Power frame and lubrication system for a reciprocating pump assembly
11746953 · 2023-09-05
Assignee
Inventors
Cpc classification
F04B53/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B23/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16N13/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B47/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16N13/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B1/053
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B53/16
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F04B53/16
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B1/053
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B23/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B47/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B53/18
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B53/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16N13/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
An apparatus according to which a power end of a reciprocating pump assembly includes a block having bores formed therethrough, and crossheads disposed in the bores and adapted to reciprocate therein. A lubrication pump is in fluid communication with the bores. The pump is operable to pump lubrication fluid into each of the bores so that the crossheads are lubricated as they reciprocate within their respective bores. In another aspect, a power end includes a crosshead block and a power frame connected thereto, the frame including rib plates and supporting the crosshead block. In yet another aspect, a method includes casting a crosshead block; fabricating rib plates; connecting the rib plates to form a frame; and connecting the cast crosshead block to the frame. In some embodiments, the power ends may be used in oilfield operations such as, for example, the cementing, acidizing, or fracturing of a subterranean wellbore.
Claims
1. An apparatus, comprising: a power end of a reciprocating pump assembly, the power end comprising: a crosshead block formed of a solitary integral mass and having a plurality of bores therethrough, at least one bore of the plurality of bores having a lubrication port and a drain port therein; a manifold in fluid communication with the lubrication port; a pump in fluid communication with the manifold, wherein the pump is operable to pump a lubrication fluid to the crosshead block, via the manifold, and wherein the lubrication port is configured to pass the lubrication fluid into the bore so that a crosshead disposed within the bore is lubricated as it reciprocates within the bore.
2. The apparatus of claim 1, wherein the power end is adapted to be mounted to a skid, the skid being adapted to be mounted and/or transported on a trailer.
3. The apparatus of claim 2, further comprising a tank in fluid communication with the drain port and the pump, the tank and the pump being external to the power end.
4. The apparatus of claim 3, wherein the drain port is in fluid communication with the tank to permit the lubrication fluid to drain back into the tank.
5. The apparatus of claim 4, further comprising a fluid return line via which the lubrication fluid drains back from the drain port into the tank, the fluid return line further comprising a filter positioned external to the power end.
6. The apparatus of claim 3, wherein the skid comprises: a base member and a platform member spaced therefrom; and a region defined between the base member and the platform member, wherein the power end is mounted on the platform member, and wherein the tank and the pump are disposed in the region.
7. The apparatus of claim 3, wherein the pump is contained within the tank.
8. The apparatus of claim 3, wherein the crosshead block comprises additional bores, each bore having a lubrication port and a drain port, each lubrication port being in fluid communication with the manifold, and each drain port being in fluid communication with the tank.
9. The apparatus of claim 2, further comprising a reciprocating pump assembly mounted on the skid, the reciprocating pump assembly comprising the power end and a fluid end operably coupled thereto.
10. The apparatus of claim 1, wherein the manifold defines a fluid chamber in fluid communication with the pump, and also in fluid communication with the bore via the lubrication port.
11. The apparatus of claim 1, wherein the power end further comprises a power frame, the power frame comprising a plurality of rib plates, each of the rib plates comprising a brace portion defining a contact surface; wherein the contact surfaces of the brace portions engage the crosshead block.
12. An apparatus, comprising: a power end of a reciprocating pump assembly, the power end comprising: a power frame comprising a plurality of rib plates in spaced relation, each rib plate comprising a brace portion that includes a contact surface; and a crosshead block, wherein the crosshead block is engaged by respective contact surfaces of the brace portions of the plurality of rib plates.
13. The apparatus of claim 12, wherein the crosshead block is formed of an integral mass, wherein each of the rib plates is not cast, and wherein each of the rib plates is fabricated.
14. The apparatus of claim 13, wherein each of the rib plates is fabricated by cutting, assembling, welding, or bending.
15. The apparatus of claim 12, wherein the power end further comprises: a power housing connected to the power frame; a first gear cover and a second gear cover connected to respective opposing sides of the power housing, wherein the first gear cover and the second gear cover are stamped or hydroformed.
16. The apparatus of claim 12, wherein each of the rib plates comprises a plurality of openings formed therethrough; wherein the respective pluralities of openings are aligned with each other; wherein the power frame further comprises a support rod connected to each of the rib plates; and wherein the support rod extends through corresponding ones of the aligned openings formed through the rib plates.
17. The apparatus of claim 16, wherein the power end further comprises a crankshaft that extends through the plurality of rib plates and is adapted to rotate; wherein each of the rib plates comprises a central opening, wherein the central opening defines, or is part of, a rotational bearing that is adapted to support the crankshaft during rotation thereof.
18. The apparatus of claim 12, wherein the respective contact surfaces of the brace portions are coplanar, and wherein the crosshead block engages each of the coplanar contact surfaces.
19. The apparatus of claim 12, further comprising: a skid, the power end being mounted on the skid; a fluid end mounted on the skid and operably coupled to the power end; a tank mounted on the skid and in fluid communication with a plurality of bores of the crosshead block; and a pump mounted on the skid and in fluid communication with the tank and each of the plurality of bores of the crosshead block, wherein the pump is operable to pump lubrication fluid from the tank and into each of the plurality of bores of the crosshead block.
20. A crosshead block of a power end of a reciprocating pump assembly, the crosshead block comprising: a solitary integral mass defining: a plurality of crosshead bores formed therethrough; a plurality of lubrication ports formed through a first side of the crosshead block and into respective ones of the plurality of crosshead bores; and a plurality of drain ports formed through a second opposite side of the crosshead block and into respective ones of the plurality of crosshead bores, wherein a lubrication fluid is configured to pass through, in series, the plurality of lubrication ports, the plurality of crosshead bores, and the plurality of drain ports, and wherein during operation, the lubrication fluid is configured to lubricate a plurality of crossheads reciprocating within respective ones of the crosshead bores.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) Various embodiments of the present disclosure will be understood more fully from the detailed description given below and from the accompanying drawings of various embodiments of the disclosure. In the drawings, like reference numbers may indicate identical or functionally similar elements.
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DETAILED DESCRIPTION
(11) Referring to
(12) The power end 14 of the reciprocating pump assembly 10 includes a crankshaft 26 that includes one or more crank throws 26a, corresponding to the one or more cylinders 16 of the fluid end 12, and a main shaft 26b. The crank throws 26a are connected to the main shaft 26b and are each offset from the rotational axis of the crankshaft 26. The crankshaft 26 is mechanically coupled to a motor (not shown) via a bull gear 28 and a pinion 30. The bull gear 28 is attached to the crankshaft 26 and the pinion 30 is connected to the motor (not shown). The gear teeth of the bull gear 28 mesh with the gear teeth of the pinion 30, thereby transmitting torque therebetween. The crank throws 26a are each coupled to a respective one of the plungers 24 via a mechanical linkage 32, each of which includes a connecting rod 34, a crosshead 36, and a pony rod 38. Each of the crossheads 36 is disposed within a corresponding crosshead bore 40, within which the crosshead 36 is adapted to reciprocate. The connecting rods 34 connect respective ones of the crossheads 36 to respective ones of the crank throws 26a. Further, the pony rods 38 connect respective ones of the crossheads 36 to respective ones of the plungers 24.
(13) In some embodiments, in operation, the motor (not shown) rotates the pinion 30, which, as a result, rotates the bull gear 28 and the crankshaft 26. The crankshaft 26 rotates the crank throws 26a about the central axis of the main shaft 26b. The crank throws 26a, in turn, are operable to drive the mechanical linkages 32, including respective ones of the connecting rods 34, the crossheads 36, and the pony rods 38, causing the crossheads 36 to reciprocate within the corresponding crosshead bores 40. The reciprocating motion of the crossheads 36 is transferred to respective ones of the plungers 24 via the pony rods 38, causing the plungers 24 to reciprocate within the corresponding pressure chambers 18. As the plungers 24 reciprocate within the respective pressure chambers 18, fluid is drawn into the pressure chambers 18 from the suction manifold 20 and, thereafter, discharged from the pressure chambers 18 into the discharge manifold 22.
(14) Referring to
(15) As shown in
(16) The power frame 42 supports the crankshaft 26, the bull gear 28, and the pinion 30 during the operation of the reciprocating pump assembly 10. In one embodiment, as shown in
(17) In some embodiments, the crosshead block 44 is manufactured by casting, forming, and/or machining a solitary integral mass. During the manufacturing process, the crosshead bores 40 are formed through the crosshead block 44. As a result, the crosshead bores 40 are distributed across the crosshead block 44, which extends laterally across the power end 14 and is connected to, and supported by, the power frame 42. Specifically, the rib plates 42a each include a brace portion 46 that supports at least a portion of the crosshead block 44. The brace portions 46 each include a contact surface 48, which engages the crosshead block 44. In an embodiment, the contact surfaces 48 of the respective rib plates 42a are coplanar and thus substantially aligned with one another, thus defining a plane 49 upon which the crosshead block 44 is disposed. The crosshead block 44 is engaged with the contact surfaces 48, and is connected to the brace portions 46 at the contact surfaces 48. As a result, the brace portions 46 of the rib plates 42a support the crosshead block 44 in a fixed position relative to the crankshaft 26. Consequently, respective ones of the crosshead bores 40 are maintained in fixed positions that are substantially aligned with respective ones of the crank throws 26a.
(18) With continuing reference to
(19) Referring to
(20) In some embodiments, casting the crosshead block 44 at the step 53a reduces the quantity of weld joints in the power end 14; since in many cases structural failures occur at weld joints, reducing the number of weld joints, by casting the crosshead block 44, reduces the risk of structural failure in the power end 14. In some embodiments, the step 53f reduces the overall mass or weight of the power end 14. In some embodiments, the step 53g reduces the weight of the power end 14, and also reduces the cost of the power end 14 with respect to material costs and labor costs; since at the step 53g the gear covers 52 are either stamped or hydroformed, the costs associated with manufacturing processes such as folding, bending, and welding metal for the covers 52 are either eliminated or significantly reduced.
(21) In an embodiment, as illustrated in
(22) As shown in
(23) The manifold 58 includes a plurality of lubrication ports 64, each corresponding to, and aligned with, the respective lubrication ports 56a of the crosshead block 44. A plurality of lubrication lines 66 connect the lubrication ports 64 of the manifold 58 to the respective lubrication ports 56a of the crosshead block 44. As a result, the lubrication lines 66 provide fluid communication between the fluid chamber 58c of the manifold 58 and the respective crosshead bores 40 of the crosshead block 44. A fluid return line 67a (shown in
(24) Referring to
(25) As shown in
(26) With continuing reference to
(27) In some embodiments, the lubrication system 54 is mounted on the skid 68 and thus the components of the lubrication system 54, including the tank 60, are separate from, or independent of, any trailer on which the skid 68 may be mounted and/or transported, such as a trailer 70, which is shown in
(28) In some embodiments, while different steps, processes, and procedures are described as appearing as distinct acts, one or more of the steps, one or more of the processes, and/or one or more of the procedures may also be performed in different orders, simultaneously and/or sequentially. In some embodiments, the steps, processes and/or procedures may be merged into one or more steps, processes and/or procedures.
(29) In some embodiments, one or more of the operational steps in each embodiment may be omitted. Moreover, in some instances, some features of the present disclosure may be employed without a corresponding use of the other features. Moreover, one or more of the above-described embodiments and/or variations may be combined in whole or in part with any one or more of the other above-described embodiments and/or variations.
(30) In the foregoing description of certain embodiments, specific terminology has been resorted to for the sake of clarity. However, the disclosure is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes other technical equivalents which operate in a similar manner to accomplish a similar technical purpose. Terms such as “left” and right”, “front” and “rear”, “above” and “below” and the like are used as words of convenience to provide reference points and are not to be construed as limiting terms.
(31) In this specification, the word “comprising” is to be understood in its “open” sense, that is, in the sense of “including”, and thus not limited to its “closed” sense, that is the sense of “consisting only of”. A corresponding meaning is to be attributed to the corresponding words “comprise”, “comprised” and “comprises” where they appear.
(32) Although several embodiments have been described in detail above, the embodiments described are not limiting, and those skilled in the art will readily appreciate that many other modifications, changes, and/or substitutions are possible in the embodiments without materially departing from the novel teachings and advantages of the present disclosure. Accordingly, all such modifications, changes, and/or substitutions are intended to be included within the scope of this disclosure as defined in the following claims. In the claims, any means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. Moreover, it is the express intention of the applicant not to invoke 35 U.S.C. § 112, paragraph 6, for any limitations of any of the claims herein, except for those in which the claim expressly uses the word “means” together with an associated function.