Plenum Suction Manifold Radiused Ports Fracturing Pumps
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Solution Overview
Problem
High-pressure plunger-type pumps used in oil well hydraulic fracturing face premature valve failure and incomplete filling of plunger bores due to abrasive fluids, leading to fluid energy loss and increased stress on valve components, primarily caused by poorly designed suction manifolds that result in turbulence and friction.
Innovation Solution
A plenum-style suction manifold with a centrally located external intake connection and radiused ports, eliminating ducts and allowing bi-directional flow, reduces turbulence and friction, ensuring complete filling of the plunger bore and minimizing valve impact loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a traditional suction manifold design with ducts is used, then the manifold can supply fluid to suction valves, but turbulence and friction occur causing fluid energy loss and incomplete plunger bore filling
Solution Approach 1:
The patent applies radiused ports instead of sharp-cornered ducts in the suction manifold. The curved transitions eliminate flow separation and reduce turbulence, allowing complete plunger bore filling while maintaining fluid energy. This curvature principle directly addresses the energy loss and filling completeness contradiction.
2Productivity
If a non-centered external intake connection is used, then the manifold structure is simpler, but unequal fluid distribution to multiple suction valves occurs causing incomplete filling
Solution Approach 1:
The patent employs an asymmetric, non-centered external intake connection positioned to provide equal fluid distribution to multiple suction valves. This asymmetric positioning, combined with radiused ports, ensures equal flow distribution to all plungers while maintaining a relatively simple manifold structure, resolving the contradiction between productivity and device complexity.
3Reliability
If conventional suction manifold designs are used, then manufacturing is straightforward, but valve impact loads increase causing premature valve failure
Solution Approach 1:
The radiused ports with smooth curved transitions eliminate turbulence and reduce valve impact loads, extending valve component lifespan. The manufacturing process for these curved ports remains straightforward using conventional machining techniques, thus resolving the contradiction between reliability and ease of manufacture.
4Stress or pressure
If ducted suction manifold design is used, then fluid can be supplied to valves, but friction and turbulence cause stress on fluid end housing
Solution Approach 1:
The radiused ports create smooth fluid flow paths that eliminate turbulence and reduce friction, thereby decreasing stress on the fluid end housing while maintaining efficient fluid flow to the valves. This directly resolves the contradiction between stress reduction and flow efficiency.
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 design maintains high fluid energy, reduces valve impact loads, and extends the lifespan of valve components by minimizing fluid energy loss and stress on the fluid end housing, while being cost-effective and suitable for use on fracturing truck trailers.
Implementation Method 1
The design maintains high fluid energy, reduces valve impact loads, and extends the lifespan of valve components by minimizing fluid energy loss and stress on the fluid end housing
Implementation Method 2
A plenum-style suction manifold with a centrally located external intake connection and radiused ports, eliminating ducts and allowing bi-directional flow, reduces turbulence and friction
Data Source
AI summary
A fluid end assembly comprising: a housing, valves, seals, seats, springs, plungers, plunger packing, and other associated parts, paired with a suction manifold that facilitates fluid feeding through a centrally located external suction intake. The suction manifold of this invention is designed to preserve fluid energy that will ensure complete filling of the cylinder in extreme pumping conditions. The suction manifold utilizes a chamber design positioned immediately below the suction valves, eliminating all connecting ducts. The design of the manifold of this invention can be easily fabricated utilizing commercially available steel plate, pipe, and pipe fittings.