Segmented Fluid End Assembly With Wedge-Jointed Field Repair
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Solution Overview
Problem
Conventional fluid end assemblies in hydraulic fracturing pumps are prone to high maintenance costs, frequent downtime, and costly replacements due to wear and cracking, requiring complex and expensive repairs that cannot be performed in the field, leading to increased operational expenses and reduced efficiency.
Innovation Solution
A segmented fluid end assembly utilizing tapered wedges and slots for module attachment, allowing for easy assembly and disassembly with conventional tools, eliminating the need for external manifolds and tie rods, and enabling the use of partitioned monoblock segments for extended service life and reduced repair time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional mono block fluid end assemblies are used, then structural strength and integrity are maintained, but maintenance costs increase and downtime increases due to inability to perform field repairs
Solution Approach 1:
The fluid end assembly is divided into multiple replaceable segments (cylinder segments, manifold segments, valve segments) that can be independently removed and replaced in the field. Each segment is designed with external threading for direct attachment to the power end, allowing individual segment replacement without removing the entire assembly, thus enabling field repairs while maintaining overall structural integrity.
2Ease of manufacture
If conventional mono block fluid end assemblies are used, then manufacturing simplicity is maintained, but loss of time increases due to complete replacement requirements
Solution Approach 1:
The assembly is segmented into modular components that can be manufactured separately and assembled. When a segment wears or cracks, only that specific segment needs to be replaced rather than the entire assembly, dramatically reducing downtime while each segment maintains manufacturing simplicity through standardized external threading and attachment mechanisms.
Solution Approach 2:
Multiple segments are designed to be pre-manufactured and stored, allowing immediate replacement of failed segments without waiting for complex on-site fabrication or complete assembly removal, thus reducing downtime while maintaining ease of manufacture for each individual segment.
3Ease of repair
If conventional segmented fluid ends are used, then some repair capability is provided, but device complexity increases due to multiple attachment components
Solution Approach 1:
The fluid end is divided into segments that attach to the power end via simple external threading, eliminating the need for complex internal manifolds and multiple attachment components. Each segment is a self-contained unit with standardized threading, simplifying the overall attachment mechanism while maintaining ease of repair through simple segment replacement.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution reduces maintenance costs, extends the life of fluid end components, allows for field repairs of damaged segments, and minimizes downtime by enabling quick replacement of faulty segments without scrapping the entire assembly, thus lowering operational expenses and improving operational efficiency.
Implementation Method 1
The connector is received in the slots of the first and second modules so as to fix the first module to the second module
Implementation Method 2
A segmented fluid end assembly utilizing tapered wedges and slots for module attachment
Data Source
AI summary
A segmented fluid end assembly has a first module having a body with a first side surface and a slot formed therein and extending along at least a portion of the first side surface, a second module having a body with a first side surface and having a slot formed in the first side surface and generally aligned with the slot of the first module, and a connector received in the slots of the first and second module so as to fix the first module against the second module. The connector is in the nature of a wedge. Each of the slots has a generally dovetail configuration. The wedge has a generally hourglass cross-section. The wedge is engaged in friction-fit relationship in the slots.