Erosion, Corrosion, and Fatigue Prevention for High-Pressure Pumps

Abstract

Disclosed are methods of enhancing resistance to erosion, corrosion, wear and tear, and fatigue in high-pressure pumps. One method includes providing a fluid end that comprises a body defining a pressure chamber in fluid communication with a plunger bore having a plunger reciprocably disposed therein, a suction valve pocket defined in the body and having inlet valve assembly arranged therein that includes a suction valve and a suction valve seat, and a discharge valve pocket defined in the body and having a discharge valve assembly arranged therein that includes a discharge valve and a discharge valve seat, and applying a wear-resistant substance directly to a surface of at least one of the pressure chamber, the plunger, the suction valve pocket, the suction valve, the suction valve seat, the discharge valve, and the discharge seat.

1 . A fluid end for a high-pressure pump, comprising:
 a body defining a pressure chamber in fluid communication with a plunger bore having a reciprocating plunger disposed therein;   a suction valve pocket defined in the body and in fluid communication with the pressure chamber, the suction valve pocket having inlet valve assembly arranged therein that includes a suction valve and a suction valve seat;   a discharge valve pocket defined in the body and in fluid communication with the pressure chamber, the discharge valve pocket having a discharge valve assembly arranged therein that includes a discharge valve and a discharge valve seat; and   a wear-resistant substance applied directly to a surface of at least one of the pressure chamber, the plunger, the suction valve pocket, the suction valve, the suction valve seat, the discharge valve, and the discharge seat,   wherein a discharge cage is arranged within the discharge valve pocket and the wear-resistant substance is applied directly to surfaces of the discharge cage.   
     
     
         2 . The fluid end of  claim 1 , wherein the high pressure pump is a positive-displacement pump selected from the group consisting of a reciprocating pump, a centrifugal pump, a gear pump, a screw pump, and a rotary vane pump. 
     
     
         3 . The fluid end of  claim 1 , wherein the plunger bore and the discharge valve pocket are axially aligned. 
     
     
         4 . (canceled) 
     
     
         5 . The fluid end of  claim 1 , further comprising a plug assembly arranged at a distal end of the discharge valve pocket and having a cover that  3  Preliminary Amendment defines an inner bore, wherein the wear-resistant substance is further applied directly to surfaces of the inner bore. 
     
     
         6 . The fluid end of  claim 1 , wherein the wear-resistant substance is a substance selected from the group consisting of tungsten carbide-cobalt, tungsten carbide, cobalt, cobalt alloys, thermal barrier coating of zirconium, yittria-stabilized zirconia, aluminium, zinc, molybdenum, molybdenum and molybdenum blend coatings, zinc chromate, chromium, chromium carbide, nickel chromium, colmonoy 6 (NiCrSiB), fused self-fluxing alloys, aluminum bronze, copper nickel indium, and nickel alloys. 
     
     
         7 . The fluid end of  claim 1 , wherein the wear-resistant substance is applied to the surface by a thermal spraying process. 
     
     
         8 . The fluid end of  claim 7 , wherein the thermal spraying process is at least one of wire arc spraying, flame spraying, plasma spraying, supersonic spraying, controlled atmosphere plasma spraying, low pressure plasma spraying, cold spraying, warm spraying, underwater plasma spraying, combustion wire thermal spraying, combustion powder thermal spraying, detonation thermal spraying, and high velocity oxygen fuel thermal spraying. 
     
     
         9 . The fluid end of  claim 1 , wherein the wear-resistant substance is applied to the surface by a sintering process. 
     
     
         10 . The fluid end of  claim 9 , wherein the sintering process is at least one of ceramic sintering, metallic powder sintering, liquid phase sintering, electric current sintering, spark plasma sintering, and pressure-less sintering. 
     
     
         11 . A method, comprising:
 providing a fluid end that comprises:   a body defining a pressure chamber in fluid communication with a plunger bore having a reciprocating plunger disposed therein;   a suction valve pocket defined in the body and in fluid communication with the pressure chamber, the suction valve pocket having inlet valve assembly arranged therein that includes a suction valve and a suction valve seat; and   a discharge valve pocket defined in the body and in fluid communication with the pressure chamber, the discharge valve pocket having a discharge valve assembly arranged therein that includes a discharge valve and a discharge valve seat;   a discharge cage arranged within the discharge valve pocket;   applying a wear-resistant substance directly to a surface of at least one of the pressure chamber, the plunger, the suction valve pocket, the suction valve, the suction valve seat, the discharge valve, and the discharge seat; and   applying the wear-resistant substance directly to a surface of the discharge cage.   
     
     
         12 . (canceled) 
     
     
         13 . The method of  claim 11 , wherein the fluid end further comprises a plug assembly arranged at a distal end of the discharge valve pocket and having a cover that defines an inner bore, the method further comprising applying the wear-resistant substance directly to a surface of the inner bore. 
     
     
         14 . The method of  claim 11 , wherein applying the wear-resistant substance comprises thermally spraying the wear-resistant substance directly on the surface. 
     
     
         15 . The method of  claim 14 , wherein thermally spraying is accomplished by at least one of wire arc spraying, flame spraying, plasma spraying, supersonic spraying, controlled atmosphere plasma spraying, low pressure plasma spraying, cold spraying, warm spraying, underwater plasma spraying, combustion wire thermal spraying, combustion powder thermal spraying, detonation thermal spraying, and high velocity oxygen fuel thermal spraying. 
     
     
         16 . The method of  claim 11 , wherein applying the wear-resistant substance comprises sintering the wear-resistant substance directly on the surface. 
     
     
         17 . The method of  claim 16 , wherein sintering the wear-resistant substance is accomplished by at least one of ceramic sintering, metallic powder sintering, liquid phase sintering, electric current sintering, spark plasma sintering, and pressure-less sintering. 
     
     
         18 . The method of  claim 11 , further comprising machining the wear-resistant substance applied to the surface. 
     
     
         19 . The method of  claim 11 , further comprising periodically re-applying the wear-resistant substance to the surface. 
     
     
         20 . The method of  claim 11 , wherein the wear-resistant substance is a substance selected from the group consisting of tungsten carbide-cobalt, tungsten carbide, cobalt, cobalt alloys, thermal barrier coating of zirconium, yittria-stabilized zirconia, aluminium, zinc, molybdenum, molybdenum and molybdenum blend coatings, zinc chromate, chromium, chromium carbide, nickel chromium, colmonoy 6 (NiCrSiB), fused self-fluxing alloys, aluminum bronze, copper nickel indium, and nickel alloys.