Hydraulically Coupled Pump Cylinders for Fracturing Reliability
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Solution Overview
Problem
Current high pressure pump systems used for hydraulic fracturing of wellbores are prone to damage, operating failures, and reduced service life due to severe operating conditions, leading to reliability issues and increased maintenance costs.
Innovation Solution
A long stroke pump system comprising a power system, a drive system, and a frac fluid pumping assembly with mechanically decoupled but hydraulically coupled hydraulic cylinders, allowing for efficient energy transfer while facilitating easy maintenance and repair.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If hydraulic cylinders are mechanically coupled to transfer energy directly, then energy transfer efficiency is improved, but reliability is reduced due to increased wear and damage from severe operating conditions
Solution Approach 1:
The patent replaces direct mechanical coupling between hydraulic cylinders with a hydraulic coupling system. Instead of mechanical linkages that directly transfer force, the system uses hydraulic fluid to transmit energy from one cylinder to another through hydraulic lines, eliminating mechanical wear points while maintaining energy transfer efficiency.
Solution Approach 2:
The patent introduces hydraulic fluid as an intermediary medium between hydraulic cylinders. The hydraulic fluid acts as a mediator that transfers energy from one cylinder to another without requiring direct mechanical contact, thereby reducing wear and improving reliability while maintaining efficient energy transfer.
2Reliability
If hydraulic cylinders are mechanically decoupled to improve reliability, then component wear is reduced, but energy transfer efficiency may be compromised
Solution Approach 1:
The patent employs hydraulic principles to achieve energy transfer between mechanically decoupled cylinders. By using hydraulic fluid under pressure to transmit energy, the system maintains efficient energy transfer while avoiding direct mechanical coupling, thus resolving the contradiction between reliability and energy efficiency.
3Productivity
If pump system components are designed for high-pressure operation, then productivity is improved, but service life is reduced due to severe operating conditions
Solution Approach 1:
The patent divides the pump system into separate, independently maintainable components including hydraulically coupled cylinders, spool assemblies, and valve components. This segmentation allows individual parts to be replaced or maintained without replacing the entire system, extending overall service life while maintaining high-pressure operational capability for productivity.
Solution Approach 2:
The patent designs the system with replaceable components that can be easily discarded when worn and recovered when functional. This approach allows the system to maintain high productivity through continuous operation while extending overall service life by replacing only worn components rather than the entire system.
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 enhances reliability and reduces maintenance costs by allowing for longer service times and reduced wear on components, while maintaining efficient operation in high-pressure hydraulic fracturing environments.
Implementation Method 1
Each pair of hydraulic cylinders are hydraulically coupled because energy is transferred from one hydraulic cylinder to the other hydraulic cylinder through an operating hydraulic fluid
Data Source
AI summary
A new and improved long stroke pump system used for wellbore hydraulic fracturing operations. The pump system comprises a power system, a drive system, and a frac fluid pumping assembly. The frac fluid pumping assembly comprises one or more pairs of hydraulic cylinders that are mechanically decoupled from each other but are hydraulically coupled to each other.