Modular Fluid End Assembly for High-Pressure Pump Reliability
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Solution Overview
Problem
Conventional fluid ends used in hydraulic fracturing operations experience frequent failures due to high operational pressures, corrosion, and erosion from proppants, leading to short operational lifespans and the need for frequent replacements.
Innovation Solution
A modular fluid end assembly with multiple sections, each with a single horizontal bore and no intersecting bores, reducing stress points and manufacturing costs, and featuring a fluid routing plug with angled passages to manage fluid flow and minimize wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fluid ends are used with intersecting bores, then fluid flow is achieved, but stress concentration and structural failures increase due to high operational pressures
Solution Approach 1:
The fluid end is divided into multiple separate sections (first section, second section, third section) that are joined together. Each section has its own bore, eliminating the need for intersecting bores in a single housing. This segmentation distributes stress across multiple components and eliminates stress concentration at bore intersections, thereby improving structural reliability under high operational pressures.
2Reliability
If modular fluid end sections are used, then stress distribution and reliability improve, but device complexity increases due to multiple components
Solution Approach 1:
Multiple fluid end sections are joined together using coupling mechanisms (such as flanges, bolts, or tapered connections) to form a complete fluid end assembly. This merging of separate sections achieves the benefits of stress distribution and improved reliability while maintaining a functional integrated structure that can be assembled and disassembled as needed.
3Productivity
If proppants are delivered with pressurized fluid, then hydraulic fracturing effectiveness improves, but erosion and maintenance needs increase
Solution Approach 1:
The interior surfaces of the fluid end sections are designed with specific local qualities such as hardened coatings, smooth finishes, or erosion-resistant materials in areas where proppants are most likely to cause wear. This local enhancement of surface properties protects against erosion from proppants while maintaining the ability to deliver highly pressurized fluid effectively.
Data Source
AI summary
A high pressure pump comprising a fluid end mechanically coupled to a power end. The power end is modular and comprises a crankshaft section, a crosshead section, and a connector section coupled together by a first set of stay rods. The fluid end comprises a plurality of fluid end sections positioned in a side-by-side relationship. Each of the plurality of fluid end sections are attached to the power end using a plurality of second set of stay rods.