Linear Well Service Pump Axial Stroke Design
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Solution Overview
Problem
Current well servicing pumps, particularly those used in fracturing operations, face limitations in stroke length due to size constraints and mechanical complexity, leading to increased cyclic fatigue and reduced operational efficiency under modern high-pressure, long-duration conditions.
Innovation Solution
The implementation of a well service pump system that utilizes a diesel engine, hydraulic drive gear box, open loop hydraulic pumps, and hydraulic ram cylinders, eliminating the need for a crankshaft and automatic transmission, allowing for longer stroke lengths and a more efficient, pulseless fluid delivery through axial alignment of hydraulic and plunger rods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the pump size is reduced to meet DOT requirements, then the width from manifold to manifold is reduced, but the stroke length is reduced
Solution Approach 1:
The patent reorients the pump components from a traditional right-angle configuration to an in-line configuration where the driveline, crankshaft, and discharge are aligned axially. This dimensional reorganization allows the pump to achieve a more compact footprint in the lateral direction (meeting DOT width requirements) while maintaining or increasing the stroke length in the axial direction through the extended crankshaft arrangement.
2Area of stationary object
If the stroke length is reduced, then the width from manifold to manifold is reduced, but the cyclic fatigue increases
Solution Approach 1:
By transitioning to an in-line configuration with extended axial stroke, the patent allows for longer stroke lengths that reduce the number of cycles required per unit of fluid pumped. This directly reduces cyclic fatigue on the fluid end components while achieving compact lateral dimensions through the reorganized component layout.
Solution Approach 2:
The patent replaces the traditional right-angle mechanical transmission system with a direct in-line mechanical arrangement. This substitution eliminates the need for complex intermediate transmission components and allows for a more efficient force transmission path that reduces mechanical stress and fatigue on critical components.
3Area of stationary object
If the pump size is reduced, then the width from manifold to manifold is reduced, but the mechanical complexity increases
Solution Approach 1:
The in-line configuration simplifies the mechanical arrangement by eliminating right-angle transmissions and complex intermediate components. The axial alignment of driveline, crankshaft, and discharge creates a more straightforward mechanical path that reduces overall system complexity while achieving compact lateral dimensions.
Solution Approach 2:
The patent merges previously separate functional components into a more integrated in-line arrangement. The driveline, crankshaft, and discharge are aligned and closely integrated, reducing the number of separate mechanical assemblies and simplifying the overall system architecture.
4Reliability
If the stroke length is increased, then the cyclic fatigue is reduced, but the width from manifold to manifold increases
Solution Approach 1:
The patent resolves this contradiction by orienting the increased stroke length in the axial direction rather than the lateral direction. The in-line configuration allows the crankshaft and connecting rods to extend axially, providing long stroke lengths that reduce cyclic fatigue while keeping the lateral width compact to meet DOT requirements.
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 configuration significantly reduces cyclic fatigue, extends fluid end life, and enables longer operational periods with fewer units, improving efficiency and reducing maintenance needs, while also minimizing weight and footprint.
Implementation Method 1
a hydraulic system which provides hydraulic fluid under pressure to a first hydraulic ram cylinder and a second hydraulic ram cylinder
Data Source
AI summary
A well service pump system supplies high pressure working fluid to a well. The pump system is a linear design which incorporates a diesel engine, a hydraulic drive gear box, open loop hydraulic Pumps, hydraulic ram cylinders, controls for the hydraulic system hydraulic cylinders, working fluid end cylinders and a coupling to connect the hydraulic cylinders and the working fluid ends. The engine powers the hydraulic system which, in turn, provides hydraulic fluid to operate the hydraulic ram cylinders. Each of the polished rods of the hydraulic ram cylinders is connected axially to a plunger rod end of a working fluid end cylinder. There is no crankshaft or automatic transmission required. The linear design allows for a longer plunger stroke length while still allowing highway transport on a truck or skid.