Well service pump

Abstract

A well service pump system supplies high pressure working fluid to a well. The pump system is a linear design which incorporates a diesel engine, a hydraulic drive gear box, open loop hydraulic Pumps, hydraulic ram cylinders, controls for the hydraulic system hydraulic cylinders, working fluid end cylinders and a coupling to connect the hydraulic cylinders and the working fluid ends. The engine powers the hydraulic system which, in turn, provides hydraulic fluid to operate the hydraulic ram cylinders. Each of the polished rods of the hydraulic ram cylinders is connected axially to a plunger rod end of a working fluid end cylinder. There is no crankshaft or automatic transmission required. The linear design allows for a longer plunger stroke length while still allowing highway transport on a truck or skid.

Claims

1. A well service pump system for delivering fracturing fluid at high pressure to a well, the pump system comprising: at least two working fluid pump assemblies, each comprising: a working fluid end cylinder having an end cylinder housing and a plunger rod configured to reciprocate in the end cylinder housing; and a hydraulic ram cylinder having a ram cylinder housing, a ram piston configured to reciprocate in the ram cylinder housing, and a piston rod coupled to the ram piston and coupled to the plunger rod of the working fluid end cylinder such that the ram piston of the hydraulic ram cylinder can be actuated to move the plunger rod of the working fluid end cylinder: in a first direction to expel working fluid from the end cylinder housing during a forward stroke of the plunger rod, and in a second direction to draw working fluid into the end cylinder housing during a return stroke of the plunger rod; wherein the ram cylinder housing includes a first port on a first side of the ram piston and a second port on a second side of the ram piston; a control system configured to actuate the hydraulic ram cylinder of each of the working fluid pump assemblies independently of the hydraulic ram cylinder of each other of the working fluid pump assemblies between: a first configuration in which driving fluid is directed into the hydraulic ram cylinder housing via the first port to effectuate the forward stroke of the plunger rod; and a second configuration in which driving fluid is directed into the hydraulic ram cylinder housing via the second port to effectuate the return stroke of the plunger rod.

2. The well service pump system of claim 1, where each of the working fluid pump assemblies further comprises a coupling member coupled to the plunger rod of the working fluid end cylinder and to the piston rod of the hydraulic ram cylinder.

3. The well service pump system of claim 1, where, in each of the working fluid pump assemblies, the piston rod of the hydraulic ram cylinder is axially aligned with the plunger rod of the working fluid end cylinder.

4. The well service pump system of claim 1, where in each of the working fluid pump assemblies, the end cylinder housing of the working fluid end cylinder has a cylindrical inner wall defining an end cylinder inner diameter, and the plunger rod has an outer surface that is spaced apart from the cylindrical inner wall such that the working fluid end cylinder can pump an abrasive fluid without the plunger rod and the cylindrical-inner wall simultaneously contacting individual particles in the abrasive fluid.

5. The well service pump system of claim 4, where the outer diameter of the plunger rod is between 70 percent and 98 percent of the end cylinder inner diameter.

6. The well service pump system of claim 4, where the plunger rod has a length that exceeds 12 inches.

7. The well service pump system of claim 1, comprising a source of the driving fluid, wherein the source of the driving fluid comprises one or more hydraulic pumps.

8. The well service pump system of claim 7, where the hydraulic pump(s) each comprise a variable-displacement hydraulic pump.

9. The well service pump system of claim 1, where each of the working fluid pump assemblies further comprises: an inlet check valve coupled to the end cylinder housing and configured to permit working fluid to be drawn into the end cylinder housing but prevent working fluid from exiting the end cylinder housing through the inlet check valve; and an outlet check valve coupled to the end cylinder housing and configured to permit working fluid to exit the end cylinder housing while preventing working fluid from being drawn into the end cylinder housing.

10. The well service pump system of claim 9, further comprising: a suction manifold coupled to the inlet check valves of the working fluid pump assemblies; and a discharge manifold coupled to the outlet check valves of the working fluid pump assemblies.

11. The well service pump system of claim 10, where the suction manifold includes a plurality of inlet flow channels each coupled to a different one of the working fluid pump assemblies via the inlet check valve and having a cross-sectional area at least as large as the cross-sectional area of the interior of the working fluid end cylinder.

12. The well service pump system of claim 10, where the discharge manifold includes a plurality of outlet flow channels, each coupled to a different one of the working fluid pump assemblies via the outlet check valve and having a cross-sectional area that is smaller than the cross-sectional area of the interior of the working fluid end cylinder.

13. The well service pump system of claim 1, comprising a valve system configured to be coupled to a source of the driving fluid and to the hydraulic ram cylinders of the working fluid pump assemblies to direct driving fluid to and from the hydraulic ram cylinders, the valve system having, for each of the working fluid pump assemblies: a directional control valve in fluid communication with the source of the driving fluid and to each of the first port and the second port to selectively direct driving fluid to the first port or to the second port.

14. The well service pump system of claim 1, where the control system comprises a processor or programmable logic controller (PLC) configured to sequentially actuate the working fluid pump assemblies such that the hydraulic ram cylinder of a first one of the working fluid pump assemblies is beginning its forward stroke as the hydraulic ram cylinder of a second one of the working fluid pump assemblies is ending its forward stroke.

15. The well service pump system of claim 14, where the processor or PLC is configured to sequentially actuate the working fluid pump assemblies such that the hydraulic ram cylinder of a third one of the working fluid pump assemblies is beginning its forward stroke when the hydraulic ram cylinder of the first one of the working fluid pump assemblies is one half of the way through its forward stroke.

16. The well service pump system of claim 15, where the working fluid pump assemblies comprise a number of the working fluid pump assemblies that is a multiple of three.

17. The well service pump system of claim 16, where the processor or PLC is configured to actuate each of the working fluid pump assemblies such that the duration of the forward stroke is twice the duration of the return stroke.

18. The well service pump system of claim 14, where: the control system further comprises a plurality of position sensors, each coupled to a different one of the hydraulic ram cylinders and configured to detect the position of the ram piston in the ram cylinder housing; and the processor or PLC is coupled to the position sensors and is further configured to adjust the timing of actuation of the working fluid pump assemblies based, at least in part, on the detected positions of the ram pistons.

19. A method comprising: delivering fluid to a well with a well service pump system of claim 1.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a simplified, schematic diagram of the operative components of a prior art well service pump system.

(2) FIG. 2 is a simplified, schematic diagram of the operative components of an embodiment of the present well service pump systems.

(3) FIG. 3 is a simplified view of an in-line hydraulic cylinders, piston rods, plunger rods and working fluid end cylinders used in the pump system of FIG. 2.

(4) FIG. 4 depicts a perspective view of a second embodiment of the present well service pump systems.

(5) FIG. 5 depicts a side view of the system of FIG. 4.

(6) FIG. 6 depicts an enlarged side view of a working fluid pump assembly portion of the system of FIG. 4.

(7) FIG. 7 depicts an enlarged, cutaway perspective view of a working fluid pump assembly portion of the system of FIG. 4.

(8) FIG. 8 depicts a cross-sectional side view of one of the working fluid pump assemblies of the system of FIG. 4.

(9) FIG. 9 depicts an enlarged, cross-sectional side view of a coupling member coupling a piston rod of the working fluid pump assembly to a plunger rod of the working fluid pump assembly.

(10) FIG. 10 depicts an enlarged, cross-sectional side view of a plunger and seal portion of working fluid end cylinder of the working fluid pump assembly.

(11) FIG. 11 depicts an enlarged perspective view of a working fluid manifold portion of the system of FIG. 4.

(12) FIG. 12 depicts an enlarged, cross-sectional side view of working fluid end cylinder and working fluid manifold portion of the working fluid pump assembly.

(13) FIG. 13 depicts a schematic diagram of the system of FIG. 4.

(14) FIG. 14 depicts an enlarged portion of the schematic diagram of FIG. 13.

(15) FIG. 15 depicts a perspective view of one example of a hydraulic cylinder with a position sensor that is suitable for at least some of the present systems.

(16) FIG. 16 illustrates an exemplary actuation sequence for the system of FIG. 4.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

(17) The following drawings illustrate by way of example and not limitation. For the sake of brevity and clarity, every feature of a given structure is not always labeled in every figure in which that structure appears. Identical reference numbers do not necessarily indicate an identical structure. Rather, the same reference number may be used to indicate a similar feature or a feature with similar functionality, as may non-identical reference numbers. The figures are drawn to scale (unless otherwise noted), meaning the sizes of the depicted elements are accurate relative to each other for at least the embodiment depicted in the figures.

(18) FIG. 1 is a simplified, schematic flow diagram of a prior art well service pump system 10 of the type toward which the improvements of the present invention are directed. As has been briefly discussed, such well service pumps typically utilize a diesel engine 14, which will usually be 2,000 bhp or larger. The diesel engine transfers its power to a large automatic transmission 18. Transmission 18 then transfers power through a large driveline 22 into a gear reduction box 26 mounted on the frac pump 30. The driveline enters the frac pump at a right angle to the connecting rods, plungers and pump discharge (illustrated in simplified fashion generally at 34 in FIG. 1).

(19) The operation of one embodiment 50 of the present well service pump systems is illustrated in simplified fashion in FIG. 2. As has been briefly described, a diesel engine 54 and hydraulic gear box 58 provide power to one or more open loop hydraulic pumps 62 which provide a source of driving fluid under high pressure. The diesel engine and hydraulic gear box are commercially available and will be familiar to those skilled in the relevant industry. Hydraulic pumps 62 provide the driving fluid to operate the hydraulic ram cylinders 66 which, in turn, operate the fluid end cylinders 70 to pump working fluid into a well under high pressure. The hydraulic pumps may be obtained commercially, for example the Parker™ P16 Series, available from Parker Hannifin Corporation.

(20) A hydraulic control system 74 controls the supply of driving fluid to the hydraulic ram cylinders 66. As will be discussed more fully with respect to FIG. 3, it will be appreciated from the simplified schematic view presented in FIG. 2 that the hydraulic ram cylinder piston rods and the plunger rods of the working fluid end cylinders are located in-line, in linear fashion (connected by a coupling member 78). This is to be contrasted to the right angle arrangement of the driveline 22 and pump gear box 26 shown in the prior art system of FIG. 1.

(21) FIG. 3 is a simplified view of a working fluid pump assembly 82 that includes the in-line components of system 50, as shown. More particularly, FIG. 3 shows one of the hydraulic ram fluid cylinders 66 and associated working fluid end cylinder 70. Preferably at least two units or assemblies 82 are provided for a system 50, each assembly 82 being sequentially operated to reciprocate working fluid end cylinder 70. Each of working fluid end cylinders 70 includes a reciprocating plunger rod 86 for supplying a working fluid under high pressure to the well. The inlet or entrance 90 and outlet or exit 94 for the working fluid are illustrated in simplified fashion. In the embodiment shown, system 50 includes an in-line discharge valve 98 which eliminates the need for right angle components and consequently reduces the metal fatigue in the fluid end cylinder.

(22) As shown in FIG. 3, hydraulic ram cylinder 66 has a ram piston rod 102 which is connected for operating each of the working fluid ends. In the embodiment shown, a coupling member or bracket 78 is operably connected between piston rod 102 and plunger rod 86 so that the piston rod and plunger rod are arranged in an in-line, linear fashion. Each hydraulic ram fluid cylinders 66 of a system 50 can conveniently be mounted on the bed of a truck or skid by means of a mounting flanges 106, 110 and stay rods 114.

(23) The hydraulic ram fluid cylinders 43 can be, for example, the same type hydraulic cylinders that are used to power a traditional “snubbing unit.” For an example snubbing unit, see the Hydra Rig™ HRP-2 commercially available unit.

(24) As mentioned above, a valve system can be operably associated with each hydraulic ram cylinder for delivering driving fluid to each hydraulic ram cylinder at a driving pressure. A control system (74 in FIG. 2) is provided for operating the valve system to alternately pressurize each hydraulic ram cylinder on a forward stroke thereof and to depressurize the hydraulic ram cylinder on a return stroke thereof to thereby deliver a continuous and pulseless output flow of the working fluid from the working fluid end cylinders to the well.

(25) In some embodiments, the system includes a directional control valve connected to the source of driving fluid and movable between a pressurizing position which admits driving fluid for pressurizing a respective ram cylinder at the beginning of its forward stroke and for exhausting the respective ram cylinder during its return stroke. One example of such a directional control valve is the Parker™ R04C3 Directional Control Valve available from Parker Hannifin Corporation.

(26) In addition to the use of directional control valves, the present systems may also include one or more proportional control valves (sometimes called proportional throttle valves). The directional control valve controls the direction of the flow of the hydraulic fluid. In one position, it allows a hydraulic ram cylinder 66 to charge and in the other position it allows the ram piston to return. A proportional control valve component of the system can be computer controlled to provide real time, exact control of the position of the respective ram piston rod. An example would be the Parker™ TDP series valve. In some embodiments, for example, this can allow the system to have one ram piston accelerating one ram half way thru its travel while another ram decelerates, to closely approximate the timing of the current crankshaft designs, without the disadvantages of the crankshaft discussed above.

(27) Hydraulic ram cylinder 66 has an internal diameter and internal cylindrical sidewalls, a piston (not shown in FIG. 3) with an outer diameter that fits closely and in a substantially sealed relationship with the inner cylindrical sidewalls as is typical for hydraulic power cylinders, and a piston rod 102 coupled to the piston and extending out of the cylinder housing as shown. In contrast, in the embodiment shown, working fluid end cylinder 70 includes a plunger rod 86 (e.g., a plunger that is unitary with and/or has a substantially equal outer diameter to that of the plunger rod, as shown). In this embodiment, the outer diameter of plunger rod 86 is smaller than the inner diameter of the inner diameter defined by inner walls 118 of the housing of fluid end cylinder 70, as shown. As such, plunger rod 86 is received in spaced-apart fashion from walls 118 so that abrasive fluids may be pumped without undue wear on the plunger rod or cylinder walls. For example, the space between the outer surface of the plunger rod and the inner walls of the housing of end cylinder 70 is larger than the largest expected transverse dimension of any particles in the working fluid to prevent any single particle in the working fluid from simultaneously contacting the outer surface of the plunger and the inner surface of the housing. In the embodiment shown, coupling member 78 is configured to couple a first rod end 122 of hydraulic ram cylinder 66 to a second rod end 126 of plunger rod 86 in order to achieve the in-line arrangement, and such that reciprocal movement of the rod of hydraulic ram cylinder 66 causes reciprocal movement of the plunger of working fluid end cylinder 70.

(28) Referring now to FIGS. 4-14, a second embodiment 50a of the present system is shown. In the embodiment shown, system 50a comprises at least two (six in this embodiment) of working fluid pump assemblies 82a (82a-1, 82a-2, 82a-3, 82a-4, 82a-5, 82a-6) and a source of pressurized driving fluid 130. In the embodiment shown, system 50a is coupled to and carried by a trailer 134 (e.g., a semi trailer) for transportation to and from job sites for fracing operations. In other embodiments, system 50a can be coupled to a skid frame that can then be loaded onto and offloaded from a trailer. In the embodiment shown, the source of pressurized driving fluid (130) comprises: a diesel engine 54a (e.g., 2,500 HP), a hydraulic drive gear box 58a coupled to an output shaft of the diesel engine (e.g., crankshaft); one or more (e.g., four as shown) hydraulic pumps 62a coupled to hydraulic drive gear box 58a, and one or more hydraulic fluid reservoirs 138. Fuel for engine 54a may be carried by tanks 142 on trailer 134, or may be separately provided for at a work site. In the depicted embodiment, gear box 58a comprises a cotta box pump drive available from Cotta Transmission Company (Wisconsin). In this embodiment, each of pumps 62a comprises a variable-displacement hydraulic pump to permit adjustment of the rate at which ram cylinders 66a are actuated. The configuration of system 50a is such that an automatic transmission is not necessary, and such that the working fluid pump assemblies (82a) do not include a crank shaft.

(29) In the embodiment shown, each working fluid pump assembly 82a comprises: a working fluid end cylinder 70a (70a-1, 70a-2, 70a-3, 70a-4, 70a-5, 70a-6) and a hydraulic ram cylinder 66a (66a-1, 66a-2, 66a-3, 66a-4, 66a-5, 66a-6). In this embodiment, working fluid end cylinder 70a includes an end cylinder housing 150 and a plunger rod 86a configured to reciprocate in the end cylinder housing. In this embodiment, hydraulic ram cylinder 66a includes a ram cylinder housing 154, a ram piston 156 configured to reciprocate in the ram cylinder housing. For example, in the embodiment shown, the bore of cylinder housing 154 has a diameter of 7 inches, and piston rod 102a has an outer diameter of 5 inches. In the depicted embodiment, each pump assembly 82a (via end cylinder housing 150 and ram cylinder housing 154) is connected in fixed relation to a rigid I-beam 158 which is, in turn, supported on trailer 134 by a plurality (e.g., four, as shown) vibration-dampening mounts 160. As shown, piston rod 102a is coupled to the ram piston and coupled to plunger rod 86a such that piston can be actuated to move the plunger rod: in a first direction 162 to expel working fluid from the end cylinder housing during a forward stroke of the plunger rod, and in a second direction 166 to draw working fluid into the end cylinder housing during a return stroke of the plunger rod. More particularly, in the embodiment shown, coupling member 78a couples first end 122a of plunger rod 86a to second end 126a of piston rod 102a. In the depicted embodiment, second end 126a of the piston rod is convex and first end 122a of plunger rod 86a is concave such that the convex and concave ends cooperate to center the rods relative to one another. In this embodiment, plunger rod 86a and piston rod 102a include annular grooves 170 adjacent to their respective ends, such that the grooves can receive bushings or journals 174 and radial protrusions 178 of coupling member 78a to resist separation of the plunger rod and piston rod.

(30) In the embodiment shown, hydraulic ram cylinders 66a are similar to traditional hydraulic power cylinders in that housing 154 includes an cylindrical inner wall defining an inner diameter and piston 158 fits closely (e.g., in substantially sealed relation to) the inner wall such that delivery of pressurized driving (e.g., hydraulic) fluid to a first port 182 on a first side of piston 158 pushes piston 158 (and piston rod 102a) in first direction 162 to actuate the forward stroke of assembly 82a, and delivery of pressurized driving fluid to a second port 186 on a second, opposite side of piston 158 pushes piston 158 (and piston rod 102a) in second direction 166 to actuate the return stroke of assembly 82a. In contrast, in the embodiment shown, working fluid end cylinder housing 150 has a cylindrical inner wall 190 defining an inner diameter 194, and plunger rod 86a has a cylindrical outer surface 198 that is spaced apart from cylindrical inner wall 10 such that the working fluid end cylinder can pump abrasive fluids without the plunger rod and the end cylinder inner wall simultaneously contacting individual particles in the working fluid. An outer diameter 202 of the portion of the plunger rod that enters housing 150 may be between 70 percent and 98 percent (e.g., between 85 percent and 95 percent) of inner diameter 194. For example, in the embodiment shown, inner diameter 194 is 5 inches and outer diameter 202 is 4.5 inches. In other embodiments, inner diameter 194 is 3.5 inches and outer diameter 202 is 3.25 inches (e.g., reduction of inner diameter 194 relative to the inner diameter of the bore of hydraulic ram cylinder 66a amplifies pressure in end cylinder 70a relative to hydraulic ram cylinder 66a.

(31) In the embodiment shown, rather than having an enlarged plunger head, the seal between housing 150 and plunger rod 86a is provided by an end seal or packing 206 that provides a tight seal around the outer surface, and assists with maintaining alignment, of the plunger rod. In this embodiment, for example, seal 206 comprises a hydraulic seal (pressurized via port 210), as illustrated in FIG. 10. In the depicted embodiment, during a forward stroke of pump assembly 82a, the volume of plunger rod 86a occupies a majority of the volume of the interior of housing 150, thereby reducing the volume available for working fluid and thereby forcing working fluid out of end cylinder 70a. The space between inner surface 150 and outer surface 198 can be selected to exceed the maximum transverse dimension (e.g., diameter) of any particulates (e.g., proppants) in the working fluid such that particles are not contacted by both surfaces at one, thereby reducing and/or eliminating abrasion of the respective surfaces. In some embodiments, the length of plunger rod 86a (e.g., and the length of the portion of the plunger rod that extends inward of seal 206) exceeds 12 inches (e.g., exceeds 40 inches and/or is between 50 inches and 60 inches). For example, in the embodiment shown, end cylinders 70a each have a stroke length of 48 inches.

(32) In the embodiment shown, each working fluid pump assembly 82a (e.g., end cylinder 70a) further comprises an inlet check valve 214 coupled to end cylinder housing 150 and configured to permit working fluid to be drawn into the end cylinder housing but prevent working fluid from exiting the end cylinder housing through the inlet check valve. In operation of the system, the inlet check valve prevents working fluid from exiting through the fluid inlet thereby enabling working fluid to be pressurized in the cylinder and directed solely to the well. In this embodiment, each working fluid pump assembly 82a (e.g., end cylinder 70a) further comprises an outlet check valve 218 coupled to end cylinder housing 150 and configured to permit working fluid to exit the end cylinder housing while preventing working fluid from being drawn into the end cylinder housing. In operation of the system, the outlet check valve prevents working fluid pressurized downstream of the outlet check (e.g., in the outlet manifold described below) valve from entering the cylinder housing during the return stroke of plunger rod 86a (e.g., during the forward stroke of other working fluid pump assemblies). The outlet check valve and inlet check valve may, in some embodiments, be at least partially in the end cylinder housing. For example, in the embodiment shown, end cylinder housing 150 includes an end block 222 defining an outlet passage 226 (within which outlet check valve 218 is disposed), and an inlet passage 230 (within which inlet check valve 214 is disposed). In this embodiment, the outlet passage is substantially aligned with a longitudinal axis (and the direction of movement) of the plunger rod, such as, for example, to reduce “hammering” effects, mechanical stresses, and undesirable flow patterns that could otherwise result from forcing pressurized working fluid through a bend. In the depicted embodiment, the inlet passage is disposed at a 90 degree angle relative to the outlet passage, the orientation of which is functionally acceptable because the working fluid entering through the inlet is not pressurized to the same degree as working fluid exiting the exit check valve.

(33) In the embodiment shown, system 50a further comprises a suction manifold 234 coupled to the inlet check valves (214) and inlet passages (230) of each working fluid pump assemblies 82a; and a discharge manifold 238 coupled to the outlet check valves (218) and outlet passages (226) of the working fluid pump assemblies. In this embodiment, suction manifold 234 includes a plurality of inlet flow channels 242 each coupled to a different one of the working fluid pump assemblies 82a via the corresponding inlet check valve (214) and inlet flow channel (230). In this embodiment, each inlet flow channel 242 has a cross-sectional area at least as large as the cross-sectional area of the interior of the working fluid end cylinder to which the inlet flow channel is coupled. For example, in the embodiment shown, inlet flow channel 242 has a circular cross-section with a diameter of 5 inches, and end cylinder housing 150 defines an interior having a circular cross-section with a diameter of 5 inches.

(34) In the embodiment shown, suction manifold 234 includes a primary (e.g., tubular) member 246 defining a primary chamber 250 that extends laterally across all of the pump assemblies 82a. In this embodiment, suction manifold 234 also includes a plurality of connection (e.g., tubular) members 254 each defining an inlet flow channel 242 and connecting the primary chamber 250 with the inlet channel (218) of a respective end cylinder 70a (e.g., via a flange 258 that is removably coupled to the end block 222 of the respective end cylinder 70a, as shown). This embodiment of suction manifold 234 further includes an intake member 262 defining an intake passage in fluid communication with primary chamber 250, and dual intake ports 266 each controlled by a (e.g., butterfly) valve 270. In the depicted embodiment, the ends of primary member 246 are closed with end caps 274 that are removable to facilitate cleaning of suction manifold 234 (e.g., to remove slurry and/or particulates that may be deposited from the working fluid). End caps 274 may also be removed to use the ends of primary member 246 as additional or alternative inlets for working fluid. Similarly, in this embodiment, intake member 262 is coupled to primary member 246 via a flange and is thereby removable to further facilitate cleaning and/or replacement of the intake member. In the embodiment shown, primary chamber 250 has a circular cross-section with a diameter of 8 inches, intake member 262 has a circular cross-section with a diameter of 8 inches, and each of intake ports 266 has a circular cross-section with a diameter of 4 inches.

(35) In the depicted embodiment, discharge manifold 238 includes a plurality of outlet flow channels 278 each coupled to a different one of the working fluid pump assemblies 82a via the corresponding outlet check valve (218) and outlet flow channel (226). In the depicted embodiment, at least a portion of each outlet flow channel 278 is axially aligned with the respective outlet flow passage 226 (and plunger rod 86a), as shown. In this embodiment, each outlet flow channel 278 has a cross-sectional area that is smaller than the cross-sectional area of the interior of the working fluid end cylinder to which the outlet flow channel is coupled. For example, in the embodiment shown, outlet flow channel 278 has a circular cross-section with a diameter of 3 inches, and end cylinder housing 150 defines an interior having a circular cross-section with a diameter of 5 inches.

(36) In the embodiment shown, discharge manifold 238 includes a primary chamber 282 that extends laterally across all of the pump assemblies 82a. In this embodiment, primary chamber 282 is defined by the lateral portions of a plurality of (e.g., four, as shown) tee fittings 286 and a plurality of (e.g., two, as shown) cross-fittings 290. Each of fittings 286, 290 is coupled to one of pump assemblies 82a (e.g., end block 222 of the respective end cylinder housing 150) via a flange 294 of a 45-degree elbow fitting 298 that defines outlet flow channel 278. In this embodiment, the lower branches of cross fittings 290 provide outlet connections 302 that can be connected to the well to deliver facilitate the delivery of working fluid. As with the ends of primary member 150 of suction manifold 234, the ends of the outermost tee fittings that define discharge manifold 238 are covered by end plates 306 that are removable to facilitate cleaning and/or provide additional outlet connections. As shown, when not in use, outlet connections 302 are also covered with end plates (e.g., similar to end plates 306).

(37) In the embodiment shown, system 50a also comprises a valve system 310 coupled to the source of pressurized driving fluid (variable-displacement pumps 62a) and to each hydraulic ram cylinder 66a of each of the working fluid pump assemblies to direct pressurized working fluid to and from the hydraulic ram cylinders. In this embodiment, system 50a also comprises a control system 314 coupled to valve system 310 and configured to sequentially actuate (by directing pressurized working fluid to ports 182, 186 of each hydraulic ram cylinder via valve system 310) the hydraulic ram cylinders to deliver (e.g., continuous and substantially pulseless) output flow of the working fluid from the pump system to the well.

(38) As shown, valve system 310 comprises a plurality of (e.g., six, as shown) directional valves 318, one for each of hydraulic ram cylinders 66a. In the embodiment shown, each directional valve 318 includes two upstream ports 322, 326 (with first upstream port 322 coupled to a pump 62a and second upstream port 326 coupled to reservoir 138) and two downstream ports 330, 334 (with first downstream port 330 connected to port 182 of the hydraulic ram cylinder 66a, and second downstream port 334 connected to port 186 of the hydraulic ram cylinder 66a). In use, the direction valve can be electronically actuated (e.g., by control system 314) between: (1) a first configuration in which pressurized driving fluid is directed from pump 62a, through ports 322 and 330 of valve 318-1, and into port 182 of hydraulic ram cylinder 66a-1 to push piston 156 through its forward stroke, and (2) a second configuration in which pressurized driving fluid is directed from pump 62a, through ports 322 and 334 of valve 318-1, and into port 186 of hydraulic ram cylinder 66a-1 to push piston through its return stroke. During the forward stroke of piston 156, non-pressurized or low-pressure driving fluid is directed from port 186 of hydraulic ram cylinder 66a-1, through ports 334 and 326 of valve 318-1, and to reservoir 138. During the return stroke of piston 156, non-pressurized or low-pressure driving fluid is directed from port 182 of hydraulic ram cylinder 66a-1, through ports 330 and 326 of valve 318-1, and to reservoir 138.

(39) In the embodiment shown, the rate at which piston 156 completes its forward and return strokes can be adjusted by varying the pressure and/or the rate at which pressurized driving fluid is delivered to hydraulic ram cylinder 66a-1. For example, assuming that driving fluid is delivered at a pressure that is sufficient to move piston 156, the faster the driving fluid is delivered to port 182, the faster piston 156 will complete its forward stroke. In some embodiments, and as described below, it may be advantageous for the return stroke to be completed faster (have a shorter duration) than the forward stroke. As such, in the depicted embodiment, pump 62a is a variable displacement pump that can be adjusted to vary the rate at which pressurized driving fluid is delivered from the pump. In this embodiment, pump 62a is connected to control system 314 such that the control system can electronically signal adjustments to the pump to increase or decrease displacement. In other embodiments, the valve system includes a plurality of electronically adjustable proportional flow valves each between one of pumps 62a and the corresponding directional valves 318, such that control system 314 can adjust the volume of flow to the respective hydraulic ram cylinders 66a to adjust the duration of the forward and return strokes.

(40) In the embodiment shown, system 50a (e.g., control system 314) further comprises a a plurality of position sensors 338 each coupled to a different one of the hydraulic ram cylinders (e.g., 66a-1) and configured to detect the position of the ram piston (156) in the ram cylinder housing (154). For example, position sensor 338 can comprise a linear position sensor coupled to housing 154. In some embodiments, a position indicator (e.g., a magnet, RFID tag, and/or the like) can be coupled to piston 156 and/or piston rod 102a to cooperate (e.g., be located by) sensor 338. In other embodiments, position sensor 338 may be coupled to end cylinder housing 150 of end cylinder 70, a position indicator can be coupled to plunger rod 86a, and/or position sensors 338 and/or position indicators can be coupled to both of hydraulic ram cylinders 66a and end cylinders 70a. In operation, sensing the position of the piston (156) and/or plunger rod (86a) of each pump assembly 82a can assist control system 314 with maintain precise relative timing of the pump assemblies, such as, for example, to minimize and/or eliminate pulses in the flow of working fluid into the well, as described in more detail below.

(41) In the embodiment shown, control system 314 comprises one or more processors and/or a programmable logic controllers (PLCs) configured to sequentially actuate working fluid pump assemblies 82a (i.e., via hydraulic ram cylinders 66a). Examples of suitable control systems are available from Wandfluh of America, Inc. In most embodiments, the present systems are configured to actuate the pump assemblies such that at least one of the pump assemblies is performing a forward stroke at any given point in time (e.g., such that the hydraulic ram cylinder of a first one of the working fluid pump assemblies is beginning its forward stroke as the hydraulic ram cylinder of a second one of the working fluid pump assemblies is ending its forward stroke). For example, in an embodiment with only two pump assemblies 82a, the first pump assembly would perform its forward stroke as the second pump assembly performs its return stroke of the same duration. In the embodiment shown, the fluid pump assemblies (82a) are included in a multiple of three (six) and are controlled as two groups of three.

(42) More particularly, and as illustrated in FIG. 7, the pistons (156) of the first and fourth hydraulic ram cylinders (66a-1 and 66a-4) are just beginning their forward stroke (which may be referred to as top dead center or TDC), the pistons (156) of the third and sixth hydraulic ram cylinders (66a-3 and 66a-6) are just ending their forward stroke (which may be referred to as bottom dead center or BDC), and the pistons (156) of the second and fifth hydraulic ram cylinders (66a-2 and 66a-5) are in the middle of their forward stroke (are halfway between TDC and BDC). For example, FIG. 16 illustrates the actuation of cylinders 66a-1, 66a-2, and 66a-3, from TDC to BDC (Ls), in which: at time “A,” cylinder 66a-1 is halfway through its forward stroke and cylinder 66a-2 is begins its forward stroke; at time “B,” cylinder 66a-2 is halfway through its forward stroke and cylinder 66a-3 beings its forward stroke; and, at time “C,” cylinder 66a-1 has returned to TDC and is beginning a subsequent forward stroke. In use, these relative positions between the pistons is maintained during their forward strokes such that, at any given point in time at which any two of the pistons are at TDC, two of the other four pistons are at BDC, and the remaining two pistons are half way in between TDC and BDC. In use, these relative positions result in a relatively smooth and pulseless delivery of fluid to discharge manifold 238 and to a well. For example, in the positions illustrated in FIG. 7, the third and sixth end cylinders (70a-3 and 70a-6) have just stopped expelling working fluid into the discharge manifold (238), the first and fourth end cylinders (70a-1 and 70a-4) are just about to start expelling working fluid into the discharge manifold (238), and the second and fifth end cylinders (70-a-2 and 70-a-5) are expelling working fluid into the discharge manifold (238) at a substantially constant rate. To facilitate these relative relationships between the pistons, the return stroke must be equal to or less than one half of the duration of the forward stroke. For example, when the second and fifth end cylinders (70-a-2 and 70-a-5) reach BDC, the first and fourth end cylinders (70-a-1 and 70-a-4) will be halfway through their forward stroke, and the third and sixth end cylinders (70-a-1 and 70-a-4) must be at BDC and ready to begin their forward stroke. In some embodiments, the hydraulic ram cylinders (66a) are actuated (e.g., via adjustments to pumps 62a and/or valves 318 implemented by control system 314) such that the duration of the return stroke is less than half the duration of the forward stroke (for example, as illustrated in FIG. 16) such that each piston can be paused momentarily at TDC to enable the re-synchronization of the pistons every few strokes and/or on every stroke.

(43) FIG. 15 depicts a hydraulic ram cylinder with one example of a position sensor 338a that is suitable for at least some embodiments of the present systems. In the embodiment shown, sensor 338a is a magneto-inductive position sensor that comprises a base 400, elongated transducer element 404, and an oscillator 408. As shown, base 400 is coupled to the housing of the cylinder (e.g., 66a-1) and transducer element 404 extends coaxially with and into the piston (e.g., 156) and piston rod (102a), while oscillator 408 comprises an annular magnet coupled in fixed relation to the piston (e.g., 156) such that position of the oscillator and thereby the position of the piston can be detected as it moves relative to transducer element 404. Various sensors 338a are available, for example, from Balluff, Inc.

(44) In the embodiment shown and having the dimensions described above, pump assemblies 82a are configured to deliver working fluid at pressures of up to 20,000 psi and to complete their forward strokes at linear rates of up to 150 feet per minute (2.5 feet per second, resulting in a duration of 1.6 seconds for a 48 inch stroke), for a collective pumping rate from all six pump assemblies 82a of about 7.4 barrels per minute.

(45) The present pumps and pump systems have a number of advantages relative to prior art frac pumps. At least some embodiments of the present “linear” or axial configurations utilize a diesel engine, a hydraulic drive gear box, open loop hydraulic pumps, hydraulic ram cylinders, controls for the hydraulic system hydraulic cylinders, cylindrical fluid ends and a coupling to connect the hydraulic cylinders and the fluid end cylinders. In such embodiments, the engine powers the hydraulic system which, in turn, provides hydraulic fluid to operate the hydraulic cylinders, and the (e.g., polished) rod of the hydraulic ram cylinders is connected axially to the plunger rod of the working fluid end cylinder. Such a configuration eliminates any need for a crankshaft or automatic transmission.

(46) Because the present configurations eliminate any need for a crankshaft, the stroke length can be greatly extended which can be an important factor, especially in the harsh environments that frac pumps may be required to operate. Prior art pump designs may operate at a crankshaft speed of up to 330 revolutions per minute (RPM), with the discharge at a right angle to the plunger. Such prior art designs have significant cyclic fatigue on the fluid end. The present embodiments, however, can include much longer stroke lengths (e.g., 48 inches or more) that can significantly reduce the working cycles per minute (e.g., by a factor of up to 7 to 8), and/or can include an in-line discharge outlet (and outlet passage at least part of which is axially aligned with the plunger) to eliminate right angle discharge components and thereby reduce metal fatigue in the working cylinder fluid ends.

(47) Current and prior art frac pumps were designed for intermittent use, because of the speed the pump needs to operate and the short stroke. Therefore, with use in modern shale fracing applications, prior art pumps may have to be down-rated for current frac applications. In contrast, the present embodiments are able to operate for longer periods of time because the longer stroke length permit pumping with little or no metal fatigue, such that an operator can have fewer units on location for a frac job. For example, the longer stroke length can significantly reduce the number of strokes required to pump a given volume, and thereby reduce the rate at which the plunger must cycle, reducing fatigue and extending fluid end life. The reduction in cycling rate can also reduce fuel usage. Further, the present embodiments can reduce weight and lower the center of gravity of a system on a trailer, relative to a prior art system with a rotary pump.

(48) Further, prior art frac pump designs generally must be completely shut down if one plunger bores is cracked or requires maintenance (e.g., one crack can cause the loss of 2,000+HP), and an operator may need to bring surplus frac pump units to a location as a safety factor to ensure continuous operation. In contrast, in the present embodiments, each fluid end cylinder is completely separate from the others such that a single cylinder may be shut down and repaired while keeping the other cylinders in a system (e.g., 50a) operating, thereby reducing the need for additional surplus or backup systems and, in turn, reducing the necessary area or footprint of a job location. For example, in system 50a with six pump assemblies 82a, shut down of a single pump assembly 82a results in only 16% incremental decrease in system capacity.

(49) Prior art frac pump designs typically use a rectangular fluid end that is monoblock design that can weigh as much as 6,000 lbs and which, if it fails on location, can require the entire unit to be taken out of line and taken back to the maintenance shop to be repaired. In contrast, in the embodiment of system 50a shown and described above, each end cylinder 70a is independently removable and will weigh about 1,000 lbs, making it relatively easy to replace end cylinders on location (e.g., by a field service truck that normally has a one-ton crane on board).

(50) In the present embodiments, the use of directional control valves and proportional control valves can also reduce and/or eliminate the hammering effect that are sometimes encountered with the prior art crankshaft systems. The precise control of flow through system 50a facilitates smooth and constant flow, thereby significantly reducing the types of wear and fatigue that often caused iron to prematurely fail in the prior art systems. For example, the significant reduction in cyclic rate greatly reduces the number of possible pressure spikes, thereby extending the working life of hydraulic fluid. Vibrations are also reduced, and the linear design can substantially eliminate exposed rotating components.

(51) The above specification and examples provide a complete description of the structure and use of illustrative embodiments. Although certain embodiments have been described above with a certain degree of particularity, or with reference to one or more individual embodiments, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the scope of this invention. As such, the various illustrative embodiments of the methods and systems are not intended to be limited to the particular forms disclosed. Rather, they include all modifications and alternatives falling within the scope of the claims, and embodiments other than the one shown may include some or all of the features of the depicted embodiment. For example, elements may be omitted or combined as a unitary structure, and/or connections may be substituted. Further, where appropriate, aspects of any of the examples described above may be combined with aspects of any of the other examples described to form further examples having comparable or different properties and/or functions, and addressing the same or different problems. Similarly, it will be understood that the benefits and advantages described above may relate to one embodiment or may relate to several embodiments. For example, embodiments of the present methods and systems may be practiced and/or implemented using different structural configurations, materials, ionically conductive media, monitoring methods, and/or control methods.

(52) The claims are not intended to include, and should not be interpreted to include, means-plus- or step-plus-function limitations, unless such a limitation is explicitly recited in a given claim using the phrase(s) “means for” or “step for,” respectively.