Segmented Fluid End Housing for Crack-Resistant Fracturing Pumps
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Solution Overview
Problem
Traditional fluid ends used in hydraulic fracturing operations experience frequent failures due to extreme pressures, vibrations, and abrasive conditions, leading to structural issues such as cracking and leakage, which reduces their operational lifespan and requires frequent replacement.
Innovation Solution
The design of a fluid end comprising multiple sections instead of a single housing, with each section having a single horizontal bore and a modular configuration, allowing for easier replacement of individual sections and reducing manufacturing costs and complexity, while also eliminating high-stress areas that contribute to fatigue cracks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single housing design is used for fluid end, then manufacturing is simpler, but stress concentration occurs leading to cracking and reduced lifespan
Solution Approach 1:
The fluid end housing is divided into multiple separate sections (first section, second section, third section) that are joined together. This segmentation eliminates stress concentration at intersections while allowing each section to be manufactured independently and assembled modularly, resolving the contradiction between manufacturing simplicity and structural reliability.
2Adaptability or versatility
If multiple bores intersect in the housing, then fluid routing is achieved, but high-stress areas are created causing fatigue cracks
Solution Approach 1:
Instead of creating intersecting bores in a single housing, the patent segments the housing into multiple sections where fluid routing is achieved through separate bores in each section and connection interfaces between sections. This eliminates the high-stress intersection zones while maintaining fluid routing capability.
Solution Approach 2:
Connection interfaces (flanges, bolts, gaskets) act as intermediaries between housing sections, providing fluid pathways without creating stress concentration points. The modular connection system allows fluid to pass between sections without requiring intersecting bores in a monolithic structure.
3Reliability
If the entire fluid end housing is replaced upon failure, then reliability is restored, but maintenance costs and downtime increase
Solution Approach 1:
The segmented housing design allows individual sections to be replaced independently rather than requiring replacement of the entire housing assembly. This modular approach reduces maintenance downtime and costs while restoring reliability by replacing only the failed component.
Solution Approach 2:
The patent enables selective replacement of damaged housing sections while retaining and reusing intact sections. This reduces waste and maintenance costs by recovering functional components rather than discarding the entire assembly.
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.