Fluid End Valve Cover Locking Assembly for Pressure-Safe Maintenance
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Solution Overview
Problem
Workers conducting maintenance and/or repair on fluid ends of frac pumps or mud pumps are at risk of injury due to unknowingly removing valve covers while the fluid end is still under pressure.
Innovation Solution
A safety device for fluid ends featuring a valve cover with a jam structure and a locking assembly that includes a movable jam structure and an actuator with tapered surfaces, wedges, and biasing elements to prevent the unlocking of the valve cover when under pressure, ensuring it remains locked during operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a locking assembly is used to secure the valve cover, then the valve cover remains securely locked during operation, but the complexity of the device increases due to additional locking components
Solution Approach 1:
The jam structure is nested within the valve cover assembly, with the first and second segments positioned between the valve cover and fluid end body. The biasing element is contained within the jam structure, creating a compact nested arrangement that provides locking functionality without adding significant external complexity
Solution Approach 2:
The biasing element continuously applies force to maintain the jam structure in a locked position before any malfunction occurs. This preliminary action ensures the valve cover remains secured during normal operation and automatically prevents unlocking if pressure builds up, eliminating the need for complex control systems
2Ease of operation
If the valve cover can be easily removed for maintenance, then the ease of operation improves, but the risk of accidental removal under pressure increases causing worker injury
Solution Approach 1:
The jam structure and biasing element create a preliminary counter-action that prevents the valve cover from being removed under pressure. The biasing element continuously exerts force to maintain the jam structure in position, creating an automatic safety mechanism that opposes any attempt to remove the cover while pressure is present, thereby preventing worker injury
Solution Approach 2:
The safety device is self-activating based on pressure conditions. When pressure builds up in the fluid end, it automatically engages the jam structure to prevent valve cover removal, without requiring external monitoring or control systems. The device serves itself by using the pressure it detects to trigger the locking action
3Reliability
If a jam structure with biasing element is used to prevent accidental unlocking, then safety improves, but the device complexity increases due to additional components
Solution Approach 1:
The jam structure is nested within the valve cover assembly, with the first and second segments positioned between the valve cover and fluid end body. The biasing element is contained within the jam structure, creating a compact nested arrangement that provides safety functionality while minimizing additional space requirements
Solution Approach 2:
The biasing element automatically maintains the jam structure in the locked position and the device self-activates when pressure builds up, using the pressure itself to trigger the safety mechanism. This eliminates the need for external control systems, sensors, or complex actuation mechanisms
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
Prevents accidental unlocking of the valve cover when the fluid end is pressurized, reducing the risk of worker injury and maintaining the integrity of the fluid end components, thereby enhancing safety and operational efficiency.
Implementation Method 1
one or more biasing elements configured to bias the first segment and second segment toward each other
Implementation Method 2
an actuator including one or more tapered surfaces and an actuator opening, and a plurality of wedges disposed about the actuator and movable between an unlocked position and a locked position
Data Source
AI summary
The present disclosure relates to safety devices, locking assemblies, fluid ends, and related methods for pumping operations. One safety device for fluid ends includes a valve cover including an outer shoulder and a receptacle opening, and a jam structure movable in the receptacle opening of the valve cover. The jam structure includes a first plate, a second plate, a rod between the first plate and the second plate, and one or more extensions extending relative to the second plate. Another safety device includes one or more locking plates configured to prevent opening of the fluid end when under pressure.