

29. The fluid end of claim 27, wherein the exterior suction surface of the suction member body comprises:an exterior suction portion having a first outer diameter at the first suction member end, andan exterior shoulder portion having a second outer diameter at the second suction member end, the second outer diameter being greater than the first outer diameter.

30. The fluid end of claim 21, wherein the discharge member body comprises:a discharge member head, anda discharge member stem connected to the discharge member head, the discharge member head at least partially defining the discharge surface, and the discharge surface facing a direction generally opposite a direction in which the discharge member stem extends.

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