Internal-Bore Fracturing Plunger for Lower Stress Pump Assembly
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Solution Overview
Problem
Existing hydraulic fracturing pumps face issues with stress and fatigue failures due to intersecting bores, and there is a need for improved manufacturing processes and reduced risk of damaging dynamic seals during assembly.
Innovation Solution
The introduction of a sleeve within the plunger for easier valve assembly, a split static section design to reduce seal damage, and the use of hardened inserts and twist-on locking retainers to enhance durability and ease of installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional plungers with integrated valve seats are used, then manufacturing is simpler, but valve assembly and disassembly become difficult and time-consuming
Solution Approach 1:
The plunger is divided into multiple components: a plunger body, a separate valve seat, and a sleeve. The valve seat is installed in the plunger body, and the sleeve is subsequently installed over the valve seat. This segmentation allows the valve assembly to be easily removed and replaced without removing the entire plunger, significantly improving maintenance efficiency while keeping the manufacturing process relatively simple.
2Productivity
If intersecting bores are used in pump design, then fluid delivery paths are established, but stress and fatigue failures increase
Solution Approach 1:
The patent transitions from traditional intersecting bore designs to a linear arrangement where fluid enters through suction ports in the plunger body, travels axially through the valve seat and sleeve, and exits through discharge ports. This one-dimensional linear flow path eliminates the stress concentrations associated with intersecting bores while maintaining effective fluid delivery.
3Reliability
If dynamic seals are used in assembly processes, then sealing is achieved, but risk of damage during assembly increases
Solution Approach 1:
The valve seat is pre-installed in the plunger body before the sleeve is installed. This preliminary arrangement allows the sleeve to be slid over the already-positioned valve seat, preventing misalignment and reducing the risk of damaging dynamic seals during assembly. The sequential installation process ensures proper positioning without requiring forceful operations that could compromise seal integrity.
4Strength
If traditional valve assembly designs are used, then structural integrity is maintained, but operational life is reduced due to wear
Solution Approach 1:
The sleeve is designed as a replaceable component that can be removed and replaced when worn. The valve seat remains permanently installed in the plunger body, while the sleeve is periodically replaced to maintain optimal performance. This approach extends the operational life of the overall valve assembly by allowing selective replacement of wear-prone components without replacing the entire structure.
Data Source
AI summary
A fluid end made of a housing and a plunger reciprocating therein. The plunger has a hollow bore formed therein, and a valve assembly situated on one end of the plunger. The plunger may have a sleeve situated within the bore that aids in the installation of the valve assembly. The plunger may have a second bore extending perpendicularly from the hollow bore. The first bore may be connected to an attachment piece which connects to a conduit. The conduit may then be connected to a manifold which is configured to provide a fluid to the plunger's bore. The housing may be made of a static section and a plurality of dynamic sections. The dynamic sections may thread into the housing. The static section may be made of two pieces to aid with installation of a dynamic seal.