Variable-Torque Fluid Pump Drive Without Torque Converters
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Solution Overview
Problem
Existing pump systems for high-pressure applications, such as hydraulic fracturing, require specialized and costly prime movers to handle high torque requirements, leading to increased weight, complexity, and inefficiency due to the need for transmissions, torque converters, or specialized turbine engines.
Innovation Solution
A pump system that includes a fluid end with a plunger and valves, coupled to a power end driven by a prime mover, which can variably control torque requirements using a gearbox or electric motor, eliminating the need for transmissions or specialized equipment by dynamically adjusting torque through suction valve control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a reciprocating engine is used to drive a high-pressure pump, then the pump can operate, but a transmission and torque converter are needed to handle high torque requirement, which adds significant weight and bulk to the pump system
Solution Approach 1:
The patent applies dynamics by making the torque requirement variable rather than fixed. The suction valve control system dynamically adjusts the torque requirement based on operating conditions, allowing the engine to operate efficiently without requiring a torque converter or transmission to handle peak torque demands. This dynamic adjustment eliminates the need for heavy torque multiplication devices.
Solution Approach 2:
The patent changes the parameter of torque requirement from a constant high value to a variable value that can be controlled. By controlling when the suction valve opens and closes, the system varies the torque demand on the engine, enabling the use of a lighter, less complex engine configuration without requiring additional torque multiplication equipment.
2Power
If a torque converter is added to handle high torque requirement, then the pump can start against pressure, but the torque converter generates significant heat that requires a cooler, adding more weight and complexity
Solution Approach 1:
The patent extracts the torque multiplication function from separate components (torque converter and transmission) and integrates it into the pump's suction valve control system. By controlling the timing of suction valve operation, the system achieves variable torque requirements without needing external torque multiplication devices, thereby eliminating the torque converter and its associated cooler and complexity.
Solution Approach 2:
The pump system serves its own torque management needs through internal suction valve control rather than requiring external torque multiplication devices. The suction valve control system self-regulates the torque demand to match the engine's capabilities, eliminating the need for separate torque converter and cooler systems.
3Power
If a twin-shaft turbine engine with 100% turndown ratio is used, then the pump can be started against pressure, but the turbine engine is highly specialized, costly, and adds complexity to the pump system
Solution Approach 1:
The patent makes the suction valve control system universal by enabling standard turbine engines (without specialized 100% turndown ratio capabilities) to operate the pump effectively. The variable torque control allows any appropriately rated turbine engine to be used, not just specialized models, thereby reducing cost and complexity while maintaining the ability to start against pressure.
Solution Approach 2:
The patent changes the operating parameters of the turbine engine by dynamically adjusting the torque requirement through suction valve control. This allows standard turbine engines to operate within their optimal ranges while still being able to handle the pump's starting requirements, eliminating the need for expensive specialized 100% turndown ratio engines.
4Power
If a specialized motor with variable frequency drive is used, then the pump can be started against pressure, but the motor and VFD add significant weight, cost, and complexity to the pump system
Solution Approach 1:
The patent extracts the variable speed control function from the motor-VFD combination and relocates it to the suction valve control system. By controlling valve timing rather than motor speed, the system achieves variable torque requirements without needing a VFD, thereby eliminating significant weight, cost, and complexity associated with VFD equipment.
Solution Approach 2:
The patent replaces the electrical control system (VFD) with a mechanical control system (suction valve timing mechanism). Instead of using electrical frequency control to manage torque requirements, the system uses mechanical valve control, thereby eliminating the need for heavy VFD equipment while achieving the same variable torque management capability.
Data Source
AI summary
A pump system may include a fluid pump including a fluid end. The fluid end may include a plunger configured for reciprocating movement, a suction valve biased to a closed position and configured to open during suction cycles of the fluid pump, and a discharge valve biased to a closed position and configured to open during discharge cycles of the fluid pump.The fluid pump may include a power end configured to drive reciprocating movement of the plunger. The pump system may be configured to variably control a torque requirement of the fluid pump. The pump system may include a reciprocating engine to produce torque to drive the power end of the fluid pump. The pump system may include a fixed-ratio gearbox or a dual-ratio gearbox operably coupling the power end of the fluid pump to the reciprocating engine using a non-fluid coupling.