Monolithic Fluid Cover Sealing for High-Pressure Pump Fluid Ends
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Solution Overview
Problem
High-pressure and high-power operations in hydraulic fracturing pumping systems lead to damage and reduced usability of fluid end components, resulting in operational downtime and increased costs due to rugged environments and cyclic stress.
Innovation Solution
A monolithic fluid cover with a first and second portion, where the first portion is received in the open end portion of the fluid chamber and the second portion is mechanically connected to the fluid end block body, providing enhanced sealing and alignment, and constructed from metallic, polymeric, or composite materials to resist wear and failure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If traditional fluid end components are used in high-pressure hydraulic fracturing systems, then the pumping system can operate at high pressure and power, but the components become damaged and unusable due to cyclic stress and water hammer effect, reducing service life
Solution Approach 1:
The fluid cover is divided into two distinct portions: a first portion that seals the open end portion of the fluid chamber, and a second portion that is mechanically connected to the fluid end block body. This segmentation allows each portion to be optimized for its specific function, improving overall reliability under high-power operations
Solution Approach 2:
The first portion of the fluid cover is installed in advance to seal the fluid chamber before the second portion is mechanically connected to the fluid end block body. This preliminary sealing action prevents fluid leakage and protects the chamber from damage before full assembly is complete
2Device complexity
If traditional fluid covers are used, then assembly is simpler, but sealing effectiveness is reduced leading to increased leakage
Solution Approach 1:
The fluid cover is segmented into a first portion for sealing and a second portion for mechanical connection. This division allows the first portion to focus exclusively on sealing effectiveness while the second portion handles structural attachment, preventing leakage without significantly increasing overall complexity
Solution Approach 2:
The first portion of the fluid cover acts as an intermediary sealing element between the fluid chamber and the external environment. This intermediate sealing layer prevents direct exposure of the fluid chamber to leakage paths, effectively blocking fluid escape
3Ease of manufacture
If conventional fluid end blocks are used, then manufacturing is less complex, but maintenance cycles increase due to wear and failure in rugged environments
Solution Approach 1:
The fluid cover portions are constructed from metallic, polymeric, or composite materials that combine the advantages of different material types. This composite construction provides wear resistance and failure resistance in rugged environments while maintaining manufacturability through established material processing techniques
Solution Approach 2:
The fluid cover components are pre-assembled with sealing portions installed before final mechanical connection to the fluid end block body. This preliminary assembly ensures proper sealing is established before the component is subjected to operational stresses, reducing wear and extending maintenance intervals
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
The monolithic fluid cover enhances durability, reduces maintenance cycles, minimizes leakage, and extends the service life of fluid end block assemblies by providing a robust seal and resisting the water hammer effect, thus reducing operational downtime and costs.
Implementation Method 1
The first portion may be sealably engaged with the fluid end block body
Implementation Method 2
resisting the water hammer effect
Data Source
AI summary
Embodiments of a high-pressure, high power, reciprocating positive displacement fluid pumping system and methods are included. The system may include a high-pressure, high power, reciprocating positive displacement pump including a pump plunger, a fluid end block assembly, and a fluid cover. The fluid end block assembly may include a fluid end block body, a suction port, a discharge port, a pump bore positioned in and extending through the fluid end block body, and a fluid chamber positioned in the fluid end block body and in fluid communication with each of the suction port, the discharge port, and the pump bore. The fluid chamber has an open end portion, and the pump plunger may be positioned to move in the pump bore to pressurize one or more fluids in the fluid chamber. The fluid cover includes a monolithic body having a first portion and a second portion, the first portion being received in the open end portion and sealably engaged with the fluid end block body, the second portion being mechanically connected to the fluid end block body.