Well Stimulation Pump Suction Valve Control for Startup Load Relief
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing hydraulic fracturing systems face challenges in starting backup pumps due to high pressure loads, leading to high fuel and electrical demands, and potential damage to prime movers and pumps, especially when starting or winding down under high load conditions.
Innovation Solution
A fluid end system with a suction valve mechanism that can be controlled to open or close based on sensor data, allowing fluid circulation between the pump chamber and intake manifold during prime mover startup or shutdown, reducing the load on the system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the suction valve is kept closed during prime mover startup or shutdown, then the pump maintains high pressure output, but the prime mover experiences excessive load leading to high fuel consumption, electrical power requirements, and potential damage
Solution Approach 1:
The suction valve position is made dynamic rather than fixed, allowing it to switch between closed (during normal operation) and open (during startup/shutdown) states based on system conditions, thereby optimizing performance across different operational phases
Solution Approach 2:
The suction valve is opened in advance during startup or shutdown conditions to prevent excessive pressure buildup before the prime mover reaches full operational speed, reducing the initial load surge
2Use of energy by moving object
If the suction valve is opened during prime mover startup or shutdown, then the load on the prime mover is reduced, but the pump cannot maintain high pressure output
Solution Approach 1:
The system dynamically adjusts the suction valve position based on operational phase, maintaining closed position during normal operation for high pressure output and opening during startup/shutdown for reduced load
Solution Approach 2:
The suction valve is opened preliminarily during startup or shutdown to reduce load on the prime mover before it reaches full operational capacity, preventing excessive stress on the system
3Reliability
If the suction valve remains closed during startup or shutdown, then the pump maintains system pressure, but the prime mover and pump components may be damaged or their useful life reduced
Solution Approach 1:
The suction valve is opened in advance during startup or shutdown conditions to prevent excessive pressure buildup that could damage components, while maintaining closed position during normal operation to preserve system pressure
Solution Approach 2:
The suction valve position is dynamically controlled based on operational conditions, switching between open and closed states to balance pressure maintenance with component protection during different phases of operation
Data Source
AI summary
An example system includes a fluid end having a block, a suction bore formed in the block, a suction valve seat disposed within the suction bore, and a suction valve disposed within the suction bore, the suction valve, in a closed position, being configured to contact the suction valve seat to seal the suction bore. The system also includes a rod configured to engage the suction valve, the rod being moveable between a first position and a second position, wherein in the first position the suction valve is in the closed position, and in the second position, engagement of the rod with the suction valve causes the suction valve to be in an open position.