Modular High-Pressure Pump Assembly for Stress and Wear Reduction
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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 lifespans and increased maintenance needs, while traditional power ends also face issues like uneven lubrication and stress concentration, resulting in reduced reliability and efficiency.
Innovation Solution
A modular fluid end assembly with multiple sections and improved lubrication systems, featuring a single horizontal bore design, offset fluid end configuration, and enhanced sealing mechanisms to reduce stress points and extend component lifespan, along with a modular power end design to mitigate stress concentration and improve lubrication distribution.
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 frequent failures occur due to high operational pressures, corrosion, and erosion from proppants
Solution Approach 1:
The fluid end is divided into multiple independent sections (first fluid end section, second fluid end section, etc.) that can be separately replaced. This segmentation allows only the worn or damaged section to be replaced rather than the entire fluid end, thereby extending overall system lifespan while maintaining high pressure operational capability
Solution Approach 2:
The patent modifies the structural parameters of the fluid end sections, including the configuration of bores, valves, and sealing mechanisms. These parameter changes optimize the sections for withstanding high operational pressures while reducing susceptibility to corrosion and erosion from proppants
2Power
If traditional power ends are used, then engine power is delivered, but uneven lubrication and stress concentration occur, resulting in reduced reliability
Solution Approach 1:
The power end is segmented into modular components including separate crankshaft assemblies, connecting rod assemblies, and piston assemblies. This modular segmentation enables independent optimization of each component's lubrication pathways and stress distribution, improving overall reliability while maintaining power delivery
Solution Approach 2:
The patent introduces improved lubrication systems that act as intermediaries between moving parts. Enhanced lubrication galleries and oil delivery mechanisms ensure uniform lubrication distribution across all moving components, reducing friction and wear while maintaining engine power output
3Ease of manufacture
If single-piece fluid end housing is used, then manufacturing is simplified, but stress concentration occurs at critical points leading to frequent failures
Solution Approach 1:
The fluid end housing is divided into multiple castable sections that can be manufactured separately and then assembled. This segmentation eliminates stress concentration points that would occur in single-piece constructions, as each section can be optimized for its specific stress profile. The sections are joined using robust flanged connections that maintain structural integrity
Solution Approach 2:
Multiple fluid end sections are merged through flanged connections to form a complete fluid end assembly. This merging approach maintains the manufacturing advantages of modular construction while achieving the structural integrity needed to withstand high pressures without stress concentration
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.