Suction Valve Control for Rapid Fluid Pump Unloading

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Solution Overview

Problem

Large pumps used in oil and gas extraction face challenges in rapidly terminating discharge flow during overpressure or sand off events due to the prime mover's slow response, leading to potential damage and adverse consequences.

Innovation Solution

A suction valve control system that maintains the suction valve in an open position during discharge cycles, controlled by a controller, allowing fluid to be pumped back into the suction manifold instead of pressurizing it for discharge, thereby facilitating rapid unloading of the prime mover.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the prime mover is used to drive the pump during normal operation, then the pump can maintain continuous discharge flow, but the prime mover takes too long to slow down when rapid termination is needed

Engineering Contradiction:

Improvecontinuous discharge flowVSAvoidtime to terminate discharge flow

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The pump system is segmented into independent suction valves that can be controlled separately from the prime mover operation. Each suction valve can be independently actuated to open or close, allowing the pump to be rapidly unloaded without waiting for the prime mover to slow down. This segmentation enables the pump to terminate discharge flow independently of the prime mover's inertia.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The suction valves are actuated in advance to open position before the prime mover can naturally slow down. By preliminarily opening the suction valves during the discharge stroke, the pump chamber is rapidly unloaded, causing the discharge valve to close and terminating flow almost immediately. This preliminary action bypasses the delay inherent in prime mover deceleration.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If traditional valve control is used where suction valves close during discharge cycles, then the pump maintains proper discharge pressure, but rapid termination of discharge flow cannot be achieved

Engineering Contradiction:

Improvedischarge pressure controlVSAvoidrapid flow termination capability

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The suction valve control system dynamically adjusts valve operation based on real-time pump conditions. During normal operation, suction valves close during discharge cycles to maintain proper pressure. When rapid termination is required, the control system dynamically switches behavior to keep suction valves open throughout the discharge stroke, enabling immediate flow termination while maintaining reliability during steady-state operation.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes the operational parameters of the suction valves from their normal closed-during-discharge state to an open-during-discharge state when rapid termination is needed. This parameter change transforms the pump from a pressure-maintaining mode to a rapid-unloading mode, allowing the discharge valve to close immediately and terminate flow without compromising normal operational reliability.

Inventive Principle:

Principle #35Parameter changes

3Loss of time

If the suction valve is maintained open during discharge cycles for rapid unloading, then discharge flow can be terminated immediately, but the pump system becomes more complex

Engineering Contradiction:

Improvetime to terminate discharge flowVSAvoidvalve control system complexity

Core Design Contradiction:

Loss of timeVSDevice complexity

Solution Approach 1:

The valve control system uses feedback from pump operating conditions to automatically control suction valve actuation. Sensors monitor pump pressure, flow rate, and cycle timing, and this feedback information is used by the control system to determine when to open or close suction valves. This feedback mechanism automates the complex control logic, reducing the need for manual intervention and simplifying the overall system operation despite the added valve control components.

Inventive Principle:

Principle #23Feedback

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

Enables rapid termination of discharge flow without waiting for the prime mover to slow down, preventing damage and simplifying the pump system by eliminating the need for transmission disengagement.

Implementation Method 1

poppet-style valves that open and close by differential pressure across the valves

Methodology Applied

Scientific EffectDifferential pressure: Pressure Gradient

Implementation Method 2

causing termination of discharge flow from the fluid pump

Methodology Applied

Scientific EffectPressure differential control: Pressure Gradient

Data Source

PatentUS20250382956A1Controlling suction valves of a fluid pump

Publication Date: 2025.12.18 SPM OIL & GAS INC

AI summary

A controller may monitor an operating parameter relating to at least one of a fluid pump or a prime mover for the fluid pump. The fluid pump may be configured to discharge fluid during a plurality of discharge cycles. The fluid pump may have a suction valve configured to close during the plurality of discharge cycles. The controller may cause, responsive to the operating parameter indicating that the fluid pump is to be deactivated, the suction valve to be maintained in an open position throughout one or more discharge cycles of the plurality of discharge cycles.