Fluid Routing Plug Passages for Modular High-Pressure Fluid Ends
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Solution Overview
Problem
Traditional fluid ends used in hydraulic fracturing operations are prone to structural failure due to high operational pressures and abrasive proppants, leading to frequent leakage and short operational lifespans, necessitating frequent replacements.
Innovation Solution
A modular fluid end design comprising multiple sections instead of a single housing, with each section having a single horizontal bore and a fluid routing plug to manage fluid flow, reducing stress points and allowing for easier replacement of individual sections rather than the entire unit, and utilizing a dual intake manifold system for different fluid types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If a single housing design is used for fluid ends, then the structure is simpler to manufacture, but stress concentrations lead to structural failure and short operational lifespan
Solution Approach 1:
The fluid end housing is divided into multiple modular sections (first section, second section, third section) that can be independently manufactured and assembled. Each section has standardized interfaces with fluid routing plugs that contain internal bores for fluid flow. This segmentation distributes stress concentrations across multiple joints rather than creating single points of failure, thereby extending operational lifespan while maintaining manufacturability through standardized components.
2Stress or pressure
If high pressure operation is maintained for hydraulic fracturing, then the fluid delivery capability is sufficient, but structural failure occurs due to pressure stresses
Solution Approach 1:
The housing is segmented into multiple sections connected by standardized interfaces with fluid routing plugs. This segmentation allows each section to be optimized for specific pressure ranges and enables localized replacement of damaged sections rather than replacing the entire housing, thereby maintaining structural reliability under high pressure operations.
Solution Approach 2:
Different sections of the housing can be manufactured with locally optimized properties - such as wall thickness, material composition, and reinforcement features - based on the specific stress patterns and functional requirements of each section. This allows the structure to withstand high pressures while distributing stress concentrations through varied local geometries and material properties.
3Reliability
If the entire fluid end housing is replaced upon failure, then structural integrity is restored, but manufacturing costs and downtime increase
Solution Approach 1:
The modular housing design with standardized interfaces enables replacement of only the failed section rather than the entire housing. Each section can be independently manufactured and stocked, reducing manufacturing costs through economies of scale for standardized components and minimizing downtime by allowing rapid replacement of individual sections while maintaining structural integrity through the standardized connection interfaces.
4Productivity
If abrasive proppants are pumped through the fluid end, then hydraulic fracturing functionality is achieved, but wear and leakage occur reducing operational lifespan
Solution Approach 1:
The fluid routing plugs with internal bores create smooth, continuous flow paths through each section that minimize turbulence and abrasive wear on the housing walls. The segmented design allows these wear-resistant internal passages to be replaced independently if damaged, thereby maintaining fluid delivery capability while extending operational lifespan through localized maintenance.
Data Source
AI summary
A fluid routing plug for use with a fluid end section. The fluid end section being one of a plurality of fluid end sections making up a fluid end side of a high pressure pump. The fluid routing plug is installed within a horizontal bore formed in a fluid end section and is configured to route fluid between an intake and discharge bore. The fluid routing plug comprises a plurality of first and second fluid passages. The first and second passages do not intersect and are offset from one another. The first fluid passages are configured to direct fluid delivered to the horizontal bore from intake bores towards a reciprocating plunger. The second fluid passages are configured to direct fluid pressurized by the plunger towards a discharge bore.