Hydrocarbons, such as oil and gas, are commonly obtained from subterranean formations that may be located onshore or offshore. The development of subterranean operations and the processes involved in removing hydrocarbons from a subterranean formation are complex. Typically, subterranean operations involve a number of different steps such as, for example, drilling a wellbore at a desired well site, treating the wellbore to optimize production of hydrocarbons, and performing the necessary steps to produce and process the hydrocarbons from the subterranean formation.
Positive displacement pumps (e.g., reciprocating pumps) are used in all phases of well servicing operations including to pump water, cement, fracturing fluids, and other stimulation or servicing fluids as well as other pumping operations.
Reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
In the drawings and descriptions that follow, like parts are typically marked throughout the specification and drawings with the same reference numerals, respectively. The drawn figures are not necessarily, but may be, to scale. Certain features of the disclosure may be shown exaggerated in scale or in somewhat schematic form and some details of certain elements may not be shown in the interest of clarity and conciseness. The present disclosure may be implemented in embodiments of different forms.
Specific embodiments are described in detail and are shown in the drawings, with the understanding that the present disclosure is to be considered an exemplification of the principles of the disclosure, and is not intended to limit the disclosure to that illustrated and described herein. It is to be fully recognized that the different teachings of the embodiments discussed herein may be employed separately or in any suitable combination to produce desired results. Moreover, all statements herein reciting principles and aspects of the disclosure, as well as specific examples thereof, are intended to encompass equivalents thereof. Additionally, the term, “or,” as used herein, refers to a non-exclusive or, unless otherwise indicated.
Unless otherwise specified, use of the terms “connect,” “engage,” “couple,” “attach,” or any other like term describing an interaction between elements is not meant to limit the interaction to direct interaction between the elements and may also include indirect interaction between the elements described.
Unless otherwise specified, use of the terms “up,” “upper,” “upward,” “uphole,” “upstream,” or other like terms shall be construed as generally away from the bottom, terminal end of a well, regardless of the wellbore orientation; likewise, use of the terms “down,” “lower,” “downward,” “downhole,” or other like terms shall be construed as generally toward the bottom, terminal end of a well, regardless of the wellbore orientation. Use of any one or more of the foregoing terms shall not be construed as denoting positions along a perfectly vertical or horizontal axis. Unless otherwise specified, use of the term “subterranean formation” shall be construed as encompassing both areas below exposed earth and areas below earth covered by water, such as ocean or fresh water.
Referring initially to
A subsea conduit 145 extends from the platform 115 to a wellhead installation 150, which may include one or more subsea blow-out preventers 155. A wellbore 160 extends through the various earth strata including the subterranean formation 110. In the embodiment of
Turning to
In at least one embodiment, the fluid section 250 includes a valve system 255. In one or more embodiments, the valve system 255 may comprise multiple chambers 260 with plungers 265 driven by a crankshaft 220 (e.g., single crankshaft 220) of the power section 210. In the illustrated embodiment, the valve system 255 includes four chambers 260a, 260b, 260c, 260d connected to the crankshaft 220. For each chamber 260 of the valve system 255, the crankshaft 220 drives the plunger 265 located within the chamber 260. While the embodiment of
In one or more embodiments, each chamber 260 includes a suction valve 270 and a discharge valve 272. The suction valve 270 connects a servicing fluid source to the pumping system 200 via an inlet conduit 274. The pumping system 200, including the power section 210 and the fluid section 250, pressurizes the servicing fluid and pumps or discharges the servicing fluid via the discharge valve 272 to an outlet conduit 276 and on to a desired location. As noted above, the servicing fluid source may comprise any type of servicing fluid for any type of application. For example, in a well servicing application, the servicing fluid may comprise a well servicing fluid that may include, but is not limited to, any one or more of water, fracturing or stimulation fluid, mud, slurry, and any other fluid required to be pumped to a wellbore or downhole.
The power section 210 of the fluid pump 205 is coupled to the gearbox 290. The gearbox 290, in accordance with one or more embodiments, transmits rotational motion to the crankshaft 220 for powering the fluid pump 205. In one or more embodiments, the gearbox 290 is driven by an electric motor. In one or more embodiments, the electric motor may be coupled to a control system. In accordance with this one embodiment, the control system may control the speed of the electric motor.
In one or more embodiments of the disclosure, at least a portion of the fluid pump 205 includes a fluid pump housing (not easily shown in
Turning to
In the illustrated embodiment of
In the illustrated embodiment of
In yet another embodiment (e.g., an embodiment wherein the one or more joining flanges 340 collectively extend along at least 75 percent of the circumference), a single one of the one or more joining flanges 340 individually extends along at least 50 percent of the circumference. In even yet another embodiment (e.g., an embodiment wherein the one or more joining flanges 340 collectively extend along at least 90 percent of the circumference), a single one of the one or more joining flanges 340 individually extends along at least 75 percent of the circumference.
In at least one embodiment, the one or more flanges 340 form a first circumferential weld profile 345, and further wherein at least 60 percent of the first circumferential weld profile 345 is in a same first plane. In accordance with this one embodiment, 40 percent or less of the total circumferential weld profile (e.g., for a given side of the main plate 310, such as the first side edge 320) would be in a second parallel but offset plane and/or perpendicular plane. In at least one other embodiment, at least 75 percent of the first circumferential weld profile 345 is in the same first plane. In accordance with this one embodiment, 25 percent or less of the total circumferential weld profile (e.g., for a given side of the main plate 310, such as the first side edge 320) would be in the second parallel but offset plane and/or perpendicular plane. In even yet another embodiment, at least 90 percent of the first circumferential weld profile 345 is in the same first plane. In accordance with this one embodiment, 10 percent or less of the total circumferential weld profile (e.g., for a given side of the main plate 310, such as the first side edge 320) would be in the second parallel but offset plane and/or perpendicular plane.
In the embodiment of
In the illustrated embodiment of
The fluid pump housing section 300, in the illustrated embodiment, may additionally include one or more second joining flanges 370 extending from the second side edge 325 of the main plate 310. In accordance with at least one embodiment, the one or more second joining flanges 370 collectively extend along at least 60 percent of the circumference. Notwithstanding, the one or more second joining flanges 370 may have any of the features disclosed above with regard to the one or more joining flanges 340, and in fact will be similarly shaped (e.g., within 90 percent) of the one or more joining flanges 340. The fluid pump housing section 300, in the illustrated embodiment, may additionally include one or more support ears 380.
In accordance with at least one embodiment of the disclosure, the fluid pump housing section 300 comprises a single unitary piece. For example, the main plate 310 and the one or more joining flanges 340, and optionally the one or more second joining flanges 370 and the one or more support ears 380, may comprise a single unitary piece (e.g., single uninterrupted unitary piece). Accordingly, in at least one embodiment, no material joints will exist between the main plate 310 and the one or more joining flanges 340, and optionally the one or more second joining flanges 370 and the one or more support ears 380. Thus, in at least one embodiment, the main plate 310 and the one or more joining flanges 340, and optionally the one or more second joining flanges 370 and one or more support ears 380, are cast or forged into the single unitary piece. In yet another embodiment, the main plate 310 and the one or more joining flanges 340, and optionally the one or more second joining flanges 370 and the one or more support ears 380, are formed using an additive manufacturing process that provides the single unitary piece. In yet another embodiment, the main plate 310 and the one or more joining flanges 340, and optionally the one or more second joining flanges 370 and the one or more support ears 380, are milled from a single block of material to provide the single unitary piece.
Turning now to
As shown, the fluid pump housing sections 410, 420, 430 form a substantial portion of the total fluid pump housing, as opposed to just a skeleton as might be found in the prior art. In comparison, prior art housings might employ a few (e.g., four to eight) discrete posts that come together to form a skeleton of the housing, and thereafter, skins of thinner material would wrap around the skeletal housing to complete the enclosure. In the prior art, the combination of the few discrete posts, as well as the skins, presents a situation wherein the circumferential welds are circuitous, and thus require many starts and stops to complete. The present disclosure has recognized, for the first time, that such circuitous circumferential welds present reliability problems in certain higher pressure pumps. Accordingly, the present disclosure has deviated from the existing desire to provide lighter weight fluid pump housings, and proposes a new fluid pump housing design that includes or more joining flanges collectively extending along a greater percentage of the circumference of the main plate, one that is much heavier and much more costly to manufacture. Such a deviation, given the known desires in the art, is a non-obvious design choice.
Turning now to
Aspects disclosed herein include:
A. A fluid pump housing section, the fluid pump housing section including: 1) a main plate, the main plate having a circumference, as well as a thickness (t) defining a first side edge and a second opposing side edge; 2) one or more transverse openings located through the thickness (t) of the main plate; and 3) one or more joining flanges extending from the first side edge of the main plate, the one or more joining flanges collectively extending along at least 60 percent of the circumference.
B. A pumping system, the fluid pump system including: 1) a fluid pump, the fluid pump having a fluid pump housing, the fluid pump housing including two or more fluid pump housing sections, each fluid pump housing section including: a) a main plate, the main plate having a circumference, as well as a thickness (t) defining a first side edge and a second opposing side edge; b) one or more transverse openings located through the thickness (t) of the main plate; and c) one or more joining flanges extending from the first side edge of the main plate, the one or more joining flanges collectively extending along at least 60 percent of the circumference; and 2) a gearbox coupled to the fluid pump housing, the gearbox configured to rotate a crank shaft located within the fluid pump housing to move a servicing fluid therethrough.
C. A method for forming a fluid pump housing, the method including: 1) providing a first fluid pump housing section, the first fluid pump housing section including: a) a first main plate, the first main plate having a first circumference, as well as a first thickness (t) defining a first side edge and a first opposing side edge; b) one or more first transverse openings located through the first thickness (t) of the first main plate; and c) one or more first joining flanges extending from the first side edge of the first main plate, the one or more first joining flanges collectively extending along at least 60 percent of the first circumference; 2) providing a second fluid pump housing section, the second fluid pump housing section including: a) a second main plate, the second main plate having a second circumference, as well as a second thickness (t) defining a second side edge and a second opposing side edge; b) one or more second transverse openings located through the second thickness (t) of the second main plate; and c) one or more second joining flanges extending from the second side edge of the second main plate, the one or more second joining flanges collectively extending along at least 60 percent of the second circumference; and 3) welding the first fluid pump housing section and the second fluid pump housing section together using a full penetration weld to form a fluid pump housing.
Aspects A, B, and C may have one or more of the following additional elements in combination: Element 1: wherein the one or more joining flanges collectively extend along at least 75 percent of the circumference. Element 2: wherein a single one of the one or more joining flanges individually extends along at least 50 percent of the circumference. Element 3: wherein the one or more joining flanges collectively extend along at least 90 percent of the circumference. Element 4: wherein a single one of the one or more joining flanges individually extends along at least 75 percent of the circumference. Element 5: wherein the one or more joining flanges is a single joining flange that extends along at least 90 percent of the circumference. Element 6: wherein the one or more flanges form a first circumferential weld profile, and further wherein at least 60 percent of the first circumferential weld profile is in a same first plane. Element 7: wherein the one or more joining flanges have a first similarly shaped groove at a first outer edge of the one or more joining flanges or at a second opposing inner edge of the one or more flanges, the first similarly shaped grooves forming a reduced thickness weld profile for obtaining a full penetration weld when coupling two adjacent fluid pump housing sections together to form a fluid pump housing. Element 8: further including one or more second joining flanges extending from the second side edge of the main plate, the one or more second joining flanges collectively extending along at least 60 percent of the circumference. Element 9: wherein at least one of the one or more transverse openings is a crank shaft bore. Element 10: wherein the one or more joining flanges collectively extend along at least 75 percent of the circumference. Element 11: wherein the one or more joining flanges collectively extend along at least 90 percent of the circumference. Element 12: wherein the fluid pump housing section is a first fluid pump housing, and further including second and third fluid pump housing sections coupled with the first fluid pump housing section to form the fluid pump housing, the second and third fluid pump housing sections each including: 1) another main plate, the another main plate having another circumference, as well as another thickness (t) defining another first side edge and another second opposing side edge; 2) another one or more transverse openings located through the another thickness (t) of the another main plate; and 3) another one or more joining flanges extending from the another first side edge of the another main plate, the another one or more joining flanges collectively extending along at least 60 percent of the another circumference.
Those skilled in the art to which this application relates will appreciate that other and further additions, deletions, substitutions and modifications may be made to the described embodiments.