External Crosshead Lubrication for Reciprocating Pump Power Frames
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Solution Overview
Problem
Reciprocating pumps used in oilfield operations face performance and reliability issues due to inadequate lubrication of crossheads within their bores, which is time-consuming and labor-intensive to address, and often requires inefficient and unreliable delivery of lubrication fluid.
Innovation Solution
An external, self-contained integrated lubrication system is introduced, comprising a tank, pump, and manifold that pumps lubrication fluid into crosshead bores, with a skid-mounted setup allowing independent operation and serviceability without interfering with the power end, and a power frame with parallel-spaced rib plates to support the crosshead block, reducing weld joints and enhancing structural support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an integrated lubrication system is built into the power end, then lubrication reliability is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The lubrication system is segmented into independent components (tank, pump, manifold, nozzles) that can be manufactured separately and assembled externally on the power end. This segmentation reduces the complexity of manufacturing the power frame itself while ensuring reliable lubrication through a dedicated, modular system.
Solution Approach 2:
The lubrication system is extracted from the power end structure and implemented as an external, add-on system. This takes out the complexity of integrating lubrication components into the power frame manufacturing process while maintaining the reliability benefits of a dedicated lubrication system.
2Device complexity
If traditional lubrication delivery methods are used, then device complexity is reduced, but lubrication effectiveness and reliability deteriorate
Solution Approach 1:
A manifold with multiple nozzles acts as an intermediary device that distributes lubrication fluid from a single pump to multiple crosshead bores simultaneously. This intermediary structure ensures reliable lubrication delivery to all crossheads without requiring complex individual pumping systems for each bore.
Solution Approach 2:
The system uses hydraulic principles to deliver lubrication fluid under pressure through a manifold and nozzles to the crosshead bores. This hydraulic approach ensures reliable lubrication delivery while keeping the overall system relatively simple compared to alternative mechanical delivery methods.
3Strength
If the power frame is manufactured as a single integrated component, then structural strength is improved, but manufacturing time and labor intensity increase
Solution Approach 1:
The power frame is segmented into modular components that can be manufactured using standard machining processes and then assembled. This segmentation maintains the structural strength of the power frame while dramatically improving manufacturing efficiency by allowing parallel production of multiple components and reducing labor intensity.
4Reliability
If the lubrication system is integrated into the power end, then lubrication reliability is improved, but ease of maintenance deteriorates
Solution Approach 1:
The lubrication system components (tank, pump, manifold) are extracted from the power end and mounted separately on the skid. This extraction maintains reliable lubrication delivery while dramatically improving ease of maintenance, as components can be accessed, serviced, or replaced without disassembling the power end structure.
Solution Approach 2:
The lubrication system is designed with dynamic accessibility, allowing components to be easily accessed and serviced by positioning them externally on the skid rather than integrating them into the fixed power end structure. This dynamic arrangement improves maintenance ease while maintaining operational reliability.
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 solution ensures effective lubrication of crossheads during operation, reducing wear and tear, improving pump performance and reliability, and allowing for easier maintenance and transportation of the reciprocating pump assembly.
Implementation Method 1
a pump in fluid communication with the tank and each of the bores; wherein the pump is operable to pump lubrication fluid from the tank and into each of the bores
Implementation Method 2
so that the crossheads are lubricated as they reciprocate within their respective bores
Data Source
AI summary
An apparatus according to which a power end of a reciprocating pump assembly includes a block having bores formed therethrough, and crossheads disposed in the bores and adapted to reciprocate therein. A lubrication pump is in fluid communication with the bores. The pump is operable to pump lubrication fluid into each of the bores so that the crossheads are lubricated as they reciprocate within their respective bores. In another aspect, a power end includes a crosshead block and a power frame connected thereto, the frame including rib plates and supporting the crosshead block. In yet another aspect, a method includes casting a crosshead block; fabricating rib plates; connecting the rib plates to form a frame; and connecting the cast crosshead block to the frame. In some embodiments, the power ends may be used in oilfield operations such as, for example, the cementing, acidizing, or fracturing of a subterranean wellbore.