Pump Housing Inline Valve Stress Reduction
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Solution Overview
Problem
Conventional high-pressure plunger pumps in oil field operations face issues with fluid energy loss due to non-linear fluid paths and high stress concentrations at bore intersections, leading to fatigue cracks and reduced pump life, especially when handling heavy slurry fluids.
Innovation Solution
The fluid end housing design features a co-linear arrangement of suction and plunger bores, a rectangular or square cross-section for the plunger bore with generously sized filleted corners, and an optional tapered oblong discharge port to reduce stress concentrations and maintain flow area, resulting in a flat bore intersection with zero pitch.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional Cross-Bore block design is used, then the housing structure is simple and easy to manufacture, but stress concentrations occur at bore intersections leading to fatigue cracks and reduced reliability
Solution Approach 1:
The housing is divided into multiple bores (suction bore, discharge bore, plunger bore) that are strategically positioned and oriented to minimize stress concentrations. Each bore is segmented to perform specific functions while maintaining structural integrity at intersection points.
Solution Approach 2:
The invention transitions from a conventional 3D intersecting bore configuration to a co-linear arrangement where the suction bore and plunger bore are aligned in the same dimension. This dimensional reconfiguration eliminates the stress concentration problems associated with multi-dimensional bore intersections.
2Use of energy by moving object
If conventional 90-degree bore intersections are used, then manufacturing is straightforward, but fluid energy is lost due to sharp turns requiring smaller supercharging pumps
Solution Approach 1:
The co-linear bore arrangement creates an equipotential flow path where fluid moves in a straight line from the suction bore through the plunger bore to the discharge bore. This eliminates the kinetic energy losses associated with directional changes, maintaining fluid energy throughout the pumping cycle.
3Stress or pressure
If large intersecting curved areas are created at bore intersections, then stress distribution improves, but the intersection area becomes too large reducing pump efficiency
Solution Approach 1:
The invention extracts the problematic intersecting curved areas from the design by eliminating the intersections entirely. The co-linear bore configuration removes the need for large curved transition zones, maintaining both stress distribution integrity and pump efficiency.
4Reliability
If co-linear bore arrangement is implemented, then fluid energy is maintained and stress at intersections is reduced, but the housing design becomes more complex
Solution Approach 1:
The suction bore and plunger bore are merged into a co-linear arrangement, creating a unified flow path that eliminates stress concentration points. This merging of bore functions achieves both reliability improvement and design simplification by reducing the number of intersection points.
Data Source
AI summary
A plunger pump fluid end housing assembly comprising: a fluid end housing, multiple plungers, a single in-line suction valve and seat corresponding with each said plunger, a discharge valve and seat corresponding with each said plunger; wherein axis of said suction valve and seat are parallel with said plunger, and the suction manifold is positioned to feed the fluid chamber opposite the power end of the fluid end. Plunger chamber of said fluid end housing is square or rectangular in cross section with large fillets at corners and flats between said fillets. Said flats are approximately equal in width to radii of said fillets.