In-Line Fracturing Pump Fluid End to Reduce Stress and Leakage
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Solution Overview
Problem
Conventional fluid ends used in hydraulic fracturing operations experience premature failure due to high operational pressures, corrosion, and erosion, leading to structural weaknesses and leakage, necessitating frequent replacements.
Innovation Solution
The in-line fluid end design eliminates intersecting bores, reduces stress concentration areas, and uses lower strength materials, along with improved sealing mechanisms and replaceable components to enhance durability and longevity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fluid ends use traditional designs with intersecting bores, then structural complexity is reduced, but stress concentration areas increase leading to premature failure
Solution Approach 1:
The fluid end body is segmented into distinct functional zones: a first portion with a first bore and a second portion with a second bore, where the bores are positioned to avoid intersection. This segmentation eliminates the stress concentration areas that would occur at intersecting bores, thereby improving reliability and durability without requiring complex structural designs.
2Power
If fluid ends operate at high pressures (5,000-15,000+ psi), then hydraulic fracturing effectiveness is improved, but structural failure and leakage increase
Solution Approach 1:
The fluid end body employs different material properties in different regions: the first and second portions are made from materials selected to resist corrosion and erosion from the highly pressurized fluid. The bores are positioned and sized to minimize stress concentration, allowing the structure to withstand high operational pressures (5,000-15,000+ psi) without failing or leaking.
3Reliability
If fluid ends are replaced frequently due to failure, then operational reliability is maintained, but loss of time and manufacturing costs increase
Solution Approach 1:
The fluid end body is designed with corrosion and erosion resistant materials from the outset, and the bore configuration is optimized to prevent stress concentration. This preliminary design action extends the service life of the fluid end, reducing the frequency of replacements and minimizing loss of time and manufacturing costs associated with frequent replacements.
4Productivity
If proppants are delivered with pressurized fluid, then fracture stimulation effectiveness is improved, but erosion at weak points increases
Solution Approach 1:
The fluid end body is designed with corrosion and erosion resistant materials that preemptively counteract the erosive effects of proppants and highly pressurized fluid. The bore configuration minimizes stress concentration points where erosion would otherwise occur, allowing the fluid end to withstand the harsh environment created by proppant delivery without suffering significant damage.
Data Source
AI summary
A fluid end for use with a power end. The fluid end comprises a plurality of fluid end sections positioned adjacent one another. Each section includes a single horizontally positioned bore. A plunger is installed within the bore and includes a fluid passageway. Low-pressure fluid enters the bore through the plunger and high-pressure fluid exits the fluid end through an outlet valve installed within the bore. The intake of low-pressure fluid within the fluid end section is regulated by an inlet valve installed within the plunger. Low-pressure fluid enters the plunger through an inlet component attached to both the plunger and an inlet manifold.