Cover for fluid systems and related methods

Abstract

Embodiments of a high-pressure, high power, reciprocating positive displacement fluid pumping system and methods are included. The system may include a high-pressure, high power, reciprocating positive displacement pump including a pump plunger, a fluid end block assembly, and a fluid cover. The fluid end block assembly may include a fluid end block body, a suction port, a discharge port, a pump bore positioned in and extending through the fluid end block body, and a fluid chamber positioned in the fluid end block body and in fluid communication with each of the suction port, the discharge port, and the pump bore. The fluid chamber has an open end portion, and the pump plunger may be positioned to move in the pump bore to pressurize one or more fluids in the fluid chamber. The fluid cover includes a monolithic body having a first portion and a second portion, the first portion being received in the open end portion and sealably engaged with the fluid end block body, the second portion being mechanically connected to the fluid end block body.

Claims

1. A high-pressure, high power, reciprocating positive displacement fluid pumping system, the system comprising: a high-pressure, high power, reciprocating positive displacement pump comprising a pump plunger; a fluid end block assembly including a fluid end block body, a suction port, a discharge port, a pump bore positioned in and extending through the fluid end block body, and a fluid chamber positioned in the fluid end block body and in fluid communication with each of the suction port, the discharge port, and the pump bore, the fluid chamber having an open end portion, the fluid end block body having an interior chamfered surface positioned along interior peripheries of the open end portion of the fluid chamber, and the pump plunger being movably positioned in the pump bore to pressurize one or more fluids in the fluid chamber; and a fluid cover including: a monolithic body including a first portion and a second portion, the first portion having an outer cylindrical surface that extends from an end of the monolithic body toward the second portion, the outer cylindrical surface having a first outer diameter; at least one first seal member positioned on the outer cylindrical surface of the first portion such that the outer cylindrical surface is spaced away from an inner cylindrical wall of the open end portion by the at least one first seal member and such that the at least one first seal member is sealingly engaged with the inner cylindrical wall; the second portion having a second outer diameter greater than the first outer diameter and a threaded portion mechanically connected to the fluid end block body, the second portion including a flange portion positioned adjacent the threaded portion and the first portion, and the first portion including an annular groove adjacent the flange portion; and a second seal member at least partially received in the annular groove adjacent the flange portion such that the second seal member is compressed against the interior chamfered surface to a reduced profile.

2. The fluid pumping system of claim 1, wherein the at least one first seal member is located between the flange portion and a distal end of the first portion.

3. The fluid pumping system of claim 1, wherein the fluid end block body has a threaded interior surface positioned along the interior peripheries of the open end portion of the fluid chamber, the threaded portion of the fluid cover engaging the threaded interior surface of the fluid end block body to secure the fluid cover to the fluid end block assembly, and wherein the second portion includes an end surface of the fluid cover, the end surface of the fluid cover having a tool engagement feature to engage with a tool.

4. The fluid pumping system of claim 1, wherein the second seal member and the annular groove are configured such that a portion of the second seal member extends radially outward beyond the first outer diameter of the first portion to provide a fluid-resistant seal against the interior chamfered surface of the fluid end block body.

5. The fluid pumping system of claim 1, wherein the flange portion of the fluid cover is positioned to seat against an internal surface of the open end portion of the fluid chamber.

6. The fluid pumping system of claim 1, wherein the second seal member is positioned to engage the interior chamfered surface, such that the second seal member at least partially fills a space between the flange portion and the fluid end block body.

7. The fluid pumping system of claim 1, wherein the second seal member comprises an O-ring.

8. The fluid pumping system of claim 1, wherein the end of the monolithic body is positioned within the open end portion, and wherein the outer cylindrical surface is spaced from the inner cylindrical wall at the end of the monolithic body by the at least one first seal member.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate the embodiments of the disclosure.

(2) FIG. 1A is a schematic diagram of showing a layout of a fluid pumping system according to an embodiment of the disclosure.

(3) FIG. 1B is an enlarged, sectional view of a fluid end block assembly of the fluid pumping system of FIG. 1A according to an embodiment of the disclosure.

(4) FIG. 2A is a perspective view of a fluid cover component of a conventional fluid cover assembly according to an embodiment of the disclosure.

(5) FIG. 2B is a side view of the fluid cover component of FIG. 2A according to an embodiment of the disclosure.

(6) FIG. 3A is a perspective view of a retainer component of a conventional fluid cover assembly according to an embodiment of the disclosure.

(7) FIG. 3B is a side view of the retainer component of FIG. 3A according to an embodiment of the disclosure.

(8) FIG. 4 is an enlarged, sectional view of an operation of the fluid end block assembly of FIG. 1B according to an embodiment of the disclosure.

(9) FIG. 5 is another enlarged, sectional view of the fluid end block assembly of FIG. 1B according to an embodiment of the disclosure.

(10) FIG. 6A is a perspective view of an integrated fluid cover according to a first exemplary embodiment of the disclosure.

(11) FIG. 6B is a side view of the integrated fluid cover of FIG. 6A according to an embodiment of the disclosure.

(12) FIG. 6C is a top view of the integrated fluid cover of FIG. 6A according to an embodiment of the disclosure.

(13) FIG. 7A is a side view of an integrated fluid cover according to a second exemplary embodiment of the disclosure.

(14) FIG. 7B is another side view of the integrated fluid cover of FIG. 7A, with a seal member shown in cross-section according to an embodiment of the disclosure.

(15) FIG. 8 is a sectional view of the integrated fluid cover of FIG. 7A sealably coupled with a fluid end block assembly of a fluid pumping system according to an embodiment of the disclosure.

(16) FIG. 9 is a side view of an integrated fluid cover according to a third exemplary embodiment of the disclosure.

(17) FIG. 10 is a sectional view of the integrated fluid cover of FIG. 9 sealably coupled with a fluid end block assembly of a fluid pumping system according to an embodiment of the disclosure.

(18) Corresponding parts are designated by corresponding reference numbers throughout the drawings.

DETAILED DESCRIPTION

(19) The embodiments of the present disclosure are directed to pressurized fluid systems, for example, high pressure single acting reciprocating pumping systems such as those that include hydraulic fracturing single acting reciprocating pumps. In particular, the embodiments of the present disclosure are directed to fluid covers for use with such pressurized fluid systems.

(20) FIG. 1A illustrates a schematic view of a high-pressure, high power, reciprocating positive displacement fluid pumping system 100 according to an embodiment of the disclosure. The diagram of the system 100 shows a typical pad layout for a fracturing pump system, and the system 100 includes a plurality of fracturing or frac pumps or pumping units FP1, FP2, FP3, FP4, FP5, FP6, FP7, FP8 with the pumping units all operatively connected to a manifold M that is operatively connected to a wellhead W. By way of an example, in order to achieve a maximum rated horsepower of 24,000 HP for the pumping system 100, a quantity of eight (8) 3000 horsepower (HP) pumping units may be used. It will be understood that the fluid pumping system 100 may include associated service equipment such as hoses, connections, and assemblies, among other devices and tools. Each of the pumping units FP1, FP2, FP3, FP4, FP5, FP6, FP7, FP8 may include a fluid end block assembly 101.

(21) FIG. 1B illustrates a portion of a fluid end block assembly 101 of the embodiment of the fluid pumping system 100 as shown in a sectional view. In one embodiment, the fluid end block assembly 101 may be in fluid communication with and/or may form a portion of the manifold M. In this regard, one or more of the frac pumps or pumping units FP1, FP2, FP3, FP4, FP5, FP6, FP7, FP8 may be fluidly coupled to the fluid end block assembly 101.

(22) The fluid end block assembly 101, as shown, includes a fluid end block body 121 having intersecting horizontal and vertical bore passages that are each in fluid communication with a fluid end chamber 105 in the fluid end block body 121. The vertical bore passage includes an intake port or suction port 102. The fluid may enter the fluid end block body 121 from an intake source, for example, a fluid supply manifold. The vertical bore passage also includes an outlet port or discharge port 103 through which fluid may exit the fluid end block body 121 or flow to another portion of the fluid end block assembly 101. One or both of the suction port 102 and the discharge port 103 thus collectively provide access to and from the fluid end chamber 105 and may include fluid handling elements or components such as seats, valves, springs, and so forth, as will be understood by those skilled in the art.

(23) The discharge port 103, as shown, includes a discharge bore 104, e.g., an opening or fluid channel, through which pressurized fluid may exit the fluid end block assembly 101 to downstream components of the fluid pumping system coupled to the fluid end block assembly 101. A discharge cover assembly or discharge cap assembly 116 may be coupled to a portion of the discharge port 103, as described further herein.

(24) As shown, a piston/plunger 107 (broadly, “pump member”) is positioned in a pump bore 108 along the horizontal bore of the fluid end block assembly 101. The plunger 107 is movable in the pump bore 108, for example, via reciprocating actuation of one or more of the pumping units FP1, FP2, FP3, FP4, FP5, FP6, FP7, FP8, with a forward stroke in the direction of the fluid chamber 105 and that terminates proximate the fluid chamber 105, and a rearward stroke in a direction away from the fluid chamber 105 and opposite the direction of the forward stroke. One or more of the pumping units FP1, FP2, FP3, FP4, FP5, FP6, FP7, FP8 may actuate the plunger 107 to move/reciprocate in the pump bore 108, for example, via a controller or control system, as will be understood by those skilled in the art, that may be in electronic communication with one or more of the pumping units, and which may be operated under manual and/or processor control.

(25) As shown, the forward stroke of the plunger 107 terminates opposite an open end portion 106 of the fluid chamber 105. In one embodiment, the open end portion 106 of the fluid chamber 105 is positioned in a portion of the fluid end block body 121 that includes an oblique or chamfered surface 123 that extends toward an interior threaded portion 127 of the fluid end block body 121 along interior peripheries of the open end portion 106 of the fluid chamber 105 (see FIG. 5).

(26) A fluid cover assembly 109 (broadly, “suction cap assembly” or “suction cover assembly” or “intake cap assembly” or “intake cover assembly”) may be sealingly engaged with and coupled to the fluid end block body 121, as described further herein.

(27) An embodiment of the fluid cover assembly 109 may include a fluid cover component 110 having a generally cylindrical body with a flanged head 111 including a tool engagement feature 113 for being engaged by a tool to place, position, help secure to, and/or remove the fluid cover component 110 from the end portion 106 of the fluid chamber 105 (see FIGS. 2A-2B and 3A-3B). In this regard, the fluid cover component 110 may be at least partially received within the end portion 106 of the fluid chamber 105 opposite the reciprocating path of the plunger 107. A sealing member 114, e.g., a rubber or other polymeric annular seal, may be positioned on the cylindrical body of the fluid cover component 110.

(28) The fluid cover component 110 may be at least partially received in the end portion 106 of the fluid chamber 105, and the fluid cover assembly 109 may be mechanically connected to the fluid end block assembly 101 via the mechanical connection of a retainer component 112 to the fluid end block body 121.

(29) The retainer component 112, as shown in FIGS. 3A and 3B, may be a retainer nut or other fastener having a generally cylindrical body with an outer surface that defines a threaded portion 126 that is configured to threadably engage the corresponding interior threaded portion 127 of the fluid end block body 121. In this regard, the retainer component 112 may be threadably advanced into the end portion 106 of the fluid chamber 105 to abut the flanged head portion 111 of the fluid cover component 110, for example, such that an end of the retainer component 112 contacts the head portion of the fluid cover component 112 at an interface, e.g., a discontinuity between the material of the fluid cover component 110 and the material of the retainer component 112. As shown, the retainer component 112 may also define a tool engagement feature 117 for being engaged by a tool to place, position, and/or remove the retainer component 112 from the end portion 106 of the fluid chamber 105.

(30) It will be understood that the discharge cap/cover assembly 116 of the discharge port 103 may have a configuration that is generally similar to the configuration of the fluid cover assembly 109 positioned at the open end portion 106 of the fluid chamber 105 near the suction port 102. The discharge cap/cover assembly 116 of the discharge port 103 may have a different configuration without departing from the disclosure.

(31) Referring to FIG. 4, fluid may be delivered via the suction port 102, for example, from a pump suction manifold and valve assembly, into the fluid chamber 105. The fluid in the fluid chamber 105 may be compressed by the plunger 107 upon a compression or delivery stroke, e.g., toward the fluid chamber 105.

(32) In the embodiment illustrated in FIG. 4, the full extension length of the plunger 107 may extend at least partially toward the fluid chamber 105 to compress fluids disposed therein. In this regard, as the plunger 107 commences its delivery or compression stroke, the fluid positioned inside of the fluid end chamber 105 is compressed by the plunger 107 and such compression forces are translated into the surrounding walls of the fluid chamber 105. As the end portion 106 of the fluid chamber 105 is closed by the fluid cover assembly 109 sealingly engaged with the fluid end block body 121, the pressurized fluid in the fluid end chamber 105 flows into the discharge port 103, and out the discharge bore 104.

(33) Following/preceding the above-described compression or delivery stroke of the plunger 107, in an intake or suction stroke, the plunger 107 translates along the pump bore 108 of the fluid end block assembly 101 away from the fluid chamber 105 to create a suction, e.g., negative pressure or vacuum, in the fluid chamber 105 that draws additional fluid into the fluid chamber 105 in preparation for a subsequent compression or delivery stroke.

(34) Referring to FIGS. 6A-6C, an integrated fluid cover according to a first exemplary embodiment of the disclosure is generally designated 221, and may be used in a fluid pumping system that may be otherwise similar to the fluid pumping system 100 described above.

(35) In the illustrated embodiment, the integrated fluid cover 221 includes a monolithic body 223, e.g., a body monolithically formed of a single continuous piece or block of material that has a unitary configuration so as to be free from any seams or discontinuities that extend from an outer surface of the body 223 to an interior portion of the body 223. It will be understood that the body 223 of the integrated fluid cover 221 may include metallic, polymeric, and/or composite materials.

(36) The body 223 of the integrated fluid cover 221 defines a fluid cover portion 225 (broadly, “first portion”) and a retainer portion 227 (broadly, “second portion”). Each of the fluid cover portion 225 and the retainer portion 227 has a generally cylindrical configuration, with the fluid cover portion 225 having a first diameter D1 that is smaller than a second diameter D2 of the fluid cover portion 225.

(37) The fluid cover portion 225 has a generally cylindrical configuration with a free end or distal end 226 facing the fluid chamber 105. The fluid cover portion 225 extends from the distal end 226 to a flange portion 228 of the retainer portion 227. In this regard, the fluid cover portion 225 of the integrated fluid cover 221 may be at least partially received within the end portion 106 of the fluid chamber 105 of the fluid end block assembly 101.

(38) As shown, the flange portion 228 of the retainer portion 227 extends radially outwardly from the fluid cover portion 225. The retainer portion 227 also includes a threaded portion 229 extending away from the flange portion 228 and that is configured to engage the interior threaded portion 127 of the fluid end block body 121 to mechanically connect to the fluid end block body 121 as described above. In one embodiment, the flange portion 228 of the retainer portion 227 may extend radially outwardly from the threaded portion 229 so as to form a protrusion or protuberance along the outer surface of the retainer portion 227.

(39) As shown, the seal member 114 (broadly, “first seal member”) may be positioned on the fluid cover portion 225 of the integrated fluid cover 221 between the distal end 226 and the flange portion 228 of the retainer portion 227. In this regard, when the fluid cover portion 225 of the integrated fluid cover 221 is at least partially received in the end portion 106 of the fluid chamber 105, the seal member 114 may be positioned to sealingly engage interior surfaces of the fluid end block body 121. The seal member 114 may align or center the fluid cover portion 225 within the end portion 106 of the fluid chamber 105.

(40) As also shown, the body 223 of the integrated fluid cover 221 defines a tool engagement feature 231 at a free end or proximal end surface 232 of the retainer portion 227. The tool engagement feature 231 may be, for example and without limitation, a polygonal (e.g., hexagonal) recess having a configuration complementary to that of an insertion or removal or securing tool, such as an Allen wrench or other driver when positioned to secure the integrated fluid cover 221. Optionally, the tool engagement feature may have a different configuration, for example and without limitation, a protrusion, without departing from the disclosure.

(41) In this regard, rotation of the integrated fluid cover 221 via engagement of a tool with the tool engagement feature 231 may cause rotation of both the fluid cover portion 225 and the retainer portion 227 of the integrated fluid cover 221 due to the monolithic construction of the body 223 of the integrated fluid cover 221. Such a configuration may obviate and reduce the number of tools required for insertion, removal, and other maintenance of a fluid cover in which, for example, a retainer portion and a fluid cover portion are separate components.

(42) Furthermore, the aforementioned monolithic construction of the body 223 of the integrated fluid cover 221 may provide a higher mass single body as compared to the bodies of a fluid cover portion and a retainer portion provided as separate components of a fluid cover assembly. In this regard, the integrated fluid cover 221 provides enhanced material integrity, durability, and fatigue resistance in high pressure fluid environments.

(43) For example, in a conventional fluid cover assembly that includes a separately coupled fluid cover portion and retainer portion, cyclic high fluid pressures produced in a fluid pump system may result in a water hammer effect in which impacts the fluid cover portion and which is translated towards the retainer portion. These fluid pulsations may be influenced by factors such as pump operating pressure, pump crankshaft rotation speed, suction and discharge valve efficiency, and effective fluid end chamber fill volume per plunger stroke. The fluid pulses/forces thus produce a constant vibration and wear on components of the fluid block assembly 101, and may cause relative movement of the fluid cover portion and the retainer portion, which may result, for example, in wearing down or away of threaded portions or other coupling features that may create a clearance gap (see FIG. 5) between the fluid cover portion and the separate retainer portion, backing out or disengagement of the retainer portion from an end portion of a fluid end block, the loss of seal integrity between the fluid cover portion and the end portion of the fluid end block that may lead to leakage of fluids from the fluid end block, etc.

(44) Accordingly, the disclosed integrated fluid cover 221 is resistant to wear and failure produced in the cyclic high pressure fluid environments in a fluid end block assembly 101 so as to reduce damage (e.g., wash, wear, cracking, etc.), reduce maintenance cycles and downtimes, minimize consumable components for the fluid end block assembly 101, ensure the maintenance of proper sealing contact with surfaces of the fluid end block assembly 101, and reduce leakage from the fluid end block assembly 101.

(45) In addition, because the tool engagement feature 231 may be engaged to both position and seat the fluid cover portion 225 in the end portion 106 of the fluid end block assembly 101 as well as engage/couple the retainer portion 227 with the fluid end block body 121, the number of tools employed for installation/maintenance of components of the fluid end block assembly 101 may be reduced, as well as obviating the need to align a separate fluid cover portion and a retainer portion.

(46) Further, constructing or manufacturing the fluid cover portion 225 and the retainer portion 227 into a single monolithic body of the fluid cover 221 may increase resistance to backing out and/or rotation of the fluid cover 221 during the rugged environment associated with operation of a fluid end. For example, with a separate fluid cover portion and retainer portion (see FIGS. 2A-3B), the fluid cover portion is subject to translation forces towards and away from the retainer portion as a result of what is known as the water hammer effect as will be understood by those skilled in the art, and the retainer portion is subject to rotational forces as a result of the retainer portion engaging the flange thereof. In contrast, the monolithic body of the fluid cover 221 increases a mass resisting the water hammer effect. In addition, as the retainer portion 227 and the fluid cover portion 225 are monolithically formed together, the water hammer effect may be reduced by eliminating movement between the retainer portion 227 and the fluid cover portion 225. Additionally, the frictional engagement between the monolithic fluid cover 221 may be increased to further resist the water hammer effect. For example, the seal member 114 frictionally engages the inner surface of the fluid end block body 121 which may increase resistance to rotation of the fluid cover portion 225 relative to the fluid end block body 121 when compared to a non-monolithically formed fluid cover. This engagement further may increase a service life of the fluid cover 221 and/or the fluid end block body 121 by reducing the number of component parts and by reducing the risk of failure of this particular component part due to its construction as illustrated and described in the associated embodiments.

(47) Referring to FIGS. 7A and 7B, an integrated fluid cover according to a second exemplary embodiment of the disclosure is generally designated 321, and may be sealably coupled to the fluid end block assembly 101 of a fluid pumping system 300 that may be otherwise similar to the fluid pumping systems described above, e.g., system 100. The integrated fluid cover 321 may have one or more features that are substantially similar to those described above with regard to the integrated fluid cover 221, and like or similar features are designated with like or similar reference numerals.

(48) The integrated fluid cover 321 has a body 323 that is substantially similar to the body 223 of the integrated fluid cover 221, except that the body 321 defines a machined or molded annular recess or groove 322 along the fluid cover portion 225 adjacent the flange portion 228 of the retainer portion 227 and for at least partially receiving a seal member 324 (broadly, “second seal member”) therein. The seal member 324 may be a flexible and/or resilient member, such as a polymeric (e.g., rubber) ring, for example and without limitation, an O-ring.

(49) In this regard, the annular groove 322 may provide for an arrangement of the seal member 324 about the fluid cover portion 225 of the integrated fluid cover 321 that has a low or minimized profile, e.g., such that a minimal portion of the seal member 324 extends above the annular groove 322. Accordingly, the annular groove 322 and seal member 324 cooperate to provide an arrangement of the seal member 324 that enhances a fluid-resistant seal against the fluid end block body 121, but does not interfere with proper placement or receipt of the fluid cover portion 225 in the end portion 106 of the fluid chamber 105.

(50) Furthermore, and with additional reference to FIG. 8, when the fluid cover portion 225 of the integrated fluid cover 321 is at least partially received with the end portion 106 of the fluid chamber 105, the seal member 324 may be compressed to a reduced profile, which may also have the effect of enhancing the sealing engagement of the seal member 324 against the fluid end block body 121. As shown in FIG. 8, the flange portion 228 of the integrated fluid cover 321 is positioned to seat against an internal surface 128 of end portion 106 of the fluid chamber 105. Specifically, the seal member 324 may be configured to engage the chamfered surface 123 of the fluid end block body 121 such that the seal member 324 fills space or at least some of the interstitial space between the retainer portion 225 and the fluid end block body 121 as will be understood by those skilled in the art.

(51) Referring now to FIG. 9, an integrated fluid cover according to a third exemplary embodiment of the disclosure is generally designated 421, which may be sealably coupled to the fluid end block assembly 101 of a fluid pumping system 400 that may be otherwise similar to the fluid pumping systems described above, e.g., systems 100, 300. The integrated fluid cover 421 may have one or more features that are substantially similar to those described above with regard to the integrated fluid covers 221, 321 and like or similar features are designated with like or similar reference numerals.

(52) The integrated fluid cover 421 has a body 423 that is substantially similar to the body 223 of the integrated fluid cover 221, except that the body 421 includes a neck portion or shoulder 422 extending from a surface of the fluid cover portion 225 to the flange portion 228 of the retainer portion 227. In this regard, the shoulder 422 of the integrated fluid cover 421 has a tapered configuration that provides an oblique annular surface positioned between the fluid cover portion 225 and the retainer portion 227 to substantially surround the fluid cover 421. The oblique annular surface of the shoulder 422 increases in diameter as the shoulder 422 extends towards the flange portion 228 of the retainer portion 227.

(53) Accordingly, and with additional reference to FIG. 10, when the fluid cover portion 225 of the integrated fluid cover 421 is at least partially received with the end portion 106 of the fluid chamber 105, the shoulder 422 may sealingly engage the chamfered surface 123 in a frictional and/or wedged arrangement so as to provide an enhanced seal of the integrated fluid cover 421 against the fluid end block body 121 that may resist fluid leakage from the fluid chamber 105. In one embodiment, both the fluid end block body 101 and at least the shoulder 422 of the integrated fluid cover 421 may be comprised of metal such that the interface of the shoulder 422 with the outer edge of the end portion 106 of the fluid chamber is a metal-to-metal interface that provides an enhanced seal. In some embodiments, the shoulder 422 may interact with the chamfered surface 123 to align or center the integrated fluid cover 421 with the end portion 106 of the fluid chamber 105.

(54) The foregoing description of the disclosure illustrates and describes various exemplary embodiments. Various additions, modifications, changes, etc., could be made to the exemplary embodiments without departing from the spirit and scope of the disclosure. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. Additionally, the disclosure shows and describes only selected embodiments of the disclosure, but the disclosure is capable of use in various other combinations, modifications, and environments and is capable of changes or modifications within the scope of the inventive concept as expressed herein, commensurate with the above teachings, and/or within the skill or knowledge of the relevant art. Furthermore, certain features and characteristics of each embodiment may be selectively interchanged and applied to other illustrated and non-illustrated embodiments of the disclosure.