Reciprocating Pump Integrated Skid Support and Crosshead Assembly
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Solution Overview
Problem
High-pressure pumps used in the oil and gas industry face significant wear and tear due to extreme operating conditions, leading to frequent maintenance and replacement of components, which results in machine downtime and increased production costs, and existing support structures often cause installation issues such as deflection and misalignment.
Innovation Solution
The design incorporates an integrated skid support structure, a single forging/casting structure for the noseplate and crosshead guide tubes, and a wear-coated crosshead, along with a unified stay rod assembly to enhance structural integrity, reduce maintenance needs, and improve alignment, using external fillet welds for assembly and eliminating separate bronze sleeves and shoes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate bronze sleeves and shoes are used in the crosshead assembly, then ease of manufacture is improved, but device complexity and maintenance requirements increase
Solution Approach 1:
The patent combines multiple separate components (crosshead, bronze sleeves, and shoes) into a single integrated crosshead assembly. The crosshead is provided with integrated wear surfaces that eliminate the need for separate bronze sleeves and shoes, thereby reducing device complexity while maintaining manufacturability through a unified structure.
2Ease of operation
If separate stay rods and tubes are used to connect power end and fluid end, then ease of assembly is improved, but reliability and alignment precision deteriorate due to deflection and misalignment
Solution Approach 1:
The patent integrates the stay rods and tubes into a unified stay rod assembly that is directly connected to the integrated crosshead and pump body. This merging of components eliminates misalignment issues between separate parts while maintaining ease of assembly through a streamlined connection system.
3Ease of manufacture
If conventional separate components are used, then ease of manufacture is improved, but maintenance frequency increases due to wear and tear in extreme conditions
Solution Approach 1:
The integrated crosshead assembly with unified wear surfaces reduces the number of separate components that can wear out. By combining the crosshead, sleeves, and shoes into one structure, the patent reduces maintenance frequency as fewer separate parts are subject to wear and tear in extreme operating conditions.
4Adaptability or versatility
If multiple separate components are used, then manufacturing flexibility is improved, but installation time increases due to alignment and assembly requirements
Solution Approach 1:
The patent reduces installation time by integrating multiple components into unified structures. The integrated crosshead assembly and stay rod assembly eliminate the need for complex alignment procedures between separate parts, thereby speeding up installation while maintaining manufacturing flexibility through modular design.
Data Source
AI summary
A reciprocating pump includes a frame for a power end, a skid support structure integrally formed at a base of the power end frame to provide proper support and rigidity for the pump power end, where the integral skid support structure has a plurality of struts forming a series of chambers.