High-pressure Plunger Pump Research Articles

Effects of distribution valve spring stiffness and opening pressure on the volumetric efficiency of micro high-pressure plunger pump

With the rapid development of material science and manufacturing capabilities, hydraulic technology is increasingly high-pressure, lightweight and miniaturizing. Micro plunger pump is widely used in the field of deep-sea hydraulic equipment and advanced intelligent hydraulic equipment, owing to its high-power density, high output pressure and many other advantages. Its broad application aims to examine the inlet and outlet distribution valve spring parameters change on the micro high-pressure plunger pump volumetric efficiency, by changing the inlet and outlet distribution valve. This paper is based on the simulation of AMESim engineering software to derive multiple sets of data. It compared and analysed the specific effect of different spring stiffness and opening pressure on the volumetric efficiency of the micro high-pressure plunger pump which was then verified through experiment. Results of this study have certain reference significance for the design of the spring of the inlet and outlet distribution valve of the micro high-pressure plunger pump, which facilitates the optimization and improvement of the dynamic performance of the micro high-pressure plunger pump.

Fatigue and Autofrettage Analysis of Steel Sleeve Based on Precision Fit under Ultra High Pressure

Abstract In order to ensure precision fit between steel sleeve and plunger, copper sleeve and the other parts of the ultra high pressure plunger pump, as well as increase the fatigue life of steel sleeve, this paper made the analysis of work process and fatigue life of ultra high pressure autofrettage steel sleeve of plunger pump based on both analytical method and FEM. The elastic-plastic boundary radius, radial stress and plastic zone displacement were obtained based on the elastic-plastic mechanics analysis of ultra high pressure steel sleeve. The functional relationship built related to precision fit among autofrettage pressure, inner diameter expectation and displacement could ensure the machining dimension of inner diameter of steel sleeve and realize the precise control of inner diameter of steel sleeve. The analytical method and FEM for calculating fatigue life was also proposed, which are verified by experiment. The research shows that machining dimension is determined by inner diameter expectation in the autofrettage process to ensure precision fit; autofrettage treatment can reduce the working stress level of the steel sleeve and extend the fatigue life remarkably. These conclusions contribute to guide the design of steel sleeve.

Vibration Isolation Performance of a Constrained Damping Base for a High-Pressure Plunger Pump

Based on the effect of damped shear deformation on energy dissipation, a new constrained damping base for a polymer injection platform deck is proposed to reduce the excessive vibrations caused when multiple plunger pumps are jointly operated. A model for analyzing the vibration response of an I-beam-constrained damping base for a polymer injection platform with multiple plunger pumps was established using Abaqus 6.14 software and compared with rigid base and traditional rubber vibration isolators in terms of its vibration isolation performance. Furthermore, the effects of the damping material’s loss factor, the thickness of the damping layer, and the number of expansion layers on the vibration isolation characteristics of the constrained damping base were explored. This study shows that, with an increase in the damping material’s loss factor, the thickness of the damping layer and the number of extended layers, the vibration isolation performance of the constrained damping base is gradually enhanced. When the damping material’s loss factor is 1.0, the thickness of the damping layer is 20 mm, and the number of extended layers is 3, the constrained damping base’s vibration damping effect is optimized, and its vibration isolation rate becomes as high as 46.63%, which can significantly reduce the vibration response of the polymer injection platform.

Vibrational Analysis and Optimization of a Water Injection Pipeline in a High-pressure Plunger Pump

Vibrational Analysis and Optimization of a Water Injection Pipeline in a High-pressure Plunger Pump

Numerical Simulation and Experimental Research on Oil Film Characteristics of High-Pressure Piston Pump Slipper Pair

The high-pressure axial piston pump is widely used in the field of coal machinery equipment due to its compact structure, high power density, and easy variable control. Failure affects pump performance. In this paper, the sliding shoe pair of the high-pressure plunger pump is taken as the research object, the variation law of the oil film pressure field is numerically simulated by Matlab software, and the high-pressure pump sliding shoe pair test bench is built. The full-cycle dynamic evaluation of the influence of the speed change of the drive shaft on the oil film characteristics is obtained.

Failure mechanism tracing of the crankshaft for reciprocating High-Pressure plunger pump

Crankshaft fracture is a typical failure form of reciprocating high-pressure plunger pump. Different from traditional power machinery, the number of plungers in plunger pumps is usually odd, which leads to unbalanced radial force of the crankshaft and greatly increases the risk of failure. The crankshaft of a 250 kW high-pressure plunger pump was fractured, and the fracture morphology was river-shaped, which was a typical fatigue failure. To trace the failure of the crankshaft, a Constructure-Kinematics-Materials-Craftsmanship (CKMC) method was brought out. The microstructure of the damage zone was observed, and a three-dimensional transient finite element model was established to find the most dangerous zone and damage mechanism. The results show that high-cycle fatigue of fillet zone is the main reason for crankshaft fatigue failure. Material defects and lack of nitrided layer at fillet are the key factors to accelerate crankshaft failure. Finally, recommendations for preventing future failures were presented.

Cavitation flow pulsation mechanism of axial high-pressure plunger pump in the sea water desalination system

Cavitation flow pulsation mechanism of axial high-pressure plunger pump in the sea water desalination system

Simulation and Experimental Study on Characteristics of Multiorifice Nozzle in Radial Jet Drilling

The radial jet drilling (RJD) is a key technology to improve the development efficiency of low-permeability oil and gas resources. In order to seek a reasonable hydraulic engineering parameter combination of hydraulic radial jet drilling, to obtain the optimal hydraulic energy distribution, a jet radial horizontal drilling simulation experiment system of the casing windowing is designed. A sequence of experimental investigations focused on engineering parameters of pump displacement, rotating speed, and frequency of high-pressure plunger pump is performed, and the operability and the feasibility of the experiment are verified. To evaluate the maximum drillable length and the self-propelled force of a jet nozzle, a 3D numerical model based on ANSYS-CFX is developed to evaluate the effects of the inlet flow displacement, the flow rates ratio K , and the angle ratio F : B of the forward orifice and backward orifice of the jet nozzle on its maximum drillable length and self-propelled force by sensitivity analysis. Finally, the comparison of numerical simulation results (Ln), mathematical results (Lm), and experiment results (Le) of the maximum drillable length are presented. It is observed that the simulation results are consistent with the experiment results with an average accuracy of 97.07%. Therefore, the proposed numerical model has a good performance in predicting the maximum drillable length of the multiorifice nozzle. The research results can provide theoretical guidance for improving the rock breaking and drilling capability of radial jet drilling technology.

Optimization of plunger pump suction manifold parameters

Hydraulic fracturing plays an important role in increasing oil and gas reserves. In hydraulic fracturing, fluid is injected until the fluid pressure overcomes the stresses inherent in the rock or exceeds the forces holding the rock together. The fracturing fluid is a cohesive-dispersed system characterized by a continuous spatial structure. It is assumed that the configuration of the suction manifold, velocity and pressure pulsations lead to changes in the volumetric characteristics of the system phases at the pump outlet. The purpose of the study, is to analyze the movement of liquid with proppant through three suction manifolds of different design, to identify the design with the lowest volume of proppant sedimentation. The paper considers three design variants of suction manifold of high-pressure plunger pump. The hydrodynamic analysis of fluid motion with proppant has been carried out, data on distribution of velocities, pressures and proppant concentration in the manifold have been obtained. A series of numerical experiments carried out for different designs of three-plunger pump suction lines confirms the hypothesis about influence of manifold design, velocity and pressure pulsation on change of volume characteristics of system phases.

Study on swage autofrettage of steel sleeve for the high pressure plunger pump

Based on bilinear hardening material model, the swage autofrettage technology of steel sleeve for pump is analyzed. The theoretical calculation formulas of stress, strain, residual stress and strain and punch thrust of swage autofrettage steel sleeve are derived by the elastic-plastic analysis. The accuracy of the theoretical formulas is verified by the swage autofrettage experiment. The result of theoretical calculation is consistent with that of the experiment, and the process of the second loading does not affect the autofrettage result. The theoretical calculation formulas can be used to guide the swage autofrettage technology design of the steel sleeve for the pump.

Strength analysis of the TWS 600 plunger pump body in Solid Works Simulation

Introduction. The relevance of the presented paper is due to the widespread use of plunger pumps in industrial practice, in particular, in gas and oil production. The quality of working operations and the efficiency of further well operation depend largely on their reliability. The improvement of plunger pumps involves increasing their reliability, increasing their service life, efficiency, downsizing, reduction in weight, labor intensity of installation and repair work. The modernization of the mechanism includes its power study since the found forces are used for subsequent strength calculations. Before the appearance of programs for the numerical analysis of solid objects, the analytical solution to the problem of strength calculation of the high-pressure pump drive frame was a very time-consuming and expensive procedure. The situation has changed with the development of computer technologies and the inclusion of the finite element method in the computer-aided design systems. The objective of this work is to perform a strength calculationon the TWS 600 plunger pump body made of 09G2S steel. Materials and Methods. A method for determining the reactions of the crank shaft supports of a high-pressure plunger pump and strength calculation of the drive part housing is developed. The direction and magnitude of the resulting forces and reactions of the supports are determined graphically according to the superposition principle of the force action on the supports. Strength calculations were performed using the finite element method in the computer-aided design system Solid Works Simulation. In this case, solid and finite-element models of the body with imposed boundary conditions were used, which were identified during the analysis of the design and the calculation of the forces arising under the pump operation. Results. The reactions in the crankshaft supports are described with account for the forces generated by the plunger depending on its operating mode and the crank position. The forces acting on each of the plungers and the resulting reactions in each of the supports are determined. The diagrams of stresses and the safety factor are presented, which provide assessing the strength of the body and developing recommendations for creating a more rational design. Discussion and Conclusions. As a result of the calculations, we have identified areas of the structure with minimum safety factors, and areas that are several times higher than the recommended values. This provides optimizing the designunder study through strengthening the first and reducing the thickness of the metal on the second. From the point of view of weight and size characteristics and maintainability, the results of the strength calculation performed can be used to optimize the design of the pump body under typical operating conditions.

Interpretable Anomaly Prediction: Predicting anomalous behavior in industry 4.0 settings via regularized logistic regression tools

Prediction of anomalous behavior in industrial assets based on sensor reading represents a key focus in modern business practice. As a matter of fact, forecast of forthcoming faults is crucial to implement predictive maintenance, i.e. maintenance decision making based on real time information from components and systems, which allows, among other benefits, to reduce maintenance cost, minimize downtime, increase safety, enhance product quality and productivity. However, building a model able to predict the future occurrence of a failure is challenging for various reasons. First, data are usually highly imbalanced, meaning that patterns describing a faulty regime are much less numerous than normal behavior instances, which makes model design difficult. Second, model predictions should be not only accurate (to avoid false alarms and missed detections) but also explainable to operators responsible for scheduling maintenance or control actions. In this paper we introduce a method called Interpretable Anomaly Prediction (IAP) allowing to handle these issues by using regularized logistic regression as core prediction model. In particular, in contrast to anomaly detection algorithms which permit to identify if the current data are anomalous or not, the proposed technique is able to predict the probability that future data will be abnormal. Furthermore, feature extraction and selection mechanisms give insights on the possible root causes leading to failures. The proposed strategy is validated with a large imbalanced multivariate time-series dataset consisting of measurements of several process variables surrounding an high pressure plunger pump situated in a complex chemical plant.

PRODUCTION OF EXTRACTS FROM VEGETABLE RAW MATERIALS BY CARBON DIOXIDE

The unique properties of supercritical carbon dioxide as a solvent are widely used for extraction. In supercritical media, the dissolution of molecules of various chemical nature is possible. The purpose of this investigation was to study the extraction process and obtain extracts from valuable regional plant materials by applying CO2 extraction under pre- and supercritical conditions. The objects of research were: ground seeds of melon, pumpkin and licorice roots, as well as mint leaves, mulberry and jida flowers. For extraction, a laboratory setup was used that allows extraction when the CO2 is supplied by a high-pressure plunger pump in the sub- and supercritical state using a heat pump. The pressure range is 3-15 MPa, temperatures 295–330 K, and the volumetric flow rate above the critical CO2 is 800–900 g. Experiments with ground seeds of melon and pumpkin showed that as a result of 4 sequentially performed extraction cycles on a single load with supercritical CO2 parameters ( 315–330 K; 3–7.5 MPa) the decrease in the mass of melon seeds was 90 g (pumpkins 80 g). During the total extraction time (2.5 hours), 20 kg of CO2 were pumped through the reactor (25 l at 290 K and 6.8 MPa), while the average oil content in the extract was 4 g per 1 kg of CO2 (3.0 g per 1 l of SС-CO2) In experiments with jida flowers, the maximum amount of solid extractable substance (2% by weight of the raw material) was obtained at a temperature in the extractor of 308 K and a pressure of 7.5 MPa. Upon extraction under critical conditions in collection 2, the liquid phase was absent; only a yellow-green paste was released in it. According to the results of experiments with mint leaves, the maximum yield of a greenish liquid was observed at T = 315 K and P = 4 MPa., Mulberry - at T = 306 K and P = 6.0 MPa. The results of the extraction of oils and extracts from ground seeds of melon, pumpkin and licorice roots, as well as mint leaves, mulberries and jida flowers confirm that the maximum yield of the extracted substance is achieved with supercritical CO2 parameters in the extractor (310 K, 7.5 MPa). When liquid CO2 is extracted (300 K and 6-8 MPa), up to 2% of a yellow substance is extracted, which does not differ in appearance from a supercritical extract.

Fatigue performance of hydraulic unit of high-pressure plunger pump

The present paper considers a hydraulic unit of high-pressure plunger pump that relates to the main types of equipment for oil-and-gas well drilling, completing or repairing. The problem of fatigue breakdowns of hydraulic units of high-pressure plunger pumps is posed in the paper. According to the leading pump manufacturers, the main source of stress concentration in a valve casing of a pump is the edgings of crossing of cylindrical surfaces of seating fits, valves or plunger bores. The value of stresses in the concentrator zone was assessed, and values of safety coefficients of fatigue strength depending on geometric parameters of stress concentrators were compared. To solve the problem set by the leading manufacturers of pumps, the full-scale model of hydraulic unit was elaborated, stress condition and its effect on fatigue parameters of valve casing of hydraulic unit of oilfield high-pressure plunger pump were analyzed. The obtained calculation results quantitatively clarify the pattern of stress distribution in zones of stress concentration in a valve casing of hydraulic unit of a high-pressure plunger pump. Certain conclusions were made on how the parameters under consideration affect the values of fatigue stresses and on priority research directions for the problem under study.

Design & Static Structural Analysis of Crankshaft for High Pressure Plunger Pump

Design & Static Structural Analysis of Crankshaft for High Pressure Plunger Pump

Kinematic Analysis of Swash Plate Axial Piston Pump Based on Adams Simulation

The swash plate axial piston pump is a main part in liquid press system.It is a positive displacement pump which rely on the change of the plunger cavity content to realize oil absorption or discharge of oil by the reciprocating movement of the plunger in the plunger cavity. Plunger, the slippery boots, oil pan, cylinder body are important parts of the swash plate axial piston pump. Sliding boots is one of commonly used by high-pressure plunger pump form, it can meet the needs of the high pressure high speed;the oil distribution plate and cylinder directly affect of the pump efficiency and life span[1]. Because the swash plate axial piston pump has the advantages of compact structure, fewer parts, good manufacture ability, low cost, small volume, light weight, than the radial pump has the advantages of simple structure, easy to realize step less variable and convenient maintenance, it has been widely used in the industrial production.

Reconstruction Analysis of LH45 Type High Pressure Triplex Plunger Pump Shell

Due to the corrosion of liquid and dual role of job stress, the pump housing of the LH45 type three cylinder high pressure plunger pump was caused the breakage in the practical work, and its service life was greatly reduced. Studied the pump housing broken state and laws to selected material to manufacture. Established 3D entity of the pump housing model in the 3D CAD software so that the stress and strain state of remade shell can be analyzed using finite element software ANSYS. Compared with the state of stress and strain before shell remaking, the pump housing remaking is proved to be valid.

Alleviation of flux decline in cross flow nanofiltration of two-component dye and salt mixture by low frequency ultrasonic irradiation

Gradual reduction of steady state permeate flux (throughput) over a period of time often mars the performance of nanofiltration process. In the present study, nanofiltration of two-component dye and NaCl mixture containing Reactive Black 5 and C.I Reactive yellow 160 was carried out in a flat sheet membrane module with hydrophilized polyamide membrane (molecular weight cut off 400) over a range of operating conditions. Results indicate that the flux decline with time could be significantly mitigated under low frequency (34±3kHz) ultrasonic irradiation when compared with the conventional unassisted nanofiltration. Various filtration resistances were determined using a simple resistance-in-series model, which revealed that concentration polarization resistance could be effectively decreased by ultrasonic irradiation. Effect of several parameters such as mode of irradiation (viz. continuous and intermittent), trans-membrane pressure and temperature were studied and discussed with respect to existing theories. The power consumption of the high pressure plunger pump at different feed pressures and the ultrasonic power transferred to the water bath at three different temperatures were estimated. More than 96% of color, and 65% TDS were removed from the treated water accompanied by a marked reduction of COD. The process allowed the production of permeate stream with great reutilization possibilities.

圧力式ホモジナイザーにおける内部流れと乳化効果の研究(流体工学,流体機械)

The homogenizer is extensively used to emulsify, disperse the products in various industrial fields including: food, chemical, pharmaceutical and biotechnology. The homogenizer basically consists of a high-pressure plunger pump usually with triple plungers to minimize pressure fluctuations and a homogenizing valve with a narrow gap. However, the flow within the homogenizing valve is not clarified theoretically. If the flow pattern within the homogenizing valve could be solved, a more efficient and stabilized emulsification could be carried out. In this paper, the influence of shape modification of the homogenizing valve was investigated in the emulsification effect. The experiments using a small homogenizer are conducted. We studied the influence of the flow pattern (velocity distributions, pressure distributions, shear stress) on the drop size distribution obtained in the experiment, and investigated the relation between the average value of wall shear stress and the emulsification effect in the homogenizing valve. The flow patterns were investigated using a Computational Fluid Dynamic model of the flow in the homogenizing valve. The purpose of this paper is to clarify the effects of differences in the shapes of valves on the results of emulsification.

The Study of Hydrostatic Lubrication of the Slipper in a High-Pressure Plunger Pump

The lubrication condition between the slipper and the oblique plate of a high pressure pump affects its operating life. One of the studies in this paper is to analyze the oil film pressure distribution and load characteristics, considering the pressure-viscosity effect of the lubricant and the pressure-elasticity effect of the lubricating surface. In addition, a laser holographic photoelastic experimental verification is proposed. Another aspect of the study concerns the investigation of the dynamic stiffness properties of the oil film and its experimental verification. The conclusions obtained here provide a new theoretical basis for the design and parameter selection of a J high pressure plunger pump.