Multi-Piece Fluid End Housing for High-Pressure Section Replacement
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Solution Overview
Problem
Conventional fluid ends used in hydraulic fracturing operations experience structural failures due to high operational pressures and abrasive proppants, leading to frequent replacements and reduced operational lifespan.
Innovation Solution
The design of a modular fluid end assembly with a multi-piece housing structure, allowing individual sections to be replaced independently, and the use of reinforced components to withstand high pressures and abrasion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fluid ends are used under high operational pressures and abrasive conditions, then they can deliver required fluid volumes and pressures, but they experience structural failures and reduced operational lifespan
Solution Approach 1:
The housing is divided into multiple separable sections (first housing section, second housing section, third housing section) that can be independently removed and replaced. This segmentation allows worn sections to be replaced without replacing the entire fluid end assembly, extending operational lifespan while maintaining reliability under high pressure and abrasive conditions
Solution Approach 2:
Different housing sections are designed with specific local properties - some sections have internal passages optimized for fluid flow, others for structural support, and others for connection interfaces. This localized optimization allows each section to withstand specific stressors (pressure, abrasion) appropriately, improving overall reliability
2Reliability
If the entire fluid end assembly is replaced when one section wears out, then reliability is restored, but maintenance time and cost increase
Solution Approach 1:
The housing sections are designed as separable modular units with connection features (flanges, bolts, sealing interfaces) that enable quick detachment. When one section wears out, only that specific section needs to be removed and replaced, not the entire assembly, significantly reducing maintenance time while restoring reliability
Solution Approach 2:
Worn housing sections can be discarded and replaced with new or refurbished sections. The separable design allows the remaining functional sections to be retained and reused, reducing overall maintenance time and cost while maintaining operational reliability
3Strength
If reinforced components are used to withstand high pressures and abrasion, then durability improves, but device complexity and manufacturing difficulty increase
Solution Approach 1:
Instead of manufacturing one complex heavily reinforced housing, the design segments the housing into multiple sections, each with moderate reinforcement requirements. This allows each section to be manufactured more easily using standard processes, then assembled into a complete assembly that withstands high pressure and abrasion through the combined strength of all sections
Solution Approach 2:
The housing sections may use composite material constructions or different materials for different sections optimized for their specific functions (e.g., harder materials for abrasion-prone areas, more ductile materials for pressure-containing areas). This allows achieving high strength and abrasion resistance while maintaining ease of manufacture through material selection rather than complex design
Data Source
AI summary
A fluid end assembly made of a plurality of fluid end sections positioned in a side-by-side relationship. Each fluid end section comprises a plurality of individual components joined together in a row. Two sets of fasteners are used to secure various components of each fluid end section together. When the fluid end section is assembled, a first set of fasteners is in a spaced relationship with and faces a second set of fasteners. At least one component making up the multi-piece fluid end section is configured to have a plurality of stay rods attached thereto. The stay rods interconnect the fluid end assembly and a power end assembly.