Modular Fluid End Sections to Eliminate Bore Stress Cracking
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Solution Overview
Problem
Traditional fluid ends used in hydraulic fracturing operations experience frequent failures due to high operational pressures and abrasive conditions, leading to structural issues such as cracking and erosion, resulting in short operational lifespans and the need for frequent replacements.
Innovation Solution
The fluid end is designed with multiple sections instead of a single housing, eliminating intersecting bores that are common stress points, allowing for easier replacement of individual sections and reducing manufacturing costs and complexity, while using a modular power end and advanced sealing systems to enhance durability and longevity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional single-housing fluid ends are used, then they can deliver high volumes of highly pressurized fluid, but they experience frequent failures due to cracking and erosion from high operational pressures and abrasive conditions
Solution Approach 1:
The fluid end is divided into multiple independent sections (first section, second section, third section) that can be manufactured separately and assembled together. Each section contains its own bores and can be replaced individually if damaged, preventing total failure of the entire fluid end and extending operational lifespan through modular replacement.
2Ease of manufacture
If intersecting bores are used in traditional fluid ends, then fluid can be routed through the housing, but these intersecting bores create common stress points that lead to cracking and failure
Solution Approach 1:
The fluid routing is segmented across multiple sections rather than using intersecting bores in a single housing. Each section has its own bores that do not intersect with other bores in the same section, eliminating stress concentration points while maintaining fluid routing capability through the modular assembly.
Solution Approach 2:
The problematic intersecting bore configuration is extracted from the design entirely. Instead of having bores intersect within a single housing, the fluid routing function is achieved through separate bores in separate sections that are assembled together, removing the stress concentration source.
3Ease of manufacture
If traditional fluid ends with intersecting bores are used, then they can route fluid through the housing, but the design complexity and manufacturing difficulty increase due to the need for precise intersecting bore alignment
Solution Approach 1:
The complex intersecting bore configuration is segmented into separate, non-intersecting bores distributed across multiple sections. Each section can be manufactured independently with simpler bore configurations, reducing manufacturing complexity while achieving the same fluid routing function through modular assembly.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design significantly delays or prevents wear and failure, extending the operational lifespan of the fluid end and reducing maintenance and replacement costs by allowing for section-by-section replacement and using lower-strength, less costly materials.
Implementation Method 1
the plunger is reciprocated within the bore to pressurize the fluid
Implementation Method 2
The seal prevents fluid from passing around the plunger during operation
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.