Reciprocating Pump Linear Actuation for Lower Valve Wear
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Solution Overview
Problem
Reciprocating pumps experience high wear on valve assemblies due to a relatively short stroke length and non-uniform flow rates, leading to undesirable flow rate surges during operations like fracking.
Innovation Solution
The use of linear actuators to increase the stroke length of plungers and control fluid flow rates, reducing sealing events and providing a steady, uniform flow through the fluid end section.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a crankshaft is used to reciprocate the plunger, then the pump can operate at a higher cyclical rate, but the stroke length becomes relatively short which increases wear on valve assemblies
Solution Approach 1:
The patent replaces the traditional crankshaft mechanism with a linear actuator system. The linear actuator directly reciprocates the plunger without converting rotational motion, eliminating the mechanical constraints that limit stroke length. This substitution allows for longer stroke lengths while maintaining high cyclical rates, thereby reducing the number of sealing events and wear on valve assemblies.
2Speed
If a crankshaft provides relatively short stroke length, then the cyclical rate increases, but this causes a relatively large number of sealing events which increases wear
Solution Approach 1:
The linear actuator system allows for dynamic adjustment of stroke length and reciprocation speed. By optimizing these parameters, the system can achieve high cyclical rates with longer stroke lengths, reducing the frequency of sealing events. The dynamic control capability enables the pump to operate in an optimal range that minimizes wear while maintaining productivity.
3Productivity
If the pump operates with short stroke length, then the cyclical rate is high, but flow rate becomes non-uniform with surges
Solution Approach 1:
The linear actuator system incorporates control mechanisms that can sense and adjust reciprocation parameters in real-time. By monitoring flow rate and stroke characteristics, the control system can make adjustments to maintain uniform flow output, eliminating surges while preserving high cyclical operation. This feedback control ensures stable flow composition regardless of operating conditions.
Data Source
AI summary
A reciprocating pump assembly includes a fluid end section having a pressure chamber and a plunger bore that fluidly communicates with the pressure chamber. The reciprocating pump assembly includes a plunger configured to be held within the plunger bore of the fluid end section, and a linear actuator operatively connected to the plunger such that the linear actuator is configured to reciprocate the plunger within the plunger bore during operation of the reciprocating pump to thereby pump fluid through the fluid end section.