Fluid Routing Plug Structure for Modular High-Pressure Fluid Ends
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional fluid ends used in hydraulic fracturing operations are prone to structural failure due to high operational pressures, vibrations, and abrasives, leading to frequent failures and the need for frequent replacement.
Innovation Solution
The development of a fluid end assembly with a modular housing design, where each fluid end section is attached to the power end assembly via stay rods, allowing for easy replacement of individual sections without replacing the entire housing, thereby reducing wear and extending the lifespan of the fluid end.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fluid ends operate under high pressures and abrasives, then hydraulic fracturing operations can be performed, but structural failure and wear occur frequently
Solution Approach 1:
The housing is divided into multiple replaceable sections (first section, second section, third section) that can be individually replaced without replacing the entire housing. This segmentation allows worn sections to be exchanged while preserving other sections, thereby reducing overall wear impact and extending fluid end lifespan.
Solution Approach 2:
Worn or failed housing sections are discarded and replaced with new sections, while the remaining functional sections are recovered and retained in service. This approach prevents the need to discard the entire housing assembly, reducing waste and maintenance costs.
2Reliability
If the entire housing is replaced upon section failure, then reliability is restored, but loss of time and increased cost occur
Solution Approach 1:
The housing is segmented into interchangeable sections that can be replaced independently. When one section fails, only that specific section needs to be replaced rather than the entire housing, significantly reducing replacement time and maintaining fluid end functionality with minimal downtime.
Solution Approach 2:
Replacement sections can be prepared in advance and stored ready for installation. When a section fails, the pre-prepared replacement section can be quickly installed, minimizing the time the fluid end is out of service.
3Ease of repair
If modular housing sections are used, then ease of repair improves, but device complexity increases
Solution Approach 1:
The housing is divided into standardized sections connected by stay rods and fasteners. This segmentation simplifies repair by allowing individual section replacement, and the use of standard connection mechanisms (stay rods, fasteners) across all sections maintains ease of assembly despite the modular complexity.
Solution Approach 2:
Multiple housing sections are designed with universal connection features (stay rods, fasteners, sealing surfaces) that allow any section to be replaced with any other section of the same type. This universality simplifies the repair process by enabling interchangeable parts while managing complexity through standardized 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.