Flangeless Fluid End Structure for High-Pressure Fatigue Resistance
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Solution Overview
Problem
Traditional fluid ends in hydraulic fracturing operations experience frequent failures due to high operational pressures, corrosion, erosion, and fatigue cracks, leading to short operational lifespans and increased maintenance costs.
Innovation Solution
A flangeless, multi-piece fluid end design made from stainless steel, featuring beveled corners and optimized plug and retainer systems to reduce stress concentrations and torque requirements, enhancing durability and longevity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fluid ends are used with flanges and traditional materials, then they can be manufactured and assembled, but they experience frequent fatigue failures and structural cracks under high operational pressures
Solution Approach 1:
The patent removes the flange component entirely from the fluid end assembly. By eliminating the flange, the design eliminates the stress concentration points and fatigue failure zones that existed at the flange connections, directly improving reliability under high pressure operations.
Solution Approach 2:
The patent specifies using stainless steel material for the fluid end body, which provides superior corrosion resistance and strength-to-weight ratio compared to traditional materials. This material selection enhances both the strength and reliability of the component in harsh hydraulic fracturing environments.
2Stress or pressure
If high pressure operations are maintained, then hydraulic fracturing effectiveness is achieved, but structural expansion and cracking of the fluid end occur
Solution Approach 1:
By removing the flange structure, the design eliminates the primary location where high operational pressures caused expansion and cracking. The direct connection without flange intermediaries prevents stress accumulation and structural failure under sustained high pressure conditions.
Solution Approach 2:
The stainless steel construction provides enhanced structural integrity and resistance to pressure-induced expansion and cracking, allowing the fluid end to withstand the extreme operational pressures required for effective hydraulic fracturing.
3Ease of manufacture
If traditional single-piece fluid end design is used, then manufacturing is simpler, but material wastage and manufacturing costs increase
Solution Approach 1:
The patent divides the fluid end into multiple modular pieces (body, plug, retainer, seals) that can be manufactured separately from smaller material blocks and then assembled. This segmentation reduces material wastage during manufacturing while maintaining manufacturing simplicity through standardized assembly procedures.
4Ease of operation
If flanged connection design is used, then assembly is straightforward, but torque requirements and stress concentrations increase
Solution Approach 1:
By eliminating the flange and its bolted connection system, the design removes the high torque requirements associated with flange assembly. The direct threaded connection requires significantly less torque while maintaining assembly straightforwardness through simplified geometry.
Data Source
AI summary
A flangeless fluid end comprising a fluid end body releasably attached to a connect plate. The connect plate is attached to a power source using stay rods. The flow bores of the fluid end are sealed without threading a retainer nut into the walls of each bore. Instead, the flow bores are sealed by bolting a retainer to the fluid end body. Plungers to drive fluid through the fluid end body are installed within removable stuffing box sleeves. These sleeves are maintained within the plunger bores by the bolted retainers. A number of features, including the location of seals within bore walls and carbide inserts within valve structures, aid in reducing or transferring wear.