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Transportation Research Procedia 00 (2022) 000–000
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X International Scientific Siberian Transport Forum

X International Scientific Siberian Transport Forum
Optimization of plunger pump suction manifold parameters
Optimization of plunger pump suction manifold parameters
Valentin Stepanovaa, Marina Korchaginaaa, Sergey Kireeva,a, *, Anastasiya Billaa
Valentin Stepanov , Marina Korchagina , Sergey Kireev *, Anastasiya Bill
a
Don State Technical University, 1. Gagarina Square, Rostov-on-Don, 344000, Russia
a
Don State Technical University, 1. Gagarina Square, Rostov-on-Don, 344000, Russia
Abstract
Abstract
Hydraulic fracturing plays an important role in increasing oil and gas reserves. In hydraulic fracturing, fluid is injected until the
Hydraulic
fluid fracturing
pressure playsthe
overcomes anstresses
important role ininincreasing
inherent the rock oroil and gasthereserves.
exceeds In hydraulic
forces holding fracturing,
the rock together.fluid
The is injected fluid
fracturing until is
thea
fluid pressure overcomes
cohesive-dispersed systemthecharacterized
stresses inherent
by aincontinuous
the rock orspatial
exceeds the forces
structure. It holding the rock
is assumed that together. The fracturing
the configuration of thefluid is a
suction
cohesive-dispersed
manifold, velocity and system characterized
pressure pulsations bylead
a continuous
to changesspatial
in thestructure.
volumetric It characteristics
is assumed thatofthe theconfiguration
system phasesofatthe thesuction
pump
manifold,
outlet. Thevelocity
purposeand pressure
of the study, pulsations
is to analyze lead
thetomovement
changes in of the volumetric
liquid characteristics
with proppant of thesuction
through three systemmanifolds
phases atofthe pump
different
outlet. The
design, purposethe
to identify of the study,
design is to
with theanalyze
lowest the movement
volume of liquid
of proppant with proppantThe
sedimentation. through
paperthree suction
considers manifolds
three design of different
variants of
design, manifold
suction to identifyofthe design withplunger
high-pressure the lowest
pump. volume of proppant sedimentation.
The hydrodynamic analysis of fluidThe paperwith
motion considers three
proppant hasdesign variantsout,
been carried of
suction
data on manifold of of
distribution high-pressure plunger pump.
velocities, pressures The hydrodynamic
and proppant concentration analysis of fluid motion
in the manifold withobtained.
have been proppantAhas beenofcarried
series out,
numerical
data on distribution
experiments carriedofout
velocities, pressures
for different andof
designs proppant concentration
three-plunger in the manifold
pump suction have been
lines confirms the obtained.
hypothesisA series
about of numerical
influence of
experiments
manifold carried
design, out for
velocity anddifferent
pressure designs
pulsationofonthree-plunger pump characteristics
change of volume suction lines confirms
of systemthe hypothesis about influence of
phases.
manifold
© 2022 The design, velocity
Authors. and pressure
Published pulsationB.V.
by ELSEVIER on change of volume characteristics of system phases.
© 2022 The Authors. Published by ELSEVIER B.V.
© 2022
This is The
an Authors.
open access Published
article by ELSEVIER
under the CC B.V.
BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0)
(https://creativecommons.org/licenses/by-nc-nd/4.0)
This is an open access article under the CC BY-NC-ND license
This is an open
Peer-review
Peer-review access
under
under article under
responsibility
responsibility ofofthe CC BY-NC-ND
thescientific
scientificcommittee license
committee of of (https://creativecommons.org/licenses/by-nc-nd/4.0)
thethe X International
X International Scientific
Scientific Siberian
Siberian Transport
Transport Forum Forum
Peer-review
Keywords: underpump;
Triplex responsibility of the proppant;
suction manifold; scientificsedimentation.
committee of the X International Scientific Siberian Transport Forum
Keywords: Triplex pump; suction manifold; proppant; sedimentation.
1. Introduction
1. Introduction
Performing works on development and maintenance of debit of oil and gas wells, which are part of the set of
Performing
works of oil andworks on development
gas wells service, are and maintenance
the most of debit
responsible of oil associated
operations and gas wells, which
with the use are part of the setand
of high-pressure of
works of oil and
high-capacity gas wells
pumps. service,
Hydraulic are the most
fracturing playsresponsible operations
an important associated oil
role in increasing with thegas
and usereserves.
of high-pressure and
In hydraulic
high-capacity
fracturing, pumps.
fluid Hydraulic
is injected fracturing
until the plays an
fluid pressure importantthe
overcomes role in increasing
inherent stressesoil
in and gas reserves.
the rock or exceedsIn the
hydraulic
forces
fracturing,
holding thefluid
rock istogether.
injectedThis
untilcauses
the fluid
thepressure overcomes
rock to fracture, the inherent
forming stresses
a fracture. The in the rockfluid
fracturing or exceeds
must bethepumped
forces
holding
into the rock fast
the fracture together.
enoughThis causes
to hold thethe rock toopen
fracture fracture, forming
and allow the afracturing
fracture. agent
The fracturing
carried byfluid must to
the fluid beenter
pumped
the
into the fracture
fracture and holdfastit enough to hold the
open, indicating fracture
Boyun Guo open and(2017).
et al. allow the
Thefracturing
authors ofagent
the carried by the fluidJosifovic
work Aleksandar to enter the
al.
fracture and hold it open, indicating Boyun Guo et al. (2017). The authors of the work Aleksandar Josifovic al.
* Corresponding author. Tel.: +7-961-292-4767; fax: +7-961-292-4767.

* E-mail
Corresponding kireevso@yandex.ru
address:author. Tel.: +7-961-292-4767; fax: +7-961-292-4767.
E-mail address: kireevso@yandex.ru
2352-1465 © 2022 The Authors. Published by ELSEVIER B.V.
This is an open
2352-1465 access
© 2022 Thearticle under
Authors. the CC BY-NC-ND
Published by ELSEVIER B.V.(https://creativecommons.org/licenses/by-nc-nd/4.0)
license
Peer-review under
This is an open responsibility
access of the scientific
article under CC BY-NC-NDcommittee
license (https://creativecommons.org/licenses/by-nc-nd/4.0
of the X International Scientific Siberian Transport Forum )
Peer-review under responsibility of the scientific committee of the X International Scientific Siberian Transport Forum
2352-1465 © 2022 The Authors. Published by ELSEVIER B.V.
This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0)
Peer-review under responsibility of the scientific committee of the X International Scientific Siberian Transport Forum
10.1016/j.trpro.2022.06.074
Valentin Stepanov et al. / Transportation Research Procedia 63 (2022) 778–788 779
2 Valentin Stepanov et al / Transportation Research Procedia 00 (2019) 000–000
(2016) note that the modern approach to hydraulic fracturing requires the transportation, installation and operation
of a large amount of industrial equipment discussed in detail in Lebedev A. et al (2022), Kireev S. et al (2022),
Kaderov H. et al (2022). A significant part of this equipment is the fleet of pumps required to provide high pressures
and flows required for well stimulation. Piston pumps with working pressure up to 40 MPa and flow rate up to 50 l/s
are necessary for well construction, pumps with working pressure up to 70 MPa and flow rate up to 40 l/s described
in Egor Secrieru et al (2022), hydraulic fracturing requires plunger pumps with a working pressure of 105 MPa or
more and flow rate up to 15 l/s point API GUIDENCE DOCUMENT HF1. FIRSTEDITOR, OCTOBER (2009).
Liquids for these operations can be both water-based and hydrocarbon-based muds and mixtures. Density of water-
based drilling fluids is from 1.03 to 2.2 g/cm3, hydrocarbon-based from 0.98 to 2.1 g/cm3
The density of plugging solution may vary from 1.3 to 2.2 g/cm3 and more. Mixtures of proppant and proppant
fluid with concentration up to 500 kg/m3 are used for hydraulic fracturing. The main property of a fluid common to
the process of drilling, cementing and hydraulic fracturing is its homogeneity and stability. Assuming that the
mixing units supply a homogeneous mixture of constant concentration to the pump, the suction manifolds of the
pumps must ensure this homogeneity after increasing the pressure at the pump outlet.
When drilling oil wells, drilling fluids are used, the main purpose of which is to clean and maintain hydrostatic
pressure in the wellbore. The study of the stability of drilling fluids is of high importance for understanding solids-
liquid interactions. Drilling and plugging fluids and fracturing fluids are multicomponent heterogeneous
polydisperse systems, discussed in the article Yang Bai et al. (2021). The dispersed phase of such solutions are
particles of a solid insoluble substance uniformly distributed in the dispersion medium. Dispersant medium is
usually liquid. Drilling and plugging solutions belong to polydisperse systems, i.e. having disperse phase particles of
different sizes. The degree of dispersion of particles is characterized by dispersibility, D - a value inverse of the
transverse particle size, d (cm-1). The higher the dispersity, the greater the total surface area of the interface.
According to the degree of dispersion systems are divided into highly dispersed (colloidal) and coarse dispersed.
The size of colloidal particles is within 5-8 microns. Of course disperse systems, suspensions, emulsions and aerated
fluids are used as drilling fluids. Suspensions are turbid liquids with particles of solid matter suspended in them.
These particles are deposited by gravity, i.e., they sediment. The sedimentation index indirectly characterizes the
stability of the drilling fluid. When drilling oil and gas wells, the drilling mud is fed to the drill bit and performs the
tasks of carrying the drilled rock from the bottomhole to the surface of the well, cooling and lubricating the tool.
Drilling mud is a multi-component system, which includes water (for water-based mud), alumina, polymers,
lubricants, defoamers, weighting agents, etc. The size of the disperse fraction of clay particles is 5-10 microns.
Cement slurry mixtures are designed to create cement slurry for casing string cementing. A plugging mixture
includes a mixing fluid (water with additives), plugging cement and additives for appropriate cementing conditions
(sand, clay powder, weighting agent, viscosity reducers, etc.). Drilling and plugging fluids belong to polydisperse
systems, i.e. having disperse phase particles of different sizes. Optimal size of disperse fraction of cement particles
is less than 7 microns. Nara Brandão Costa Santos et al (2018) point out that the formulation of drilling fluids affects
the separation process in suspensions, so it must be adapted to the operating conditions.
For hydraulic fracturing, the composition of the fluid medium is different. Proppant-carrier fluids are designed to
deliver to the fractures the propping material formed after the first stage of hydraulic fracturing. Fracturing fluid is a
cohesive disperse system called a "gel" and is distinguished by the presence of a continuous spatial structure. It is
viscous, ductile, strong, elastic, etc. In the handbook Liquids—Hydraulics (2014) the properties of the fracking fluid
(viscosity and injection rate) are given and it is noted that the viscosity of the fracking fluid can significantly affect
the morphology and character of fracture propagation. A typical proppant carrier fluid is water and a thickening
polymer. The disperse fraction of proppant is quartz sand of 0.425-0.85 mm fraction. The concentration of sand in
the mixture is up to 600 kg/m3. The quality of wellbore sinking, cementing of the cased well and, most importantly,
during the hydraulic fracturing process depends on the stability of the systems.
The high-pressure pump suction manifold is filled with drilling and squeezing fluids by gravity, while a booster
pump is used to supply hydraulic fracturing fluid. Through the suction manifold, the fluid is brought to the suction
valve system of the pump hydrogroup (3 or 5 valve boxes).
The operation mode of valve boxes is characterized by alternating dynamic opening and closing of the valves,
which creates large pulsations of velocity and pressure in the system, the variation of velocity and pressure field
780 Valentin Stepanov et al. / Transportation Research Procedia 63 (2022) 778–788
Valentin Stepanov et al / Transportation Research Procedia 00 (2019) 000–000 3
flow in the suction and discharge chambers of a five-cylinder plunger pump are discussed in detail in Zhanghua Lian
et al (2018).
Fracking companies have encountered the problem of flow restriction and pump cavitation due to proppant
precipitation.
It is assumed that the intake manifold configuration, velocity and pressure pulsations lead to changes in the
volumetric characteristics of the system phases at the pump outlet.
2. Problem Statement
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 smallest volume of deposited proppant. As the hydroblock
investigated in detail in the paper Stepanov Valentin et al (2018), the model of three-plunger high-pressure pump
NP-720 is used. The fluid motion along the manifold from the gate valve to the suction valve seat is considered.
Density of proppant-carrier liquid is 1100 kg/m3, dynamic viscosity is 0.25 Pa∙s. Silica sand with 0.5 mm fraction
and density of 2650 kg/m3 was used as proppant in the analysis. The maximum flow at the inlet of the manifold is
20 l/s indicated in SPM Flow Control Products Catalog (2016), which corresponds to the maximum recommended
flow rate through the high-pressure manifold of 2" diameter, proppant mass fraction of 600 kg/m3. The design of the
first version (Fig.1a) of the suction manifold uses the "classical" direct flow model «ChecV», is most commonly
used in well-known models of triplex pumps such as SPM® TWS 600S Heavy Duty (HD) Pump (2016), The
disadvantages of this design are considered to be the welded pipe manifolds that create turbulence, causing
excessive abrasion of the inner walls, which leads to leaks along the weld seams. Design of the second version
«ChecOp» (Fig.1b) of the suction manifold is based on the model proposed by DIXON designed for efficient fluid
movement and reduction of pump cavitation caused by sand deposition. The use of a one-piece construction
eliminates premature failures due to failure of welds indicates the manufacturer DIXON. BOSS™ LPS. Low
Pressure Systems (2018). Design of the third option «ChecRing» (Fig. 1c) of the suction manifold is the model
proposed by F.E.T. Frac Pumps. Racetrack Suction Manifolds (2022) to ensure high capacity, flow rate and
cavitation prevention. A hydrodynamic analysis was performed when three suction valves were opened for three
suction manifold design types.
Fig. 1. Designs of the suction manifold: (а) – ChecV; (b) – ChecOpt; (c) – ChecRing.
3. Choice of research method
The movement of the mixture through the intake manifold of the pump is described by the equations of
hydrodynamics for the motion of a continuous medium. Navier-Stokes equations for the motion of a viscous
incompressible medium used to calculate ANSYS Fluent Theory Guide, (2022):
4 ValentinValentin
StepanovStepanov et al. / Transportation
et al / Transportation ResearchResearch
ProcediaProcedia 63000–000
00 (2019) (2022) 778–788 781
∂u ∂u ∂u ∂u −1 ∂p
+ u ⋅ + v ⋅ + w ⋅ = ⋅ + η ⋅ ∆u + g x (1)
∂t ∂x ∂y ∂z p ∂x
∂v ∂v ∂v ∂v −1 ∂p
+ u ⋅ + v ⋅ + w ⋅ = ⋅ + η ⋅ ∆v + g y (2)
∂t ∂x ∂y ∂z p ∂y
∂w ∂w ∂w ∂w −1 ∂p
+u⋅ +v⋅ + w⋅ = ⋅ + η ⋅ ∆W + g z (3)
∂t ∂x ∂y ∂z p ∂z
Where u, v, w are components of the velocity vector in the Cartesian coordinate system x, y, z; η is kinematic
viscosity; g x , g y , g z are components of mass forces; ρ is matter density.
The continuity equation:
∂u ∂v ∂w
+ + 0.
= (4)
∂x ∂y ∂z
To conduct the study, a numerical multiphase flow modeling apparatus based on the Euler method in the
nonstationary formulation was used. In this method, the proppant-carrier fluid phase and the proppant phase are
considered to be inseparable and interpenetrating throughout the motion process. The derivatives of the differential
equations and boundary conditions expressing the conservation laws were approximated by a difference-grid model,
that is, the continuous medium was replaced by its discrete counterpart as described in Zhicheng Xiao et al (2021).
4. Problem Solution
A hydraulically smooth pipe of conditional diameter 5" (inside diameter 127 mm) was taken as the initial cross-
section of the suction manifold of the pump. Constant parameters to solve the problem are: volume of suction
manifold of each design (a - 0.0246 m3, b - 0.0191 m3, c - 0.0349 m3), flow characteristics of all manifold designs
(20 l/s), proppant-carrier fluid viscosity. The design of the suction manifold and the order of opening and closing the
valves are varied during the study. Controllable (output) parameters of mixture motion considered in the article
Borovkov, V.S. et al (2012), for the three design types of manifolds are: volume mass of deposited proppant in the
manifold, Reynolds number (Re), flow rate of mixture through the valve box. For approbation and calibration of
finite-element model the preliminary calculations have been carried out by using water (density 998 kg/m3 and
dynamic viscosity 8.9∙10-4 Pa∙s) as proppant-carrier liquid in non-stationary statement according to the paper M.
Vasilyeva et al (2019). After analyzing the results obtained for aqueous dispersion medium, the mesh model of
manifolds was corrected (the zone of near-wall mesh layers was increased to 5 with its size reduced to 3 mm in the
saddle zone). Two series of numerical experiments have been carried out in unsteady formulation on "gel" proppant
medium with dynamic viscosity of 0.25 Pa∙s and density of 1100 kg/m3, for different modes of valve unit operation.
Numerical values of mass flow rate, deposited proppant and Reynolds number for each valve considered
irrespective of operation mode of neighboring valves Table 1.
Table 1. Values of the parameters when changing the position of the discretely considered pump valves.
Constructive type/ valve position Mass flow rate, kg/sec Reynolds number Percentage of deposited
proppant in the manifold. %
35.0833 10.884 2.542

а/1ChecV
35.075 10.117 2.55

а/2ChecV
35.084 9.061 2.54

а/3ChecV
35.057 10.726 3.14

b/1ChecOpt
35.049 9.029 3.16

b/2ChecOpt
35.02 10.62 3.14

b/3ChecOpt
35.23 10.52 1.71

c/1ChecRing
35.13 16.007 1.72

c/2ChecRing
35.15 12.02 1.72

c/3ChecRing
Based on the data obtained, the following dependencies were plotte: shown in figure 2:
6 ValentinValentin
StepanovStepanov et al. / Transportation
et al / Transportation ResearchResearch
ProcediaProcedia 63000–000
00 (2019) (2022) 778–788 783
Percentage of
Reynolds
proppant
number
deposited, %
а)
Reynolds Percentage of
number proppant
deposited, %
b)
Reynolds
number Percentage of
proppant
deposited, %
с)
Fig. 2. Flow and proppant deposition parameters for different designs when changing the position of discretely considered valves: (а) – ChecV;
(b) – ChecOpt; (c) – ChecRing..
For a visual understanding of the processes occurring in the manifolds, Figures 3, 4 show the distribution of flow
velocity fields, flow lines, proppant distribution.
a)
b)
c)
Fig. 3. Velocity field for the furthest valve in different designs:(а) – ChecV; (b) – ChecOpt; (c) – ChecRing.
a)
b)
c)
Fig. 4. Current lines for the furthest valve in the various designs: (а) – ChecV; (b) – ChecOpt; (c) – ChecRing.
In real pump operation the valves open sequentially and the hydrodynamic mode of operation of the suction
manifold is influenced not only by the position, but also by the order of opening of the valves and their interaction.
The results of numerical experiment for sequential change of position of the pump valves are presented in table 2.
Table 2. Values of the parameters when changing the position of the pump valves in series.
Constructive type/ valve Mass flow rate. kg/sec Average Reynolds Percentage of deposited
position number proppant in the manifold. %
a/ChecV 35.2
35.01
490 7.09
35.09
b/ChecOpt 35.13
35.17
700 8.98
35.90
c/ChecRing 35.18
35.16
1023 8.05
35.45
Reynolds Percentage of
number deposited
proppant, %
Fig. 5. Flow and proppant deposition parameters for different discrete valve designs at discrete valve position changes.
а) b) c)
Fig. 6. Volumetric fraction of deposited proppant during sequential valve operation for different designs.
5. Discussion of the results obtained
Analysis of the results obtained for the discrete consideration of the valves, depending on their location in the
system presented in Table 1, revealed that the influence of the design and location of the valve does not have a
significant impact on the flow characteristics, with the given parameters of the hydraulic unit of the pump. The
deviation of the mass flow rate of the mixture passing through the valve box is in the range of 0.01- 0.50 kg/s.
The dependences shown in Fig. 2 show the character of changes in the Reynolds number and the percentage of
deposited proppant for different variants of the suction valve opening within each of the considered design. In this
case, the flow character and its hydrodynamic characteristics are most significantly influenced by the geometric
position of the valve in the manifold design.
The considered parameters do not change significantly when changing the position of the operating valve within
the same design, a more significant difference in the studied parameters is observed when changing the design of the
manifold. So, the analysis of diagrams Fig. 3,4 shows that the lowest flow velocity is observed in the design c) –
«ChecRing», at the same time whirls are formed due to design features that in a discrete consideration of the
operation of an individual valve gives the smallest percentage of proppant deposition.
The data obtained at a sequential mode of operation of valves, taking into account the system changes in the
hydraulic characteristics show that at this mode of operation of the valves also does not reveal the influence of the
design on the mass flow rate characteristics in the valve assembly, the scatter of the mass flow rate of the mixture
does not exceed unity.
The lowest percentage of sedimentation is observed in design (a) "ChecV", the highest percentage of proppant
sedimentation is observed in the lower part of the annular pipeline design c) – «ChecRing».
6. Conclusions
A series of numerical experiments carried out for various suction line designs of a three-plunger pump confirm
the hypothesis about the influence of manifold design, velocity and pressure pulsation on changes in the volume
characteristics of the system phases and allow the following conclusions:
1 The flow characteristics of the valve box for all types of manifold designs considered are approximately the
same 34-36 kg/sec;
2 The calculated Reynolds number for all types of manifold designs under consideration reflects the laminar type
of fluid motion in the section under consideration;
3 According to the value of deposited proppant, the "classical" design of straight-through suction manifold has
the best characteristics.
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X International Scientific Siberian Transport Forum

* Corresponding author. Tel.: +7-961-292-4767; fax: +7-961-292-4767.

3. Choice of research method

35.0833 10.884 2.542

35.075 10.117 2.55

35.084 9.061 2.54

35.057 10.726 3.14

35.049 9.029 3.16

35.02 10.62 3.14

35.23 10.52 1.71

35.13 16.007 1.72

35.15 12.02 1.72

5. Discussion of the results obtained

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