Modular Fluid End Sections for Wear and Stress Reduction
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Solution Overview
Problem
Conventional fluid ends used in hydraulic fracturing operations experience frequent failures due to extreme pressures, vibrations, and abrasives, leading to short operational lifespans and high maintenance costs.
Innovation Solution
The fluid end is configured with multiple sections instead of a single housing, eliminating internal chambers and reducing manufacturing costs and complexity. This design minimizes stress points and allows for easier replacement of individual sections, enhancing durability and longevity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single housing design is used, then manufacturing is simpler, but stress points increase and durability decreases
Solution Approach 1:
The fluid end is divided into multiple separate sections (first section, second section, third section) instead of a single housing. Each section can be manufactured independently and assembled together, reducing stress points and improving durability while allowing for easier replacement of individual worn sections.
2Ease of manufacture
If internal chambers are included, then fluid routing is integrated, but manufacturing complexity and cost increase
Solution Approach 1:
The design eliminates internal chambers from the main housing by using separate, simpler sections that are assembled together. This segmentation approach reduces manufacturing complexity and cost while achieving the same fluid routing functionality through the modular configuration of sections.
3Reliability
If the entire fluid end is replaced upon wear, then reliability is restored, but operational time is lost and costs increase
Solution Approach 1:
The fluid end is segmented into multiple replaceable sections. When wear occurs in one section, only that specific section needs to be replaced rather than the entire fluid end assembly. This reduces downtime and replacement costs while maintaining operational reliability.
Solution Approach 2:
Individual worn sections are discarded and replaced with new or refurbished sections, while the remaining functional sections are retained and reused. This extends the overall operational life of the fluid end system and reduces waste.
Data Source
AI summary
A fluid end comprising a plurality of fluid end sections positioned in a side-by-side relationship. Each fluid end section is releasably attached to a connect plate. Each connect plate is attached to a power source using a plurality of stay rods. Each fluid end section comprises a housing in fluid communication with a pair of intake manifolds and a discharge conduit. A fluid routing plug is installed within each housing and is configured to route fluid throughout the housing. A plunger is installed within stuffing box attached to each housing. A number of features, including the location of seals within bore walls and carbide inserts within valve guides, aid in reducing or transferring wear.