Plunger-Actuated Valve Layout for Full-Open Proppant Flow
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional pumping systems for proppant fluids in fracturing operations often experience premature erosion and clogging due to incomplete valve opening, leading to reduced lifespan and increased maintenance costs.
Innovation Solution
The design incorporates a suction valve and discharge valve configuration that ensures maximum opening distance, with a latching component and seal and packing set to maintain centered positioning and prevent uneven wear, allowing for unobstructed fluid flow and minimized resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional valve configurations are used in proppant pumping systems, then the valves experience premature erosion and clogging, but the system structure remains simple
Solution Approach 1:
The patent implements a dynamic valve configuration where the plunger actively actuates both the suction and discharge valves through mechanical coupling. The suction valve is directly coupled to the plunger, causing it to open fully during the suction stroke, while the discharge valve is actuated through the plunger's motion during the discharge stroke. This dynamic actuation ensures complete valve opening, preventing proppant accumulation and clogging, thereby extending valve lifespan without requiring complex external actuation mechanisms.
Solution Approach 2:
The plunger serves multiple functions: it compresses the proppant slurry, actuates the suction valve to open, and actuates the discharge valve to open. By integrating valve actuation functionality into the plunger itself, the system eliminates the need for separate actuation mechanisms for each valve, reducing overall system complexity while improving reliability through consistent, plunger-driven valve operation.
2Reliability
If valves are kept closed with resistive force, then fluid flow is prevented, but incomplete opening leads to erosion and clogging
Solution Approach 1:
The valve system transitions from a static spring-loaded design to a dynamic plunger-actuated design. During the suction stroke, the plunger directly opens the suction valve to its full opening distance, maximizing fluid intake. During the discharge stroke, the plunger actuates the discharge valve to open completely, ensuring unobstructed proppant and fluid ejection. This dynamic full-opening mechanism prevents proppant accumulation that causes clogging and erosion, thereby improving both durability and flow efficiency.
Solution Approach 2:
The patent changes the operational parameter of valve opening distance from partial/incomplete to maximum/full opening. By ensuring valves open to their maximum extent during each stroke, the system eliminates the partial-opening condition that leads to proppant trapping, erosion, and clogging. This parameter change optimizes both fluid flow efficiency and valve durability simultaneously.
3Power
If plunger compresses fluid with high pressure, then proppant is pumped effectively, but uneven wear occurs on valve components
Solution Approach 1:
The patent employs asymmetric valve positioning and actuation mechanisms. The suction valve is directly coupled to the plunger, while the discharge valve is actuated through a different mechanical arrangement. This asymmetric configuration ensures that each valve opens to its maximum extent in its respective stroke, distributing wear more evenly across valve components by preventing localized proppant accumulation and ensuring consistent sealing surfaces during high-pressure operation.
Data Source
AI summary
A plunger actuated valve system is provided. The plunger actuated valve system includes a discharge valve, a stem extending from the discharge valve, and a suction valve coupled with the stem. The suction valve can be operable to abut against a plunger as the plunger translates in a first direction such that the suction valve is in a closed configuration. The suction valve includes a latching component operable to abut against a catch surface of the plunger when the plunger translates in a second direction opposite of the first direction such that the suction valve translates in the second direction.