Sectional Fluid End Structure for Wear and Leakage Control
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Solution Overview
Problem
Traditional fluid ends used in hydraulic fracturing operations are prone to structural failures due to high operational pressures, vibrations, and abrasives, leading to fluid leakage and short operational lifespans.
Innovation Solution
The fluid end is configured with multiple sections instead of a single housing, eliminating internal chambers and reducing manufacturing costs and complexity. This design minimizes stress points and allows for easier replacement of individual sections rather than the entire unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional single-housing fluid end design is used, then manufacturing is simpler, but structural failure risk increases due to high operational pressures and stress points
Solution Approach 1:
The fluid end is divided into multiple independent sections (first section, second section, third section) that can be manufactured separately and assembled together. Each section has its own housing and internal components, allowing the complex high-pressure fluid end to be broken down into manageable units with fewer stress points each, thereby improving overall structural integrity while managing design complexity through modular construction
2Duration of action of stationary object
If traditional fluid end design is used, then initial manufacturing cost may be lower, but operational lifespan is short due to wear and failure from high pressures and abrasives
Solution Approach 1:
By segmenting the fluid end into multiple replaceable sections, the design allows individual sections to be replaced when worn rather than replacing the entire unit. This modular approach extends operational lifespan by enabling selective replacement of only the affected sections, while the manufacturing complexity is managed through standardized interfaces and repeated use of similar component designs across sections
Solution Approach 2:
The modular section design enables discarding only the worn or failed section while retaining and reusing the other sections. This extends the overall operational lifespan of the fluid end assembly by recovering and continuing to use the still-functional sections, reducing the frequency of complete unit replacement
3Reliability
If traditional fluid end design is used, then device structure is simpler, but fluid leakage occurs more frequently due to wear from high pressures and abrasives
Solution Approach 1:
Dividing the fluid end into multiple sealed sections with individual seals and packing arrangements improves leakage resistance by containing potential leaks to specific sections. If one section develops a leak, it can be isolated and replaced without affecting the other sections, thereby maintaining overall system reliability. The structural complexity is offset by using standardized sealing interfaces between sections
4Duration of action of stationary object
If traditional single-unit design is used, then replacement is simpler, but operational lifespan is short requiring frequent complete unit replacement
Solution Approach 1:
The fluid end is segmented into multiple independent sections with standardized interfaces, allowing individual sections to be replaced rather than the entire unit. This extends operational lifespan by enabling selective replacement of only worn sections while retaining functional ones. The replacement process is simplified through standardized mounting interfaces (such as flange connections) that allow quick detachment and reattachment of sections
Data Source
AI summary
A fluid end made of a plurality of fluid end sections positioned in a side-by-side relationship. Each fluid end section is made of a housing having a discharge bore and an intake bore formed therein. A fluid routing plug is installed within each housing and is configured to route fluid throughout the housing and between the discharge and intake bores. The fluid routing plug carries seals that engage sealing surfaces formed within the housing. A number of features, including the location of seals within bore walls and carbide inserts within valve guides, aid in reducing or transferring wear within each housing.