Pump system using variable control of a torque requirement of a fluid pump

Abstract

A pump system may include a fluid pump including a fluid end. The fluid end may include a plunger configured for reciprocating movement, a suction valve biased to a closed position and configured to open during suction cycles of the fluid pump, and a discharge valve biased to a closed position and configured to open during discharge cycles of the fluid pump. The fluid pump may include a power end configured to drive reciprocating movement of the plunger. The pump system may be configured to variably control a torque requirement of the fluid pump. The pump system may include a reciprocating engine to produce torque to drive the power end of the fluid pump. The pump system may include a fixed-ratio gearbox or a dual-ratio gearbox operably coupling the power end of the fluid pump to the reciprocating engine using a non-fluid coupling.

1 . A pump system, comprising:
 a fluid pump, comprising:
 a fluid end, comprising:
 a plunger configured for reciprocating movement; 
 a suction valve biased to a closed position and configured to open during suction cycles of the fluid pump; and 
 a discharge valve biased to a closed position and configured to open during discharge cycles of the fluid pump; and 
 
 a power end configured to drive reciprocating movement of the plunger,
 wherein the pump system is configured to variably control a torque requirement of the fluid pump; 
 
   a reciprocating engine to produce torque to drive the power end of the fluid pump; and   a fixed-ratio gearbox that provides a constant gear ratio operably coupling the power end of the fluid pump to the reciprocating engine using a non-fluid coupling.   
     
     
         2 . The pump system of  claim 1 , wherein the reciprocating engine is a variable speed reciprocating engine. 
     
     
         3 . The pump system of  claim 1 , wherein the reciprocating engine is a constant speed reciprocating engine. 
     
     
         4 . The pump system of  claim 1 , wherein the reciprocating engine is coupled to the fluid pump via the fixed-ratio gearbox without a variable-ratio transmission. 
     
     
         5 . The pump system of  claim 1 , wherein the reciprocating engine is coupled to the fluid pump via the fixed-ratio gearbox without a torque converter. 
     
     
         6 . The pump system of  claim 1 , further comprising:
 a valve control component engaged with the fluid pump and configured to maintain the suction valve in an open position during a discharge cycle of the fluid pump.   
     
     
         7 . The pump system of  claim 1 , further comprising a trailer,
 wherein the fluid pump, the reciprocating engine, and the fixed-ratio gearbox are mounted on the trailer.   
     
     
         8 . The pump system of  claim 1 , wherein the pump system is configured to variably control the torque requirement of the fluid pump by maintaining the torque requirement of the fluid pump below an available torque of the reciprocating engine. 
     
     
         9 - 20 . (canceled) 
     
     
         21 . The pump system of  claim 1 , further comprising:
 a plunger-type actuator, configured to actuate between a retracted position and an extended position, and positioned such that in the extended position the plunger-type actuator reaches an underside of the suction valve when the suction valve is in an open position to hold open the suction valve.   
     
     
         22 . A trailer for a hydraulic fracturing system, comprising:
 a fluid pump, configured to variably control a torque requirement of the fluid pump, comprising:
 a fluid end, comprising:
 a plunger configured for reciprocating movement; 
 a suction valve biased to a closed position and configured to open during suction cycles of the fluid pump; and 
 a discharge valve biased to a closed position and configured to open during discharge cycles of the fluid pump; and 
 
 a power end configured to drive reciprocating movement of the plunger; 
   a reciprocating engine to produce torque to drive the power end of the fluid pump; and   a fixed-ratio gearbox that provides a constant gear ratio operably coupling the power end of the fluid pump to the reciprocating engine using a non-fluid coupling.   
     
     
         23 . The trailer of  claim 22 , wherein the reciprocating engine is a constant speed reciprocating engine. 
     
     
         24 . The trailer of  claim 22 , wherein the reciprocating engine is coupled to the fluid pump via the fixed-ratio gearbox without a variable-ratio transmission. 
     
     
         25 . The trailer of  claim 22 , wherein the reciprocating engine is coupled to the fluid pump via the fixed-ratio gearbox without a torque converter. 
     
     
         26 . The trailer of  claim 22 , further comprising:
 a valve control component engaged with the fluid pump and configured to maintain the suction valve in an open position during a discharge cycle of the fluid pump.   
     
     
         27 . The trailer of  claim 22 , further comprising:
 a plunger-type actuator, configured to actuate between a retracted position and an extended position, and positioned such that in the extended position the plunger-type actuator reaches an underside of the suction valve when the suction valve is in an open position to hold open the suction valve.   
     
     
         28 . The trailer of  claim 22 , wherein the fluid pump, the reciprocating engine, and the fixed-ratio gearbox are mounted to a trailer bed of the trailer. 
     
     
         29 . A pump system, comprising:
 a fluid pump, comprising:
 a fluid end, comprising:
 a plunger configured for reciprocating movement; 
 a suction valve biased to a closed position and configured to open during suction cycles of the fluid pump; and 
 a discharge valve biased to a closed position and configured to open during discharge cycles of the fluid pump; and 
 
 a power end configured to drive reciprocating movement of the plunger,
 wherein the pump system is configured to variably control a torque requirement of the fluid pump; 
 
   a reciprocating engine to produce torque to drive the power end of the fluid pump; and   a fixed-ratio gearbox that provides a constant gear ratio operably coupling the power end of the fluid pump to the reciprocating engine.   
     
     
         30 . The pump system of  claim 29 , wherein the reciprocating engine is a constant speed reciprocating engine.