Linear FRAC Pump Safety Deflector for Seal-Failure Fluid Venting
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Solution Overview
Problem
Existing frac pumps face plunger packing seal failures under high pressure, leading to harsh frac fluid escape and potential damage to the pump, especially in linear configurations where the fluid and drive systems are aligned.
Innovation Solution
A safety deflector with an angled conical surface is integrated between the fluid end and drive system, deflecting high-pressure frac fluid away from the drive system and venting it to the atmosphere, thereby protecting the drive system from damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a chevron-style packing seal is used on the plunger to create a robust seal against high-pressure frac fluid, then sealing effectiveness is improved, but the seal has limited life and may fail during service pumping operations
Solution Approach 1:
A deflector is introduced as an intermediary component between the plunger packing seal and the drive system. When the packing seal fails, the deflector intercepts the high-pressure frac fluid jet and redirects it away from the drive system, preventing direct contact and damage. This mediator approach allows the system to tolerate seal failure without catastrophic consequences.
Solution Approach 2:
The deflector is pre-positioned in the pump assembly before operation begins. This advance preparation ensures that if the packing seal fails at any point during service, the protective deflection mechanism is already in place to redirect the escaping fluid, cushioning the drive system from potential damage.
2Ease of operation
If the plunger packing seal fails under high pressure, then the harsh frac fluid escapes, but this creates potential damage to the pump drive system
Solution Approach 1:
The deflector serves as a protective intermediary that stands between the escaped frac fluid and the drive system. It intercepts the harmful fluid jet and redirects it to a safe path, allowing continuous operation to proceed without interruption while protecting the drive system from damage.
Solution Approach 2:
The deflector takes the harmful escaped frac fluid and converts its potentially damaging direct impact into a controlled redirected flow. By changing the fluid's trajectory, the system transforms a harmful situation (fluid escaping toward the drive system) into a benign outcome (fluid redirected away from critical components).
3Productivity
If a linear pump configuration is used where the fluid end and drive system are in linear alignment, then pumping efficiency is improved, but the risk of damage to the power end due to packing seal failure is even higher
Solution Approach 1:
In the linear pump configuration where the fluid end and drive system are aligned, the deflector is strategically positioned to intercept any frac fluid that escapes from the plunger packing seal. This intermediary component breaks the direct linear pathway that would otherwise allow escaped fluid to damage the drive system, enabling the efficient linear configuration to operate safely.
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 deflector effectively prevents frac fluid from reaching the drive system, safeguarding it from damage even in the event of packing seal failure, ensuring operational safety and integrity.
Implementation Method 1
A safety deflector with an angled conical surface is integrated between the fluid end and drive system, deflecting high-pressure frac fluid away from the drive system and venting it to the atmosphere
Data Source
AI summary
A linear pump includes a centrally-disposed drive system and a plunger having a center portion coupled to the drive system, and first and second fluid ends disposed at the first and second ends of the plunger. The pump further includes first and second packing seals each being disposed about the plunger to isolate fluids within the respective first and second fluid ends. First and second adapters are disposed at an interface between the drive system and respective first and second fluid ends, each adapter incorporating an angled deflector configured to deflect and redirect high-pressure fluids escaping past the respective packing seal toward the drive system.