Flexible Hose End Fitting Assembly for Replaceable Coupling Repair
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Solution Overview
Problem
Premature failures in flexible hoses used in hydraulic fracturing applications often occur at the end fittings, leading to leaks, threaded connection failures, and requiring the entire flexible hose assembly to be replaced.
Innovation Solution
The flexible hose end fitting assembly is designed with two separable portions: a flexible hose coupling and a connection coupling to a hammer union/safety iron, allowing for the replacement of only the failed coupling portion without replacing the entire flexible hose assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the end coupling is integrated into the flexible hose as a single unit, then the structural integrity is improved, but the maintenance cost and waste increase when failures occur at the end fitting
Solution Approach 1:
The end fitting assembly is divided into two separable portions: a flexible hose coupling portion and a connection coupling portion. This segmentation allows the connection coupling to be replaced independently when it fails, preventing the need to discard the entire flexible hose assembly and reducing material waste.
Solution Approach 2:
The design enables selective discarding of only the failed connection coupling portion while recovering and reusing the flexible hose coupling portion and hose. This partial replacement strategy reduces material loss and disposal costs compared to replacing the entire integrated assembly.
2Ease of manufacture
If the end coupling is integrated into the flexible hose as a single unit, then the manufacturing simplicity is improved, but the repairability deteriorates when failures occur at the end fitting
Solution Approach 1:
By segmenting the end fitting into separable coupling portions, the design improves repairability without significantly complicating manufacturing. Each portion can be manufactured separately using standard machining processes, then assembled through simple mechanical connections.
Solution Approach 2:
The connection coupling portion is extracted as a separate replaceable component from the flexible hose assembly. This extraction enables independent replacement of the failed connection coupling without affecting the flexible hose or coupling portion, significantly improving ease of repair.
3Device complexity
If the end coupling is integrated into the flexible hose as a single unit, then the device complexity is reduced, but the operational cost increases due to complete assembly replacement
Solution Approach 1:
The segmented design adds minimal structural complexity while enabling cost-effective maintenance. The separation of the connection coupling portion allows selective replacement, reducing operational costs by avoiding unnecessary replacement of the expensive flexible hose and coupling portions.
Solution Approach 2:
The design enables recovery and reuse of the flexible hose and coupling portions after connection coupling failure. This partial replacement approach significantly reduces operational costs compared to discarding and replacing the entire integrated assembly.
4Reliability
If the end coupling is integrated into the flexible hose as a single unit, then the connection reliability is improved, but the lifecycle duration decreases due to complete assembly replacement
Solution Approach 1:
The segmented design maintains connection reliability through proper mechanical coupling between portions while extending lifecycle duration. When the connection coupling fails, it can be replaced without affecting the reliable connection between the flexible hose and coupling portion, allowing the assembly to be reused multiple times.
Solution Approach 2:
The design enables recovery of the flexible hose and coupling portions after connection coupling failure. This extends the overall lifecycle of the flexible hose assembly by allowing multiple connection coupling replacements, increasing the duration of useful operation.
Data Source
AI summary
An end fitting assembly, configured to be secured to a flexible hose between a frac pump and a large bore manifold, includes a connection coupling portion including an annular flange at a first end, a connector interface at a second end, and a neck portion between the annular flange and the connector interface, wherein the annular flange includes a first axial face including a groove recessed into the first axial face, a face seal disposed in the groove, and a flexible hose coupling portion including an enlarged first end and a second end, wherein the enlarged first end includes a second axial face with a flat sealing region, and wherein coupling the enlarged first end to the annular flange brings the flat sealing region of the second axial face into sealing contact with the face seal disposed in the groove of the first axial face.