Fluid Routing Plug and Modular Fluid End for Abrasive Wear
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Solution Overview
Problem
Conventional fluid ends used in hydraulic fracturing operations experience structural failures due to high operational pressures and abrasion from proppants, leading to frequent replacements and operational inefficiencies.
Innovation Solution
A modular fluid end assembly design with a multi-piece housing construction, allowing individual sections to be replaced without replacing the entire assembly, combined with a fluid routing plug to enhance durability and reduce wear.
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 frequent replacements
Solution Approach 1:
The fluid end is divided into multiple separate housing sections (first housing section, second housing section, third housing section) that can be individually replaced. This segmentation allows replacement of only the worn or failed section rather than the entire fluid end assembly, thereby extending overall service life while maintaining structural reliability under high pressure and abrasive conditions.
2Reliability
If the entire fluid end assembly is replaced upon failure of one section, then structural reliability is restored, but operational downtime and maintenance costs increase
Solution Approach 1:
The modular housing sections enable targeted replacement of only the failed component rather than the entire assembly, significantly reducing downtime while restoring structural reliability.
Solution Approach 2:
The design allows the intact housing sections to be retained and reused after a failure, discarding only the damaged section. This recovery of functional components reduces both downtime and maintenance costs while maintaining reliability.
3Ease of repair
If multi-piece housing construction is implemented, then ease of repair and component replacement improve, but device complexity increases
Solution Approach 1:
The housing is constructed from multiple separable sections connected by fasteners, allowing individual sections to be removed and replaced independently. This segmentation significantly improves ease of repair despite increasing the number of components.
Solution Approach 2:
The standardized housing sections with consistent connection interfaces can serve multiple functions and be interchanged in different positions, reducing the overall complexity of the replacement process while maintaining ease of repair.
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.