Common Plunger Linear Pump Layout to Cut Cyclic Stress
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Solution Overview
Problem
Large reciprocating pumps used in hydraulic fracturing experience undesirable cyclic stresses due to pressure fluctuations, leading to reduced component lifespan, and existing solutions like diesel engines are limited in power and efficiency.
Innovation Solution
A linear actuated pump with a centrally-disposed drive system and a common plunger configuration, eliminating pony rods, is powered by an electric motor, which reduces cyclic stresses and allows for larger, more efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a reciprocating pump with diesel engine is used, then high power and fluid flow are achieved, but cyclic stresses shorten component lifespan
Solution Approach 1:
The patent replaces the diesel engine (combustion engine) with an electric motor to drive the pump. This substitution eliminates the cyclic stresses caused by combustion engine operation while maintaining the ability to deliver high power and fluid flow. The electric motor provides smooth, continuous power delivery without the inherent cyclic variations that plague reciprocating engines, thereby extending component lifespan.
Solution Approach 2:
The patent employs a variable speed electric motor that can dynamically adjust its operating speed based on pump requirements. This dynamic control allows the system to optimize performance while eliminating the fixed cyclic stress pattern of reciprocating engines. The motor can operate at constant speed or variable speed as needed, providing flexibility that extends component life while maintaining high power output.
2Productivity
If a reciprocating pump with pony rods is used, then pumping function is achieved, but device complexity and weight increase
Solution Approach 1:
The patent removes the pony rod mechanism from the pump system. By eliminating this complex component and its associated linkages, the design achieves the same pumping function through a simpler direct-drive configuration. The electric motor directly drives the plunger assembly without requiring the intermediate pony rod mechanism, thereby reducing device complexity while maintaining productivity.
Solution Approach 2:
The patent merges the drive function and pumping function into a more integrated system. The electric motor directly couples with the plunger assembly, eliminating the need for separate pony rod linkages. This merging of functions reduces the number of components and simplifies the overall device structure while preserving the essential pumping capability.
3Power
If diesel engine is used for power, then high power output is achieved, but fuel costs and environmental impact increase
Solution Approach 1:
The patent replaces the diesel engine with an electric motor, substituting a combustion-based power source with an electric one. This substitution eliminates fuel consumption and associated costs while maintaining high power output capability. The electric motor can be powered by various sources including grid electricity, renewable energy, or battery systems, providing flexibility and eliminating the need for expensive diesel fuel.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The linear actuated pump design enhances operational efficiency, reduces equipment size and weight, and lowers fuel costs by utilizing electric power, thereby extending component life and reducing the number of units required at each site.
Implementation Method 1
A linear actuated pump with a centrally-disposed drive system and a common plunger configuration, eliminating pony rods, is powered by an electric motor
Implementation Method 2
As the plunger moves away from the fluid chamber, the pressure inside the chamber decreases, creating a differential pressure across an inlet valve, drawing the fracturing fluid through the inlet valve into the chamber
Implementation Method 3
the differential pressure across an outlet valve increases, which causes the outlet valve to open to allow the highly pressurized fracturing fluid to discharge through the outlet valve into the wellbore
Data Source
AI summary
A linear pump assembly includes a cylinder piston disposed in a generally tubular internal cylinder chamber defined within a cylinder housing having first and second ends, a first plunger-cylinder rod securely coupled to a first end of the cylinder piston and disposed in a first generally tubular internal plunger chamber defined within a first plunger housing in linear alignment with the cylinder housing, and a second plunger-cylinder rod securely coupled to a second end of the cylinder piston and disposed in a second generally tubular internal plunger chamber defined within a second plunger housing in linear alignment with the cylinder housing and the first plunger housing. First and second fluid ends are coupled to the first and second plunger housings respectively, the first and second fluid ends each housing a suction valve and a discharge valve.