Modular Fluid End Housing for Fast Section Replacement

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Solution Overview

Problem

Conventional fluid ends used in hydraulic fracturing operations experience frequent failures due to extreme pressures, vibrations, and abrasion, leading to short operational lifetimes and high maintenance costs.

Innovation Solution

The development of a high-pressure pump system featuring a fluid end assembly with a modular housing design, where each fluid end section is attached to the power end using stay rods, allowing for easy replacement of individual sections without replacing the entire housing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional fluid ends are used under extreme hydraulic fracturing conditions, then high pressure fluid delivery is achieved, but operational lifetime is short due to wear and failure

Engineering Contradiction:

Improveoperational lifetimeVSAvoidwear from pressure, vibration, and abrasion

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The housing is divided into multiple replaceable sections (first section, second section, third section) that can be independently removed and replaced. This segmentation allows only the worn section to be replaced rather than the entire housing, extending operational lifetime while managing wear damage.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent implements a replaceable section system where worn housing sections are discarded and new sections are installed. The stay rods are designed to be reusable and remain in place while only the affected housing section is removed and replaced, recovering valuable components.

Inventive Principle:

Principle #34Discarding and recovering

2Reliability

If the entire housing is replaced when one section wears out, then reliability is restored, but loss of time and maintenance cost increase

Engineering Contradiction:

Improvefluid end functionalityVSAvoiddowntime for replacement

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The housing is segmented into multiple independent sections that can be replaced individually. When one section wears out, only that specific section needs to be removed and replaced, not the entire housing assembly. This significantly reduces replacement time and downtime while restoring reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The replaceable section design allows the worn section to be discarded and replaced while the remaining healthy sections stay in place. The stay rods and other components are recovered and reused, minimizing replacement time and waste.

Inventive Principle:

Principle #34Discarding and recovering

3Ease of repair

If modular housing sections are implemented, then ease of repair is improved, but device complexity increases

Engineering Contradiction:

Improvesection replacement capabilityVSAvoidmodular housing structure

Core Design Contradiction:

Ease of repairVSDevice complexity

Solution Approach 1:

The housing is divided into standardized sections (first section, second section, third section) connected by stay rods. Each section can be independently removed and replaced, greatly simplifying repair operations. The segmentation is designed to be straightforward with clear connection points, balancing ease of repair with manageable complexity.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS12313048B2Fluid end assembly

Publication Date: 2025.05.27 KERR MACHINE CO

AI summary

A fluid end assembly having a plurality of fluid end sections positioned in a side-by-side relationship. Each fluid end section has a housing made of multiple-piece construction. One or more pieces of the housing have a plurality of stay rods attached thereto. The stay rods interconnect the fluid end assembly and a power end assembly.