Fluid Routing Plug Layout for High-Pressure Pump Fluid Ends
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional fluid ends used in hydraulic fracturing operations are prone to structural failure due to high operational pressures and abrasive proppants, leading to frequent leakage and short lifespan, necessitating frequent replacements.
Innovation Solution
A modular fluid end design comprising multiple sections instead of a single housing, with each section having a single horizontal bore and a fluid routing plug to manage fluid flow, reducing stress points and manufacturing costs, and allowing for easier replacement of individual sections rather than the entire unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single housing design is used for fluid ends, then manufacturing is simpler, but stress concentrations increase leading to structural failure under high pressure
Solution Approach 1:
The fluid end housing is divided into multiple modular sections (first section, second section, third section) connected by section interfaces. Each section can be manufactured separately with optimized stress distribution, and the modular design allows for easier replacement and maintenance of individual sections without replacing the entire housing structure.
2Productivity
If high pressure operation is maintained for productivity, then fluid delivery volume increases, but structural failure risk increases due to pressure stress
Solution Approach 1:
The modular sectioned housing distributes pressure stress across multiple interfaces and structural components rather than concentrating it in a single housing structure. This allows the fluid end to operate at high pressures (maintaining productivity) while reducing the risk of catastrophic structural failure, as individual sections can be designed with optimized pressure distribution and replaced if needed.
3Reliability
If the entire fluid end housing is replaced upon failure, then reliability is restored, but loss of time and cost increase due to complete replacement
Solution Approach 1:
The housing is divided into replaceable modular sections. When a section fails or requires maintenance, only that specific section needs to be replaced rather than the entire housing. This significantly reduces downtime and replacement costs while restoring reliability, as the failed section can be quickly swapped out and the system returned to service.
4Ease of repair
If modular sectioned housing is used, then ease of repair improves through section replacement, but device complexity increases due to multiple components
Solution Approach 1:
The housing is segmented into standardized modular sections with consistent interfaces. While this creates multiple components, the standardization of these sections and their interfaces simplifies the overall assembly and replacement process. The modular design allows for pre-fabricated sections to be quickly installed, reducing repair complexity despite the increased number of individual components.
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 between an intake and discharge bore. The fluid routing plug comprises a plurality of first and second fluid passages. The first and second passages do not intersect and are offset from one another. The first fluid passages are configured to direct fluid delivered to the horizontal bore from intake bores towards a reciprocating plunger. The second fluid passages are configured to direct fluid pressurized by the plunger towards a discharge bore.