Tunable Fluid Ends for High-Pressure Pump Vibration Control
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Solution Overview
Problem
High-pressure reciprocating pumps used in well-stimulation face reliability issues due to valve-generated vibrations leading to fatigue cracking and premature failure, as conventional rigid check valves convert kinetic energy into destructive resonances, and existing redesigns are inadequate for current high-pressure applications.
Innovation Solution
Tunable fluid ends and hydraulic stimulators are designed to control and dampen valve-generated vibrations by shifting frequency domains and using viscoelastic and shear-thickening materials to dissipate energy as heat, while tunable hydraulic stimulators generate tailored vibration spectra for geologic material stimulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional rigid check valves are used in high-pressure reciprocating pumps, then the pump can maintain structural simplicity and manufacturing ease, but the kinetic energy from valve closure converts into destructive vibrations causing fatigue cracking and premature failure
Solution Approach 1:
The patent applies parameter changes by modifying the physical properties of the valve body material from rigid to viscoelastic. This change in material parameters allows the valve to dissipate kinetic energy through internal friction and hysteresis, converting destructive vibrations into heat energy while maintaining valve functionality under high-pressure conditions
Solution Approach 2:
The patent employs composite materials by integrating viscoelastic components into the valve structure. These composite materials combine the structural integrity needed for high-pressure operation with energy-dissipating properties, creating a valve body that simultaneously maintains mechanical strength and reduces harmful vibrations through controlled elasticity and internal damping
2Object-generated harmful factors
If viscoelastic materials are used to dampen vibrations, then destructive resonances are reduced, but the device complexity increases due to material selection and integration requirements
Solution Approach 1:
The patent applies self-service by designing the viscoelastic valve body to automatically dissipate its own vibrations through inherent material properties. The viscoelastic material inherently converts kinetic energy to heat through internal friction, eliminating the need for separate damping mechanisms or complex vibration control systems, thereby reducing overall device complexity while maintaining effectiveness
3Productivity
If hammer element strikes are used in hydraulic stimulators, then geologic material stimulation is achieved, but mechanical shock generates broad vibration spectra that may cause unwanted resonances
Solution Approach 1:
The patent applies dynamics by making the hammer element's rebound cycle time可调 (adjustable) to tune the vibration spectrum. By controlling the rebound characteristics, the system can dynamically adjust the frequency content of generated vibrations to match resonant frequencies of target geologic formations, maximizing stimulation efficiency while minimizing unwanted broad-spectrum resonances through precise temporal control of the impact cycle
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 end failures, enhances pump reliability, and optimizes well-stimulation efficiency by minimizing destructive resonances and selectively attenuating vibrations, thereby extending pump service life and improving hydrocarbon extraction.
Implementation Method 1
using viscoelastic and shear-thickening materials to dissipate energy as heat
Implementation Method 2
using viscoelastic and shear-thickening materials to dissipate energy as heat
Implementation Method 3
vibration spectra originate in the mechanical shocks (i.e., impulses) of a hammer element striking a fluid interface
Implementation Method 4
A driver element, such as an electromagnet or controller, actuates the hammer element
Data Source
AI summary
Selected designs for reciprocating pumps and down-hole well-stimulation equipment reflect disparate applications of identical technical principles (relating to, e.g., the vibration spectrum of an impulse). In certain of these designs, the vibration spectrum is controlled, suppressed and/or damped using tunable components to limit destructive excitation of resonances; in others the vibration spectrum is tuned at its source for maximum resonance excitation. For example, tunable fluid ends control valve-generated vibration to increase fluid-end reliability. By down-shifting the frequency domain of each valve-closing impulse shock, initial excitation of fluid end resonances is minimized. Subsequent damping and/or selective attenuation of vibration likely to excite one or more predetermined (and frequently localized) fluid end resonances represents further optimal use of fluid end vibration-control resources. Vibration generation in stimulators, in contrast, includes techniques for production of desired frequency bands (vibration spectra) and amplitudes (vibration energy) near explosively-formed perforations in a wellbore.