Fluid Routing Plug Assembly for Erosion-Resistant Fluid Ends
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Solution Overview
Problem
Conventional fluid ends used in hydraulic fracturing operations experience frequent failures due to extreme pressures, vibrations, and erosion from proppants, leading to short operational lifetimes and high maintenance costs.
Innovation Solution
A modular fluid end assembly design featuring a multi-piece housing with interchangeable sections, a fluid routing plug, and wear-resistant components to distribute pressure and reduce erosion, allowing for the replacement of worn parts without replacing the entire assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional fluid ends are used in hydraulic fracturing operations, then they can deliver high volumes of highly pressurized fluid, but they experience frequent failures due to extreme pressures, vibrations, and erosion from proppants
Solution Approach 1:
The fluid end is divided into multiple modular sections (first section, second section, third section) that can be independently replaced. This segmentation allows worn components to be replaced without discarding the entire fluid end assembly, thereby extending operational lifetime while maintaining high fluid delivery capability.
Solution Approach 2:
The patent changes the physical state of critical surfaces by applying hardened coatings or surface treatments to wear-resistant components. This parameter change in surface hardness and erosion resistance allows the fluid end to withstand extreme pressures and proppant erosion for longer periods, improving reliability.
2Reliability
If the entire fluid end assembly is replaced when components wear, then reliability is restored, but maintenance costs increase significantly
Solution Approach 1:
The modular design with first, second, and third sections allows selective replacement of only the worn components rather than the entire assembly. This reduces material loss and maintenance costs while restoring operational reliability.
Solution Approach 2:
Instead of discarding the entire fluid end assembly when wear occurs, the patent enables recovery and reuse of non-worn sections. The worn components (such as the second section with the fluid routing plug) can be replaced while retaining the first and third sections, reducing overall maintenance costs.
3Duration of action of stationary object
If wear-resistant components are used to reduce erosion, then operational life is extended, but device complexity increases
Solution Approach 1:
The fluid end is segmented into modular sections with wear-resistant components concentrated in specific areas (such as the second section containing the fluid routing plug). This segmentation extends operational life through targeted wear resistance while keeping the overall device complexity manageable through standardized modular interfaces.
Data Source
AI summary
A fluid routing plug for use with a fluid end section. The fluid end section being one of a plurality of fluid end sections making up a fluid end side of a high pressure pump. The fluid routing plug is installed within a horizontal bore formed in a fluid end section and is configured to route fluid throughout the fluid end section.