Fluid Routing Plug Structure for Erosion-Resistant Fluid Ends
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Solution Overview
Problem
Traditional fluid ends used in hydraulic fracturing operations experience frequent failures due to high operational pressures and erosion from proppants, leading to short 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 to reduce stress points and manufacturing costs, allowing for easier replacement of individual sections and using a fluid routing plug to manage fluid flow, which reduces stress and enhances durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single housing design is used for fluid ends, then the structure is simpler to manufacture, but stress concentrations increase leading to frequent failures under high pressure
Solution Approach 1:
The fluid end housing is divided into multiple separate sections (first section, second section, third section) that are assembled together using fastening systems. This segmentation distributes stress concentrations across multiple joints rather than creating weak points in a monolithic structure, thereby improving reliability while maintaining manufacturability through modular assembly
2Power
If conventional fluid ends operate under high pressure with proppants, then hydraulic fracturing effectiveness is achieved, but erosion from proppants causes frequent failures
Solution Approach 1:
Different sections of the fluid end housing are designed with specific local qualities - the first section receives fluid from the power end, the second section contains the fluid routing plug, and the third section directs fluid to the wellhead. This localized design allows each section to be optimized for its specific function and wear characteristics, enabling targeted replacement of eroded sections without replacing the entire housing
3Device complexity
If fluid ends are designed as single housing units, then component count is reduced, but maintenance and replacement become more complex
Solution Approach 1:
The housing is segmented into multiple sections that can be independently accessed and replaced. Fastening systems connect these sections, allowing maintenance personnel to remove and replace specific sections (such as the second section containing the fluid routing plug) without dismantling the entire housing assembly, thereby improving ease of repair
4Ease of repair
If modular sections are used instead of single housing, then component replacement is easier, but device complexity increases
Solution Approach 1:
The housing is divided into standardized modular sections (first, second, and third sections) that interface through consistent fastening systems. This segmentation enables easy replacement of individual sections while the standardized connection methods prevent the structural complexity from becoming unmanageable, achieving a balance between replaceability and complexity
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 between an intake and discharge bore. The fluid routing plug comprises a plurality of first and second fluid passages. The first and second passages do not intersect and are offset from one another. The first fluid passages are configured to direct fluid delivered to the horizontal bore from intake bores towards a reciprocating plunger. The second fluid passages are configured to direct fluid pressurized by the plunger towards a discharge bore.