Modular Fluid Routing Plug for High-Pressure Abrasive Service
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Solution Overview
Problem
Conventional fluid ends used in hydraulic fracturing operations experience structural failures due to high operational pressures and abrasive proppants, leading to frequent replacements and maintenance issues.
Innovation Solution
A modular fluid end assembly design with a multi-piece housing construction, allowing individual sections to be replaced independently, and a fluid routing plug that enhances durability and reduces wear, combined with a torque nut and alignment dowels for secure attachment to the power end assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional fluid ends are used under high operational pressures and abrasive proppants, then they can deliver required fluid volumes, but they experience structural failures and frequent replacements
Solution Approach 1:
The fluid end is divided into multiple separable components including a barrel, plunger, valve assembly, and fluid routing plug. This segmentation allows individual components to be replaced independently based on wear patterns, extending overall system life while maintaining high fluid delivery capability.
Solution Approach 2:
The patent employs composite material construction with hardened surfaces on critical components exposed to abrasive proppants. The fluid routing plug and valve seats utilize wear-resistant composite materials that maintain structural integrity under high pressure while resisting abrasive degradation from proppants.
2Productivity
If high pressure operation is maintained for fracking, then fluid delivery effectiveness is improved, but structural failures increase
Solution Approach 1:
The design incorporates pressure distribution features and reinforced structural elements in advance of potential failure points. The barrel and fluid routing plug are designed with enhanced wall thickness and structural reinforcement to preemptively withstand high operational pressures without failure.
Solution Approach 2:
High-strength composite materials are used in components subjected to maximum pressure loads. The barrel and fluid routing plug utilize materials with enhanced tensile and yield strength to maintain structural integrity during high-pressure operation up to 15,000 PSI.
3Ease of repair
If modular design is implemented for easier maintenance, then replacement time is reduced, but device complexity increases
Solution Approach 1:
The fluid end is segmented into standardized modular components with consistent interface features. Each module (barrel, plunger, valve assembly, fluid routing plug) can be independently removed and replaced, significantly reducing maintenance time despite the increased number of parts.
Solution Approach 2:
The modular components are designed with universal interface standards that allow the same replacement parts to be used across different fluid end models. The fluid routing plug and valve assemblies serve multiple functions including fluid direction, pressure regulation, and wear protection, reducing the overall number of specialized components needed.
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 throughout the fluid end section.