Abstract
A fluid end assembly comprising: a housing, valves, seals, seats, springs, plungers, plunger packing, and other associated parts, paired with a suction manifold that facilitates fluid feeding through a centrally located external suction intake. The suction manifold of this invention is designed to preserve fluid energy that will ensure complete filling of the cylinder in extreme pumping conditions. The suction manifold utilizes a chamber design positioned immediately below the suction valves, eliminating all connecting ducts. The design of the manifold of this invention can be easily fabricated utilizing commercially available steel plate, pipe, and pipe fittings.
Claims
1. A pump fluid end comprising: a plurality of suction valves; a suction manifold comprising an interior chamber, said interior chamber being located immediately below said plurality of suction valves; wherein said suction manifold has a plurality of ports equal to the number of individual suction valves in said plurality of suction valves, wherein said suction manifold is constructed with a flat top surface and said flat top surface also functions as a mounting flange, wherein a centerline of an external intake connection is located substantially equal distance from centerlines of the furthermost ports of the plurality of ports on either end of said suction manifold; wherein said interior chamber is comprised of first and second opposing lateral branches and the intersection of said first and second opposing lateral branches and the external intake connection of said manifold is filleted, wherein the angle between the centerline of the external intake connection and the plane formed by the centerlines of the plurality of ports of said suction manifold is an obtuse angle, wherein said suction manifold is constructed by cutting and welding together various pieces of commercially available steel pipe, plate, and a single TEE pipe fitting, wherein said single TEE pipe fitting is formed with a fillet at TEE intersections, wherein said single TEE pipe fitting is split in a plane parallel to a centerline of two opposite ends of said single TEE pipe fitting, and wherein the connection of said TEE pipe fitting to said mounting plate perpendicular to said centerline of the two opposite ends of said single TEE pipe fitting is undisturbed by the split” was changed to wherein a connection of said single TEE pipe fitting to a mounting plate is such that said centerline of the two opposite ends of said single TEE pipe fitting is undisturbed by the split.
2. The suction manifold of claim 1, wherein an inside diameter and a wall thickness of the single TEE pipe fitting and the steel pipe utilized in fabricating the suction manifold are substantially equal.
3. The suction manifold of claim 1, wherein the obtuse angle between the centerline of the external intake connection and the plane formed by the centerlines of the plurality of ports of said suction manifold ranges between 120 and 160 degrees.
4. The suction manifold of claim 1, wherein the radius of said fillet at the intersection of the lateral branches enclosing the interior chamber and the external intake connection of said suction manifold ranges between 10 and 30 percent of an outside diameter of the external intake connection of said suction manifold.
5. The suction manifold of claim 1, wherein a distance from the flat top surface of the mounting flange to a bottom surface of the lateral branches of said suction manifold is less than an outside diameter of the external intake connection of said suction manifold.
6. The suction manifold of claim 1, wherein the centerline of the external intake connection is substantially perpendicular to a centerline connecting centers of said plurality of ports contained in said mounting flange.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) FIG. 1 is an exterior orthogonal view of a typical plunger pump showing the power end and the fluid end with the two ends connected by stay rods. A typical suction manifold is also illustrated.
(2) FIG. 2A is an exterior view of a typical plunger pump; this view is taken looking toward the fluid end and suction manifold of the pump.
(3) FIG. 2B schematically illustrates cross-section B-B of a typical high-pressure pump and suction manifold of FIG. 2A.
(4) FIG. 3A is an exterior side view of a typical plunger pump.
(5) FIG. 3B schematically illustrates cross-section B-B of a typical high-pressure pump and suction manifold of FIG. 3A.
(6) FIG. 4 schematically illustrates an end view from the fluid end of a typical high-pressure pump similar to view of FIG. 2A with the alternate Zoomie style suction manifold.
(7) FIG. 5 schematically illustrates cross-section of a typical high-pressure pump and Zoomie style suction manifold of FIG. 4
(8) FIG. 6A schematically illustrates an end view of a typical mud pump with a centrally located external intake connection wherein the suction manifold is manufactured from a casting.
(9) FIG. 6B schematically illustrates a side view of the typical mud pump and suction manifold FIG. 6A.
(10) FIG. 7A schematically illustrates an end view of a typical mud pump with a centrally located external intake connection wherein the suction manifold is manufactured from welded pipe pieces.
(11) FIG. 7B schematically illustrates a side view of the typical mud pump and suction manifold FIG. 7A.
(12) FIG. 7C schematically illustrates section C-C of the suction manifold of FIG. 7B.
(13) FIG. 7D schematically illustrates section D-D of FIG. 7C.
(14) FIG. 8 schematically illustrates an orthogonal view of typical plunger pump similar to FIG. 1 with a suction manifold of the present invention with a centrally located external intake connection.
(15) FIG. 9A schematically illustrates a cross-sectional view through one plunger of a fluid end of a typical high-pressure pump and the suction manifold of the present invention with a centrally located external intake connection.
(16) FIG. 9B schematically illustrates an enlargement of area B-B of a typical high-pressure pump and the suction manifold of FIG. 9A.
(17) FIG. 9C schematically illustrates cross-section C-C of a typical high-pressure pump and the suction manifold of FIG. 9A.
(18) FIG. 10A schematically illustrates an orthogonal view of the suction manifold of the present invention.
(19) FIG. 10B schematically illustrates a top view of the suction manifold of FIG. 10A.
(20) FIG. 10C schematically illustrates a frontal view of the suction manifold of FIG. 10B.
(21) FIG. 10D schematically illustrates cross-section D-D of the suction manifold of FIG. 10B.
(22) FIG. 10E schematically illustrates cross-section E-E of the suction manifold of FIG. 10B.
(23) FIG. 10F schematically illustrates cross-section F-F of the suction manifold of FIG. 10D.
(24) FIG. 11A schematically illustrates an orthogonal view of a commercially available steel plate cut into a rectangular shape for the mounting plate of the present invention.
(25) FIG. 11B schematically illustrates an orthogonal view of the mounting plate of FIG. 11A with holes cut for ports and bolting connections to the fluid end housing.
(26) FIG. 11C schematically illustrates an orthogonal view of a commercially available TEE pipe fitting utilized in the construction of the suction manifold of the present invention.
(27) FIG. 11D schematically illustrates an orthogonal view of the TEE pipe fitting in FIG. 11A split into two pieces.
(28) FIG. 11E schematically illustrates an orthogonal view of the retained piece of the TEE pipe fitting in FIG. 11B.
(29) FIG. 11F schematically illustrates an orthogonal view of the cut piece of the TEE pipe fitting in FIG. 11E aligned with the mounting plate of FIG. 11B prior to welding.
(30) FIG. 11G schematically illustrates an orthogonal view of the finished weldment of the aligned pieces of FIG. 11F.
(31) FIG. 11H schematically illustrates an orthogonal view of a piece of commercial available pipe.
(32) FIG. 11I schematically illustrates an orthogonal view of the pipe of FIG. 11H after spitting said pipe into two hemi-tubular pieces.
(33) FIG. 11J schematically illustrates an orthogonal view of the weldment of FIG. 11G aligned with the split pieces of pipe of FIG. 11I prior to welding.
(34) FIG. 11K schematically illustrates an orthogonal view of the finished weldment of the aligned pieces of FIG. 11J.
(35) FIG. 11L schematically illustrates an orthogonal view of the finished weldment of FIG. 11K and two pieces of end cap aligned prior to weldment.
(36) FIG. 11M schematically illustrates an orthogonal view of the finished weldment of FIG. 11L and the finished manifold of the present invention.
DETAILED DESCRIPTION OF THE DRAWINGS
(37) FIG. 8 illustrates a pump assembly 1 similar to the pump of FIG. 1, pump assembly 1 consists of a power end 2 and fluid end assembly 10 connected by stayrods 3. Fluid end assembly 10 consists of fluid end housing 12 and various internal components and external suction manifold 30 of this invention. Suction manifold 30 intakes fluid through a centrally located external intake connection 32.
(38) FIG. 9A schematically illustrates a cross-sectional view through one plunger bore of a fluid end of a typical high-pressure pump and suction manifold of the present invention. The cross-section illustrated of pump fluid end 10 is defined by the axes of the suction valve bore 3, discharge bore 5, access bore 9, and plunger bore 7. FIG. 9A illustrates a plunger pump fluid end 10 made using a housing 12, and having suction valve bore 3, discharge valve bore 5, access bore 9, plunger bore 7, and inner volume 2. Suction valve 13, suction seat 15, suction valve spring 23, and suction valve spring retainer 27 reside in the suction valve bore 3. Discharge valve 17, discharge seat 19, discharge valve spring 21, discharge cover and spring retainer 25 reside in the discharge valve bore 5. The centerlines of the discharge valve bore and suction valve bore are substantially collinear according to some embodiments of the disclosure. Plunger 11 reciprocates back and forth within the plunger bore 7. In FIG. 9A the springs and retainers function to provide a mechanical bias to the suction valve and discharge valve, towards a closed position. FIG. 9A illustrates a suction manifold 30 with a centrally located external intake connection 32 of the present invention. Cylindrical section 37 of external intake connection 32 is utilized to connect the suction manifold 30 to external piping with a corresponding cylindrical configuration utilized for supplying fluid to the pump fluid end 10. Suction manifold 30 also comprises a mounting flange 40 usually attached to the fluid end housing 12 with bolts (not shown.) Suction manifold mounting flange 40 mates with the bottom surface 4 of fluid end housing 12. Suction manifold mounting flange 40 has a thickness P. Suction manifold 30 also contains multiple ports 43 located concentric to corresponding suction valve 13 and suction seat 15. The number of ports in the suction manifold 30 is equal to the number of suction valves 13 in the pump fluid end 10. Suction manifold interior chamber 38 is utilized to distribute fluid to ports 43.
(39) FIG. 9B schematically illustrates an enlargement of area B-B of the suction manifold 30 of FIG. 9A. Suction manifold 30 has mounting flange 40 and a port 43 to facilitate transfer of pumped fluid from the suction manifold interior chamber 38 into the suction valve bore 3 of fluid end housing 12 and then through the suction valve 13 and seat 15. Suction manifold interior chamber 38 is utilized to distribute fluid to ports 43. The circumferential edge of the port 43 is radiused with radius 45; radius 45 is approximately equal to thickness P mounting of flange 40. Top surface 42 of mounting flange 40 mates with bottom surface 4 of fluid end housing 12.
(40) FIG. 9C schematically illustrates cross-section C-C of the fluid end assembly 10 and suction manifold 30 of FIG. 9A, comprising exterior walls 31 of an undefined shape and a substantially tubular external intake connection 32 of FIG. 9A is located at equal distance from each of the farthermost ports 43 of the suction manifold 30. Tubular external intake connection 32 is utilized to connect the suction manifold 30 to external piping supplying fluid to the pump fluid end 10. Suction manifold 30 also comprises a mounting flange 40 usually attached to the fluid end housing 12 with bolts (not shown.) Suction manifold 30 also contains multiple ports 43 located concentric to corresponding suction valve bore 3. The number of ports in the suction manifold 30 is equal to the number of suction valves 13 in the pump fluid end. Suction manifold interior chamber 38 is utilized to distribute fluid to ports 43.
(41) FIG. 10A illustrates an orthogonal view of the suction manifold 30 of the present invention. Major structures of suction manifold 30 include mounting flange 40, external intake connection 32, and multiple ports 43 as previously described. Multiple bolt holes 46 in mounting flange 40 and an equal number of bolts (not shown) are utilized to secure mounting flange 40 of suction manifold 30 with the bottom of fluid end housing 12. Top surface 42 of mounting flange 40 mates with bottom surface 4 of fluid end housing 12. Bottom surface 41 of mounting flange 40 is integral with suction manifold lateral arms 36 & 35 as shown in FIG. 10C.
(42) FIG. 10B illustrates a top view of the suction manifold 30 of the present invention. Also illustrated are mounting flange 40, top surface 42, bolt holes 46, external intake connection 32, and multiple ports 43; again illustrated as in FIG. 10A. Centerline 44 connects the center of all ports 43 in mounting flange 40.
(43) FIG. 10C illustrates a frontal view of the suction manifold 30 of FIGS. 10A&B. Suction manifold interior chamber 38 is composed of the interiors of external intake connection 32, left lateral 36, and right lateral 35. The intersection of the external intake connection 32 with laterals 35 and 36 is transitioned with fillet 34. Laterals 35 and 36 are substantially hemi-tubular in form with centerline 44 of said hemi-tubular sections 35 and 36 substantially flush with bottom surface 41 of mounting flange 40. Radius R is measured from centerline 44 to outside surface 31 of laterals 35 and 36. External intake connection 32 is substantially tubular in form having an outside cylindrical surface 37. Outside surface 37 diameter D of external intake connection 32 is approximately equal to two times radius R of hemi-tubular sections of laterals 35 and 36. The intersection of the laterals 35 and 36 with the external intake connection 32 results in irregular volume on the interior of fillet 34. End caps 33 close off the lateral arms 35 and 36 at opposing ends of interior chamber 38.
(44) FIGS. 10D and 10E illustrate cross-section D-D and E-E, respectively, of FIG. 10B. Lateral arms 35 & 36 enclosing interior chamber 38 of suction manifold is joined to bottom surface 41 of mounting plate 40 of suction manifold 30. Interior chamber 38 includes interior volumes of external intake connection 32, lateral arm 36, lateral arm 35, multiple ports 43 and fillets 34. Exterior surface 37 of external intake connection 32 joins with exterior surface 31 of hemi-tubular laterals 35 and 36 at fillet 34. Wall thickness T and W of tubular external intake connection 32 and hemi-tubular laterals 35 and 36 respectively are substantially equal. Centerlines 47 and 48 of multiple ports 43 form a plane perpendicular with the top and bottom surfaces 42 and 41 respectively of mounting flange 40. Tubular external intake connection 32 is defined by centerline 39. Centerlines 39 and 48 intersect at an obtuse angle A; centerline 39 also intersects a plane formed by centerlines 47 and 48 at the same obtuse angle A. Obtuse angle A, typically ranges in value between 120 and 160 degrees. Because radius R of hemi-cylindrical surface 31 is substantially equal to one half of diameter D of the cylindrical surface 37, profile height H of the suction manifold 30 measured from top surface 42 of the mounting plate 40 to the bottom surface 31 of the lateral arms 35 and 36 is less than the outside diameter D of external intake connection 32.
(45) FIG. 10F illustrates cross section F-F of FIG. 10D. FIG. 10F again illustrates the relationship between outside diameter D of exterior cylindrical surface 37 of exterior intake connection 32 and radius R of exterior hemi-cylindrical surface 31 of lateral arms 35 and 36 of interior chamber 38. Interior and exterior radii F of fillet 34 are substantially equal. Fillet 34 radius F is always less than radius R of hemi-cylindrical exterior surfaces 31 of lateral arm 35 and 36; radius R should be maximized to improve flow and reduce turbulence and fluid friction loss at the intersection—of lateral arms 35 and 36 with exterior intake connection 32 of interior section 38.
(46) FIGS. 11A-N illustrates a method of fabrication of the suction manifold 30 of the present invention. FIG. 11A orthogonally illustrates a commercially available steel plate 401 cut into a rectangular shape suitable for making mounting flange 40 of suction manifold 30 as illustrated in FIG. 10A.
(47) FIG. 11B orthogonally illustrates mounting plate 402, made from plate 401, with ports 43, bolt holes 46, and bottom surface 41.
(48) FIG. 11C orthogonally illustrates a commercially available steel TEE pipe fitting 410. TEE pipe fittings 410 consists of a tubular section 411 with centerline 412 and a second tubular section 432 that will become external intake connection 32 in the finished suction manifold 30. Intersections of tubular sections 411 and 432 are transitioned with fillets 34.
(49) FIG. 11D illustrates TEE pipe fitting split into pieces by a plane parallel to centerline 412. After TEE pipe fitting is split, two pieces remain: 413 and 414. Piece 413 contains tubular external intake connection 432 of TEE pipe fitting 410. TEE pipe fitting 410 is split in a plane at an angle corresponding with obtuse angle A of FIG. 10D. End surfaces 418 and 419 define the opposite ends of split TEE pipe fitting 413. Remaining piece 414 is discarded.
(50) FIG. 11E orthogonally illustrates split piece 413 of FIG. 11D wherein split results in planar surfaces 415 and 416 of piece 413. Surfaces 415 and 416 are substantially co-planar with centerline 412.
(51) FIG. 11F orthogonally illustrates the mounting plate 402 of FIG. 11B and a piece of the split TEE pipe fitting 413 aligned prior to welding. Centerlines 412 and 44 are parallel; surfaces 415 and 416 of split TEE pipe fitting and bottom surface 41 of the mounting plate 402 are also parallel in this configuration. End surfaces 418 and 419 of split TEE pipe fitting 413 are perpendicular to bottom surface 41 of mounting plate 402.
(52) FIG. 11G orthogonally illustrates fabricated piece 420 after welding of mounting plate 402 to TEE split pipe fitting 413 of FIG. 11F. Centerlines 44 and 412 are now co-linear; surfaces 415 and 416 of split TEE pipe fitting are now coincident with bottom surface 41 of mounting flange 402 after being joined by welding.
(53) FIG. 11H orthogonally illustrates a piece 430 of commercially available pipe of a pipe size and wall thickness substantially equal to tubular size and wall thickness of TEE pipe fitting of FIGS. 11C and 11D.
(54) FIG. 11I orthogonally illustrates pipe piece 430 of FIG. 11H split into substantially equal hemi-tubular pieces 431 and 432 with centerlines 437 and 438 respectively. Planar surfaces 433 and 434 and centerline 437 of hemi-tubular piece 431 are substantially co-planar; similarly planar surfaces 435 and 436 and centerline 438 of hemi-tubular piece 432 are also substantially co-planar.
(55) FIG. 11J orthogonally illustrates the alignment of fabrication piece 420 of FIG. 11G with hemi-tubular pieces 431 and 432 of FIG. 11I prior to welding to form welded fabrication 440. Centerlines 437 of hemi-tubular piece 431, 438 of hemi-tubular piece 432, and 44 are parallel; surfaces 433 and 434 of hemi-tubular pipe piece 431, surfaces 435 and 436 of hemi-tubular pipe piece 432 and bottom surface 41 of the mounting plate 402 are also parallel in this configuration. Additionally, end surface 441 of hemi-tubular piece 431 is parallel with end surface 419 of split TEE pipe fitting 413 of FIG. 11F and end surface 442 of hemi-tubular piece 432 is parallel with end surface 418, also of split TEE pipe fitting 413.
(56) FIG. 11K orthogonally illustrates fabricated weldment 440, wherein surfaces 433 and 434 of hemi-tubular piece 431 are welded to bottom surface 41 of fabricated weldment 420, surfaces 435 and 436 of hemi-tubular piece 432 are welded to bottom surface 41 of fabricated weldment 420. End surface 441 of hemi-tubular piece 431 is welded to end surface 419 of weldment 420 and end surface 442 of hemi-tubular piece 432 is welded to end surface 418 of weldment 420. Centerlines 437, 438, and 44 are now substantially co-linear.
(57) FIG. 11L orthogonally illustrates the alignment of fabrication piece 440 of FIG. 11K with end cap pieces 451 and 452 prior to welding of respective end caps to surfaces 443 and 444 respectively of welded fabrication piece 440 to form welded fabrication 450.
(58) FIG. 11M orthogonally illustrates fabricated weldment 450 of FIG. 11L to form finished suction manifold 30 functionally similar to FIG. 10 of the present invention.
