FLUID END ASSEMBLY

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and benefit of 63/551,122, entitled “FLUID END ASSEMBLY,” filed Feb. 8, 2024, the contents of which are incorporated in their entirety for all purposes.

FIELD OF DISCLOSURE

The present invention relates generally to fluid end assemblies for reciprocating pumps; and more particularly, but not by way of limitation, to a fluid end assembly having a discharge port and/or valve aligned with a plunger chamber.

BACKGROUND

Reciprocating pumps, also known as positive displacement pumps, are used in many applications and industries to convert mechanical energy into hydraulic energy. Reciprocating pumps generally include two sections: a power end and a fluid end. The power end is configured to move one or more plungers toward, and away from, the fluid end. The fluid end is where the pumping takes place—fluid is drawn in and forcibly pushed out at a high pressure by the plungers.

SUMMARY

The present disclosure relates to fluid end assemblies having a discharge port and/or valve aligned with a plunger chamber. The fluid end assemblies may have a crossbore configuration and be part of reciprocating pumps having any configuration, including reciprocating pumps with inverted-V, upright-V, inverted-Y, upright-Y, and/or X cross sections. In some embodiments, a fluid end assembly has a crossbore configuration that comprises an intersecting bore internal geometry as shown in some of the figures accompanying this disclosure. Reciprocating pumps in some configurations, such as those listed above, may experience a higher accumulation of particles (e.g., sand) within the fluid end assemblies due to, for example, a downward slant of the fluid end. Aligning discharge ports and/or valves with respective plunger chambers may reduce the accumulation of particles, improve performance, and minimize maintenance requirements. Some configurations have an inlet port and/or valve aligned with an access port. Some configurations have a plunger chamber longitudinal axis aligned with a discharge port longitudinal axis. Some configurations have an inlet port longitudinal axis aligned with an access port longitudinal axis.

In a first aspect, a fluid end assembly includes one or more bodies in a crossbore configuration, each body including: a plunger chamber having a first plunger chamber end, a second plunger chamber end opposite the first plunger chamber end, and a plunger chamber longitudinal axis extending between the first and second plunger chamber ends; an inlet port comprising an inlet valve; and a discharge port having a first discharge port end, a second discharge port end opposite the first discharge port end, and a discharge port longitudinal axis extending between the first and second discharge port ends, the discharge port comprising a discharge valve, wherein the plunger chamber longitudinal axis and the discharge port longitudinal axis are aligned with each other.

In a second aspect, in combination with the first aspect, the plunger chamber longitudinal axis and the discharge port longitudinal axis are in line with each other.

In a third aspect, in combination with one or more of the first through the second aspects, the inlet port has a first inlet port end, a second inlet port end opposite the first inlet port end, and an inlet port longitudinal axis extending between the first and second inlet port ends, and the inlet port longitudinal axis is perpendicular to both the plunger chamber longitudinal axis and the discharge port longitudinal axis.

In a fourth aspect, in combination with one or more of the first through the third aspect, the body further comprises an access port, the access port having a first access port end, a second access port end opposite the first access port end, and an access port longitudinal axis extending between the first and second access port ends, and wherein the inlet port longitudinal axis and the access port longitudinal axis are aligned with each other.

In a fifth aspect, in combination with one or more of the first through the fourth aspect, the inlet port longitudinal axis and the access port longitudinal axis are in line with each other.

In a sixth aspect, in combination with one or more of the first through the fifth aspect, a first length from the first inlet port end to the second inlet port end is longer than a second length from the first access port end to the second access port end.

In a seventh aspect, in combination with one or more of the first through the sixth aspect, the one or more bodies comprise a first body, a second body, a third body, and a fourth body, and wherein the first, second, third, and fourth bodies form a unitary structure.

In an eighth aspect, in combination with one or more of the first through the seventh aspect, the plunger chamber axes of the first, second, third, and fourth bodies are parallel to each other, wherein the access ports of the first, second, third, and fourth bodies are aligned with each other, wherein the inlet ports of the first, second, third, and fourth bodies are aligned with each other, wherein the assembly has a first assembly end near the access ports of the first, second, third, and fourth bodies, wherein the assembly has a second assembly end near the inlet ports of the first, second, third, and fourth bodies, and wherein a length from the first assembly end to a plane crossing the plunger chamber longitudinal axes is shorter than a length from the second assembly end to the plane.

In a ninth aspect, in combination with one or more of the first through the eighth aspect, the discharge port further comprises a valve cover and the discharge valve comprises a stem coupled to the valve cover.

In a tenth aspect, in combination with one or more of the first through the ninth aspect, the valve cover comprises an extension coupled to the stem and having one or more drain holes.

In an eleventh aspect, in combination with one or more of the first through the tenth aspect, a reciprocating pump includes a power end frame having a crankshaft aperture; a crankshaft extending through the crankshaft aperture; a plurality of plungers connected to the crankshaft; and a fluid end assembly comprising a plurality of bodies in a crossbore configuration.

As used herein, various terminology is for the purpose of describing particular implementations only and is not intended to be limiting of implementations. For example, as used herein, an ordinal term (e.g., “first,” “second,” “third,” etc.) used to modify an element, such as a structure, a component, an operation, etc., does not by itself indicate any priority or order of the element with respect to another element, but rather merely distinguishes the element from another element having a same name (but for use of the ordinal term). The term “coupled” is defined as connected, although not necessarily directly, and not necessarily mechanically; two items that are “coupled” may be unitary with each other. The terms “a” and “an” are defined as one or more unless this disclosure explicitly requires otherwise. The term “substantially” is defined as largely but not necessarily wholly what is specified—and includes what is specified; e.g., substantially 90 degrees includes 90 degrees and substantially parallel includes parallel—as understood by a person of ordinary skill in the art. In any disclosed embodiment, the term “substantially” may be substituted with “within [a percentage] of” what is specified, where the percentage includes 0.1, 1, 5, and 10 percent; and the term “approximately” may be substituted with “within 10 percent of” what is specified. The phrase “and/or” means “and” or “or.” To illustrate, A, B, and/or C includes: A alone, B alone, C alone, a combination of A and B, a combination of A and C, a combination of B and C, or a combination of A, B, and C. In other words, “and/or” operates as an inclusive or. The phrase “A, B, C, or a combination thereof” includes A alone, B alone, C alone, a combination of A and B, a combination of A and C, a combination of B and C, or a combination of A, B, and C. In other words, “or” is used inclusively unless otherwise is expressly specified.

The terms “comprise” and any form thereof such as “comprises” and “comprising,” “have” and any form thereof such as “has” and “having,” and “include” and any form thereof such as “includes” and “including” are open-ended linking verbs. As a result, an apparatus that “comprises,” “has,” or “includes” one or more elements possesses those one or more elements, but is not limited to possessing only those elements. Likewise, a method that “comprises,” “has,” or “includes” one or more steps possesses those one or more steps, but is not limited to possessing only those one or more steps.

Any implementation of any of the apparatuses, systems, and methods can consist of or consist essentially of—rather than comprise/include/have—any of the described steps, elements, and/or features. Thus, in any of the claims, the term “consisting of” or “consisting essentially of” can be substituted for any of the open-ended linking verbs recited above, in order to change the scope of a given claim from what it would otherwise be using the open-ended linking verb. Additionally, it will be understood that the term “wherein” may be used interchangeably with “where.”

Further, a device or system that is configured in a certain way is configured in at least that way, but it can also be configured in other ways than those specifically described. Aspects of one example may be applied to other examples, even though not described or illustrated, unless expressly prohibited by this disclosure or the nature of a particular example. Some details associated with the aspects described above and others are described below.

Some details associated with the aspects are described above, and others are described below. Other implementations, advantages, and features of the present disclosure will become apparent after review of the entire application, including the following sections: Brief Description of the Drawings, Detailed Description, and the Claims.

BRIEF DESCRIPTION OF THE DRAWINGS

These drawings illustrate by way of example and not limitation. For the sake of brevity and clarity, every feature of a given structure is not always labeled in every figure in which that structure appears. Identical reference numbers do not necessarily indicate the same structure. Rather, the same reference number may be used to indicate a similar feature or a feature with similar functionality, as may non-identical reference numbers.

FIG. 1 is a cross-section view of a reciprocating pump according to some aspects of this disclosure.

FIG. 2A is a cross-section view of a reciprocating pump according to some aspects of this disclosure.

FIG. 2B is a cross-section view of a fluid end assembly according to some aspects of this disclosure.

FIG. 3 is a cross-section view of a reciprocating pump according to some aspects of this disclosure.

FIG. 4 is a plan view of a fluid end assembly according to some aspects of this disclosure.

FIG. 5 is a method of operating a fluid end according to some aspects of this disclosure.

DETAILED DESCRIPTION OF ILLUSTRATIVE ASPECTS

Referring to FIG. 1, a reciprocating pump 100 is shown. Reciprocating pump 100 has two sections: a power end 110 and a fluid end 150. Power end 110 is configured to move one or more plungers toward, and away from, fluid end 150. Fluid end 150 is where the pumping takes place—fluid is drawn in and forcibly pushed out at a high pressure by the plungers.

Power end 110 includes a plurality of plunger assemblies 120, a plurality of crankshaft assemblies 130, and a power end frame assembly having a plurality of bearing plates 140. Because FIG. 1 is a cross-section view of reciprocating pump 100, only one plunger assembly 120, crankshaft assembly 130, and bearing plate 140 is shown. Each plunger assembly 120 includes a plunger 122, a crosshead 124, and a connecting rod 126. Plunger 122 is coupled to crosshead 124 via a ponyrod 128. Connecting rod 126 couples crosshead 124 to crankshaft assembly 130 via rod cap 129. Each crankshaft assembly 130 has at least a portion partially positioned within an opening 142 on bearing plate 140 and includes a crankshaft 132 and a crankshaft bearing 134 around crankshaft 132. Crankshaft bearing 134 is supported by opening 142 and couples crankshaft 132 to bearing plate 140 while allowing crankshaft 132 to rotate within opening 142. Adjacent bearing plates 140 of the power end frame assembly form receptacles 146 that accommodate crosshead 124 and configure crosshead 124 to displace linearly as crankshaft 132 rotates.

Fluid end 150 includes a fluid end assembly 151 having a plurality of bodies 152, each body 152 having a chamber 160, an inlet port 170, a discharge port 180, and an access port 190. Because FIG. 1 is a cross-section view of reciprocating pump 100, only one body 152 is shown. Chamber 160 is configured to receive a plunger portion of plunger 122 and allow the plunger portion to reciprocate within chamber 160. Inlet port 170 includes an inlet valve 174 and is configured to receive a fluid and direct the fluid to enter chamber 160. Discharge port 180 includes a discharge valve 184 and is configured to receive the fluid from chamber 160 and direct the fluid to exit body 152. Access port 190 includes an access cover 194 and is configured to selectively allow access to components of body 152 and/or fluid end assembly 151. As shown in FIG. 1, inlet port 170 and discharge port 180 are aligned with each other (e.g., located across from each other along an imaginary line extending through body 152)—and chamber 160 and access port 190 are aligned with each other (e.g., located across from each other along an imaginary line extending through body 152 that is approximately perpendicular to the line between inlet port 170 and discharge port 180). Reciprocating pump 100 increases pressure of the fluid in chamber 160 by reciprocating plunger 122 longitudinally within chamber 160. As a result, low-pressure fluid enters chamber 160 via inlet port 170 and high-pressure fluid exits chamber 160 and is discharged via discharge port 180.

Referring to FIG. 2A, a reciprocating pump 200 is shown. Reciprocating pump 200 is similar to reciprocating pump 100, may include some or all of the components of reciprocating pump 100, and has a power end (210) and a fluid end (250). Like power end 110, power end 210 includes a power end frame assembly having a plurality of bearing plates 240, each bearing plate 240 having an opening 242 to receive a crankshaft 232 of a crankshaft assembly 230. And like fluid end 150, fluid end 250 includes a fluid end assembly (251) having a plurality of bodies (252) with a chamber (260), an inlet port (270), a discharge port (280), and an access port (290). But as shown in FIGS. 2A and 2B, in bodies 252, discharge ports 280 and chambers 260 are aligned with each other—and inlet ports 270 and access ports 290 are aligned with each other. Because FIGS. 2A and 2B are cross-section views of reciprocating pump 200 and fluid end assembly 251, only one plunger assembly 220, crankshaft assembly 230, bearing plate 240, and body 252 are shown. Fluid end assembly 251 has a first end 254 near discharge ports 280, a second end 255 near chambers 260 and opposite first end 254, a third end 256 near access ports 290, and a fourth end 257 near inlet ports 270 and opposite third end 256.

Referring to FIG. 2B, fluid end assembly 251 is shown. Chamber 260 is, in the shown configuration, a cylinder having a first chamber end 261, a second chamber end 262 opposite first chamber end 261, and a first chamber longitudinal axis 263 extending between first chamber end 261 and second chamber end 262. Chamber 260 may be configured to receive a portion of a plunger and allow the plunger portion to reciprocate within chamber 260. The plunger portion may, for example, reciprocate between first chamber end 261 and second chamber end 262. Discharge port 280 is, in the shown configuration, a bore having a first discharge port end 281 adjacent to second chamber end 262, a second discharge port end 282 opposite first discharge port end 281, and a discharge port longitudinal axis 283 extending between first discharge port end 281 and second discharge port end 282. Discharge port 280 is configured to receive fluid from the chamber and direct fluid to exit body 252. Discharge port 280 includes a discharge valve 284 (e.g., a stem and wing valve) connected to a valve cover 286. Discharge valve 284 may have a stem 285 positioned within a stem bore 287A of valve cover 286, which may accommodate a bushing for stem 285. Valve cover 286 may have drain holes 287B to prevent sand accumulation within stem bore 287A, which could hinder performance and travel of discharge valve 284. Discharge port 280 also includes discharge compartment 288 between first discharge port end 281 and second discharge port end 282. Discharge compartment 288 has a discharge opening 289 configured to direct fluid to exit body 252. As shown in FIG. 2B, chamber 260 is aligned with both discharge port 280 and discharge valve 284. In the shown configuration, for example, chamber longitudinal axis 263 and discharge port longitudinal axis 283 are in line with each other. In other embodiments, chamber 260 may be aligned with discharge port 280 and/or valve 284 in other ways (e.g., parallel).

Inlet port 270 is, in the shown configuration, a bore having a first inlet port end 271, a second inlet port end 272 opposite first inlet port end 271, and an inlet port longitudinal axis 273 extending between first inlet port end 271 and second inlet port end 272. Inlet port 270 includes an inlet valve 274 (e.g., a wing valve) and is configured to receive a fluid and direct the fluid to enter chamber 260. Inlet port 270 also includes inlet compartment 278 between first inlet port end 271 and second inlet port end 272. Access port 290 is, in the shown configuration, a bore having a first access port end 291, a second access port end 292 opposite first access port end 291, and an access port longitudinal axis 293 extending between first access port end 291 and second access port end 292. Access port 290 includes an access cover 294 and is configured to selectively allow access to components of body 252 and/or fluid end assembly 251. Access port 290 also includes access compartment 298 between first access port end 291 and second access port end 292. In the FIG. 2B configuration, inlet port 270 and inlet valve 274 are aligned with both access port 290 and access cover 294. In the shown configuration, for example, inlet port longitudinal axis 273 and access port longitudinal axis 293 are in line with each other. But inlet port 270 and/or inlet valve 274 may be aligned with access port 290 and/or access cover 294 in other ways (e.g., parallel). And in other configurations, inlet port 270 and/or inlet valve 274 may not be aligned with access port 290 and/or access cover 294. In the FIG. 2B configuration, inlet port longitudinal axis 273 and access port longitudinal axis 293 are perpendicular to both chamber longitudinal axis 263 and discharge port longitudinal axis 283.

Referring to FIG. 3, reciprocating pump 300 is shown. Reciprocating pump 300 is similar to reciprocating pumps 100 and 200 and may include some or all of the components of reciprocating pumps 100 and/or 200 described above. In the shown configuration, reciprocating pump 300 has an inverted-V cross section. Yet reciprocating pump 300 can have any other cross-section shape, including (but not limited to) upright V, inverted Y, upright Y, and/or X cross-sectional shapes. For example, reciprocating pump 300 can have an inverted-Y cross-section (e.g., when viewed in a direction substantially parallel to a longitudinal axis of the crankshaft), where another fluid end (with corresponding power-end components) is disposed above the crankshaft and extends in a vertical direction. As another example, reciprocating pump 300 can have third and fourth fluid ends (in addition to the first and second fluid ends shown in FIG. 3) and an X cross-section (e.g., when viewed in a direction substantially parallel to a longitudinal axis of the crankshaft), where the third fluid end (with corresponding power-end components) is disposed above the first fluid end and extends in a direction opposite to the second fluid end and a fourth fluid end (with corresponding power-end components) is disposed above the second fluid end and extends in a direction opposite to the first fluid end. Reciprocating pumps in some configurations, such as those listed above, may experience a higher accumulation of particles (e.g., sand) within the fluid end assemblies due to, for example, the downward slant of the fluid end. In the FIG. 3 configuration, discharge ports and valves are aligned with respective plunger chambers, which may reduce the accumulation of particles, improve performance, and minimize maintenance requirements. In some embodiments, reciprocating pump 300 may have multiple sections and the sections may have different cross-section shapes. For example, one section may have an inverted-V cross section and another section may have an X cross section.

Reciprocating pump 300 has a power end frame assembly 238 with a crankshaft aperture 242, a crankshaft 232 extending through crankshaft aperture 242, a plurality of first plungers 222A connected to crankshaft 232, a first fluid end assembly with a plurality of first fluid end bodies 252A corresponding to respective first plungers 222A, a plurality of second plungers 222B connected to crankshaft 232, and a second fluid end assembly with a plurality of second fluid end bodies 252B corresponding to respective second plungers 222B. Because FIG. 3 is a cross-section view of reciprocating pump 300, only one first plunger 222A, first fluid end body 252A, second plunger 222B, and second fluid end body 252B are shown. As shown in FIG. 3, first fluid end body 252A and second fluid end body 252B are like fluid end body 252 and may include some or all of the components of fluid end body 252 described above. In the FIG. 3 configuration, first plunger 222A is configured to reciprocate in a first plane, second plunger 222B is configured to reciprocate in a second plane, a discharge port longitudinal axis 280A of first fluid end body 252A is aligned with the first plane, and a discharge port longitudinal axis 280B of second fluid end body 252B is aligned with the second plane. And as shown in FIG. 3, discharge port longitudinal axis 280A and discharge port longitudinal axis 280B define a non-zero offset angle.

Referring to FIG. 4, fluid end assembly 251 is shown. Fluid end assembly 251 includes bodies 252a, 252b, 252c, 252d, and 252e. In the FIG. 4 configuration, bodies 252a-e form a unitary structure. Fluid end assembly 251 has first ends 254a-e near respective discharge ports (not shown) and second ends 255a-e near respective chambers (not shown) and opposite respective first ends 254a-c. Fluid end assembly 251 also has third ends 256a-e near respective access ports (not shown) and fourth ends 257a-e near respective inlet ports (not shown) and opposite respective third ends 256a-c.

Referring to FIG. 5 shown is an example of a method of operating a fluid end. The method 500 may be performed at, by, or with (A) reciprocating pumps 100, 200, and/or 300; (B) fluid ends 150 and/or 250; (C) fluid end assemblies 151 and/or 251; and/or (D) power ends 110 and/or 210. The method 500 includes a block 502: move a plunger within a chamber of a fluid end assembly from a first position to a second position, wherein a first end of the plunger is near a first end of the chamber when the plunger is in the first position, the first end of the plunger is near a second end of the chamber when the plunger is in the second position, and the first end of the chamber is opposite the second end of the chamber. The method 500 further includes a block 504: direct a fluid to the chamber via an inlet port. The method 500 further includes a block 506: direct the fluid from the chamber to a discharge port by moving the plunger from the second position to the first position, wherein the chamber and the discharge port are aligned with each other. In some configurations, the method 500 can include a block: discharge the fluid via the discharge port. In some configurations, the method 500 can include a block: discharge the fluid via an opening on the discharge port. In some configurations, the method 500 can include a block: access one or more components of the fluid end assembly via an access port aligned with the inlet port.

Those of skill in the art that one or more blocks (or operations) described with reference to FIGS. 1-5 may be combined with one or more blocks (or operations) described with reference to another of the figures. For example, one or more blocks (or operations) of FIGS. 1-4 may be combined with one or more blocks (or operations) of FIG. 5.

The above specification and examples describe the structure and use of illustrative implementations. Although certain examples have been described above with some particularity, or with reference to one or more individual examples, those skilled in the art could make numerous alterations to the disclosed implementations without departing from the scope of this invention. So the various illustrative implementations of the methods and systems are not intended to be limited to the particular forms disclosed. Rather, they include all modifications and alternatives falling within the scope of the claims, and examples other than the one shown may include some or all of the features of the depicted example. For example, elements may be omitted or combined as a unitary structure, and/or connections may be substituted. Further, where appropriate, aspects of any of the examples described above may be combined with aspects of any of the other examples described to form more examples having comparable or different properties and/or functions and addressing the same or different problems. Similarly, it will be understood that the benefits and advantages described above may relate to one embodiment or may relate to several implementations.

The claims are not intended to include, and should not be interpreted to include, means-plus- or step-plus-function limitations, unless such a limitation is explicitly recited in each claim using the phrase(s) “means for” or “step for,” respectively.