In-Line Fracturing Pump Fluid End to Eliminate Bore Stress Concentration
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Solution Overview
Problem
Conventional fluid ends used in hydraulic fracturing operations experience frequent structural failures due to high operational pressures and abrasive conditions, leading to premature wear and leakage, necessitating frequent replacements.
Innovation Solution
The in-line fluid end design eliminates intersecting bores, reduces stress concentration points, and allows for lower-cost, less strenuous material usage, incorporating a sleeve and retainer system to secure seals and valves, enhancing durability and reducing manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fluid ends use traditional designs with intersecting bores, then structural strength is maintained, but stress concentration points increase leading to frequent failures
Solution Approach 1:
The patent removes the intersecting bore configuration from the fluid end design, extracting the source of stress concentration. By eliminating the intersection of longitudinal and transverse bores, the design eliminates the stress concentration points that caused frequent failures in conventional designs, thereby improving reliability without requiring additional strengthening measures.
Solution Approach 2:
The patent separates the bore functions into distinct non-intersecting pathways. The longitudinal bore for fluid intake and the transverse bore for fluid discharge are positioned to avoid intersection, creating segmented flow paths that eliminate stress concentration at intersection points. This segmentation allows each bore to be optimized independently while improving overall structural integrity.
2Reliability
If higher strength materials are used to withstand high operational pressures, then structural reliability improves, but manufacturing costs increase
Solution Approach 1:
The patent employs standard strength materials rather than expensive high-strength alloys, accepting that the materials are not overly robust but designing the structure to prevent failure through geometric optimization. The non-intersecting bore design allows use of conventional materials like standard steel or aluminum that are easier and cheaper to manufacture, avoiding the need for costly high-strength materials while maintaining adequate reliability.
Solution Approach 2:
The patent changes the geometric parameters of the bore arrangement from intersecting to non-intersecting configurations. This parameter change in the structural design allows the use of lower-strength materials while maintaining pressure resistance, as the improved geometry distributes stress more evenly and eliminates concentration points that would otherwise require high-strength materials to prevent failure.
3Reliability
If complex sealing and valve systems are integrated into the plunger, then functional reliability improves, but device complexity increases
Solution Approach 1:
The patent integrates the inlet valve, outlet valve, and sealing components directly into the plunger body as a unified assembly. By merging these functional elements into a single integrated plunger structure rather than separate components, the design improves functional reliability through better coordination of sealing surfaces and valve mechanisms while avoiding the complexity of multiple discrete parts and assembly operations.
Solution Approach 2:
The plunger is designed as a multi-functional component that incorporates valve bodies, sealing surfaces, and fluid passage functions within a single structure. This universal design allows the plunger to perform multiple functions (fluid intake, fluid discharge, sealing, valve operation) simultaneously, improving overall system reliability while reducing the number of separate components needed in the fluid end assembly.
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.