Segmented Fluid End Housing for Cracking 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 leakage, which necessitate frequent replacements.
Innovation Solution
The fluid end is designed with multiple sections instead of a single housing, eliminating high-stress intersecting bores and allowing for individual section replacement, reducing manufacturing costs and complexity, and using a modular power end configuration with improved fluid routing and sealing systems to enhance durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single housing design is used, then manufacturing is simpler, but stress concentration at intersecting bores causes cracking and failure
Solution Approach 1:
The housing is divided into multiple separate sections (first section, second section, third section) that are joined together. This segmentation eliminates the need for intersecting bores in a single housing, as each section can have simple linear bores that are joined via coupling mechanisms, thereby reducing stress concentration while maintaining manufacturing simplicity.
2Reliability
If the entire fluid end is replaced upon failure, then reliability is restored, but cost and time are increased
Solution Approach 1:
The fluid end is segmented into replaceable sections coupled together. When one section fails, only that specific section needs to be replaced rather than the entire fluid end. The coupling mechanisms allow for quick disconnection and replacement of individual sections, reducing both time and cost while restoring reliability.
Solution Approach 2:
Failed sections can be discarded and replaced with new or refurbished sections. The modular design allows for selective replacement of only the damaged portion, recovering the functional value of the remaining intact sections and reducing overall replacement cost and time.
3Adaptability or versatility
If intersecting bores are used in the housing, then fluid routing is achieved, but stress concentration leads to cracking
Solution Approach 1:
Instead of creating intersecting bores in a single housing, the fluid routing function is achieved by joining multiple housing sections with linear bores. The coupling mechanisms between sections provide the necessary fluid pathways, eliminating stress concentration at bore intersections while maintaining versatile fluid routing capability.
4Reliability
If frequent replacements are performed, then reliability is maintained, but productivity is reduced
Solution Approach 1:
The segmented housing design with replaceable sections allows for rapid replacement of only failed components rather than entire units. This reduces downtime and maintains higher productivity while ensuring reliability through quick restoration of functional sections.
Solution Approach 2:
spare sections can be pre-manufactured and staged for quick replacement. The modular design allows for preliminary preparation of replacement components, minimizing downtime when failures occur and maintaining overall productivity while ensuring reliability.
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.