Segmented Fluid End Assembly for High-Pressure Pump Erosion
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Solution Overview
Problem
Conventional fluid ends used in hydraulic fracturing operations experience frequent structural failures due to high operational pressures and erosion from proppants, leading to short operational lifetimes and costly replacements.
Innovation Solution
A high-pressure pump design featuring a modular fluid end assembly with interchangeable sections, where each section can be replaced independently, and wear-resistant components to mitigate erosion and extend operational life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fluid ends are used in hydraulic fracturing operations, then high pressure fluid delivery is achieved, but structural failures occur frequently due to high operational pressures and erosion from proppants
Solution Approach 1:
The fluid end is divided into multiple interchangeable sections (e.g., first section, second section, third section) that can be independently replaced. This segmentation allows worn or damaged sections to be replaced without replacing the entire fluid end, thereby extending operational lifetime while maintaining structural integrity under high pressure
Solution Approach 2:
The patent employs wear-resistant components and materials in the fluid end sections to withstand erosion from proppants and high operational pressures. These enhanced materials improve both reliability and structural strength by resisting the harsh operating conditions
2Reliability
If modular fluid end sections are used, then maintenance costs are reduced and operational life is extended, but device complexity increases
Solution Approach 1:
The fluid end is segmented into standardized interchangeable sections that can be independently replaced. This modular design extends operational life by allowing selective replacement of worn sections, while the standardization of these sections helps manage complexity through consistent connection interfaces and assembly procedures
3Reliability
If wear-resistant components are used, then durability against high pressures and abrasive proppants is enhanced, but manufacturing precision requirements increase
Solution Approach 1:
Wear-resistant components are integrated into the fluid end sections to enhance durability against high pressures and abrasive proppants. These specialized materials are manufactured with precise tolerances to ensure proper fit and function, accepting that higher manufacturing precision is required to achieve the desired durability and reliability
Data Source
AI summary
A high pressure pump. The pump comprises a fluid end assembly supported on a power end assembly. The power end assembly is modular and held together by a first set of stay rods. The fluid end assembly comprises a plurality of fluid end sections positioned in a side-by-side relationship. Each fluid end section comprises a housing made of multiple-piece construction. One or more pieces of the housing are configured to having a second set of stay rods attached thereto. The second set of stay rods interconnect the fluid end assembly and a power end assembly and a vertically offset from the first set of stay rods.