Monolithic Fluid Cover Assembly for High-Pressure Pump Durability
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Solution Overview
Problem
High-pressure and high-power operations in hydraulic fracturing pumping systems lead to frequent damage and reduced lifespan of fluid end components, resulting in operational downtime and increased costs due to rugged environments and cyclic stress.
Innovation Solution
A monolithic fluid cover design for the fluid end block assembly, comprising a first portion that seals the open end portion and a second portion mechanically connected to the fluid end block body, enhancing sealing and alignment, and constructed from materials like metallic, polymeric, or composite materials to resist wear and cyclic pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If traditional fluid end components are used in high-pressure hydraulic fracturing systems, then the pumping system can operate at high pressure, but the components become damaged frequently and have reduced lifespan
Solution Approach 1:
The patent combines multiple separate components (fluid cover, seal elements, alignment features) into a single monolithic fluid end component. This integration eliminates interfaces between separate parts, reducing potential failure points and improving reliability under high-pressure cyclic operations while maintaining the required power capability
Solution Approach 2:
The monolithic component is designed to incorporate different material properties within a single structure, using composite construction techniques to achieve both the strength required for high-pressure operation and the durability needed for extended service life in harsh hydraulic fracturing environments
2Ease of manufacture
If traditional multi-part fluid cover designs are used, then manufacturing and assembly are simpler, but sealing effectiveness and alignment are insufficient leading to leakage
Solution Approach 1:
By integrating the fluid cover, seals, and alignment features into one monolithic component, the design eliminates leakage paths that exist at interfaces between separate parts. The unified structure ensures precise alignment and continuous sealing surfaces, dramatically improving sealing effectiveness while the monolithic construction simplifies manufacturing through single-piece fabrication
3Productivity
If conventional fluid end components are used in rugged environments, then the system can be deployed, but operational downtime increases due to frequent damage and maintenance
Solution Approach 1:
The monolithic design reduces the number of replaceable parts and eliminates assembly/disassembly of multiple components during maintenance. This integration allows for quicker replacement of the entire fluid end assembly, minimizing operational downtime while maintaining continuous productivity capability in rugged hydraulic fracturing environments
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The monolithic fluid cover design improves durability, reduces maintenance cycles, minimizes leakage, and extends the service life of fluid end components by providing a robust seal and resisting the water hammer effect, thus reducing operational downtime and costs.
Implementation Method 1
The fluid cover may be sealably engaged with the fluid end block assembly
Implementation Method 2
constructed from materials like metallic, polymeric, or composite materials to resist wear and cyclic pressures
Implementation Method 3
The fluid cover may include a shoulder that is positioned between the first portion and the second portion. The shoulder may be engaged with the fluid block end body to seal the open end portion. In some embodiments, the shoulder may interact with the open end portion to align the fluid cover with the open end portion.
Data Source
AI summary
Embodiments of a high-pressure, high power, reciprocating positive displacement fluid pumping system and methods are included. The system may include a high-pressure, high power, reciprocating positive displacement pump including a pump plunger, a fluid end block assembly, and a fluid cover. The fluid end block assembly may include a fluid end block body, a suction port, a discharge port, a pump bore positioned in and extending through the fluid end block body, and a fluid chamber positioned in the fluid end block body and in fluid communication with each of the suction port, the discharge port, and the pump bore. The fluid chamber has an open end portion, and the pump plunger may be positioned to move in the pump bore to pressurize one or more fluids in the fluid chamber. The fluid cover includes a monolithic body having a first portion and a second portion, the first portion being received in the open end portion and sealably engaged with the fluid end block body, the second portion being mechanically connected to the fluid end block body.