In-Line Fracturing Pump Fluid End to Eliminate Bore Stress
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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 frequent replacements and maintenance issues.
Innovation Solution
The in-line fluid end design eliminates intersecting bores, reduces stress concentration areas, and uses replaceable sleeves and hardened inserts to enhance durability and longevity, allowing for lower-cost manufacturing with less expensive materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fluid ends are used with intersecting bores and traditional materials, then initial manufacturing cost is lower, but service life and reliability are reduced due to stress concentration and erosion
Solution Approach 1:
The fluid end is divided into separate functional components: a plunger body, an inlet component, and a discharge component. This segmentation allows each part to be optimized independently for its specific function, reducing stress concentration at intersections and improving overall reliability without requiring complex monolithic construction
Solution Approach 2:
The inlet component and discharge component are positioned to nest around the plunger body, with fluid passages arranged concentrically. This nested arrangement eliminates the need for intersecting bores that create stress concentration points, while maintaining compact overall dimensions and reasonable manufacturing complexity
2Power
If high-pressure operation is maintained at 10,000-15,000 psi, then fluid pressurization efficiency is improved, but structural failure risk increases due to expansion and cracking
Solution Approach 1:
Different components are made from materials with properties optimized for their specific local conditions: the plunger body uses materials resistant to abrasive wear from proppants, while the inlet and discharge components use materials resistant to corrosive fluid attack. This localized material optimization allows the structure to withstand high pressures without failure
Solution Approach 2:
The patent employs composite construction strategies where different materials are combined in the fluid end assembly to address multiple failure modes simultaneously. This allows the structure to maintain integrity under extreme pressure while resisting both corrosion and abrasive wear
3Reliability
If proppants are delivered with the fluid, then fracture holding capability is improved, but erosion and wear at weak points increase leading to premature failure
Solution Approach 1:
Components exposed to proppant-laden fluid are specifically selected or treated to resist abrasive wear. The plunger body and sealing surfaces use materials or coatings that maintain their properties despite continuous exposure to abrasive proppants, allowing the system to deliver proppants effectively without premature failure from erosion
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The new design significantly reduces wear and failure rates, extending the lifespan of fluid ends and reducing maintenance needs, while maintaining efficient fluid pressurization capabilities.
Implementation Method 1
highly pressurized fluid is injected into a cased wellbore... Pressurized fluid is delivered to the casing 12 through a wellhead 18
Implementation Method 2
An inlet component attached to the second end of the plunger body. A second fluid passageway is formed within the inlet component and is in communication with the first fluid passageway
Implementation Method 3
Fluid ends operate under notoriously extreme conditions, enduring the same pressures, vibrations, and abrasives that are needed to fracture the deep rock formations shown in FIG. 1. Fluid used in hydraulic fracturing operations is typically pumped through the fluid end at a pressure of at least 8,000 psi, and more typically between 10,000 and 15,000 psi
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.