(12) United States Patent
`Stanton et al.
`
`(10) Patent No.:
`(45) Date of Patent:
`
`US 8,100.407 B2
`Jan. 24, 2012
`
`USOO8100407B2
`
`277/330
`
`(54) PACKING CARTRIDGES AND
`PRESSURE-DAMPENING ELEMENTS FOR
`PLUNGER-TYPE PUMPS
`
`(76) Inventors: Eddie N. Stanton, Odessa, TX (US);
`Michael L. Strickland, Odessa, TX
`(US)
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 464 days.
`
`(*) Notice:
`
`(21) Appl. No.: 10/798,693
`
`(22) Filed:
`
`Mar 11, 2004
`
`(65)
`
`Prior Publication Data
`US 2005/0200081A1
`Sep.15, 2005
`
`166/105
`
`-
`
`0
`
`3. N
`3,322 A ck
`aylor . . . . . . . . . . . . . . . . . . . . . . . . . . .
`was
`1/1974 Maurer et al.
`3,785,659 A
`9/1974 Gilliam, Sr.
`3,833,228 A
`6, 1975 McClure et al.
`3,887,198 A
`9, 1975 Maurer et al.
`3,907,307 A
`137,315.28
`1/1979 Morrison ...
`4,135,546 A *
`5/1979 Sieghartner ................... 277 396
`4,155,559 A *
`9, 1981 Kuc
`4,289,317 A
`9/1982 Maasberg et al.
`4,351,531 A
`7, 1983 Schob
`4,394,872 A
`4,602,791 A * 7/1986 Zollner ......................... 277/584
`4,630,636 A 12/1986 Cutcher
`4,758,135 A
`7, 1988 Woodward et al.
`4,775,303 A * 10/1988 Liska ............................ 417/554
`4,867.460 A
`9, 1989 Colo
`4,878,815 A 11/1989 Stachowiak
`5,062,397 A 11/1991 Larson
`Continued
`(
`)
`FOREIGN PATENT DOCUMENTS
`WO
`WOO1,09535 A1
`2, 2001
`(2006.01)
`(51) Fasa
`Primary Examiner — Gilbert Lee
`(52) U.S. Cl. .......... 277/511; 277/521; 277/522;
`(57)
`ABSTRACT
`(58) Field of Classification Search .................. 277/511, AESSEE it's inst
`277/516,520,521,522,540: 166/68, Si6.
`aspect, a packing cartridge includes: a generally-cylindrical
`lication file f
`1
`hhi 166/105
`sleeve adapted to be at least partially positioned in the pack
`See application file for complete search history.
`ing bore, a first abutment ring positioned in the sleeve, and a
`References Cited
`second abutment ring positioned in the sleeve and co-axially
`spaced apart from the first abutment ring. Telescoping struc
`tures are operatively positioned between the first abutment
`ring and the second abutment ring. According to another
`aspect, a structure forming a circumferential pressure-ring
`groove is provided. A pressure ring is positioned in the pres
`Sure-ring groove, the pressure ring having at least one Smaller
`external dimension than an internal dimension of the pres
`Sure-ring groove, whereby at least one clearance is provided
`between the pressure-ring groove and the pressure ring. These
`aspects can be advantageously practiced together.
`
`(56)
`
`U.S. PATENT DOCUMENTS
`1,013,745 A
`1/1912 Clark
`1,624,852 A
`4, 1927 Trautner
`2,126,007 A
`8, 1938 Guiberson et al.
`2,485,940 A 10, 1949 Tremolada
`2,716,034 A
`8, 1955 Main
`2,745,687 A
`5, 1956 Stack
`2,809,059 A 10, 1957 Hillis
`3,232,639 A * 2, 1966 Kosinski et al. ................ 285/81
`3,366,425 A
`1, 1968 Genz
`3.419,280 A 12/1968 Wheeler
`3,588,126 A
`6/1971 McKillop et al.
`
`31 Claims, 23 Drawing Sheets
`
`O
`
`
`
`2 / X
`SS S 22222
`
`S.
`2222222222
`
`
`
`
`
`
`
`
`
`
`
`
`
`aS8
`
`Vulcan
`Ex. 1003
`Page 1 of 45
`
`

`

`US 8,100.407 B2
`Page 2
`
`U.S. PATENT DOCUMENTS
`5,088,745 A
`2/1992 Peppiatt et al.
`5,090,087 A * 2/1992 Hipple et al. ................... 15,317
`5,263,682 A * 1 1/1993 Covert et al. ................. 251,214
`5,267,533 A 12, 1993 Smith
`5,297,805 A
`3, 1994 Merkin et al.
`5,636,688 A * 6/1997 Bassinger .................... 166,844
`
`6/1997 Tiffany et al.
`5,636.975 A
`2f1998 Wilkinson et al.
`5,716,055 A
`5,845,909 A 12/1998 Angelo et al.
`ck
`6,167,959 B1
`1/2001 Bassinger et al. ........... 166,842
`6.428.291 B1
`8, 2002 Baerlin et all
`
`* cited by examiner
`
`Vulcan
`Ex. 1003
`Page 2 of 45
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`

`

`U.S. Patent
`U.S. Patent
`
`Jan. 24, 2012
`Jan. 24, 2012
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`Jan. 24, 2012
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`Jan. 24, 2012
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`Page 5 of 45
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`Page 6 of 45
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`Page 17 of 45
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`U.S. Patent
`U.S. Patent
`
`Jan. 24, 2012
`Jan. 24, 2012
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`Sheet 16 of 23
`Sheet 16 of 23
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`US 8,100,407 B2
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`Page 18 of 45
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`

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`U.S. Patent
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`Page 19 of 45
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`Page 20 of 45
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`U.S. Patent
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`Jan. 24, 2012
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`Page 21 of 45
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`U.S. Patent
`U.S. Patent
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`Jan. 24, 2012
`Jan. 24, 2012
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`Sheet 20 of 23
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`US 8,100,407 B2
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`Page 22 of 45
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`Page 23 of 45
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`

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`U.S. Patent
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`US 8,100,407 B2
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`Page 24 of 45
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`

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`U.S. Patent
`U.S. Patent
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`Jan. 24, 2012
`Jan. 24, 2012
`
`Sheet 23 of 23
`Sheet 23 of 23
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`US 8,100,407 B2
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`Vulcan
`Ex. 1003
`Page 25 of 45
`
`

`

`US 8,100.407 B2
`
`1.
`PACKING CARTRIDGES AND
`PRESSURE-DAMPENING ELEMENTS FOR
`PLUNGER-TYPE PUMPS
`
`CROSS-REFERENCE TO RELATED
`APPLICATIONS
`
`Not applicable
`
`STATEMENT REGARDING FEDERALLY
`SPONSORED RESEARCH ORDEVELOPMENT
`
`10
`
`Not applicable
`
`REFERENCE TO MICROFICHEAPPENDIX
`
`15
`
`Not applicable
`
`TECHNICAL FIELD
`
`The present invention generally related to positive-dis
`placement pumps, and, more particularly, to plunger-type
`pumps. More particularly still, the invention related to the
`packing seals and assemblies for reciprocating plungers in
`Such pumps. The invention also related to the maintenance
`and use of Such fluid pumps.
`
`25
`
`BACKGROUND
`
`2
`to as a compression, fluid, or liquid chamber or cylinder), and
`various ports, valves, and other components.
`The pumping chamber is a chamber or plurality of cham
`bers in which the motion of the plunger(s) or piston(s) is
`imparted to the liquid (or fluid). A piston or plunger is posi
`tioned to reciprocate in a cylindrical port, which can be con
`sidered to be the pumping chamber or a portion of the pump
`ing chamber. The cylindrical port for the piston or plunger is
`a heavy-walled structure adapted for withstanding the high
`forces of containing the reciprocating piston or plunger.
`A piston is a cylindrical body that is attachable to a rod and
`is capable of exerting pressure upon a liquid within the pump
`ing chamber. A piston usually has grooves for containing
`rings that seal against the generally smooth interior cylindri
`cal wall of the cylindrical port or against a replaceable cylin
`der liner placed in the cylindrical port as the piston recipro
`Cates.
`A plunger is a Smooth rod that is attachable to a crosshead
`and is capable of exerting pressure upon a liquid within the
`pumping chamber. Sealing rings for a plunger are stationary,
`the plunger sliding within the rings. The cylindrical port for a
`plunger-type pump typically has two portions with different
`diameters, a plunger bore and an axially aligned packing
`bore. The packing bore has a larger diameter than the plunger
`bore, so that the packing bore is adapted for accommodating
`packing between the interior cylindrical wall of the packing
`bore and the outward cylindrical surface of the plunger.
`The pumping chamber can be made integral with a suction
`manifold and discharge manifold or can be made with sepa
`rate manifolds. A Suction manifold is a chamber that accepts
`liquid from the suction port(s) and distributes it to the suction
`valves. A discharge manifold is a chamber that accepts liquid
`from the individual discharge valves and directs it to the
`discharge port(s).
`The power end is that portion of the pump in which the
`rotating motion of the crankshaft is converted to a reciprocat
`ing motion through connecting rods and crossheads. The
`power frame is that portion of the power end that contains the
`crankshaft, connecting rods, crosshead and bearings used to
`transmit power and motion to the fluid end.
`The power frame of the power end is held in a substantially
`permanent, stationary position. The fluid end is typically
`bolted to the power frame and is cradled by the power frame.
`Sometimes, a frame extension connects the fluid end to the
`power frame when the fluid end is not bolted directly to the
`power frame. In any case, the fluid end is not unbolted and
`disconnected from the power end except for major mainte
`nance overhaul of the fluid end.
`The typical fluid end of a plunger-type pump includes a
`fluid-end pump body having at least one pumping chamber.
`The pumping chamber has a Suction port (sometimes referred
`to as an intake port), a discharge port, and a cylindrical port
`(or, in the case of a double-acting plunger-type pump, a pair of
`opposed cylindrical ports). The cylindrical port in a plunger
`type pump includes a plunger bore and an axially aligned
`packing bore. In some pumps, an internal lubrication port is
`provided for Supplying lubricant to the packing bore, which
`lubricant can be distributed around an internal circumference
`of the packing bore by a lantern ring, as well know to those
`skilled in the art. An example of the fluid end of this type of
`pump with original packing and parts for the packing bore is
`illustrated in FIG. 1.
`A Suction valve is positioned in the Suction port (e.g., in a
`cylindrical portion of the Suction port that is sometimes
`referred to as the Suction valve deck), and a discharge valve is
`positioned in the discharge port (e.g., in a cylindrical portion
`of the discharge port that is sometimes referred to as the
`
`A positive-displacement pump, sometimes referred to as a
`reciprocating fluid pump or as a reciprocating power pump, is
`a type of fluid pump driven by power from an outside source
`applied to the pump.
`There are several types of reciprocating power pumps.
`Typically, the pumps are classified as being plunger pumps or
`piston pumps. A plunger pump is differentiated from a piston
`pump in that a plunger moves past stationary packing,
`whereas a piston carries packing with it. A major problem
`associated with positive-displacement fluid pumps, espe
`cially high-pressure pumps, is that of providing a satisfactory
`seal for the piston or plunger.
`The pumps are also classified as either single acting or
`double acting. In a single-acting pump, liquid is discharged
`only during the forward stroke of the plunger or piston, that is,
`during one-half of the revolution. In a double-acting pump,
`liquid is discharged during both the forward and return
`strokes of the piston or pair of opposed plungers. That is,
`discharge takes place during the entire revolution.
`Further, the pumps are often classified as being horizontal
`or vertical. In a horizontal pump, the axial centerline of the
`cylinder is horizontal. In a vertical pump, the axial centerline
`of the cylinder is vertical.
`In addition, the pumps can be classified based on the num
`ber of plungers or pistons. A simplex pump contains only one
`piston or one plunger or a pair of opposed plungers driven by
`one connecting rod. A duplex pump contains two pistons or
`two plungers or two pair of opposed plungers driven by two
`connecting rods. A multiplex pump contains more than two
`pistons or two single-acting or opposed plungers. For
`example, a pump having three plungers or pairs of opposed
`plungers is commonly referred to as a triplex pump, and a
`pump having five plungers or pairs of opposed plungers is
`commonly referred to as a quintuplex pump.
`Generally, a positive-displacement pump has a fluid end
`(sometimes referred to as the liquid end) and a power end.
`The fluid end is that portion of the pump that handles the
`fluid. It consists of a pumping chamber (sometimes referred
`
`30
`
`35
`
`40
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`45
`
`50
`
`55
`
`60
`
`65
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`Vulcan
`Ex. 1003
`Page 26 of 45
`
`

`

`3
`discharge valve deck). In addition, a plunger is positioned to
`reciprocate in the cylindrical port having the packing bore and
`the plunger bore.
`The Suction valve is usually a spring-loaded check valve
`for allowing the flow offluid from the low-pressure side of the
`pump through the Suction port into the pumping chamber
`while preventing the backflow of fluid through the suction
`port. The discharge valve is usually a spring-loaded check
`valve for allowing the flow of fluid from the liquid cylinder
`through the discharge port to the high-pressure side of the
`pump with preventing backflow offluid through the discharge
`port. Preferably, although not necessarily, the Suction and
`discharge valves are vertically disposed in the pump, that is,
`the axis of each of the generally cylindrical valves is vertically
`oriented in the pump body. Furthermore, the vertical axes of
`the Suction and discharge valves are preferably, although not
`necessarily, co-axially aligned.
`The plunger of the pump is positioned to reciprocate back
`and forth in the cylindrical port of the pumping chamber. The
`cylindrical port consists of a heavy-walled structural body
`defining the plunger bore and the packing bore, of which at
`least the interior cylindrical volume of the plungerbore can be
`considered to be at least a portion of the pumping chamber.
`The heavy-walled cylinder of the cylindrical port is designed
`to withstand the high-reciprocating and high-pressure forces
`to accommodate the plunger. Typically, at the limit of its
`stroke, the plunger fills nearly the full length of the cylindrical
`port, and in some designs exceeds the full length of the
`cylindrical port and extends into another portion of the
`plumping chamber.
`During the back stroke of the plunger, the withdrawal of the
`plunger increases the volume of the pumping chamber, which
`creates decreasing fluid pressure or Suction in the chamber.
`This causes the Suction valve in the Suction port to open to
`draw fluid from the low-pressure side of the pump into the
`35
`pumping chamber. The decreased fluid pressure in the cham
`ber also causes the discharge valve in the discharge port to
`close, preventing fluid from the high-pressure side of the
`discharge port from backing up into the pumping chamber.
`During the forward stroke of the plunger, the insertion of
`40
`the plunger decreases the Volume of the pumping chamber,
`which creates increasing fluid pressure in the chamber. This
`causes the discharge valve in the discharge port to open to
`pump fluid through the discharge valve to the high-pressure
`side of the pump. The increased fluid pressure in the chamber
`also causes the Suction valve to close, preventing high-pres
`Sure fluid from the pumping chamber from being discharged
`through the Suction port.
`As mentioned above, a packing bore is provided adjacent
`the plunger bore in the cylindrical port. The packing bore has
`a generally cylindrical interior wall with an internal diameter
`(“I.D.) that is larger than an internal diameter of the plunger
`bore and that is co-axially aligned with the plunger bore. An
`annular space is defined between the interior wall of the
`packing bore and a plunger extending through the packing
`bore into the plunger bore. In other words, the annular space
`is also substantially the same as the difference between the
`I.D. of the packing bore and the I.D. of the plunger bore.
`The packing bore typically has a 'seat' (sometimes
`referred to as a “land') adjacent the high-pressure end
`thereof, which is toward the plunger bore. The seat is gener
`ally annular in shape, presenting an annular surface generally
`facing the low-pressure end of the packing bore, which is
`away from the plungerbore. The annular Surface of the seat is
`preferably at a Substantially perpendicular angle relative to
`the axis of the interior wall of the packing bore, but it can be
`at an oblique angle. The central opening in the seat allows for
`
`50
`
`45
`
`55
`
`60
`
`65
`
`US 8,100.407 B2
`
`5
`
`10
`
`15
`
`25
`
`30
`
`4
`insertion of the plunger through seat. The seat of the packing
`bore can be formed as a shoulder between the interior wall of
`the packing bore and the plunger bore.
`A removable “gland' (sometimes referred to as a “top
`gland' or “top piece') is typically positioned adjacent the
`low-pressure end of the packing bore, which is away from the
`plungerbore. The gland is for axially capturing and Squeezing
`the packing material or packing set positioned in the annular
`space within the interior wall of the packing bore against the
`seat of the packing bore. A central opening in the gland allows
`for insertion of the piston rod or plunger through the gland.
`The gland is generally annular in shape, presenting an
`annular surface generally facing the high-pressure end of the
`packing bore, which is toward the plunger bore. The annular
`Surface of the gland is preferably at a Substantially perpen
`dicular angle relative to the axis of the interior wall of the
`packing bore, but it can be at an oblique angle.
`The removable gland typically is formed as a part of a body
`adapted to be removably secured to the body forming the
`interior wall of the packing bore. For example, the gland can
`have a circumferential flange or flange lobes through which
`bolts can be secured to the body forming the interior wall of
`the packing bore. In another design, the gland can have a
`circumferential threaded connector adapted to screw with a
`corresponding circumferential threaded connector on the
`body forming the interior wall of the packing bore, in which
`case the gland is sometimes referred to as a 'gland nut.'
`The packing bore is for accommodating relatively soft
`“packing in the annular space between the interior wall of
`the packing bore and the plunger. The packing is for sealingly
`engaging the plunger to help prevent fluid leakage from
`around the plunger as it reciprocates in the plunger bore,
`which enables the compression of fluids in the pumping
`chamber.
`The packing bore can accommodate various styles of pack
`ing. Historically, loose packing material was simply 'stuffed
`into the packing bore. Early on, packing material was formed
`into ring-shaped packing elements. The packing elements can
`be formed into rings having a rectangular or square cross
`section. The packing rings can be split rings to facilitate
`assembly or removal of the packing rings from the packing
`bore. Because the packing material is relatively soft, a plu
`rality of such packing elements is often backed-up with inter
`mediate rigid washer-shaped rings or spacers. More recently,
`the engineering of the packing rings and other associated
`parts of the packing set has become increasingly sophisti
`cated. The stack of the plurality of packing elements, inter
`mediate spacers, and other pieces that can be used in the
`packing bore are collectively referred to as a "packing stack
`or “packing set or “packing assembly.
`The seat of the packing bore provides a land area for the
`packing set, including the packing and associated parts and
`pieces. With the packing rings and other pieces of a packing
`set are positioned in place in the packing bore against the seat,
`the plunger inserted through the packing set. Then the gland
`is then positioned in place over the packing set. The gland,
`when tightened, axially compresses and Squeezes the packing
`set. This action causes the shape of Soft packing material to
`distort, creating a tight sealing area between the packing bore
`and the outside diameter of the plunger, preventing any Sub
`stantial leak of internal compressed fluids from around the
`plunger.
`The packing material (or packing set) is axially captured
`and retained within the interior wall of the packing bore
`between the seat of the packing bore and the gland, which is
`positioned and tightened over the packing. Over-tightening of
`the gland on the packing can cause excessive friction as the
`
`Vulcan
`Ex. 1003
`Page 27 of 45
`
`

`

`5
`plunger reciprocates through the packing elements, causing
`excess wear, heat, and even breakage of the plunger.
`As mentioned above, a major problem associated with
`positive-displacement fluid pumps, especially high-pressure
`pumps, is that of providing a satisfactory seal for the plunger.
`This seal has normally been in the form of soft, nonabrasive
`packing elements adapted to seal the annular space between
`the pump plunger and the bore of the packing bore. During the
`power stroke of the plunger, the internal pump pressure acting
`axially on the packing set helps the packing rings to deform or
`deflect into sealing engagement between the reciprocating
`plunger and the packing bore.
`Of course, the packing seals wear as the plunger recipro
`cates, and the fluid pumps require periodic maintenance to
`replace the worn seals. The wear on the plunger packing is a
`particularly serious problem when the fluid being pumped
`contains Suspended particles of silt, clay, sand, or other abra
`sive material. The abrasive material tends to erode the pack
`ing causing early and frequent failure. Packing failure is
`normally evidenced by the leakage of fluid past the packing.
`A Small amount of leakage can be tolerated, but when this
`becomes excessive, the pumping operation must be stopped
`to permit replacement of the packing.
`The typical packing needs to be replaced ever few months
`of pump operation. This maintenance involves tedious and
`time-consuming operations, including removal of the pack
`ing gland, removal of the worn packing elements from the
`packing bore, re-assembly of new packing elements in the
`packing bore, and replacement and proper tightening of the
`gland.
`30
`Eventually, typically after about two-to-three years of
`pump operation, however, the packing bore itself will require
`a major overhaul. During the reciprocating action of the
`plunger, the parts and pieces of the packing set have slight
`movement and this, along with corrosion, vibration and other
`factors, will cause the packing bore Surface to deteriorate.
`Further, as the packing wears and loosens, the packing will in
`turn will increasingly wear on the interior cylindrical wall of
`the plunger bore. Eventually, the packing bore becomes use
`less as a sealing Surface to prevent the compressed product
`from escaping from the pumping chamber to the pump exte
`rior. Then it becomes necessary to recondition the packing
`bore diameters in a major overhaul of the pump. This is
`usually done by boring out the packing bore inside diameter
`to accommodate a sleeve, which replaces the original packing
`bore sealing Surfaces with a new one.
`Sometimes it is desirable to change the size of the plunger.
`The diameter of the packing bore, however, must be in a
`reasonable proportion to the diameter of the plunger and have
`a Sufficient clearance to accommodate the cross-section of the
`packing. For example, a plunger having a 2-inch diameter can
`be positioned in a packing bore having 3-inch diameter,
`which provides a typical circumferential clearance of 0.5
`inch. This allows for a packing material having a 0.5 inch
`cross-section (if square packing material is used) to fill the
`annular space between the outside diameter of the plunger
`and the internal packing bore diameter.
`When it is desired to change the size of the plunger, the
`packing bore would then be of the wrong proportion. Many
`times, for example, it is desirable to increase pump internal
`pressures. One way of doing this is to decrease the plunger
`diameter. Doing this, of course, increases the clearance
`between the plungerbore and plunger outer diameter. Up to a
`reasonable extent, the increased clearance can be compen
`sated with a packing having a larger cross-section. Alterna
`tively, it is possible to re-bore and sleeve the original packing
`bore to reduce the internal diameter of the packing bore, and
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`US 8,100.407 B2
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`allow for the use of a packing having a more appropriate
`cross-section. However, this alternative requires major over
`haul of the pump.
`In many pumps, the packing bore is integrally formed as
`part of the fluid-end body. An example of this type of prior-art
`pump is illustrated in FIG. 1, which is hereinafter described in
`detail.
`In a few pumps, a “'stuffing box’ is permanently captured in
`the fluid-end body by the attached powerframe, in which case
`this stuffing box provides the packing bore. An example of
`this design is the Wheatley(R“323 pump is illustrated in FIG.
`2, which is hereinafter described in more detail. However, this
`stuffing-box design is adapted for major overhaul of the fluid
`end and does not allow for the removal of the stuffing box
`without removing the fluid end from the power frame. Essen
`tially, the packing bore is formed in a non-integrally formed,
`but permanently installed stuffing box in a fluid-end body.
`The packing is routinely maintained without removal of this
`type of permanently installed stuffing box.
`In other of pumps, a “'stuffing box’ is permanently bolted to
`the fluid-end body of the pump, although it can be removed
`without removal of the fluid end from the power frame. Such
`a separate stuffing box is massive and expensive because, in
`essence, it is a structural portion of the fluid end body. Essen
`tially, the packing bore is formed in a non-integrally formed,
`but permanently attached stuffing box to a fluid-end body.
`The packing is routinely maintained without removal of this
`type of permanently attached stuffing box. When the packing
`bore wears to the point it needs major service, such a stuffing
`box portion of the fluid-end body can be removed for easier
`re-manufacturing or re-sleeving.
`Conventional plunger packings also present design prob
`lems in packing assemblies that require lubrication. In order
`to avoid excessive wear