Fracturing Pump Fluid End With Internal Plunger Passage to Reduce Bore Stress
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Solution Overview
Problem
Conventional fluid ends used in hydraulic fracturing operations experience premature failure due to high operational pressures, corrosion, and erosion, leading to frequent replacements and maintenance issues.
Innovation Solution
The design of an in-line fluid end with a single horizontally positioned bore eliminates intersecting bore intersections, reduces manufacturing costs, and allows for the use of lower strength materials, incorporating a sleeve and retainer system with replaceable seals and hardened inserts to enhance durability and longevity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fluid ends are used with intersecting bores, then fluid delivery function is achieved, but stress concentrations occur leading to premature failure
Solution Approach 1:
The fluid end is divided into separate functional sections with a single continuous bore running through it, eliminating the intersecting bore intersections that cause stress concentrations. This segmentation of the bore structure removes the problematic intersection points while maintaining fluid delivery functionality.
Solution Approach 2:
The intersecting bore intersections are completely removed from the design. The patent extracts the problematic geometric features (intersecting bores) that create stress concentrations, leaving only a single continuous bore path that eliminates these stress points while still achieving the required fluid delivery function.
2Reliability
If high strength materials are used to withstand high pressures, then durability is improved, but manufacturing cost increases
Solution Approach 1:
The fluid end structure is segmented into sections with a single continuous bore, eliminating intersecting bores. This design change reduces stress concentrations, allowing the use of lower strength materials that are easier and less expensive to manufacture while still withstanding the required operating pressures.
Solution Approach 2:
The stress distribution parameters are changed by eliminating intersecting bores, which reduces peak stress concentrations. This parameter change in the stress profile allows the material strength requirement to be reduced, enabling the use of more cost-effective materials that are easier to manufacture.
3Power
If conventional fluid ends operate under extreme pressures, then hydraulic fracturing function is achieved, but erosion and corrosion cause premature failure
Solution Approach 1:
The intersecting bore intersections that are susceptible to erosion and corrosion are completely removed from the design. By extracting these vulnerable geometric features, the patent eliminates the primary locations where erosion and corrosion would initiate, thereby extending operational lifespan while maintaining high pressure capability.
Solution Approach 2:
The fluid path is segmented into a single continuous bore rather than intersecting bores. This segmentation eliminates the intersection points that are most vulnerable to erosion and corrosion from proppants and abrasive fluids, allowing the fluid end to withstand extreme pressures for longer operational periods.
Data Source
AI summary
A fluid end for use with a power end. The fluid end comprises a plurality of fluid end sections positioned adjacent one another. Each section includes a single horizontally positioned bore. A plunger is installed within the bore and includes a fluid passageway. Low-pressure fluid enters the bore through the plunger and high-pressure fluid exits the fluid end through an outlet valve installed within the bore. The intake of low-pressure fluid within the fluid end section is regulated by an inlet valve installed within the plunger. Low-pressure fluid enters the plunger through an inlet component attached to both the plunger and an inlet manifold.