Fluid Routing Plug Passages for Modular Fluid End Durability
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Solution Overview
Problem
Conventional fluid ends used in hydraulic fracturing operations experience frequent failures due to extreme pressures, vibrations, and abrasive conditions, leading to structural issues such as cracking and leakage, which necessitate frequent replacement.
Innovation Solution
The design of a fluid end comprising multiple sections instead of a single housing, with each section having a single horizontal bore and a modular configuration, allowing for easier replacement of individual sections and reducing manufacturing complexity and cost, while eliminating high-stress areas that contribute to fatigue cracks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single housing design is used for fluid ends, then manufacturing is simpler, but the entire unit must be replaced when any section fails, increasing maintenance costs and downtime
Solution Approach 1:
The fluid end is divided into multiple independent sections, each with its own housing and internal components. When one section fails, only that specific section needs to be replaced rather than the entire fluid end assembly. This segmentation allows for targeted maintenance and reduces downtime while maintaining manufacturing efficiency through standardized section designs.
2Power
If conventional fluid ends operate under extreme pressures and abrasive conditions, then they can perform hydraulic fracturing functions, but they experience frequent failures due to cracking and leakage
Solution Approach 1:
By segmenting the fluid end into multiple sections, the stress and wear distribution across the structure is improved. Each section can be independently monitored and maintained, preventing catastrophic failures. The modular design allows for easier inspection and replacement of worn components without compromising the entire system's reliability under extreme operating conditions.
3Ease of repair
If modular sections are used instead of a single housing, then individual sections can be replaced easily, but device complexity increases
Solution Approach 1:
The fluid end is divided into multiple independent sections, each with its own housing and internal components. When one section fails, only that specific section needs to be replaced rather than the entire fluid end assembly. This segmentation allows for targeted maintenance and reduces downtime while maintaining manufacturing efficiency through standardized section designs.
Solution Approach 2:
The modular sections are designed with standardized interfaces and configurations that allow them to be universally interchangeable. Each section can potentially serve multiple functions or be used in different positions within the assembly, reducing the need for specialized components and simplifying the overall modular system despite the increased segmentation.
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.