System for Distributing Working Fluid Flow Across Inlet Passages of Reciprocating Pumps

The present disclosure relates to a reciprocating pump. More particularly, the present disclosure relates to a system and method for distributing a working fluid flow across multiple inlet passages of the reciprocating pump.

Reciprocating pumps are used in a variety of industrial operations such as fracturing, cementing, acidizing, gravel packing, snubbing, and the like. A reciprocating pump typically includes a fluid end and a power end that drives the fluid end. The fluid end may include a suction manifold to receive a working fluid. The fluid end of the pump may also include plungers to draw the working fluid from the suction manifold (e.g., into inlet passages of the fluid end) and further push out the working fluid (e.g., at high pressure) into a discharge manifold.

Over a period, proppant (which may include uniform-sized solid particles such as sand) in the working fluid may accumulate and become lodged in certain regions of the suction manifold. This may cause some valves and/or valve seats, associated with the inlet passages, to pass through more proppant than others. In effect, uneven proppant distribution in the suction manifold can result in a non-uniform flow of the working fluid into the inlet passages of the fluid end and thus may cause some valves and/or valve seats to wear out sooner than others. This may shorten the pump's maintenance cycle and may also affect an overall productivity of the reciprocating pump.

United States Patent Application No.: 2023/0321681 discloses a material spreader that permits selective liquid treatment of particulate material from the same spreader bed. The spreader bed includes a hopper, a plurality of chain belts, a liquid treatment system, and a mixing and drying assembly that delivers the treated particulate material to the spreaders. Selective bypass permits non-treated particulate material to be spread without contamination from the liquid treatment.

In an embodiment, the present disclosure relates to a system for distributing a fluid flow across multiple inlet passages of a reciprocating pump. The system comprises an auger configured to be positioned into a suction manifold fluidly coupled with the multiple inlet passages of the reciprocating pump. The auger defines an axis, a first axial end, a second axial end, and a helical body extending between the first axial end and the second axial end. The auger is receivable into the suction manifold such that the first axial end is positioned to receive the fluid flow and force the fluid to move along a helical path defined by the helical body to introduce an angular momentum into the fluid flow. Further, the second axial end is positioned towards an opening of the suction manifold. The system further comprises an end flange fixedly coupled to the second axial end proximate the opening and a clamp arrangement for the auger. The clamp arrangement is movable between a clamped state and an unclamped state. In the clamped state, the clamp arrangement engages the end flange with an end of the suction manifold defining the opening to removably and immovably retain the auger within the suction manifold. In the unclamped state, the auger is removable from the suction manifold through the opening.

In another embodiment, the present disclosure relates to a system comprising an auger configured to be positioned into a suction manifold that is fluidly coupled with multiple inlet passages of a reciprocating pump. The auger defines an axis, a first axial end, a second axial end, and a helical body extending between the first axial end and the second axial end. The system further includes an end flange fixedly coupled to the second axial end. The system further includes an end support fixedly coupled to the first axial end and configured to fit with the suction manifold to center the first axial end of the auger relative to the suction manifold. The system further includes a plurality of coupler rods fixedly connected to the helical body and fixedly connected between the end support and the end flange to fixedly retain the end support and the end flange with the helical body.

In another embodiment, the present disclosure relates to a method for distributing a fluid flow across multiple inlet passages of a reciprocating pump. The method includes positioning an auger into a suction manifold fluidly coupled with the multiple inlet passages of the reciprocating pump. The auger defines an axis, a first axial end, a second axial end, and a helical body extending between the first axial end and the second axial end. The auger is receivable into the suction manifold such that the first axial end is positioned to receive the fluid flow and force the fluid to move along a helical path defined by the helical body to induce an angular momentum into the fluid flow. The second axial end is positioned towards an opening of the suction manifold. The method further includes fixedly coupling an end flange to the second axial end proximate the opening. The method further includes using a clamp arrangement for the auger. The clamp arrangement is movable between a clamped state and an unclamped state. In the clamped state, the clamp arrangement engages the end flange with an end of the suction manifold defining the opening to removably and immovably retain the auger within the suction manifold. In the unclamped state, the auger is removable from the suction manifold through the opening.

Reference will now be made in detail to specific embodiments or features, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or the like parts.

Referring to, an exemplary reciprocating pumpis described. In the embodiment illustrated, the reciprocating pumpmay be used in a variety of industrial operations such as, but not limited to, fracturing, cementing, acidizing, gravel packing, snubbing, and the like. The reciprocating pumpmay include a power end, and a fluid end. The power endis coupled to the fluid end. The power endmay include a crank assembly (not shown) which may be driven by an external power source (not shown), such as but not limited to, an engine, a motor, and the like, which allows the reciprocating pumpto draw a fluid (e.g., fracking fluid) from a reservoir (not shown) into the fluid end. The fracturing fluid is commonly called a slurry, which may be a mixture of water, abrasive proppants (silica sand or ceramic), and corrosive chemical additives.

Referring to, the fluid endmay include a cylinder block. The cylinder blockmay include multiple inlet passagesand external surfaces. For example, the cylinder blockincludes a mounting surfacethat may be directed towards the power endand used to secure the fluid endto the power end, e.g. by using fasteners or bolts. The cylinder blockfurther includes a first surface or a top surface′, a second surface or a bottom surface″opposite to the top surface, and a third surface or a front surface′″. The cylinder blockmay be formed from a high strength steel via a forging process. In some embodiments, the fluid endmay be formed of any other material known in the art via alternate manufacturing process such as, but not limited to, casting, additive manufacturing, and the like.

Referring to, as shown in the cross-sectional view of the cylinder blockof the fluid end, the cylinder blockincludes a first internal surface, a second internal surface, a third internal surface, and a fourth internal surface. The cylinder blockdefines a first set of fluid boresand a discharge manifold. The cylinder blockmay further define other sets of fluid bores (e.g., a second set of fluid bores, a third set of fluid bores, and the like) positioned in line with the first set of fluid bores. The first set of fluid boresmay include multiple fluid bores (e.g., a first boredefined by the first internal surface, a second boredefined by the second internal surface, a third boredefined by the third internal surface, and a fourth boredefined by the fourth internal surface). The cylinder blockof the fluid endfurther defines a common volume chamberthat fluidly couples the first bore, the second bore, the third bore, and the fourth borewith each other. The first boremay extend from the second surface″ to the common volume chamber. The second boremay extend from the mounting surfaceto the common volume chamber. The third boremay extend from the third surface″′ to the common volume chamber. The fourth boremay extend from the first surface′ to the common volume chamber.

The second boreis configured to receive a plungerof the power end. The plungeris configured to reciprocate within the second bore(e.g., with the help of the crank assembly of the power end) to selectively generate a negative pressure and a positive pressure in the first set of fluid bores. For example, the negative pressure is generated in the first set of fluid boresto receive a fluid flow and the positive pressure is generated in the first set of fluid boresto discharge the fluid flow out from the first set of fluid bores. The fourth boreis fluidly coupled to a discharge passage, defined in the cylinder blockof the fluid end, which serves as a passageway to transmit the fluid (e.g., a pressurized fracking fluid) from the fourth boreto the discharge manifold.

The first boreis configured to receive an inlet valve. The inlet valveengages with the first internal surface. The inlet valvemay include a valve seatand a valve memberengaged therewith. Similarly, the fourth boreis configured to receive an outlet valve. The outlet valveengages with the fourth internal surface. The outlet valvemay include a valve seatand a valve memberengaged therewith. In some embodiments, each of the inlet valveand the outlet valvemay be a spring-loaded, unidirectional valve that is actuated by a predetermined pressure differential thereacross.

The fourth boreis configured to receive a plugand a fastener. The plugand the fastenerengage with the fourth internal surface. In some embodiments, the fastenermay be disconnected from the fluid endto provide access to the plug, the outlet valve, the fourth bore, and/or the plunger. The third boreis configured to receive another plugand another fastener. The plugand the fastenerengage with the third internal surface. In some embodiments, the fastenermay be disconnected from the fluid endto provide access to the plug, the third bore, or the inlet valve. The configuration of other multiple sets of fluid bores(e.g., the second set of fluid bores, the third set of fluid bores, and the like) may be similar to that of the first set of fluid bores.

The cylinder blockof the fluid endfurther includes the multiple inlet passages(e.g., a first inlet passage′, a second inlet passage″, a third inlet passage″′, and the like.). Each of the multiple inlet passagesmay be connected to at least a bore of the multiple sets of fluid bores. For example, the first inlet passage′ may be fluidly coupled to the first boreof the first set of fluid bores. Similarly, the other inlet passages (e.g., the second inlet passage″, the third inlet passage″′, and the like) may be respectively fluidly coupled to first bores of the other sets of fluid bores (e.g., the second set of fluid bores, the third set of fluid bores, and the like).

In operation of the reciprocating pump, as the reciprocating pumpis powered by an engine or a motor, the plungerstarts to reciprocate within the second boreand thus moves in and out relative to the common volume chamber. While the plungerexecutes a stroke in the second bore, as the plungerreciprocates out of the common volume chamber(see direction, F) (see), negative pressure may be generated inside the common volume chamber, causing the inlet valveto move to an open position, e.g., the valve membermoves upward relative to the valve seat. As a result, fluid (e.g., fracking fluid) flows through the first boreand the inlet valve, and is drawn into the common volume chamber. As the fluid flows through the inlet valveand moves into the common volume chamber, the outlet valveremains in its closed position.

Fluid continues to be drawn into the common volume chamberthrough the first boreand the inlet valveuntil the plungerreaches to an end of its stroke, e.g., away from the common volume chamber. At this point, the valve memberof the inlet valvemoves downward, causing the inlet valveto move to a closed position, e.g., the inlet valve membermoves downward relative to the valve seat. As a result, the fluid (e.g., fracking fluid) stops its flows through the first boreand the inlet valve, in turn halting further ingress of fluid into the common volume chamber.

As part of a subsequent stroke, as the plungerreverses its reciprocating direction (see direction, R) (see) and moves towards the common volume chamber, positive pressure within the common volume chamberis generated, causing the outlet valveto move to an open position. The open position of the outlet valvepermits fluid received within the first boreto be pushed out of the common volume chamber, through the fourth bore, and the outlet valve, into the discharge passage. As the fluid discharges and flows out through the fourth boreand the outlet valveinto the discharge passage, the inlet valveremains in its closed position. As the plungerreaches to an end of this subsequent stroke towards the common volume chamber, the fluid is pushed out (e.g., completely) and the outlet valvereturns to its closed position. The foregoing process may be repeated multiple times during a work cycle for continuous fluid influx and discharge relative to the reciprocating pump.

Referring again to, the fluid endfurther includes a suction manifold. The suction manifoldmay include a linearly extending, hollow cylindrical profile, defining a length, L, and may include openingsdefined exemplarily along the length, L. The openingsmay be fluidly coupled with the inlet passagesof the fluid endand, in some embodiments, may be disposed transversely or orthogonally to the inlet passages. The suction manifoldfurther includes an inner walland an inletdisposed on a first endof the suction manifoldand is configured to receive the fluid flow, e.g., from a reservoir or from a low-pressure line (not shown). The suction manifolddefines an endand an openingdisposed at the end, which may be located opposite to the first end.

Referring now to, the reciprocating pumpfurther includes a systemfor distributing (e.g., evenly distributing) the fluid flow across the multiple inlet passagesof the fluid end. The systemincludes an auger. The augeris positioned into and/or is received within the suction manifold(also see). The augerdefines an axis, A, as shown in, a first axial end, a second axial end, and a helical bodyextending (e.g., longitudinally extending) between the first axial endand the second axial endand along the axis, A. The helical bodyof the augermay define an outer diameter, Do, an inner diameter, Di, and a pitch, P. In some embodiments, the helical bodymay include a tapered cross-section from the outer diameter, Do, to the inner diameter, Di, of the helical blade (see). That is, the helical bodymay include a cross-sectional area defined at the outer diameter, Do, less than a cross-sectional area defined at the inner diameter, Di, of the helical body. In some embodiments, said cross-sectional area defined at the outer diameter and said cross-sectional area defined at the inner diameter of the augerremains consistent along or throughout the length of the helical body. The helical bodymay further define a helical face configured to receive the fluid flow from the inlet. The augermay further define dimensionally identical profiles (e.g., circular profiles) at each of the first axial endand the second axial end. Further, the augerdefines a void, V, passing through the helical bodyto define an inner helical peripheryof the helical body. The void, V, may be a longitudinal void about which the helical bodymay be wound around (e.g., spirally would around to define the helical path). In some embodiments, the void, V, defines a constant diameter or cross-section along the entire length of the helical body.

The augermay be placed within the suction manifoldin such a way that the first axial endof the augeris positioned to receive the fluid flow received through the inletof the suction manifold. In this regard, the first axial endmay be positioned towards the inlet, while the second axial endmay be positioned towards the opening. The augeris further configured to force the fluid to enable the fluid to move along a helical path, H, defined by the helical bodyto introduce an angular momentum into the fluid flow causing portions of the fluid flow to be pushed into the one or more of the inlet passagesas the portions of the fluid flow move along the helical path, H.

The systemfurther includes an end flangefixedly coupled to the second axial end. For instance, the end flangeis fixedly coupled to the second axial endproximate the opening. The end flangedefines a baseand a stepped surfaceextending from the base. The stepped surfaceis configured to be inserted or plugged into the suction manifoldthrough the openingto center the second axial endof the augerrelative to the suction manifold. The baseis configured to rest against the endof the suction manifold. In some embodiments, the baseand the stepped surfaceare concentric to each other. In some embodiments, an outer diameter of the basemay be equal to an outer diameter of the suction manifold. Further, an outer diameter of the stepped surfacemay be slightly less than the inner diameter of the suction manifold, such that the stepped surfacesnugly fits with the inner wallof the suction manifoldthrough the opening. In some embodiments, the basemay be connected to the stepped surfaceby using fasteners (not shown). In some embodiments, the baseand the stepped surfaceare fabricated from a single piece of metal.

Referring now to, the systemfurther includes a plurality of coupler rods. In some embodiments, the coupler rodsare linear and cylindrical in shape, however, different shapes, cross-sections, profiles, of the coupler rodsmay be contemplated. The coupler rodsmay be fixedly connected to the inner helical peripheryof the auger. For example, the coupler rodsare fixedly connected (e.g., by welding) to the inner helical peripheryof the auger. The coupler rodsare further connected to the end flangeto fixedly retain the end flangewith the helical body. In some embodiments, the coupler rodsmay be connected to a cylindrical hubdisposed (e.g., integrally formed) on the end flange. For example, the coupler rodsmay be inserted correspondingly into slotsdefined on the cylindrical hub. In some embodiments, the coupler rodsare arranged in a rotational array around the axis, A. Each coupler rodis equidistantly spaced with respect to one another (or to another coupler rod) along the rotational array to rigidly support the helical bodywith the end flange. In some embodiments, the coupler rodsinclude three coupler rodsseparated by an angular offset ofdegrees, along the rotational array. Use of higher or lesser number of coupler rodsmay be contemplated.

The systemfurther includes an end supportfixedly coupled to the first axial endof the auger. The end supportis engageable with the suction manifoldto center the first axial endof the augerrelative to the suction manifold. In some embodiments, the end supportis configured to fit with the suction manifoldto center the first axial endof the augerrelative to the suction manifold. The end supportincludes a hub, an outer ringcircumventing the hub, and abuttable with the inner wallof the suction manifold. The end supportfurther includes a plurality of spokescoupling the hubwith the outer ring. The plurality of coupler rodsis fixedly connected to the hub. In some embodiments, the coupler rodsmay be connected to the cylindrical hubdisposed (e.g., integrally formed) on the end support. For example, the coupler rodsmay be inserted correspondingly into slotsdefined on the cylindrical hub. In some embodiments, the coupler rodsare fixedly connected to the end supportso as to be coupled between the end supportand the end flangeto fixedly retain the end supportand the end flangewith the helical body, e.g., to retain the auger as a single, unitary unit. Further, the end supportdefines gaps, G, (see) to provide passage to the fluid flow across the end support. More particularly, the gaps, G, are defined between consecutive spokes(and are defined in the manner of a sector of a circle) to provide passage to the fluid flow across the end supportand allow the first axial endto receive the fluid flow from the inlet. In some embodiments, an outer diameter of the end supportmay be equal to the outer diameter of the stepped surfaceof the end flange. In some embodiments, the outer diameter of the end supportand the end flangemay be greater than the outer diameter, Do, of the helical body.

Referring now to, the systemfurther includes a clamp arrangementfor the auger. The clamp arrangementis configured to clamp the augerwith the suction manifold. The clamp arrangementis movable between a clamped state and an unclamped state. In the clamped state, the clamp arrangementis configured to engage the end flangewith an endof the suction manifoldto removably and immovably retain the augerwithin the suction manifold. In the unclamped state, the augeris removable from the suction manifoldthrough the opening. The clamp arrangementincludes a first clamping partand a second clamping partclaspable with the first clamping partto move the clamp arrangementto the clamped state.

The first clamping partand the second clamping partmay be semi-circular in shape and match the cylindrical shape of the end flange(or the base of the end flange) and the suction manifold. The first clamping partand the second clamping partare configured to fixedly retain the end flangewith the suction manifold. The first clamping partand the second clamping partinclude one or more boresto receive one or more fastenerstherein to couple the first clamping partto the second clamping part. In some embodiments, the first clamping partmay be hinged to the second clamping partfrom one end and a single fastenermay be used to couple the first clamping partto the second clamping part.

During assembly of the clamp arrangementon the end flangeand the suction manifold, the first clamping partis configured to engage first portionsof the endand the end flangewith each other. The second clamping partis configured to engage second portionsof the endand the end flangewith each other when the first clamping partis clasped with the second clamping partto removably and immovably retain the augerwithin the suction manifold. The fastenersare configured to couple and clasp the first clamping partwith the second clamping partto engage the end flangewith the endof the suction manifoldto removably and immovably retain the augerwithin the suction manifold. The first clamping partand the second clamping partpositively holds the suction manifoldand the end flangein position to form a fluid-tight joint between the suction manifoldand the end flange. To remove the augerfrom the suction manifold, the first clamping partis removed from the second clamping partand the end flangeis disengaged from the endof the suction manifoldto remove the augerfrom the suction manifold.

In some embodiments, the use of the clamp arrangementmay be omitted and the augermay be casted with the suction manifoldas a wholly integrated, single structure. In such a case, the end flangemay be integrated into the endof the suction manifold. Also, in case of such integration, some portions of the end flange(e.g., the stepped surface) may be omitted. In some embodiments, the augermay be welded with the suction manifold. For example, the helical bodyof the augermay be welded to the inner wallof the suction manifold. In some embodiments, the augermay be casted with the same material as that of the suction manifold. In some embodiments, the augermay be casted with material including, but not limited to, polymer, plastic composite, metal and the like.

The operation of the reciprocating pumpwill now be discussed. During operation of the reciprocating pump, the fluid flow, incoming at a relatively high pressure, is received by the end supportof the auger from the inletof the suction manifold. The fluid flow moves through the end support(e.g., through the gaps) and is then forced along the helical path, H, defined by the helical bodyof the augerto introduce an angular momentum into the fluid flow causing portions of the fluid flow to be pushed into the inlet passagesas the portions move along the helical path, H. The helical bodyof the augerreduces a velocity (e.g., a linear velocity) of the incoming fluid flow into the suction manifoldand assists the fluid flow to move along the helical path so that the fluid flow is distributed (e.g., substantially evenly distributed) across the inlet passagesof the reciprocating pump.

In one example implementation, it has been observed that a usage of the auger causes up to one fifth portion of the total fluid flow to be pushed into a first inlet passage′ or into one or more of the initial inlet passagesthat the fluid flow encounters when moving along the helical path. Similarly, various portions of the fluid flow may be pushed into respective inlet passagesas the moving fluid encounters the inlet passagesalong the helical path, H. This helps in distributing (e.g., evenly distributing) the fluid flow across the multiple inlet passagesof the fluid end. In some embodiments, a part of the fluid flow is also received into and passed through the void, V. Effectively, void, V, allows a relatively higher volume of fluid flow to enter into the suction manifoldas compared to a case where the void, V, is omitted from the auger.

Referring to, an exemplary method for distributing a fluid flow across multiple inlet passagesof a reciprocating pump, is discussed. The method is discussed by way of a flowchartthat illustrates exemplary stages (e.g., fromto) associated with the method. The method is also discussed in conjunction with. It will be appreciated that the order of steps described in the method is exemplary in nature and that the steps can be performed in a different order than what is set out below, as will be contemplated by a person skilled in the art based on the description of the present disclosure.

The method begins with positioning the augerinto the suction manifoldfluidly coupled with the multiple inlet passagesof the reciprocating pump, at block. To this end, an operator may open or remove an end cap (not shown) which may be assembled at the opening to generally close the opening from external access. Although not limited, the end cap may be shaped similarly to the end flangebut may not be connected to any auger. An opening or removal of the end cap may thus reveal an interior volume, S, of the suction manifold devoid of the auger, e.g., a hollow or an empty suction manifold. The operator may then insert and position the augerinto the suction manifoldfrom the opening. The operator may position the augerwithin the suction manifoldin such a way that the first axial endof the augeris positioned to receive the fluid flow through the inletof the suction manifoldand the second axial endof the augeris positioned towards the openingof the suction manifold. The method proceeds to block.

At block, the method includes fixedly coupling the end flangeto the second axial end. For example, the operator may place the end flangeon the endof the suction manifoldin such a way that the stepped surfaceis inserted into the suction manifoldthrough the openingto center the second axial endof the augerrelative to the suction manifold. The operator then allows the baseto be rested against the endof the suction manifold. In some embodiments, the basesits flush with the outer diameter of the suction manifold. The method proceeds to block.

At block, the method includes using the clamp arrangementfor the auger. For example, the operator may use the first clamping partto engage the first portionsof the endand the end flangetogether. Similarly, the operator may use the second clamping partto engage the second portionsof the endand the end flangetogether. The operator may then fasten the fastenersto couple and clasp the first clamping partwith the second clamping partto engage (e.g., fixedly engage) the end flangewith the endof the suction manifold. The clamp arrangement, as discussed above, is movable between the clamped state (e.g., by tightening the bolts) and the unclamped state (e.g., by loosening the bolts), and accordingly allows the auger to be selectively installed and removed from the suction manifold with relative ease. Thus, the methodhelps in installing the augerwithin the suction manifoldand allows for the distribution of the fluid flow across multiple inlet passagesof the reciprocating pump. A retention of the auger within the suction manifold by the clamp arrangement may be immovable.

In addition, the clamp arrangementbeing easily movable into the unclamped state allows the augers (such as auger) having different configurations (e.g., different flight/slope) to be placed within the suction manifold. Augers having different configurations may be used for receiving different fluid types (e.g., depending on an amount of proppant and/or additives in the fluid or the density of the fluid). Also, augers with different configurations may be used for receiving different fluid flow pressure and/or different fluid flow volumes. The generally even distribution of the fluid flow across the multiple inlet passages, as attained by way of the system, reduces or altogether mitigates untimely wear in the valves. This makes the reciprocating pump's maintenance cycle more predictable and more manageable, while also increasing the overall productivity of the reciprocating pump.

Further, the use of the coupler rods(e.g., three coupler rods) helps in overall weight reduction of the auger as compared to a case where a larger single solid rod was needed to perform the function of the coupler rods. The reduced weight of the augersaves material costs and eases out the handling of the auger. In some embodiments, it has been observed that the use of the coupler rodsinstead of the larger single solid rod reduces the weight of the overall assembly of the augerby up to eighty percent. Further, the space between the coupler rods(e.g., void, V) also helps in increasing a volume of the fluid flow into the suction manifold.

It will be apparent to those skilled in the art that various modifications and variations can be made to the method and/or system of the present disclosure without departing from the scope of the disclosure. Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice of the method and/or system disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope of the disclosure being indicated by the following claims and their equivalent.