Centrally Fed Suction Manifold for 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 fluid filling due to abrasive slurries, leading to turbulence and frictional losses in traditional suction manifold designs, which result in fluid energy loss and high valve impact loads.
Innovation Solution
A plenum-style suction manifold with a centrally located external intake connection and radiused ports, allowing bi-directional flow and minimizing turbulence and friction, is designed to maintain high fluid energy and ensure complete filling of the plunger bore, eliminating the need for costly castings and optimizing alignment for ease of installation on fracturing truck trailers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a traditional suction manifold design with end-located external intake connection is used, then the manifold structure is simpler and easier to manufacture, but fluid energy loss increases due to turbulence and frictional losses
Solution Approach 1:
The manifold is divided into multiple flow paths with separate intake connections at each end, allowing independent optimization of each flow path. This segmentation enables fluid to be drawn from both ends simultaneously, reducing the length of individual flow paths and minimizing frictional losses while maintaining a relatively simple overall structure.
Solution Approach 2:
The design transitions from a single-end intake configuration to a dual-end intake configuration, effectively adding spatial dimensionality to the fluid distribution system. This dimensional change allows fluid to enter from multiple locations, creating parallel flow paths that reduce turbulence and energy loss without significantly increasing structural complexity.
2Productivity
If abrasive slurries are pumped at high pressure, then productivity increases, but valve failure occurs prematurely due to metal wear and fatigue
Solution Approach 1:
The valve sealing surfaces are given special attention with optimized geometry and material properties. The suction and discharge valves feature enhanced sealing surfaces that are specifically designed to resist wear from abrasive slurries, allowing high-pressure pumping while extending valve service life through localized quality enhancement rather than uniform design changes.
Solution Approach 2:
The manifold design incorporates features that equalize fluid distribution to all plungers, preventing incomplete filling that would cause excessive valve impact loads. By cushioning against uneven fluid distribution and impact loads before they occur, the system maintains high productivity while reducing premature valve failure from metal fatigue.
3Ease of manufacture
If the external intake connection is located at one end of the manifold, then manufacturing is easier, but incomplete filling of plunger bore occurs leading to high valve impact loads
Solution Approach 1:
The single intake connection is segmented into multiple intake connections located at different ends of the manifold. This segmentation allows each plunger to receive fluid from the nearest intake connection, ensuring uniform fluid distribution and complete plunger bore filling while maintaining manufacturing simplicity through modular construction of the dual-end configuration.
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 solution significantly reduces fluid energy loss and turbulence, preventing premature valve failure and ensuring complete filling of the plunger bore, thereby enhancing the operational efficiency and longevity of high-pressure plunger-type pumps.
Implementation Method 1
minimizing turbulence and friction
Implementation Method 2
minimizing 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.