Offset Fluid Routing Plug for High-Pressure Pump Reliability
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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 conditions, leading to premature wear and leakage, necessitating frequent replacements.
Innovation Solution
A fluid end design that incorporates enhanced sealing mechanisms and stress-resistant materials to mitigate fatigue cracks and erosion, prolonging the lifespan and reliability of the fluid end under extreme operating conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fluid ends are used under high operational pressures and abrasive conditions, then fluid delivery function is maintained, but structural failures occur due to fatigue cracks and erosion
Solution Approach 1:
The patent applies local quality by providing reinforcement features specifically at high-stress locations within the fluid end. The reinforcement member is positioned to provide localized support where fatigue cracks are most likely to initiate and propagate, rather than uniformly strengthening the entire component. This targeted approach addresses the harmful effects of fatigue and erosion at critical locations while maintaining overall component functionality.
Solution Approach 2:
The patent employs composite materials by combining a base material with a reinforcement member made of different material properties. The reinforcement member is constructed from materials that provide enhanced resistance to fatigue cracking and erosion compared to the base material. This composite structure allows the fluid end to withstand the harsh operational conditions of high pressure and abrasive environments while maintaining structural integrity.
2Power
If fluid ends operate at high pressures (5000-15000 psi or greater), then hydraulic fracturing function is achieved, but premature wear and leakage occur
Solution Approach 1:
The patent applies beforehand cushioning by incorporating reinforcement features and sealing improvements that prevent structural failures before they occur. The reinforcement member is pre-installed to cushion against the high operational pressures and abrasive conditions, preventing fatigue cracks from initiating and propagating during normal operation. This proactive approach extends the operational lifespan of the fluid end while maintaining the required pressure delivery capability.
3Duration of action of stationary object
If fluid ends are designed with enhanced sealing mechanisms and stress-resistant materials, then operational life is extended, but device complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the reinforcement feature into separate, modular components. The reinforcement member is designed as a distinct element that can be independently manufactured, installed, and replaced. This modular approach allows for extended operational lifespan through enhanced stress resistance without significantly increasing overall device complexity, as the reinforcement can be added as a separate feature rather than redesigning the entire fluid end structure.
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.