Segmented Fluid End Pump Assembly for High-Capacity Fracturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Hydraulic fracturing operations rely on diesel-powered equipment, which is expensive, environmentally unfriendly, and poses safety risks, while turbine generators are inefficient at lower loads and have large footprints, limiting their use in fracturing sites.
Innovation Solution
A segmented fluid end pump system that combines smaller metal blocks to form larger pumps, allowing for easier manufacturing, mobility, and replacement, and enabling higher power operation without reducing the life expectancy of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single large block is used for the fluid end, then the pump can provide sufficient pumping capacity, but it restricts the ability to mobilize replacement equipment and increases manufacturing complexity
Solution Approach 1:
The fluid end is divided into multiple segments that can be manufactured separately and assembled together. Each segment contains specific plungers and can be independently replaced or maintained, eliminating the need to replace the entire fluid end while maintaining sufficient pumping capacity through the combined segments.
2Object-affected harmful factors
If turbine generators are used to power fracturing operations, then environmental friendliness and safety improve, but the turbine footprint becomes too large for fracturing sites
Solution Approach 1:
The pump system is segmented into modular components including the fluid end, power end, and drive train that can be configured in compact arrangements. This modular segmentation allows the system to achieve high pumping capacity while maintaining a smaller overall footprint suitable for fracturing sites.
Solution Approach 2:
The pump design optimizes the spatial arrangement of segments and components in three-dimensional space, utilizing vertical and radial dimensions to reduce the horizontal footprint while maintaining adequate clearance for maintenance and operation.
3Ease of repair
If a segmented fluid end is used, then ease of replacement and mobility improve, but the complexity of coupling segments together increases
Solution Approach 1:
The fluid end is segmented into modular units with standardized interfaces. Each segment is designed with matching coupling features that simplify assembly through alignment pins, sealing interfaces, and bolt patterns, making replacement easier despite the segmented nature.
Solution Approach 2:
The coupling interfaces between segments are designed with universal features that can accommodate different segment configurations. Standardized flange patterns, sealing surfaces, and alignment features allow the same coupling mechanism to work across multiple segment combinations, reducing overall system complexity.
Data Source
AI summary
A fluid end for a fracturing pump includes a plurality of segments coupled together along a discharge axis, each segment of the plurality of segments having a plurality of suction bores. The fluid end also includes respective interfaces between segment pairs formed by adjacent segments of the plurality of segments, the interfaces coupling the segment pairs together. The fluid end further includes respective access areas proximate the respective interfaces, the respective access areas configured to provide access for mechanical couplings to join the segment pairs together.