Patent Application
20210025385
Not applicable.
Not applicable.
The present disclosure relates generally to a method and apparatus for supplying pressurized fluids. More particularly, the present disclosure relates to methods and reciprocating devices for pumping fluids into a wellbore.
High-pressure pumps having reciprocating elements such as plungers or pistons are commonly employed in oil and gas production fields for operations such as drilling and well servicing. For instance, one or more reciprocating pumps may be employed to pump fluids into a wellbore in conjunction with activities including fracturing, acidizing, remediation, cementing, and other stimulation or servicing activities. Due to the harsh conditions associated with such activities, many considerations are generally taken into account when designing a pump for use in oil and gas operations. One design consideration may concern ease of access to pump fluid end components, as reciprocating pumps used in wellbore operations, for example, often encounter high cyclical pressures and various other conditions that can render pump components susceptible to wear and result in a need for servicing and maintenance of the pump.
Accordingly, it is desirable to provide a pump fluid end that facilitates replacement of components therein, such as a valve assembly, whereby maintenance can be simplified.
For a more complete understanding of this disclosure, reference is now made to the following brief description, taken in connection with the accompanying drawings and detailed description, wherein like reference numerals represent like parts.
It should be understood at the outset that although an illustrative implementation of one or more embodiments are provided below, the disclosed systems and/or methods may be implemented using any number of techniques, whether currently known or in existence. The disclosure should in no way be limited to the illustrative implementations, drawings, and techniques illustrated below, including the exemplary designs and implementations illustrated and described herein, but may be modified within the scope of the appended claims along with their full scope of equivalents.
Disclosed herein is a reciprocating apparatus for pumping pressurized fluid. In embodiments, the reciprocating apparatus comprises a pump fluid end containing a valve module. The valve module of this disclosure comprises: a cylindrical canister containing a valve assembly, wherein the valve assembly comprises a valve body and a valve seat. The valve module provides a fluid flow path from an inlet to an outlet of the valve module along a central axis of the valve module and between the valve body and the valve seat when the valve assembly is in an open configuration, and does not provide the fluid flow path when the valve assembly is in a closed configuration. The valve body and the valve seat are coaxially aligned along the central axis. The valve body contacts the valve seat in the closed configuration and does not contact the valve seat in the open configuration. In embodiments, the reciprocating apparatus is a high-pressure pump configured to operate at a pressure greater than or equal to about 3,000 psi and/or in a well servicing operation and environment. Utilization of a modularized valve assembly (e.g., a modularized suction valve assembly and/or a modularized discharge valve assembly) as per this disclosure can enhance productive time of the reciprocating apparatus by reducing downtime for maintenance of a valve assembly.
A reciprocating apparatus of this disclosure may comprise any suitable pump operable to pump fluid. Non-limiting examples of suitable pumps include, but are not limited to, piston pumps, plunger pumps, and the like. In embodiments, the pump is a rotary- or reciprocating-type pump such as a positive displacement pump operable to displace pressurized fluid. The pump comprises a pump power end, a pump fluid end, and an integration section whereby a reciprocating element (e.g., a plunger) can be mechanically connected with the pump power end such that the reciprocating element can be reciprocated within a reciprocating element bore of the pump fluid end.
The pump fluid end 22 is integrated with the pump power end 12 via the integration section 11, such that pump power end 12 is operable to reciprocate the reciprocating element 18 within a reciprocating element bore 24 (
The pump 10 may comprise any suitable pump power end 12 for enabling the pump 10 to perform pumping operations (e.g., pumping a wellbore servicing fluid downhole). Similarly, the pump 10 may include any suitable housing 14 for containing and/or supporting the pump power end 12 and components thereof. The housing 14 may comprise various combinations of inlets, outlets, channels, and the like for circulating and/or transferring fluid. Additionally, the housing 14 may include connections to other components and/or systems, such as, but not limited to, pipes, tanks, drive mechanisms, etc. Furthermore, the housing 14 may be configured with cover plates or entryways for permitting access to the pump power end 12 and/or other pump components. As such, the pump 10 may be inspected to determine whether parts need to be repaired or replaced. The pump power end may also be hydraulically driven, whether it is a non-intensifying or an intensifying system.
Those versed in the art will understand that the pump power end 12 may include various components commonly employed in pumps. Pump power end 12 can be any suitable pump known in the art and with the help of this disclosure to be operable to reciprocate reciprocating element 18 in reciprocating element bore 24. For example, without limitation, pump power end 12 can be operable via and comprise a crank and slider mechanism, a powered hydraulic/pneumatic/steam cylinder mechanism or various electric, mechanical or electro-mechanical drives.
Of course, numerous other components associated with the pump power end 12 of the pump 10 may be similarly employed, and therefore, fall within the purview of the present disclosure. Furthermore, since the construction and operation of components associated with pumps of the sort depicted in
As noted hereinabove, the pump 10 comprises a pump fluid end 22 attached to the pump power end 12. Various embodiments of the pump fluid end 22 are described in detail below in connection with other drawings, for example
In embodiments, the pump fluid end 22 may comprise a cylinder wall 26 at least partially defining a bore 24 through which the reciprocating element 18 may extend and retract. Additionally, the bore 24 may be in fluid communication with a discharge chamber 53 formed within the pump fluid end 22. Such a discharge chamber 53, for example, may be configured as a pressurized discharge chamber 53 having a discharge outlet 54 through which fluid is discharged by the reciprocating element 18. Thus, the reciprocating element 18 may be movably disposed within the reciprocating element bore 24, which may provide a fluid flow path into and/or out of the pump chamber. During operation of the pump 10, the reciprocating element 18 may be configured to reciprocate along a path (e.g., along central axis 17 within bore 24 and/or pump chamber 28, which corresponds to reciprocal movement parallel to the x-axis of
In operation, the reciprocating element 18 extends and retracts along a flow path to alternate between providing forward strokes (also referred to as discharge strokes and correlating to movement in a positive direction parallel to the x-axis of
During a return stroke, the reciprocating element 18 reciprocates or retracts away from the pump fluid end 22 and towards the pump power end 12 of the pump 10. Before the return stroke begins, the reciprocating element 18 is in a fully extended position (also referred to as top dead center (TDC) with reference to the crankshaft 16), in which case the discharge valve assembly 72 can be in a closed configuration having allowed fluid to flow out of the pump chamber 28 and the suction valve assembly 56 is in a closed configuration. When the reciprocating element 18 begins and retracts towards the pump power end 12, the discharge valve assembly 72 assumes a closed configuration, while the suction valve assembly 56 opens. As the reciprocating element 18 moves away from the discharge valve 72 during a return stroke, fluid flows through the suction valve assembly 56 and into the pump chamber 28.
With reference to the embodiments of
With reference to the embodiment of
With reference to the embodiment of
A pump 10 of this disclosure can comprise one or more access ports. For example, with reference to the cross-bore fluid end body 8 embodiments of
In embodiments, a pump fluid end 22 and pump 10 of this disclosure comprise at least one access port located on a side of the discharge valve assembly 72 opposite the suction valve assembly 56. For example, in the cross-bore pump fluid end 22 embodiment of
In embodiments, one or more seals 29 (e.g., “o-ring” seals, packing seals, or the like), also referred to herein as ‘primary’ reciprocating element packing 29 (or “packing 29”) may be arranged around the reciprocating element 18 to provide sealing between the outer walls of the reciprocating element 18 and the inner walls 26 defining at least a portion of the reciprocating element bore 24. The inner walls 26 may be provided by fluid end body 8 or a sleeve within reciprocating element bore 24, as described below. In some concentric bore fluid end designs, a second set of seals (also referred to herein as ‘secondary’ reciprocating element packing; not shown in the Figures) may be fixedly arranged around the reciprocating element 18 to provide sealing between the outer walls of the reciprocating element 18 and the inner walls of a low-pressure cylinder that defines the low pressure chamber described hereinabove (e.g., wherein the secondary packing is farther back along the x-axis and delineates a back end of the low pressure chamber that extends from the primary packing 29 to the secondary packing). In embodiments, only a primary reciprocating element packing is utilized, as fluid enters tail end 62 of reciprocating element 18 without first contacting an outer peripheral wall thereof (i.e., no secondary reciprocating element packing is needed/utilized, because no low pressure chamber external to reciprocating element 18 is utilized). Skilled artisans will recognize that the seals may comprise any suitable type of seals, and the selection of seals may depend on various factors e.g., fluid, temperature, pressure, etc.
While the foregoing discussion focused on a pump fluid end 22 comprising a single reciprocating element 18 disposed in a single reciprocating element bore 24, it is to be understood that the pump fluid end 22 may include any suitable number of reciprocating elements. As discussed further below, for example, the pump 10 may comprise a plurality of reciprocating elements 18 and associated reciprocating element bores 24 arranged in parallel and spaced apart along the z-axis of
Reciprocating element bore 24 can have an inner diameter slightly greater than the outer diameter of the reciprocating element 18, such that the reciprocating element 18 may sufficiently reciprocate within reciprocating element bore 24 (optionally, within a sleeve, as described hereinbelow). In embodiments, the fluid end body 8 of pump fluid end 22 has a pressure rating ranging from about 100 psi to about 3000 psi, or from about 2000 psi to about 10,000 psi, from about 5000 psi to about 30,000 psi, or from about 3000 psi to about 50,000 psi or greater. The fluid end body 8 of pump fluid end 22 may be cast, forged, machined, printed or formed from any suitable materials, e.g., steel, metal alloys, or the like. Those versed in the art will recognize that the type and condition of material(s) suitable for the fluid end body 8 may be selected based on various factors. In a wellbore servicing operation, for example, the selection of a material may depend on flow rates, pressure rates, wellbore service fluid types (e.g., particulate type and/or concentration present in particle laden fluids such as fracturing fluids or drilling fluids, or fluids comprising cryogenic/foams), etc. Moreover, the fluid end body 8 (e.g., cylinder wall 26 defining at least a portion of reciprocating element bore 24 and/or pump chamber 28) may include protective coatings for preventing and/or resisting abrasion, erosion, and/or corrosion.
In embodiments, the cylindrical shape (e.g., providing cylindrical wall(s) 26) of the fluid end body 8 may be pre-stressed in an initial compression. Moreover, a high-pressure cylinder(s) providing the cylindrical shape (e.g., providing cylindrical wall(s) 26) may comprise one or more sleeves (e.g., heat-shrinkable sleeves). Additionally or alternatively, the high-pressure cylinder(s) may comprise one or more composite overwraps and/or concentric sleeves (“over-sleeves”), such that an outer wrap/sleeve pre-loads an inner wrap/sleeve. The overwraps and/or over-sleeves may be non-metallic (e.g., fiber windings) and/or constructed from relatively lightweight materials. Overwraps and/or over-sleeves may be added to increase fatigue strength and overall reinforcement of the components.
The cylinders and cylindrical-shaped components (e.g., providing cylindrical wall 26) associated with the pump fluid end body 8 of pump fluid end 22 may be held in place within the pump 10 using any appropriate technique. For example, components may be assembled and connected, e.g., bolted, welded, etc. Additionally or alternatively, cylinders may be press-fit (e.g., interference fit) into openings machined or cast into the pump fluid end 22 or other suitable portion of the pump 10. Such openings may be configured to accept and rigidly hold cylinders (e.g., having cylinder wall(s) 26 at least partially defining reciprocating element bore 24) in place so as to facilitate interaction of the reciprocating element 18 and other components associated with the pump 10.
In embodiments, the reciprocating element 18 comprises a plunger or a piston. While the reciprocating element 18 may be described herein with respect to embodiments comprising a plunger, it is to be understood that the reciprocating element 18 may comprise any suitable component for displacing fluid. In a non-limiting example, the reciprocating element 18 may be a piston. As those versed in the art will readily appreciate, a piston-type pump generally employs sealing elements (e.g., rings, packing, etc.) attached to the piston and movable therewith. In contrast, a plunger-type pump generally employs fixed or static seals (e.g., primary seal or packing 29) through which the plunger moves during each stroke (e.g., suction stroke or discharge stroke).
As skilled artisans will understand, the reciprocating element 18 may include any suitable size and/or shape for extending and retracting along a flow path within the pump fluid end 22. For instance, reciprocating element 18 may comprise a generally cylindrical shape, and may be sized such that the reciprocating element 18 can sufficiently slide against or otherwise interact with the inner cylinder wall 26. In embodiments, one or more additional components or mechanical linkages 4 (
In some embodiments (e.g., cross-bore pump fluid end 22 embodiments such as
The reciprocating element 18 comprises a front or free end 60. In embodiments comprising concentric bore pump fluid end designs 22 such as shown in
As noted above, pump fluid end 22 contains a suction valve assembly 56. Suction valve assembly 56 may alternately open or close to permit or prevent fluid flow. Skilled artisans will understand that the suction valve assembly 56 may be of any suitable type or configuration (e.g., gravity- or spring-biased, flow activated, etc.). Those versed in the art will understand that the suction valve assembly 56 may be disposed within the pump fluid end 22 at any suitable location therein. For instance, the suction valve assembly 56 may be disposed within the bore 25 below central axis 17 of the pump fluid end 22, in cross-bore pump fluid end 22 designs such as
Pump 10 comprises a discharge valve assembly 72 for controlling the output of fluid through discharge chamber 53 and discharge outlet 54. Analogous to the suction valve assembly 56, the discharge valve assembly 72 may alternately open or close to permit or prevent fluid flow. Those versed in the art will understand that the discharge valve assembly 72 may be disposed within the pump chamber at any suitable location therein. For instance, the discharge valve assembly 72 may be disposed within the bore 25 proximal the top S3 of the pump fluid end 22, in cross-bore pump fluid end 22 designs such as
Further, the suction valve assembly 56 and the discharge valve assembly 72 can comprise any suitable mechanism for opening and closing valves. For example, the suction valve assembly 56 and the discharge valve assembly 72 can comprise a suction valve spring and a discharge valve spring, respectively. Additionally, any suitable structure (e.g., valve assembly comprising sealing rings, stems, valve guides, poppets, etc.) and/or components may be employed for retaining the components of the suction valve assembly 56 and the components of the discharge valve assembly 72 within the pump fluid end 22. According to embodiments of this disclosure, the discharge valve assembly 72 and/or the suction valve assembly 56 can comprise a valve poppet assembly, as described, for example, in U.S. patent application Ser. No. 16/436,356 filed Jun. 10, 2019 and entitled “Multi-Material Frac Valve Poppet”, the disclosure of which is hereby incorporated herein in its entirety for purposes not contrary to this disclosure. As detailed further hereinbelow with reference to
The fluid inlet 38 may be arranged within any suitable portion of the pump fluid end 22 and configured to supply fluid to the pump in any direction and/or angle. Moreover, the pump fluid end 22 may comprise and/or be coupled to any suitable conduit (e.g., pipe, tubing, or the like) through which a fluid source may supply fluid to the fluid inlet 38. The pump 10 may comprise and/or be coupled to any suitable fluid source for supplying fluid to the pump via the fluid inlet 38. In embodiments, the pump 10 may also comprise and/or be coupled to a pressure source such as a boost pump (e.g., a suction boost pump) fluidly connected to the pump 10 (e.g., via inlet 38) and operable to increase or “boost” the pressure of fluid introduced to pump 10 via fluid inlet 38. A boost pump may comprise any suitable type including, but not limited to, a centrifugal pump, a gear pump, a screw pump, a roller pump, a scroll pump, a piston/plunger pump, or any combination thereof. For instance, the pump 10 may comprise and/or be coupled to a boost pump known to operate efficiently in high-volume operations and/or may allow the pumping rate therefrom to be adjusted. Skilled artisans will readily appreciate that the amount of added pressure may depend and/or vary based on factors such as operating conditions, application requirements, etc. In one aspect, the boost pump may have an outlet pressure greater than or equal to about 70 psi, about 80 psi, or about 110 psi, providing fluid to the suction side of pump 10 at about said pressures. Additionally or alternatively, the boost pump may have a flow rate of greater than or equal to about 80 BPM, about 70 BPM, and/or about 50 BPM.
As noted hereinabove, the pump 10 may be implemented as a multi-cylinder pump comprising multiple cylindrical reciprocating element bores 24 and corresponding components. In embodiments, the pump 10 is a Triplex pump in which the pump fluid end 22 comprises three reciprocating assemblies, each reciprocating assembly comprising a suction valve assembly 56, a discharge valve assembly 72, a pump chamber 28, a fluid inlet 38, a discharge outlet 54, and a reciprocating element bore 24 within which a corresponding reciprocating element 18 reciprocates during operation of the pump 10 via connection therewith to a (e.g., common) pump power end 12. In embodiments, the pump 10 is a Quintuplex pump in which the pump fluid end 22 comprises five reciprocating assemblies. In a non-limiting example, the pump 10 may be a Q-10™ Quintuplex Pump or an HT-400™ Triplex Pump, produced by Halliburton Energy Services, Inc.
In embodiments, the pump fluid end 22 may comprise an external manifold (e.g., a suction header) for feeding fluid to the multiple reciprocating assemblies via any suitable inlet(s). Additionally or alternatively, the pump fluid end 22 may comprise separate conduits such as hoses fluidly connected to separate inlets for inputting fluid to each reciprocating assembly. Of course, numerous other variations may be similarly employed, and therefore, fall within the scope of the present disclosure.
Those skilled in the art will understand that the reciprocating elements of each of the reciprocating assemblies may be operatively connected to the pump power end 12 of the pump 10 according to any suitable manner. For instance, separate connectors (e.g., cranks arms/connecting rods 20, one or more additional components or mechanical linkages 4, pushrods 30, etc.) associated with the pump power end 12 may be coupled to each reciprocating element body or tail end 62. The pump 10 may employ a common crankshaft (e.g., crankshaft 16) or separate crankshafts to drive the multiple reciprocating elements.
As previously discussed, the multiple reciprocating elements may receive a supply of fluid from any suitable fluid source, which may be configured to provide a constant fluid supply. Additionally or alternatively, the pressure of supplied fluid may be increased by adding pressure (e.g., boost pressure) as described previously. In embodiments, the fluid inlet(s) 38 receive a supply of pressurized fluid comprising a pressure ranging from about 30 psi to about 300 psi.
Additionally or alternatively, the one or more discharge outlet(s) 54 may be fluidly connected to a common collection point such as a sump or distribution manifold, which may be configured to collect fluids flowing out of the fluid outlet(s) 54, or another cylinder bank and/or one or more additional pumps.
During pumping, the multiple reciprocating elements 18 will perform forward and returns strokes similarly, as described hereinabove. In embodiments, the multiple reciprocating elements 18 can be angularly offset to ensure that no two reciprocating elements are located at the same position along their respective stroke paths (i.e., the plungers are “out of phase”). For example, the reciprocating elements may be angularly distributed to have a certain offset (e.g., 120 degrees of separation in a Triplex pump) to minimize undesirable effects that may result from multiple reciprocating elements of a single pump simultaneously producing pressure pulses. The position of a reciprocating element is generally based on the number of degrees a pump crankshaft (e.g., crankshaft 16) has rotated from a bottom dead center (BDC) position. The BDC position corresponds to the position of a fully retracted reciprocating element at zero velocity, e.g., just prior to a reciprocating element moving (i.e., in a direction indicated by arrow 117 in
As described above, each reciprocating element 18 is operable to draw in fluid during a suction (backward or return) stroke and discharge fluid during a discharge (forward) stroke. Skilled artisans will understand that the multiple reciprocating elements 18 may be angularly offset or phase-shifted to improve fluid intake for each reciprocating element 18. For instance, a phase degree offset (at 360 degrees divided by the number of reciprocating elements) may be employed to ensure the multiple reciprocating elements 18 receive fluid and/or a certain quantity of fluid at all times of operation. In one implementation, the three reciprocating elements 18 of a Triplex pump may be phase-shifted by a 120-degree offset. Accordingly, when one reciprocating element 18 is at its maximum forward stroke position, a second reciprocating element 18 will be 60 degrees through its discharge stroke from BDC, and a third reciprocating element will be 120 degrees through its suction stroke from top dead center (TDC).
According to this disclosure, pump fluid end 22 comprises at least one valve module comprising a valve assembly. The valve module comprises the entire valve assembly, such that, when the valve assembly or a component thereof needs repairing and/or replacement, the entire valve module can be removed from the pump and a new or previously repaired valve module inserted in the pump fluid end 22. In embodiments, the at least one valve module is a suction valve module comprising a suction valve assembly. In embodiments, the at least one valve module is a discharge valve module comprising a discharge valve assembly. The valve module of this disclosure comprises a cylindrical canister containing a valve assembly. The valve assembly comprises a valve body and a valve seat, configured such that the valve module provides a fluid flow path from an inlet to an outlet of the valve module along a central axis of the valve module and between the valve body and the valve seat when the valve assembly is in an open configuration, and does not provide the fluid flow path when the valve assembly is in a closed configuration. The valve body and the valve seat are coaxially aligned along the central axis. The valve body contacts the valve seat in the closed configuration and does not contact the valve seat in the open configuration.
As detailed further hereinbelow with reference to
As detailed further hereinbelow with reference to
As noted hereinabove, in embodiments the valve assembly is a suction valve assembly and the valve module is a suction valve module.
Suction valve module 70A of
In the exemplary embodiments of
The suction valve module 70A and the discharge valve module 70B provide a fluid flow path (indicated by arrows) from an inlet 40 to an outlet 41 of the respective valve module along the central axis 13 thereof and between the valve body 100 and the valve seat 80 when the valve assembly (e.g., suction valve assembly 56 or discharge valve assembly 72, respectively) is in an open configuration, and does not provide the fluid flow path when the valve assembly is in a closed configuration. The valve body 100 and the valve seat 80 are coaxially aligned along the central axis 13. The valve body 100 contacts the valve seat 80 in the closed configuration and does not contact the valve seat 80 in the open configuration of the valve assembly.
As noted hereinabove, any suitable valve body 100 can be utilized as the valve body of suction valve assembly 56 of suction valve module 70A or discharge valve assembly 72 of discharge valve module 70B. In embodiments, such as depicted in
A valve seat housing 90 is located within cylindrical canister 35 of the valve module (e.g., suction valve module 70A or discharge valve module 70B). Valve seat 80 is positioned within the valve module, such that the valve seat 80 is held in the valve seat housing 90. In embodiments, the valve module further comprises a spring 31. Spring 31 can be coaxially positioned about central axis 13. In embodiments, spring 31 can be positioned closer to one side of the valve module 70A/B (e.g., first side 42 of suction valve module 70A or second side 43 of suction valve module 70A) than valve body 100. For example, spring 31 of the embodiment of
Suction valve module 70A and discharge valve module 70B can further comprise a sealing component 33. Sealing component 33 can be configured to fix one or more of the components of the valve assembly (i.e., suction valve assembly 56 or discharge valve assembly 72) within the valve module, and can be coupled with cylindrical canister 35. For example, in embodiments, a portion of an outer circumference 3 of sealing component 33 can be coupled with a portion of the inner circumference 2 of cylindrical canister 35. In embodiments, the portion of the outer circumference 3 of the sealing component 33 is threadably coupled with the portion of the inner circumference 2 of the cylindrical canister 33. In embodiments, the sealing component 33 comprises a central portion 39 that engages the valve body 100 and/or the spring 31 upon assembly of the valve module. For example, as depicted in the embodiment of
Suction valve module 70A and discharge valve module 70B can further comprise one or more tool engagement features 20, which can be operable for positioning the valve module within a fluid end body 8 of a pump fluid end 22. For example, in the embodiment of
In embodiments, valve seat 80 of suction valve assembly 56 (which is, in embodiments comprised within a suction valve module 70A) or discharge valve assembly 72 (which is, in embodiments comprised within a discharge valve module 70B) is a valve seat with supplemental retention, as described, for example, in U.S. patent application Ser. No. 16/411,898 filed May 14, 2019, which is entitled “Pump Valve Seat with Supplemental Retention”, the disclosure of which is hereby incorporated herein in its entirety for purposes not contrary to this disclosure.
Suction valve module 70A is designed such that, when inserted into a fluid end body 8 of a pump fluid end 22 comprising suction port 38, the inlet 40 of the suction valve module 70A is in fluid communication with the suction port 38. The suction port 38 can be located on a side of suction valve module 70A proximate front S1 of pump fluid end 22 (
With reference to
In embodiments, the valve module (e.g., suction valve module 70A and/or discharge valve module 50B) further comprises a valve guide. The valve guide can be coupled with the valve body 100 and configured to align the valve body 100 within the valve module during assembly thereof. In embodiments, suction valve assembly 56 and/or discharge valve assembly 72 comprises a valve assembly having a valve guide, as described, for example, in U.S. patent application Ser. No. 16/411,910 filed May 14, 2019, which is entitled “Valve Assembly for a Fluid End with Limited Access”, the disclosure of which is hereby incorporated herein in its entirety for purposes not contrary to this disclosure.
In embodiments, the valve module (e.g., suction valve module 70A and/or discharge valve module 70B) further comprises an insert (e.g., an elastomeric insert, such as poppet insert 104), designed to provide a seal between valve seat 80 and valve body 100 in the closed configuration, such that the fluid flow path is not provided. For example, in embodiments, suction valve assembly 56 and/or discharge valve assembly 72 comprises an insert. The insert is coupled with the valve body 100 and, in the closed configuration the insert contacts the valve seat 80 and, in the open configuration the insert does not contact the valve seat 80. In the embodiments of
Also disclosed herein is a pump fluid end 22 comprising a suction valve module 70A and/or a discharge valve module 70B. In embodiments, the pump fluid end 22 of this disclosure comprises a suction valve module 70A. In embodiments, the pump fluid end 22 of this disclosure comprises a discharge valve module 70B. In embodiments, the pump fluid end 22 of this disclosure comprises a suction valve module 70A and a discharge valve module 70B. In multiplex pumps 10 comprising a plurality of reciprocating assemblies, each reciprocating assembly can be associated with a suction valve module 70A and/or a discharge valve module 70B.
As described hereinabove, the pump fluid end 22 comprises a fluid end body 8, a reciprocating element 18 at least partially disposed within a reciprocating element bore 24 of the fluid end body 8, a discharge valve assembly 72 comprising a valve seat 80 (e.g., a discharge valve seat) and a valve body 100 (e.g., a discharge valve body), and a suction valve assembly 56 comprising a valve seat 80 (e.g., a suction valve seat) and a valve body 100 (e.g., a suction valve body). According to this disclosure, the suction valve assembly 56, the discharge valve assembly 72, or both the suction valve assembly 56 and the discharge valve assembly 72 is a valve assembly of a valve module 70A/B of this disclosure. That is, the pump fluid end 22 of this disclosure comprises a suction valve module 70A, a discharge valve module 70B, or both a suction valve module 70A and a discharge valve module 70B inserted within the fluid end body 8. In embodiments, a pump fluid end 22 of this disclosure comprises a suction valve module 70A, wherein the suction valve module 70A comprises a cylindrical canister 35 containing the suction valve assembly 56, wherein the suction valve module 70A provides a fluid flow path from an inlet 40 to an outlet 41 of the suction valve module 70A along a central axis 13 of the cylindrical canister 35 and between the valve body 100 and the valve seat 80 of the suction valve assembly 56 when the suction valve assembly 56 is in an open configuration, and does not provide the fluid flow path when the suction valve assembly 56 is in a closed configuration. In embodiments, a pump fluid end 22 of this disclosure comprises a discharge valve module 70B, wherein the discharge valve module 70B comprises a cylindrical canister 35 containing the discharge valve assembly 72, wherein the discharge valve module 70B provides a fluid flow path from an inlet 40 to an outlet 41 of the discharge valve module 70B along the central axis 13 of the cylindrical canister 35 and between the valve body 100 and the valve seat 80 of the discharge valve assembly 72 when the discharge valve assembly 72 is in an open configuration, and does not provide the fluid flow path when the discharge valve assembly 72 is in a closed configuration. In embodiments, a pump fluid end 22 of this disclosure comprises both a suction valve module 70A and a discharge valve module 70B. As noted hereinabove, the reciprocating element bore 24 has a reciprocating element bore central axis 17.
In embodiments, the pump fluid end 22 is a multi-bore pump fluid end, such as the cross-bore pump fluid end 22 of
As described hereinabove, pump fluid end 22 can comprise a front access port 30A, a top access port 30B, and/or a bottom access port 30C. The valve module(s) (e.g., suction valve module 70A and/or discharge valve module 70B) can be positioned within pump fluid end 22 such that one side thereof is proximate one of the pump fluid end access ports, and can be inserted into and removed from pump fluid end 22 thereby. For example, in the embodiment of
In embodiments, the pump fluid end 22 is a multi-bore pump fluid end, such as the tee-bore pump fluid end 22 of
In embodiments, the pump fluid end 22 is a concentric bore pump fluid end, such as the concentric bore pump fluid end 22 of
One or more sealing elements, such as o-rings 34 depicted in the embodiments of
In embodiments, pump fluid end 22 comprises a packing assembly, such that packing 29, a packing carrier, and a packing screw can be removed from back S2 of pump fluid end 22 when crankshaft 16 is at TDC, as described, for example, in U.S. patent application Ser. No. 16/411,911 filed May 14, 2019, which is entitled “Pump Fluid End with Positional Indifference for Maintenance”, the disclosure of which is hereby incorporated herein in its entirety for purposes not contrary to this disclosure.
In embodiments, pump fluid end 22 comprises a suction valve stop for assisting closure of suction valve assembly 56, as described, for example, in U.S. patent application Ser. No. 16/436,312 filed Jun. 10, 2019, and entitled “Pump Fluid End with Suction Valve Closure Assist”, the disclosure of which is hereby incorporated herein in its entirety for purposes not contrary to this disclosure.
In embodiments, pump 10 of this disclosure is a concentric bore pump fluid end 22 such as depicted in
In embodiments, suction valve assembly 56 of pump fluid end 22 is not modularized, and comprises an easy access suction valve, as described, for example, in U.S. patent application Ser. No. 16/411,891 filed May 14, 2019, which is entitled “Pump Fluid End with Easy Access Suction Valve”, the disclosure of which is hereby incorporated herein in its entirety for purposes not contrary to this disclosure.
In embodiments, reciprocating element 18 comprises tool engagement features on front 60 thereof, whereby reciprocating element 18 can be removed from pump fluid end 22 by engaging a tool with the engagement features, as described, for example, in U.S. patent application Ser. No. 16/411,905 filed May 14, 2019, which is entitled “Pump Plunger with Wrench Features”, the disclosure of which is hereby incorporated herein in its entirety for purposes not contrary to this disclosure.
Also disclosed herein is a pump 10 comprising a pump fluid end 22 of this disclosure, and a pump power end 12 (such as depicted in
In embodiments, reciprocating element 18 is coupled with a pushrod 32 (or another component of mechanical linkages 4 (
A pump 10 of this disclosure can comprise a multi-layer surface coating disposed on reciprocating element 18 and/or a sleeve that provides cylindrical wall 26, as described, for example, in U.S. patent application Ser. No. 16/436,389 filed Jun. 10, 2019 and is entitled “Multi-Layer Coating for Plunger and/or Packing Sleeve”, the disclosure of which is hereby incorporated herein in its entirety for purposes not contrary to this disclosure.
As noted hereinabove, a pump 10 of this disclosure can be a multiplex pump comprising a plurality of reciprocating assemblies (i.e., reciprocating elements 18, and a corresponding plurality of reciprocating element bores 24, suction valve assemblies 56 (some or all of which may each be within a suction valve module 70A), and discharge valve assemblies 72 (some or all of which may be within a discharge valve module 70B)). The plurality can comprise any number such as, for example, 2, 3, 4, 5, 6, 7, or more. For example, in embodiments, pump 10 is a triplex pump, wherein the plurality comprises three. In alternative embodiments, pump 10 comprises a Quintuplex pump, wherein the plurality comprises five.
Also disclosed herein is a method of servicing a pump 10 of this disclosure. The method comprises: opening an access port of a pump fluid end 22 of the pump 10; removing a valve module (a suction valve module 70A and/or a discharge valve module 70B) from the pump fluid end 22; and inserting another valve module (e.g., another suction valve module 70A and/or another discharge valve module 70B, respectively) into the pump fluid end 22.
In embodiments of the method, the valve module is a suction valve module 70A, wherein the valve assembly is a suction valve assembly 56, the valve body 100 is a suction valve body, and the valve seat 80 is a suction valve seat. In some such embodiments, the pump fluid end 22 is a cross-bore pump fluid end, such as depicted in the embodiment of
In embodiments, the valve module is a discharge valve module 70B, wherein the valve assembly is a discharge valve assembly 72, the valve body 100 is a discharge valve body, and the valve seat 80 is a discharge valve seat. In some such embodiments, the pump fluid end 22 is a concentric bore pump fluid end, such as depicted in the embodiment of
As noted hereinabove, in embodiments, the valve module (e.g., the suction valve module 70A and/or the discharge valve module 70B) further comprises one or more tool engagement features 20 whereby the valve module can be pushed and/or pulled by engagement of a tool with the tool engagement features 20. In such embodiments, removing the valve module from the pump fluid end 22 can further comprise engaging the tool with the tool engagement features 20 and pulling the valve module out of the pump fluid end 22. In embodiments, a pulling tool such as mechanical screw type or hydraulic pullers, can be used to pull the valve module out of the pump fluid end.
In embodiments, inserting the another valve module in the pump fluid end 22 further comprises positioning the another valve module at least partially within the pump fluid end 22 and applying a force to the valve module to seat the valve module in the pump fluid end 22. Without the use of the valve module approach disclosed, the valve seats 80 are conventionally pressed into the fluid end 22 using specialized hydraulic or screw type pushing devices that must be attached to the fluid end 22 during the installation process. Using the valve module type approach disclosed herein, such as using the suction valve 70A or discharge valve module 70B, the pressing can be effected at a designated shop or facility, and inserting the valve module can comprise sliding the valve module into the fluid end 22, until prior to engaging of the tight portions. These portions or parts can comprise the sealing portions or components (e.g., sealing component 33) of the valve module. Using the hydraulic preload mechanism, the mechanism can initially be attached to the fluid end, 22 using hand tightening process, and possibly using lightweight tools to deliver a slightly higher torque, until a desired depth is nearly reached. (In embodiments, the total stroke of the mechanism is relatively short, meaning that the slack does not exceed the stroke of the preload mechanism.) Pressurizing the preload mechanism, can be utilized, in embodiments, to push the valve module to its intended location, rendering the valve module ready for use. For example, when the access port is associated with a hydraulic preload mechanism, as described hereinabove, the inserting of the another valve module in the pump fluid end 22 can further comprise utilizing the preload mechanism (e.g., a piston 37 associated therewith) to force the valve module into the fluid end body 8 of the pump fluid end 22. In embodiments, the valve module is a suction valve module 70A and inserting the another valve module in the pump fluid end 22 further comprises aligning inlet 40 and outlet 41 of suction valve module 70A such that inlet 40 is in fluid communication with suction port 38 and suction manifold 83 and outlet 41 of suction valve module 70A is in fluid communication with pump chamber 28. In embodiments, the valve module is a discharge valve module 70B and inserting the another valve module in the pump fluid end 22 further comprises aligning inlet 40 of discharge valve module 70B and outlet 41 of discharge valve module 70B such that inlet 40 of discharge valve module 70B is in fluid communication with pump chamber 28 and outlet 41 of discharge valve module 70B is in fluid communication with discharge outlet 54.
The method can further comprise repairing the valve module removed from the pump fluid end 22 and utilizing it as the another valve module inserted into the pump fluid end 22 (or another pump fluid end 22) during a subsequent servicing of the pump 10 (or a servicing of another pump 10). The repair of the removed valve module can comprise replacing one or more components thereof, and/or can be performed on-site or off-site in a repair shop. In this manner, a time needed for valve assembly (e.g., suction valve assembly 56 and/or discharge valve assembly 72) replacement within the module can be significantly reduced relative to a time needed for replacement of a valve assembly that is not modularized as described herein. In embodiments, during servicing of the pump 10, the pump 10 is offline for the servicing of the pump 10 for a downtime that is at least about 20, 30, 40, 50, 60, 70, or 75% less than a downtime needed for servicing a pump 10 that does not comprise the valve module (e.g., does not comprise a suction valve module 70A and/or a discharge valve module 70B).
Also disclosed herein are a method of servicing a wellbore and a wellbore servicing system 200 comprising a pump of this disclosure. An embodiment of a wellbore servicing system 200 and a method of servicing a wellbore via the wellbore servicing system 200 will now be described with reference to
A method of servicing a wellbore 224 according to this disclosure comprises: fluidly coupling a pump 10 of this disclosure to a source of a wellbore servicing fluid and to the wellbore; and communicating wellbore 224 servicing fluid into the wellbore 224 via the pump 10. According to this disclosure, as described hereinabove, the pump 10 comprises a pump fluid end 22 and a pump power end 12. The pump power end 12 is operable to reciprocate reciprocating element 18 within a reciprocating element bore 24 of the pump fluid end 22. The pump fluid end 22 comprises a fluid end body 8, the reciprocating element 18 at least partially disposed within the reciprocating element bore 24, a discharge valve assembly 72 comprising a (discharge) valve seat 80 and a (discharge) valve body 100, a suction valve assembly 56 comprising a (suction) valve seat 80 and a (suction) valve body 100, and at least one valve module inserted within the fluid end body 8, wherein the valve module comprises a suction valve module 70A or a discharge valve module 70B. As depicted in
In embodiments, the method further comprises discontinuing the communicating of the wellbore servicing fluid into the wellbore 224 via the pump 10, subjecting the pump 10 to maintenance to provide a maintained pump 10, and communicating the or another wellbore servicing fluid into the wellbore 224 via the maintained pump 10. Subjecting the pump 10 to maintenance can comprise servicing the pump 10, as described hereinabove. For example, in embodiments, subjecting the pump 10 to maintenance comprises removing one of the at least one valve modules from the pump fluid end 22 and inserting another valve module into the pump fluid end 22.
It will be appreciated that the wellbore servicing system 200 disclosed herein can be used for any purpose. In embodiments, the wellbore servicing system 200 may be used to service a wellbore 224 that penetrates a subterranean formation by pumping a wellbore servicing fluid into the wellbore and/or subterranean formation. As used herein, a “wellbore servicing fluid” or “servicing fluid” refers to a fluid used to drill, complete, work over, fracture, repair, or in any way prepare a well bore for the recovery of materials residing in a subterranean formation penetrated by the well bore. It is to be understood that “subterranean formation” encompasses both areas below exposed earth and areas below earth covered by water such as ocean or fresh water. Examples of servicing fluids suitable for use as the wellbore servicing fluid, the another wellbore servicing fluid, or both include, but are not limited to, cementitious fluids (e.g., cement slurries), drilling fluids or muds, spacer fluids, fracturing fluids or completion fluids, and gravel pack fluids, remedial fluids, perforating fluids, diverter fluids, sealants, drilling fluids, completion fluids, gelation fluids, polymeric fluids, aqueous fluids, oleaginous fluids, etc.
In embodiments, the wellbore servicing system 200 comprises one or more pumps 10 operable to perform oilfield and/or well servicing operations. Such operations may include, but are not limited to, drilling operations, fracturing operations, perforating operations, fluid loss operations, primary cementing operations, secondary or remedial cementing operations, well abandonment processes, or any combination of operations thereof. Although a wellbore servicing system is illustrated, skilled artisans will readily appreciate that the pump 10 disclosed herein may be employed in any suitable operation.
In embodiments, the wellbore servicing system 200 may be a system such as a fracturing spread for fracturing wells in a hydrocarbon-containing reservoir. In fracturing operations, wellbore servicing fluids, such as particle laden fluids, are pumped at high-pressure into a wellbore. The particle laden fluids may then be introduced into a portion of a subterranean formation at a sufficient pressure and velocity to cut a casing and/or create perforation tunnels and fractures within the subterranean formation. Proppants, such as grains of sand, are mixed with the wellbore servicing fluid to keep the fractures open so that hydrocarbons may be produced from the subterranean formation and flow into the wellbore. Hydraulic fracturing may desirably create high-conductivity fluid communication between the wellbore and the subterranean formation.
The wellbore servicing system 200 comprises a blender 202 that is coupled to a wellbore services manifold trailer 204 via flowline 206. As used herein, the term “wellbore services manifold trailer” includes a truck and/or trailer comprising one or more manifolds for receiving, organizing, and/or distributing wellbore servicing fluids during wellbore servicing operations. In this embodiment, the wellbore services manifold trailer 204 is coupled to six positive displacement pumps (e.g., such as pump 10 that may be mounted to a trailer and transported to the wellsite via a semi-tractor) via outlet flowlines 208 and inlet flowlines 210. In alternative embodiments, however, there may be more or less pumps used in a wellbore servicing operation. Outlet flowlines 208 are outlet lines from the wellbore services manifold trailer 204 that supply fluid to the pumps 10. Inlet flowlines 210 are inlet lines from the pumps 10 that supply fluid to the wellbore services manifold trailer 204.
The blender 202 mixes solid and fluid components to achieve a well-blended wellbore servicing fluid. As depicted, sand or proppant 212, water 214, and additives 216 are fed into the blender 202 via feedlines 218, 220, and 212, respectively. The water 214 may be potable, non-potable, untreated, partially treated, or treated water. In embodiments, the water 214 may be produced water that has been extracted from the wellbore while producing hydrocarbons form the wellbore. The produced water may comprise dissolved and/or entrained organic materials, salts, minerals, paraffins, aromatics, resins, asphaltenes, and/or other natural or synthetic constituents that are displaced from a hydrocarbon formation during the production of the hydrocarbons. In embodiments, the water 214 may be flowback water that has previously been introduced into the wellbore during wellbore servicing operation. The flowback water may comprise some hydrocarbons, gelling agents, friction reducers, surfactants and/or remnants of wellbore servicing fluids previously introduced into the wellbore during wellbore servicing operations.
The water 214 may further comprise local surface water contained in natural and/or manmade water features (such as ditches, ponds, rivers, lakes, oceans, etc.). Still further, the water 214 may comprise water stored in local or remote containers. The water 214 may be water that originated from near the wellbore and/or may be water that has been transported to an area near the wellbore from any distance. In some embodiments, the water 214 may comprise any combination of produced water, flowback water, local surface water, and/or container stored water. In some implementations, water may be substituted by nitrogen or carbon dioxide; some in a foaming condition. In some embodiments, water may be substituted by acids, such as hydrochloric acids or hydrofluoric acids; with acid concentrations that are low (like 4%) to very high (above 30%). Water could be gelled using various gelling agents or even plugging agents. Fuels, such as diesel or produced gas, can also be used as treatment fluid, in embodiments.
In embodiments, the blender 202 may be an Advanced Dry Polymer (ADP) blender and the additives 216 are dry blended and dry fed into the blender 202. In alternative embodiments, however, additives may be pre-blended with water using other suitable blenders, such as, but not limited to, a GEL PRO blender, which is a commercially available preblender trailer from Halliburton Energy Services, Inc., to form a liquid gel concentrate that may be fed into the blender 202. The mixing conditions of the blender 202, including time period, agitation method, pressure, and temperature of the blender 202, may be chosen by one of ordinary skill in the art with the aid of this disclosure to produce a homogeneous blend having a desirable composition, density, and viscosity. In alternative embodiments, however, sand or proppant, water, and additives may be premixed and/or stored in a storage tank before entering a wellbore services manifold trailer 204.
In embodiments, the pump(s) 10 (e.g., pump(s) 10 and/or maintained pump(s) 10) pressurize the wellbore servicing fluid to a pressure suitable for delivery into a wellbore 224 or wellhead. For example, the pumps 10 may increase the pressure of the wellbore servicing fluid (e.g., the wellbore servicing fluid and/or the another wellbore servicing fluid) to a pressure of greater than or equal to about 3,000 psi, 5,000 psi, 10,000 psi, 20,000 psi, 30,000 psi, 40,000 psi, or 50,000 psi, or higher.
From the pumps 10, the wellbore servicing fluid may reenter the wellbore services manifold trailer 204 via inlet flowlines 210 and be combined so that the wellbore servicing fluid may have a total fluid flow rate that exits from the wellbore services manifold trailer 204 through flowline 226 to the flow connector wellbore 1128 of between about 1 BPM to about 200 BPM, alternatively from between about 50 BPM to about 150 BPM, alternatively about 100 BPM. In embodiments, each of one or more pumps 10 discharge wellbore servicing fluid at a fluid flow rate of between about 1 BPM to about 200 BPM, alternatively from between about 50 BPM to about 150 BPM, alternatively about 100 BPM. In embodiments, each of one or more pumps 10 discharge wellbore servicing fluid at a volumetric flow rate of greater than or equal to about 3, 10, or 20 barrels per minute (BPM), or in a range of from about 3 to about 20, from about 10 to about 20, or from about 5 to about 20 BPM.
Persons of ordinary skill in the art with the aid of this disclosure will appreciate that the flowlines described herein are piping that are connected together for example via flanges, collars, welds, etc. These flowlines may include various configurations of pipe tees, elbows, and the like. These flowlines connect together the various wellbore servicing fluid process equipment described herein.
Also disclosed herein are methods for servicing a wellbore (e.g., wellbore 224). Without limitation, servicing the wellbore may include: positioning the wellbore servicing composition in the wellbore 224 (e.g., via one or more pumps 10 as described herein) to isolate the subterranean formation from a portion of the wellbore; to support a conduit in the wellbore; to plug a void or crack in the conduit; to plug a void or crack in a cement sheath disposed in an annulus of the wellbore; to plug a perforation; to plug an opening between the cement sheath and the conduit; to prevent the loss of aqueous or nonaqueous drilling fluids into loss circulation zones such as a void, vugular zone, or fracture; to plug a well for abandonment purposes; to divert treatment fluids; and/or to seal an annulus between the wellbore and an expandable pipe or pipe string. In other embodiments, the wellbore servicing systems and methods may be employed in well completion operations such as primary and secondary cementing operation to isolate the subterranean formation from a different portion of the wellbore.
In embodiments, a wellbore servicing method may comprise transporting a positive displacement pump (e.g., pump 10) to a site for performing a servicing operation. Additionally or alternatively, one or more pumps may be situated on a suitable structural support. Non-limiting examples of a suitable structural support or supports include a trailer, truck, skid, barge or combinations thereof. In embodiments, a motor or other power source for a pump may be situated on a common structural support.
In embodiments, a wellbore servicing method may comprise providing a source for a wellbore servicing fluid. As described above, the wellbore servicing fluid may comprise any suitable fluid or combinations of fluid as may be appropriate based upon the servicing operation being performed. Non-limiting examples of suitable wellbore servicing fluid include a fracturing fluid (e.g., a particle laden fluid, as described herein), a perforating fluid, a cementitious fluid, a sealant, a remedial fluid, a drilling fluid (e.g., mud), a spacer fluid, a gelation fluid, a polymeric fluid, an aqueous fluid, an oleaginous fluid, an emulsion, various other wellbore servicing fluid as will be appreciated by one of skill in the art with the aid of this disclosure, and combinations thereof. The wellbore servicing fluid may be prepared on-site (e.g., via the operation of one or more blenders) or, alternatively, transported to the site of the servicing operation.
In embodiments, a wellbore servicing method may comprise fluidly coupling a pump 10 to the wellbore servicing fluid source. As such, wellbore servicing fluid may be drawn into and emitted from the pump 10. Additionally or alternatively, a portion of a wellbore servicing fluid placed in a wellbore 224 may be recycled, i.e., mixed with the water stream obtained from a water source and treated in fluid treatment system. Furthermore, a wellbore servicing method may comprise conveying the wellbore servicing fluid from its source to the wellbore via the operation of the pump 10 disclosed herein.
In alternative embodiments, the reciprocating apparatus may comprise a compressor. In embodiments, a compressor similar to the pump 10 may comprise at least one each of a cylinder, plunger, connecting rod, crankshaft, and housing, and may be coupled to a motor. In embodiments, such a compressor may be similar in form to a pump and may be configured to compress a compressible fluid (e.g., a gas) and thereby increase the pressure of the compressible fluid. For example, a compressor may be configured to direct the discharge therefrom to a chamber or vessel that collects the compressible fluid from the discharge of the compressor until a predetermined pressure is built up in the chamber. Generally, a pressure sensing device may be arranged and configured to monitor the pressure as it builds up in the chamber and to interact with the compressor when a predetermined pressure is reached. At that point, the compressor may either be shut off, or alternatively the discharge may be directed to another chamber for continued operation.
In embodiments, a reciprocating apparatus comprises an internal combustion engine, hereinafter referred to as an engine. Such engines are also well known, and typically include at least one each of a plunger, cylinder, connecting rod, and crankshaft. The arrangement of these components is substantially the same in an engine and a pump (e.g. pump 10). A reciprocating element 18 such as a plunger may be similarly arranged to move in reciprocating fashion within the cylinder. Skilled artisans will appreciate that operation of an engine may somewhat differ from that of a pump. In a pump, rotational power is generally applied to a crankshaft acting on the plunger via the connecting rod, whereas in an engine, rotational power generally results from a force (e.g., an internal combustion) exerted on or against the plunger, which acts against the crankshaft via the connecting rod.
For example, in a typical 4-stroke engine, arbitrarily beginning with the exhaust stroke, the plunger is fully extended during the exhaust stroke, (e.g., minimizing the internal volume of the cylinder). The plunger may then be retracted by inertia or other forces of the engine componentry during the intake stroke. As the plunger retracts within the cylinder, the internal volume of cylinder increases, creating a low pressure within the cylinder into which an air/fuel mixture is drawn. When the plunger is fully retracted within the cylinder, the intake stroke is complete, and the cylinder is substantially filled with the air/fuel mixture. As the crankshaft continues to rotate, the plunger may then be extended, during the compression stroke, into the cylinder compressing the air-fuel mixture within the cylinder to a higher pressure.
A spark plug may be provided to ignite the fuel at a predetermined point in the compression stroke. This ignition increases the temperature and pressure within the cylinder substantially and rapidly. In a diesel engine, however, the spark plug may be omitted, as the heat of compression derived from the high compression ratios associated with diesel engines suffices to provide spontaneous combustion of the air-fuel mixture. In either case, the heat and pressure act forcibly against the plunger and cause it to retract back into the cylinder during the power cycle at a substantial force, which may then be exerted on the connecting rod, and thereby on to the crankshaft.
Those of ordinary skill in the art will readily appreciate various benefits that may be realized by the present disclosure. For instance, the herein disclosed pump fluid end 22 design comprising a valve module (e.g., a suction valve module 70A and/or a discharge valve module 70B) according to this disclosure enables rapid replacement of a valve assembly (e.g., a suction valve assembly 56 and/or a discharge valve assembly 72). The use of a modularized valve assembly can reduce a downtime of a pump 10 for replacement of a suction valve assembly 56 and/or a discharge valve assembly 72. By utilizing a valve module that contains all the parts of the suction valve assembly 56 or the discharge valve assembly 72 (e.g., valve/body 100, insert/seal 104, valve seat 80, valve spring 31, and/or flow paths (indicated by arrows in
As operating pumps at high pressure can result in erosion, corrosion, and cracking of components such as components of a valve assembly, high costs can be incurred (e.g., for parts and downtime) for replacing such components, and reducing downtime as described herein can reduce costs. By utilizing valve module(s) as disclosed herein, a valve assembly can be removed from a pump fluid end 22 and quickly replaced with a new or previously repaired valve module(s). The removed valve module can be repaired or refurbished (e.g., sent to a shop for repair), and subsequently utilized as a replacement valve module for the or another pump fluid end 22. Via the utilization of the valve module(s) as per this disclosure, time is not lost separately removing various components (e.g., a valve spring 31, a valve guide, a valve body (e.g., a valve poppet assembly) 100, a valve disabler 50 and/or a valve seat 80 of a valve assembly) from the pump fluid end 22 and inserting a replacement (e.g., a new or repaired) valve disabler, valve seat 80, valve guide, valve body (e.g., a valve poppet assembly) 100, and/or a valve spring into the pump fluid end 22.
The following are non-limiting, specific embodiments in accordance with the present disclosure:
Embodiment A: A valve module comprising: a cylindrical canister containing a valve assembly for a high pressure pump, wherein the valve assembly comprises a valve body and a valve seat, wherein the valve module provides a fluid flow path from an inlet to an outlet of the valve module from one side of the valve seat along a central axis of the valve module to the other side of the valve seat along the central axis and between the valve body and the valve seat when the valve assembly is in an open configuration, and does not provide the fluid flow path when the valve assembly is in a closed configuration.
Embodiment B: The valve module of Embodiment A, wherein the inlet and the outlet of the valve module are centrally aligned along the central axis of the valve module.
Embodiment C: The valve module of Embodiment A, wherein the inlet and the outlet of the valve module are angularly aligned along the central axis of the valve module.
Embodiment D: The valve module of any of Embodiment A to Embodiment C, wherein the valve body and the valve seat are coaxially aligned along the central axis of the valve module.
Embodiment E: The valve module of any of Embodiment A to Embodiment D, wherein the valve body contacts the valve seat in the closed configuration and does not contact the valve seat in the open configuration.
Embodiment F: The valve module of any of Embodiment A to Embodiment E, wherein the cylindrical canister further comprises one or more tool engagement features whereby the valve module can be pushed and/or pulled by engagement of a tool with the tool engagement features.
Embodiment G: The valve module of Embodiment F, wherein the one or more tool engagement features are located on a top side or a bottom side of the valve module.
Embodiment H: The valve module of any of Embodiment A to Embodiment G, wherein the valve assembly is a discharge valve assembly.
Embodiment I: The valve module of any of Embodiment H, wherein the valve module is designed such that, when inserted into a fluid end body of a pump fluid end comprising a discharge port, the outlet of the valve module aligns with the discharge port.
Embodiment J: The valve module of any of Embodiment A to Embodiment G, wherein the valve assembly is a suction valve assembly.
Embodiment K: The valve module of Embodiment J, wherein the valve module is designed such that, when inserted into a fluid end body of a pump fluid end comprising a suction port, the inlet of the valve module aligns with the suction port.
Embodiment L: The valve module of Embodiment J or Embodiment K further comprising a valve disabler, wherein the valve disabler is cylindrical and is aligned with the valve body along the central axis, such that, when actuated, the valve disabler can prevent contact of the valve body with the valve seat.
Embodiment M: The valve module of Embodiment L, wherein the valve disabler is hydraulically, electrically or mechanically actuatable.
Embodiment N: The valve module of any of Embodiment A to Embodiment M, wherein the valve body comprises a poppet.
Embodiment O: The valve module of any of Embodiment A to Embodiment N, wherein the valve assembly further comprises a valve guide, an insert, or a combination thereof, wherein the valve guide is coupled with the valve body and configured to align the valve body within the valve module during assembly thereof, and wherein the insert is coupled with the valve body and, in the closed configuration the insert contacts the valve seat and, in the open configuration the insert does not contact the valve seat.
Embodiment P: A pump fluid end comprising: a fluid end body; a reciprocating element at least partially disposed within a reciprocating element bore of the fluid end body, wherein the reciprocating element bore has a reciprocating element bore central axis; a discharge valve assembly comprising a discharge valve seat and a discharge valve body; a suction valve assembly comprising a suction valve seat and a suction valve body; and a suction valve module, a discharge valve module, or both a suction valve module and a discharge valve module inserted within the fluid end body, wherein the suction valve module comprises a cylindrical canister containing the suction valve assembly, wherein the suction valve module provides a fluid flow path from an inlet to an outlet of the valve module from one side of the valve seat along a central axis of the valve module to the other side of the valve seat along the central axis and between the valve body and the valve seat when the suction valve assembly is in an open configuration, and does not provide the fluid flow path when the suction valve assembly is in a closed configuration, and wherein the discharge valve module comprises a cylindrical canister containing the discharge valve assembly, wherein the discharge valve module provides a fluid flow path from an inlet to an outlet of the valve module from one side of the valve seat along a central axis of the valve module to the other side of the valve seat along the central axis and between the valve body and the valve seat when the discharge valve assembly is in an open configuration, and does not provide the fluid flow path when the discharge valve assembly is in a closed configuration.
Embodiment Q: The pump fluid end of Embodiment P, wherein the pump fluid end is a cross-bore pump fluid end and comprises the suction valve module and the discharge valve module.
Embodiment R: The pump fluid end of Embodiment Q, wherein the cross-bore pump fluid end is a T-bore pump fluid end.
Embodiment S: The pump fluid end of Embodiment P, wherein the pump fluid end is a concentric bore pump fluid end and comprises the discharge valve module.
Embodiment T: A pump comprising: the pump fluid end of any of Embodiment P to Embodiment S; and a pump power end, wherein the pump power end is operable to reciprocate the reciprocating element within the reciprocating element bore of the pump fluid end.
Embodiment U: The pump of Embodiment T, wherein the pump fluid end comprises the suction valve module.
Embodiment V: The pump of Embodiment U, wherein the fluid end body further comprises a suction port, and wherein the inlet of the suction valve module aligns with the suction port of the fluid end body.
Embodiment W: The pump of Embodiment U or Embodiment V, wherein the suction valve module further comprises a valve disabler.
Embodiment X: The pump of Embodiment W, wherein the suction valve disabler is hydraulically or mechanically actuatable.
Embodiment Y: The pump of any of Embodiment T to Embodiment X, wherein the pump fluid end comprises the discharge valve module.
Embodiment Z1: The pump of Embodiment Y, wherein the fluid end body further comprises a discharge port, and wherein the outlet of the discharge valve module aligns with the discharge port of the fluid end body.
Embodiment Z2: A method of servicing a pump, the method comprising: opening an access port of a pump fluid end of the pump; removing a valve module from the pump fluid end; and inserting another valve module into the pump fluid end, wherein the valve module comprises: a cylindrical canister containing a valve assembly, wherein the valve assembly comprises a valve body and a valve seat, wherein the valve module provides a fluid flow path from an inlet to an outlet of the valve module from one side of the valve seat along a central axis of the valve module to the other side of the valve seat along the central axis and between the valve body and the valve seat when the valve assembly is in an open configuration, and does not provide the fluid flow path when the valve assembly is in a closed configuration.
Embodiment Z3: The method of Embodiment Z2, wherein the valve module is a suction valve module, wherein the valve assembly is a suction valve assembly, wherein the valve body is a suction valve body, and wherein the valve seat is a suction valve seat.
Embodiment Z4: The method of Embodiment Z3 wherein the pump fluid end is a cross-bore pump fluid end, and wherein the access port is a bottom access port located on a side of the suction valve module opposite the outlet thereof.
Embodiment Z5: The method of Embodiment Z2, wherein the valve module is a discharge valve module, wherein the valve assembly is a discharge valve assembly, wherein the valve body is a discharge valve body, and wherein the valve seat is a discharge valve seat.
Embodiment Z6: The method of Embodiment Z5, wherein the pump fluid end is a concentric bore pump fluid end, and wherein the access port is a front access port located on a side of the discharge valve module opposite the inlet thereof.
Embodiment Z7: The method of Embodiment Z5, wherein the pump fluid end is a cross-bore pump fluid end, and wherein the access port is a top access port located on a side of the discharge valve module opposite the inlet thereof.
Embodiment Z8 The method of Embodiment Z2, wherein the valve module further comprises one or more tool engagement features whereby the valve module can be pushed and/or pulled by engagement of a tool with the tool engagement features, and wherein removing the valve module from the pump fluid end further comprises engaging the tool with the tool engagement features and pulling the valve module.
Embodiment Z9: The method of any Embodiment Z2 to Embodiment Z8, wherein inserting the another valve module in the pump fluid end further comprises positioning the another valve module at least partially within the pump fluid end and applying a force to the valve module to seat the valve module in the pump fluid end.
Embodiment Z10: The method of Embodiment Z9, wherein applying the force to the valve module to seat the valve module in the pump fluid end comprises hammering, pressing with a piston, or a combination thereof.
Embodiment Z11: The method of Embodiment Z10, wherein the access port is associated with a hydraulic preload mechanism, and wherein the inserting of the another valve module in the pump fluid end further comprises utilizing the preload mechanism.
Embodiment Z12: The method of any of Embodiment Z2 to Embodiment Z11 further comprising repairing the valve module removed from the pump fluid end and utilizing it as the another valve module inserted into the pump fluid end during a subsequent servicing of the pump or a servicing of another pump.
Embodiment Z13: The method of any of Embodiment Z2 to Embodiment Z12, wherein the pump is offline for the servicing of the pump for a downtime that is at least about 20, 30, 40, 50, 60, 70, or 75% less than a downtime needed for servicing a pump that does not comprise the valve module.
Embodiment Z14: A method of servicing a wellbore, the method comprising: fluidly coupling a pump to a source of a wellbore servicing fluid and to the wellbore; and communicating wellbore servicing fluid into the wellbore via the pump, wherein the pump comprises a pump fluid end and a pump power end, wherein the pump power end is operable to reciprocate a reciprocating element within a reciprocating element bore of the pump fluid end, and wherein the pump fluid end comprises: a fluid end body; the reciprocating element at least partially disposed within the reciprocating element bore, wherein the reciprocating element bore has a reciprocating element bore central axis; a discharge valve assembly comprising a discharge valve seat and a discharge valve body; a suction valve assembly comprising a suction valve seat and a suction valve body; and at least one valve module inserted within the fluid end body, wherein the at least one valve module comprises a suction valve module and/or a discharge valve module, wherein the suction valve module comprises a cylindrical canister containing the suction valve assembly, wherein the suction valve module provides from an inlet to an outlet of the suction valve module from one side of the suction valve seat along a central axis of the suction valve module to the other side of the suction valve seat along the central axis and between the suction valve body and the suction valve seat when the suction valve assembly is in an open configuration, and does not provide the fluid flow path when the suction valve assembly is in a closed configuration, and wherein the discharge valve module comprises a cylindrical canister containing the discharge valve assembly, wherein the discharge valve module provides a fluid flow path from an inlet to an outlet of the discharge valve module from one side of the discharge valve seat along a central axis of the discharge valve module to the other side of the discharge valve seat along the central axis and between the discharge valve body and the discharge valve seat when the discharge valve assembly is in an open configuration, and does not provide the fluid flow path when the discharge valve assembly is in a closed configuration.
Embodiment Z15: The method of Embodiment Z14 further comprising: discontinuing the communicating of the wellbore servicing fluid into the wellbore via the pump; subjecting the pump to maintenance to provide a maintained pump; and communicating the or another wellbore servicing fluid into the wellbore via the maintained pump, wherein subjecting the pump to maintenance comprises: removing one of the at least one valve modules from the pump fluid end and inserting another valve module into the pump fluid end.
Embodiment Z16: The method of Embodiment Z14 or Embodiment Z15, wherein the wellbore servicing fluid, the another wellbore servicing fluid, or both the wellbore servicing fluid and the another wellbore servicing fluid comprise a fracturing fluid, a cementitious fluid, a remedial fluid, a perforating fluid, a sealant, a drilling fluid, a spacer fluid, a completion fluid, a gravel pack fluid, a gelation fluid, a polymeric fluid, an aqueous fluid, an oleaginous fluid, or a combination thereof.
Embodiment Z17: The method of any of Embodiment Z14 to Embodiment Z16, wherein the pump or the maintained pump operates during the pumping of the wellbore servicing fluid or the another wellbore servicing fluid at a pressure of greater than or equal to about 3,000 psi, 5,000 psi, 10,000 psi, 20,000 psi, 30,000 psi, 40,000 psi, or 50,000 psi.
Embodiment Z18: The method of any of Embodiment Z14 to Embodiment Z17, wherein the pump or the maintained pump operates during the pumping of the wellbore servicing fluid or the another wellbore servicing fluid at a volumetric flow rate of greater than or equal to about 3, 10, or 20 barrels per minute (BPM), or in a range of from about 3 to about 20, from about 10 to about 20, or from about 5 to about 20 BPM.
Embodiment Z19: A valve module comprising: a cylindrical canister containing: a valve assembly comprising a valve body and a valve seat, a valve seat housing, a spring, and a sealing component, wherein the valve body and the valve seat are coaxially aligned along a central axis of the valve module, wherein the valve body does not contact the valve seat in an open configuration and contacts the valve seat in a closed configuration, wherein the valve seat is seated in a valve seat housing of the cylindrical canister, wherein the spring is coupled with the valve body, and wherein the sealing component is coupled with the cylindrical canister and with the valve body and retains the valve body in position within the valve module; wherein the valve module provides a fluid flow path from an inlet to an outlet of the valve module from one side of the valve seat along a central axis of the valve module to the other side of the valve seat along the central axis and between the valve body and the valve seat when the valve assembly is in the open configuration, and does not provide the fluid flow path when the valve assembly is in the closed configuration.
Embodiment Z20: The valve module of Embodiment Z19, wherein the cylindrical canister further contains a valve disabler, wherein the valve disabler comprises a cylindrical piston coaxially aligned along the central axis of the valve module on a side of the valve body opposite the outlet of the valve module, wherein the valve disabler is operable to prevent the valve assembly from assuming the closed configuration.
Embodiment Z21: The valve module of Embodiment Z19 or Embodiment Z20, wherein the inlet is perpendicular to the central axis of the valve module or parallel to the central axis of the valve module.
While embodiments have been shown and described, modifications thereof can be made by one skilled in the art without departing from the spirit and teachings of this disclosure. The embodiments described herein are exemplary only, and are not intended to be limiting. Many variations and modifications of the embodiments disclosed herein are possible and are within the scope of this disclosure. Where numerical ranges or limitations are expressly stated, such express ranges or limitations should be understood to include iterative ranges or limitations of like magnitude falling within the expressly stated ranges or limitations (e.g., from about 1 to about 10 includes, 2, 3, 4, etc.; greater than 0.10 includes 0.11, 0.12, 0.13, etc.). For example, whenever a numerical range with a lower limit, Rl, and an upper limit, Ru, is disclosed, any number falling within the range is specifically disclosed. In particular, the following numbers within the range are specifically disclosed: R=Rl+k*(Ru−Rl), wherein k is a variable ranging from 1 percent to 100 percent with a 1 percent increment, i.e., k is 1 percent, 2 percent, 3 percent, 4 percent, 5 percent, . . . 50 percent, 51 percent, 52 percent, . . . , 95 percent, 96 percent, 97 percent, 98 percent, 99 percent, or 100 percent. Moreover, any numerical range defined by two R numbers as defined in the above is also specifically disclosed. Use of the term “optionally” with respect to any element of a claim is intended to mean that the subject element is required, or alternatively, is not required. Both alternatives are intended to be within the scope of the claim. Use of broader terms such as comprises, includes, having, etc. should be understood to provide support for narrower terms such as consisting of, consisting essentially of, comprised substantially of, etc.
Accordingly, the scope of protection is not limited by the description set out above but is only limited by the claims which follow, that scope including all equivalents of the subject matter of the claims. Each and every claim is incorporated into the specification as an embodiment of the present disclosure. Thus, the claims are a further description and are an addition to the embodiments of the present disclosure. The discussion of a reference herein is not an admission that it is prior art, especially any reference that may have a publication date after the priority date of this application. The disclosures of all patents, patent applications, and publications cited herein are hereby incorporated by reference, to the extent that they provide exemplary, procedural, or other details supplementary to those set forth herein.
