Packing Lubrication System for Hydraulic Fracturing Pumps
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Solution Overview
Problem
Hydraulic fracturing operations face increased equipment wear and maintenance challenges due to the use of abrasive proppant-laden fluids and the need for frequent refilling of individual lubricant reservoirs for hydraulic fracturing pumps, which can be hazardous and labor-intensive.
Innovation Solution
A packing lubrication system that supplies a steady, controlled flow of lubricant from a single remotely located reservoir to multiple hydraulic fracturing pumping units, using a lubricant pump, regulating valves, and a control system to monitor and adjust lubricant flow, reducing the need for frequent refilling and allowing remote operation and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual lubricant reservoirs are used for each hydraulic fracturing pump, then each pump can be lubricated independently, but frequent refilling is required which increases labor and downtime
Solution Approach 1:
The patent combines multiple individual lubricant reservoirs into a single common reservoir that serves multiple hydraulic fracturing pumps. This consolidation allows one reservoir to supply lubricant to multiple pumps through a shared distribution system, eliminating the need for frequent refilling of individual reservoirs and reducing downtime while maintaining reliable lubrication for each pump
2Adaptability or versatility
If individual lubricant reservoirs are used for each hydraulic fracturing pump, then lubrication can be provided to multiple pumps, but frequent refilling increases labor requirements
Solution Approach 1:
The patent merges multiple individual reservoirs into a single common reservoir that can serve multiple hydraulic fracturing pumps simultaneously. This single reservoir is equipped with multiple outlets that connect to different pumps via tubing, allowing one reservoir to provide lubrication to multiple pumps without requiring frequent refilling operations, thereby reducing labor requirements while maintaining broad lubrication coverage
3Loss of time
If a single common lubricant reservoir is used for multiple pumps, then refilling frequency is reduced, but lubricant flow control becomes more challenging
Solution Approach 1:
The patent introduces flow control devices (such as flow control valves or orifices) as intermediary components between the single common reservoir and each pump outlet. These flow control devices regulate the lubricant flow rate to each individual pump, ensuring that each pump receives the appropriate amount of lubricant even though they all draw from the same reservoir, thereby managing flow control complexity while reducing refilling frequency
4Productivity
If lubricant reservoirs are located close to the pumps, then lubricant delivery is efficient, but remote maintenance and access become difficult
Solution Approach 1:
The patent segments the lubrication system into a remotely located common reservoir and multiple distributed pump outlets. The reservoir is positioned in a remote, accessible location separate from the pumps, while tubing distributes lubricant to each pump. This segmentation allows the reservoir to be maintained and refilled remotely without requiring proximity to the pumps, improving maintenance accessibility while maintaining efficient lubricant delivery through the distributed tubing network
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 equipment wear, minimizes labor and downtime, and allows for continuous operation by providing a consistent lubricant supply to multiple pumps, enabling remote access and automatic monitoring and adjustment of lubricant flow.
Implementation Method 1
A packing lubrication system comprises a single lubricant reservoir, a single lubricant pump fluidically coupled to the lubricant reservoir
Implementation Method 2
at least two regulating valves fluidically coupled to the lubricant pump
Implementation Method 3
A hydraulic fracture pump may use a lubrication system to improve pump efficiency and to increase the useful life of the pump. The lubrication system may reduce component wear by lubricating pump components thereby reducing the grinding of components against one another.
Implementation Method 4
The lubrication system may also cool these pump components by absorbing and transferring heat from the pump components.
Data Source
AI summary
Automatic packing lubrication systems for lubricating a hydraulic fracturing pump unit and methods of lubricating hydraulic fracturing pump units. An example system includes a single lubricant reservoir, a single lubricant pump fluidically coupled to the lubricant reservoir, at least two regulating valves fluidically coupled to the lubricant pump, at least two divider blocks, wherein one divider block is individually fluidically coupled to one regulating valve. For every divider block there is a regulating valve fluidically coupled between the divider block and the single lubricant pump. The system further includes a control system connected to and configured to control the regulating valve.