Sensor-Controlled Frac Pump Discharge Valve Timing to Reduce Wear
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Solution Overview
Problem
Existing valve designs in pumps used for downhole operations suffer from issues such as incomplete opening due to low pressure differentials, leading to increased wear and frequent opening/closing, which exacerbates valve and seat wear.
Innovation Solution
A pump system with a plunger and fluid end that includes position and pressure sensors, coupled with a controller to operate discharge valves based on sensor data, ensuring precise timing of valve opening and closing to minimize wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a spring-operated valve is used to control fluid flow, then the valve can automatically open when pressure differential is sufficient, but the valve may not fully open due to low pressure differential causing increased wear and frequent opening/closing
Solution Approach 1:
The system uses position sensors to detect plunger position and pressure sensors to monitor pressure differentials, feeding this information to a controller that actuates the discharge valve accordingly. This feedback mechanism ensures the valve opens fully when needed and remains closed when pressure differential is insufficient, preventing wear from partial opening and frequent cycling.
Solution Approach 2:
The patent replaces the purely mechanical spring-operated valve system with an automated control system using position sensors, pressure sensors, and an actuator. This substitution allows for more precise control of valve opening based on actual plunger position and pressure conditions, eliminating the wear problems associated with spring-operated valves that cannot fully open under low pressure differential.
2Productivity
If the valve opens and closes frequently due to low pressure differential, then fluid flow can be maintained, but wear on the valve or valve seat increases significantly
Solution Approach 1:
The controller receives continuous feedback from position sensors and pressure sensors to determine the optimal timing for valve actuation. By monitoring the actual plunger position and pressure differential, the system avoids unnecessary valve opening/closing cycles that would occur with fixed pressure thresholds, thereby extending valve service life while maintaining fluid flow continuity.
Solution Approach 2:
The system actuates the discharge valve in advance based on predicted plunger position and pressure conditions. By using position sensors to anticipate when sufficient pressure differential will be achieved, the valve can be opened proactively before the plunger reaches the point where pressure differential becomes sufficient, preventing frequent reactive opening/closing cycles and reducing wear.
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 system reduces wear on valves by maintaining optimal valve positions and pressures, thereby extending valve life and reducing maintenance costs.
Implementation Method 1
The pump includes at least one of a position sensor for measuring a position of the plunger
Implementation Method 2
a pressure sensor for measuring a pressure of the crossbore, the inlet bore, or the outlet bore
Data Source
AI summary
A pump includes a power end and a fluid end coupled to the power end. The power end includes a plunger, and the fluid end includes a crossbore in selective fluid communication with inlet and outlet bores. A suction valve controls fluid communication between the inlet bore and the crossbore, and a discharge valve controls fluid communication between the outlet bore and the crossbore. An actuation device is used to move the discharge valve between an open position and a closed position. A position sensor measures a position of the plunger. A pressure sensor measures a pressure of the crossbore, the inlet bore, or the outlet bore. A controller operates the discharge valve based on data from at least one of the position sensor or the pressure sensor.