Modular Fluid End Assembly for High-Pressure Pump Wear
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Solution Overview
Problem
Conventional fluid ends used in hydraulic fracturing operations experience mechanical failure due to high operational pressures, vibrations, and abrasions, leading to structural damage, fluid leakage, and erosion, resulting in frequent replacements and high maintenance costs.
Innovation Solution
A modular high-pressure pump design with a fluid end assembly comprising multiple replaceable sections, each with a multi-piece housing and fastening system, allowing individual section replacement and improved durability under extreme conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If conventional fluid ends are used in hydraulic fracturing operations, then high pressure fluid delivery is achieved, but mechanical failure occurs due to high operational pressures, vibrations, and abrasions
Solution Approach 1:
The fluid end assembly is divided into multiple replaceable sections (first section, second section, third section) that can be independently replaced. Each section contains specific components (valves, seals, structural elements) that are susceptible to different types of damage. This segmentation allows targeted replacement of only the damaged section rather than the entire fluid end, improving reliability by enabling maintenance without complete replacement.
Solution Approach 2:
The patent employs different material properties and structural parameters for different sections to withstand specific operational stresses. For example, certain sections may use hardened materials resistant to abrasion from proppants, while other sections use materials with different mechanical properties to withstand high pressure or vibration. This parameter optimization reduces mechanical failure under extreme operating conditions.
2Power
If conventional fluid ends are used, then fluid pressurization is achieved, but structural damage and erosion occur leading to frequent replacements
Solution Approach 1:
The fluid end is segmented into multiple sections that can be independently inspected and replaced. This allows the operational life of the entire assembly to be extended by replacing only the worn sections while retaining functional sections, thereby increasing the overall duration of action without sacrificing pressurization capability.
Solution Approach 2:
Instead of discarding the entire fluid end when one section becomes damaged or eroded, the patent allows for recovery and continued use of undamaged sections. The damaged section is removed and replaced, while the remaining sections are retained and reused, maximizing the operational life of the fluid end assembly.
3Reliability
If modular design with replaceable sections is implemented, then maintenance frequency is reduced, but device complexity increases
Solution Approach 1:
While segmentation into multiple sections does increase structural complexity, it dramatically reduces maintenance frequency and operational downtime. The modular design allows quick replacement of specific sections without disassembling the entire fluid end, making the complexity worthwhile by improving reliability and reducing maintenance intervals.
Solution Approach 2:
The modular sections are designed with universal features that allow them to be interchanged in different positions or configurations. For example, sections can be designed with standardized connection interfaces and mounting patterns, allowing a single section design to serve multiple functions or be replaced in various locations, thereby reducing the overall complexity of the modular system.
Data Source
AI summary
A high pressure pump. The pump comprises a fluid end assembly supported on a power end assembly. The power end assembly is modular and held together by a first set of stay rods. The fluid end assembly comprises a plurality of fluid end sections positioned in a side-by-side relationship. Each fluid end section comprises a housing made of multiple-piece construction. One or more pieces of the housing are configured to having a second set of stay rods attached thereto. The second set of stay rods interconnect the fluid end assembly and a power end assembly and are vertically offset from the first set of stay rods.