Modular Fluid Routing Plug Assembly for Fracturing Wear Control
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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
1Reliability
If conventional fluid ends are used under extreme hydraulic fracturing conditions, then high pressure fluid delivery is achieved, but frequent failures occur due to wear and erosion
Solution Approach 1:
The fluid end is divided into multiple interchangeable sections (e.g., barrel sections, plunger sections) 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 reliability under extreme hydraulic fracturing conditions.
Solution Approach 2:
Wear-resistant materials and coatings are applied specifically to areas most susceptible to erosion from proppants, such as the barrel interior and plunger surfaces. This localized enhancement of material properties addresses the harmful effects of wear and erosion without requiring complete replacement of the entire fluid end assembly.
2Reliability
If the entire fluid end assembly is replaced upon component wear, then reliability is restored, but maintenance costs and downtime increase
Solution Approach 1:
The modular sectional design enables rapid replacement of only the worn components (e.g., individual barrel or plunger sections) rather than the entire fluid end assembly. This significantly reduces maintenance downtime and allows operational continuity while restoring reliability through targeted component replacement.
Solution Approach 2:
Worn or damaged sections are discarded and replaced with new or refurbished sections, while the remaining functional sections are retained and reused. This approach minimizes waste and reduces maintenance costs while maintaining operational reliability with minimal downtime.
3Ease of manufacture
If modular interchangeable sections are implemented, then maintenance costs are reduced, but device complexity increases
Solution Approach 1:
The fluid end is constructed with standardized interchangeable sections that use simple connection mechanisms (e.g., threaded joints, flanged connections). This segmentation reduces maintenance costs by enabling targeted replacement of worn components, while the standardized design minimizes the increase in device complexity through modular assembly.
Solution Approach 2:
Multiple sections are designed with universal interfaces and standardized dimensions, allowing the same connection methods and mounting mechanisms to be used across different sections. This universality reduces the overall complexity of the modular assembly while enabling cost-effective maintenance through interchangeable 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 throughout the fluid end section.