Segmented Fluid End for Hydraulic Fracturing Pumps

Solution Overview

Problem

Conventional fluid ends in hydraulic fracturing pumps, such as mono block and segmented designs, require extensive maintenance, leading to high costs and downtime due to wear and tear, necessitating frequent replacement and increased operational expenses.

Innovation Solution

A segmented fluid end design featuring interchangeable plunger manifolds, intake heads, and pressure heads allows for easy manufacturing, servicing, and repair, enabling field maintenance and extending the life of components through modular replacement and rotation of worn parts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional mono block or one piece segmented fluid end designs are used, then structural strength and integrity are maintained, but maintenance time and downtime increase significantly due to inability to perform field repairs

Engineering Contradiction:

Improveoperational continuityVSAvoidmaintenance downtime

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The fluid end is divided into multiple separable segments including plunger manifolds, intake heads, and pressure heads that can be independently removed and replaced. This segmentation enables field maintenance without requiring complete disassembly of the entire fluid end assembly, directly reducing maintenance downtime while maintaining structural integrity through proper segmentation.

Inventive Principle:

Principle #1Segmentation

2Ease of repair

If conventional one piece segmented fluid end designs are used, then manufacturing simplicity is maintained, but repairability deteriorates as entire assemblies must be removed and replaced

Engineering Contradiction:

Improvefield serviceabilityVSAvoidassembly structure

Core Design Contradiction:

Ease of repairVSDevice complexity

Solution Approach 1:

The fluid end is divided into multiple separable segments including plunger manifolds, intake heads, and pressure heads that can be independently removed and replaced. This segmentation enables field maintenance without requiring complete disassembly of the entire fluid end assembly, directly reducing maintenance downtime while maintaining structural integrity through proper segmentation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The intake head and pressure head are extracted as separate, independently replaceable components from the plunger manifold assembly. This extraction allows these wear-prone components to be quickly swapped in the field without removing the entire fluid end, significantly improving repairability while adding minimal structural complexity.

Inventive Principle:

Principle #2Taking out (Extraction)

3Productivity

If conventional fluid end designs are used, then initial manufacturing cost is lower, but operational costs increase due to frequent complete replacements

Engineering Contradiction:

Improvecost efficiencyVSAvoidmaterial waste

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The intake head and pressure head are extracted as separate, independently replaceable components from the plunger manifold assembly. This extraction allows these wear-prone components to be quickly swapped in the field without removing the entire fluid end, significantly improving repairability while adding minimal structural complexity.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of discarding entire fluid end assemblies when components wear, the design allows selective replacement of only the worn intake or pressure heads while retaining the serviceable plunger manifold and other components. This recovers valuable materials and reduces waste, improving cost efficiency over time.

Inventive Principle:

Principle #34Discarding and recovering

Data Source

PatentUS10184470B2Segmented fluid end

Publication Date: 2019.01.22 BARNETT JR W H

AI summary

A segmented fluid end is provided, the fluid end comprising a plurality of fluid end segments, each comprising a plunger manifold, intake head, and pressure head. In preferred embodiments, the fluid end comprises three fluid end segments (“triplex”) or five fluid end segments (“quint”). The plunger manifold comprises first and second mounting surfaces, each comprising a fluid opening. An intake head mounting flange is adapted to be removably coupled to the first mounting surface and a pressure head mounting flange is adapted to be removably coupled to the second mounting surface. The plunger manifold comprises a plunger mounting member comprising a plunger opening adapted to receive a plunger. The pressure heads are adapted for cooperative coupling to adjacent pressure heads, such that, when coupled, the pressure heads are in fluid communication with one another. Methods of replacing the fluid end segments, plunger manifolds, pressure heads, and intake heads are provided.