Segmented Fluid End Housing for Bore Stress and Wear Reduction
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Solution Overview
Problem
Traditional fluid ends used in hydraulic fracturing operations experience frequent failures due to extreme pressures, vibrations, and abrasive conditions, leading to structural issues such as cracking and erosion, resulting in short operational lifespans and the need for frequent replacements.
Innovation Solution
The fluid end is designed with multiple sections instead of a single housing, eliminating intersecting bores that are common stress points, allowing for easier replacement of individual sections and reducing manufacturing costs and complexity, while using a modular power end and advanced sealing systems to enhance durability and fluid routing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional single-housing fluid ends are used, then manufacturing is simpler, but structural stress points and failure risk increase due to intersecting bores
Solution Approach 1:
The fluid end housing is divided into multiple separate sections (first section, second section, third section) that are assembled together using coupling mechanisms. This segmentation eliminates the need for intersecting bores in a single housing, removing stress concentration points and improving structural reliability while allowing for easier manufacturing of individual sections.
2Ease of repair
If multiple fluid end sections are used, then individual section replacement becomes easier, but device assembly complexity increases
Solution Approach 1:
The housing is segmented into replaceable sections that can be individually removed and replaced. Each section is designed with coupling mechanisms that allow for straightforward assembly and disconnection, enabling maintenance personnel to replace only the worn section rather than the entire housing, thus improving ease of repair.
Solution Approach 2:
The coupling mechanisms and connection interfaces are designed to be universal across different sections, allowing the same coupling design to be used throughout the fluid end assembly. This standardization reduces assembly complexity despite the multi-section construction.
3Reliability
If intersecting bores are used in single housing, then fluid routing is achieved, but stress concentration and cracking occur at bore intersections
Solution Approach 1:
Instead of creating intersecting bores in a single housing, the patent divides the housing into multiple sections where fluid passages are routed through separate, non-intersecting paths in each section. This eliminates stress concentration at bore intersections while maintaining effective fluid routing capabilities.
Data Source
AI summary
A fluid end comprising a plurality of fluid end sections positioned in a side-by-side relationship. Each fluid end section is releasably attached to a connect plate. Each connect plate is attached to a power source using a plurality of stay rods. Each fluid end section comprises a housing in fluid communication with a pair of intake manifolds and a discharge conduit. A fluid routing plug is installed within each housing and is configured to route fluid throughout the housing. A plunger is installed within stuffing box attached to each housing. A number of features, including the location of seals within bore walls and carbide inserts within valve guides, aid in reducing or transferring wear.