Fracturing Pump Screw Mechanism Reducing Valve Fatigue
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Solution Overview
Problem
Conventional fracturing fluid pumps experience rapid fatigue and high maintenance needs due to extreme pressures and abrasive/corrosive fracturing fluids, leading to inefficiencies and increased costs in fracturing operations.
Innovation Solution
A fracturing pump assembly with a hydraulic cylinder and a screw mechanism that converts rotational motion into linear actuation of a compression member, reducing valve cycles and maintenance requirements by using a screw rod to pressurize fracturing fluid for delivery to a borehole.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If conventional mechanical pumps with short strokes and high cycles per minute are used to pump fracturing fluid at high pressure, then the required high pressure is achieved, but the pumps experience rapid fatigue and require frequent maintenance
Solution Approach 1:
The patent applies the dynamics principle by transitioning from a conventional reciprocating pump mechanism to a continuous rotary screw mechanism. The screw mechanism rotates continuously to pressurize and move the fracturing fluid, eliminating the repeated start-stop cycles and valve operations of traditional pumps. This continuous rotational motion reduces mechanical stress cycles and fatigue on the system components, thereby improving reliability while maintaining the required high pressure output.
2Productivity
If the number of pressure cycles is increased to reduce service life, then more fracturing fluid can be pumped, but wear and tear on mechanical components increases
Solution Approach 1:
The patent replaces the traditional reciprocating mechanical pump system with a rotary screw mechanism. This substitution eliminates the need for repeated valve operations and reciprocating motions that cause wear. The screw mechanism uses continuous rotational motion to pressurize and transport the fracturing fluid, significantly reducing mechanical wear and tear on components while maintaining high productivity in terms of fluid volume pumped.
3Stress or pressure
If conventional intensifiers with multiple cylinders and return rams are used, then the pumping system can achieve required pressure, but the device complexity and mechanical maintenance requirements increase
Solution Approach 1:
The patent merges multiple separate mechanical components into a single integrated screw mechanism. Instead of using multiple cylinders, return rams, and associated valve systems, the invention employs one continuous rotary screw that performs both the pressurizing and fluid transport functions. This consolidation simplifies the device structure, reduces the number of moving parts, and lowers maintenance requirements while achieving the necessary pressurizing capability.
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 extends the service life of pumping systems by reducing valve cycles and maintenance, enhancing the efficiency and cost-effectiveness of fracturing operations by minimizing wear and tear on mechanical components.
Implementation Method 1
a screw mechanism that converts rotational motion into linear actuation of a compression member, reducing valve cycles and maintenance requirements by using a screw rod to pressurize fracturing fluid
Implementation Method 2
The compression member separates a compression area of the hydraulic cylinder filled with a first fluid from an area of the hydraulic cylinder void of the first fluid and pressurizes the first fluid within the compression area via linear actuation of the compression member
Data Source
AI summary
A fracturing pump assembly includes an intensifier including a hydraulic cylinder, a compression member arranged within the hydraulic cylinder and a rotatable member, wherein the compression member is linearly actuated within the hydraulic cylinder by rotation of the rotatable member.