External Crosshead Lubrication for Reciprocating Pump Power Ends
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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 for the power end of a reciprocating pump, comprising a tank, pump, and manifold that pumps lubrication fluid into crosshead bores, with drain ports and a filter for fluid return, allowing for independent operation and serviceability without interfering with the power end.
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, filters) that can be manufactured separately and assembled externally to the power end. This segmentation reduces the complexity of the power frame manufacturing while ensuring reliable lubrication delivery through dedicated external components.
Solution Approach 2:
The lubrication system is extracted from the power end structure and positioned externally. The tank is mounted on the skid frame rather than being integrated into the power end, and the pump is positioned externally with separate fluid communication pathways. This extraction simplifies power frame manufacturing while maintaining lubrication reliability through dedicated external components.
2Reliability
If lubrication system components are integrated into the power end, then lubrication delivery is improved, but ease of repair and serviceability worsen
Solution Approach 1:
The tank, pump, and filter components are extracted from the power end and positioned externally on the skid frame. This allows these components to be serviced, repaired, or replaced independently without interfering with the power end operations, thereby improving ease of repair while maintaining reliable lubrication delivery through dedicated external pathways.
Solution Approach 2:
The manifold acts as an intermediary component that connects the externally positioned pump to the crosshead bores. This intermediary structure enables independent serviceability of the pump and tank while ensuring continuous lubrication delivery to the crossheads through the manifold's fluid distribution network.
3Ease of operation
If lubrication system is made portable on skid, then ease of operation and transportation are improved, but device complexity increases
Solution Approach 1:
The tank, pump, manifold, and filter components are merged into a single integrated assembly mounted on the skid frame. This unified configuration improves ease of operation and transportation by allowing the entire lubrication system to be moved as one unit, while the integration is achieved through standardized external connections that minimize overall system complexity.
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
This solution ensures consistent lubrication of crossheads, reducing wear and tear, enhancing the reliability and performance of the reciprocating pump, and allowing for easier maintenance and transportation of the lubrication system.
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.