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Drilling consumables such as mud pump systems and their components can drastically increase your uptime while reducing costs and health/safety/environmental (HSE) risks. To support your drilling needs, Forum’s patented P-Quip® mud pump system offers a single-source solution that integrates high-quality fluid end components for maximum longevity and performance.

With more than 20 years of successful operation in severe environments, P-Quip offers a proven track record for the lowest cost of ownership in the industry. As part of our commitment to quality, our mud pump parts use patented Banded Bore™ technology that significantly reduces stress concentrations and leads to longer module life.

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Chrome-Iron Liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Zirconia-Ceramic Liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Mud-Pump Gear Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

The invention relates to an assembly for quickly securing and releasing a component to a pump housing and more particularly to a retainer assembly for releasably mounting a piston liner within a hydraulic cylinder on the module of a pump.

Heavy duty large horsepower pumps are used to pump fluids or slurries with entrained solids. In the oil industry, for example, slush or mud pumps are used to pump viscous fluids, such as drilling muds, cement, or other well fluids. Although mud pumps may be either centrifugal or reciprocating type pumps, typically mud pumps are reciprocating pumps using one or more pistons and hydraulic cylinders with liners to generate the high pressures required to pump these viscous fluids in and out of the well.

Mud pumps include a fluid end and a power end. In the fluid end of one type of a triplex mud pump, for example, there are three sets of suction modules and discharge modules in fluid communication. A suction manifold is connected to the fluid inlets of the suction modules for receiving fluids and passing those fluids to each of the suction modules. A discharge manifold is connected to the fluid outlets of the discharge modules for discharging the pumped fluids. Each module encloses a set of flow passages with check valves for controlling the direction of flow of the fluids. A check valve is disposed at the suction module fluid inlet to only allow fluids to enter the suction module inlet end of the module and another check valve is disposed at the discharge module fluid outlet to only allow fluids to exit the the discharge module for flow into the discharge manifold.

Each discharge module includes a liner retainer flange attached to the discharge module. The liner retainer flange attaches to a replaceable liner within which a pump piston reciprocates. The piston is a generally cylindrical steel member having a polymer, such as polyurethane, bonded to its outer diameter for sealingly engaging the inner cylindrical wall of the liner to ensure a fluid tight seal required for drawing the low pressure fluids through the suction manifold and module flow passages. The seal integrity must be maintained to withstand the high discharge pressure on the discharge stroke. The power end contains the gears that reciprocate the pump piston within the liner for pumping the fluid through the module passages in the fluid end and thence out the discharge valve.

In operation, on the suction stroke, the pump piston draws fluids through the suction manifold and suction valve as the piston strokes within the liner. On the discharge stroke, the check valve in the discharge module opens simultaneously as the suction valve closes preventing suction back flow into the suction module. Fluid in the liner is compressed and pressure is built up until the pressure overcomes well bore pressure so as to pump the mud into the well. The piston then reverses for another suction stroke whereby the check valve in the suction module opens and the discharge valve closes simultaneously, the piston now making a suction stroke.

As the piston reciprocates within the liner, friction wears the liner. Further, the fluid passing through the fluid end includes particulates and other solids which wear away and destroy the liner and piston. When the liner and piston degrade, the fluid seal is lost and the pump becomes much less efficient. Also, the reciprocation of the piston in the liner causes pulsations that over time cause the liner to become loose within the containment of the liner retainer flange thus resulting in a degradation of the seal at the face of the liner and the seal at the face of the liner wear plate. Therefore, it is important to be able to replace the liner as a part of routine maintenance (or when emergencies occur from seal failure while drilling) to ensure that the pump operates efficiently and can control well pressure. It is also important to have a means for fastening the liner to the liner retainer flange so as to ensure that the liner remains firmly secured despite extended reciprocation of the piston assembly within the liner.

Typically each liner retainer flange, and the cradle of the pump power end are all secured to the fluid end module by studs and threaded connections. Because of the environment in which the mud pump operates and the corrosive nature of the fluids being pumped, the studs and threaded connections, such as nuts, become corroded and are difficult to unthread for the replacement of the liner. Often, the threaded connections have been over tightened, making it even more difficult to unthread. Where the liner is retained by an end cap, a steel bar is inserted into a guide hole in the side of the end cap and then the cap is unscrewed using a significant amount of torque. This end cap is very heavy as it must have sufficient strength to keep the liner from moving, even with pressures up to 7500 psi. Where a nut or end cap resists unscrewing, a sledge hammer is used to hammer on a socket wrench or a special hammer wrench is used to loosen the nut or cap. Such activity is obviously dangerous. In some regions of the world local laws prohibit the use of sledge hammers for personnel safety reasons or to avoid the risk of an explosion due to sparks.

Prior art liner retention systems include spring mechanisms around each stud with an end flange for securing the liner against a fluid end module. Hydraulic pressure is applied to the spring mechanism of each stud by a small hydraulic pump to remove the clamping force of the spring mechanism. The release of the clamping force allows the removal of the clamping flange of the liner retention system. Individually actuated spring loaded studs cause an uneven pressure to be applied to the clamping flange. Further, the clamping force is limited because of the limited space available to hold numerous springs.

The liner retainer assembly of the present invention includes a liner retainer flange that is mounted on the discharge module of the fluid end of a pump. A pressure actuated hydraulic clamping piston with related actuated, conical dished washers and necessary static and sliding seals is disposed within the retainer flange . The hydraulic pressure actuated clamping piston is configured to receive and hold the liner. The hydraulic clamping piston and an end cap maintain the liner in contact with the module during actuation. The hydraulic clamping cylinder includes a counterbore which is divided by the hydraulic piston into a fluid cavity and a spring cavity. The spring cavity houses a plurality of springs which bias the hydraulic piston, end cap, and liner towards the module, thus providing a strong clamping securing force when the hydraulic pressure is released. The fluid cavity communicates with a supply of hydraulic fluid for biasing the hydraulic piston away from the module to activate the springs. By pressurizing the fluid cavity, the springs are compressed so as to disengage the liner retaining end cap from the liner and allow the unthreading of the liner end cap to then remove the liner.

The liner retainer assembly permits preloading or prestressing of the liner against the module of the fluid end of the pump so that the liner will not loosen upon the reciprocation of the pump piston within the liner. Further, the liner may be easily secured and unsecured from the module without the necessity of a sledge hammer or other methods for applying excessive amounts of torque to a securing fitting. The assembly of the present invention permits the easy and quick replacement of the liner as necessary.

Referring first to FIGS. 1 and 2, there is shown a fluid end module 10 and a cradle 28 of the pump power end. The pump is of the type used to pump fluids, such as drilling muds, cement or the like. Pumps of this type are well known. A wear plate 14 defines a bore 16 which leads into liner 20. The module 10 is used for the transfer of fluid from the suction manifold and suction module (not shown) to the discharge manifold (not shown) and discharge module.

An exemplary liner retaining flange assembly 18 of the present invention is used to secure liner 20 within a hydraulic cylinder 30 mounted on module 10 and liner retainer flange 22. Those of skill in the art will understand that a pump piston (not shown) attached to the power end of the pump is reciprocated within the liner 20 to effect the desired pumping action to flow fluid through the fluid end module 10 of the pump. Hydraulic cylinder 30 provides an open end into which the liner 20 is inserted. Module 10 also provides a counterbore 12 for the adjacent wear plate 14 against which it is desired to retain the liner 20 during operation of the pump piston. It can be appreciated that the purpose of wear plate 14 is to avoid the end of liner 20 wearing module 10 due to the reciprocation of the piston within liner 20. However, wear plate 14 may cause wear to the module 10 if the liner 20 is not securely affixed. Wear plate 14 may be replaced should that wear become excessive. It is noted that the end of the liner 20 adjacent the wear plate 14 includes an internal annular groove 59 with seal member 61 for sealingly engaging the wear plate 14 and the other open end 15 of liner 20 includes an external annular load-bearing shoulder 60 which retains end cap 64 (FIG. 2).

The hydraulic cylinder 30 includes a threaded, reduced diameter portion 24 and an enlarged diameter portion 32. Reduced diameter portion 24 is secured in a threaded or splined relation at 23 to liner retainer flange 22 that is located in an abutting relation to the module 10. Bolted studs 26 secure the cradle 28 of the pump power end, the liner retaining flange 22 and hydraulic cylinder 30 to module 10.

When these components are assembled, the annular flange 44 of piston 42 forms hydraulic cavity 58 and outer spring cavity 35. The hydraulic fluid port and fitting 38 communicates with hydraulic cavity 58 for applying hydraulic pressure to flange 44. The spring cavity 35 houses a plurality of axially compressible Belleville springs or washers 56. Retainer ring 48 has external threads 50 which threadingly mate in a complimentary fashion with the internal threads 34 of enlarged diameter portion 32. The washers 56 bear against the retainer ring 48 and annular flange 44. Enough springs are used so as to insure sufficient force is generated to prevent movement of liner 20 when pump pressure is at maximum. The retainer ring 48 secures the washers 56 and hydraulic piston 42 within the enlarged diameter portion 32 of hydraulic cylinder 30. O-ring 49 provides a fluid-tight seal between the piston 42 and enlarged diameter portion 32.

It is noted that the arrangement of the present invention permits a liner to be replaced rapidly and easily and without the use of extra tools or having to apply excessive torque. Further, a prestress force is applied to the liner 20 so that it is longitudinally compressed against wear plate 14 and module 10. This load or prestress securely holds the liner 20 against the wear plate 14 despite repeated reciprocation of the pump piston within liner 20.

Manufacturer of mud pump systems and premium well servicing equipment. The company designs and produces mud pump products which include fluid end modules, pistons, liners, and other related products used during onshore and offshore drilling of oil and gas wells to major drilling companies across the globe. It"s servicing equipment division focuses on the manufacturing of new equipment used in well completion, stimulation, and intervention such as frac pumpers, coil tubing, nitrogen and snubbing units.

abstractNote = {Failure of a liner seal is one of the more critical failures on a mud pump because this seal interfaces with the pump body. Therefore, failures, usually damage the pump body, leading to repair or replacement of the fluid end itself. One of the more common liner seal problems involves counter-bore-type seals. This type of seal is easily affected by two aspects of the problem that are found in the mud pump fluid end-wear and foreign matter in the seal groove. Factors relative to difficult liner removal are discussed. Piston damage, careless seal installation and corrosion damage are also examined.},

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