Segmented Fluid End for High-Pressure Plunger Pumps
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Solution Overview
Problem
High-pressure plunger pumps used in the oil and gas industry face issues with erosion, wear, and fatigue when pumping two-phase slurries, leading to potential damage and costly repairs or replacements of the fluid end.
Innovation Solution
A segmented fluid end design featuring modular components with a strain bolt assembly and ring joint gasket system, allowing for precise alignment and reduced hoop stress, enabling individual module replacement without disrupting the entire assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional mono-block fluid end is used, then the structure is simple and manufacturing is easier, but the reliability decreases due to erosion, wear, and fatigue damage from two-phase slurries
Solution Approach 1:
The fluid end is divided into multiple separate modules (first fluid end module, second fluid end module, etc.) that can be independently manufactured and assembled. Each module has its own body, cover, and internal components, allowing the system to be segmented into manageable units that reduce overall stress and improve reliability while maintaining structural integrity.
2Ease of repair
If the fluid end is segmented into multiple modules, then the reliability improves and maintenance becomes easier, but the device complexity increases
Solution Approach 1:
The fluid end is divided into multiple separate modules (first fluid end module, second fluid end module, etc.) that can be independently manufactured and assembled. Each module has its own body, cover, and internal components, allowing the system to be segmented into manageable units that reduce overall stress and improve reliability while maintaining structural integrity.
Solution Approach 2:
Multiple fluid end modules are combined into a single integrated assembly that functions as one cohesive unit. The modules are connected through common interfaces and shared components, allowing them to operate together as a unified system while maintaining the benefits of individual modularity for maintenance and repair purposes.
3Ease of repair
If individual modules can be removed independently, then the ease of repair improves, but the manufacturing precision requirements increase to ensure proper alignment and sealing
Solution Approach 1:
A common interface structure serves as an intermediary element between adjacent fluid end modules. This interface includes aligned boreholes, sealing surfaces, and connection features that ensure precise alignment and proper sealing when modules are assembled or disassembled, facilitating easy repair while maintaining manufacturing precision requirements.
Data Source
AI summary
Disclosed is an improved segmented fluid end for high-pressure plunger pumps. One segmented fluid end includes one or more fluid end modules, each fluid end module including a body providing a plunger bore configured to receive a plunger therein and a discharge outlet in fluid communication with the plunger bore, wherein a pressurized working fluid may exit the body of each fluid end module via the discharge outlet, a discharge manifold having an elongate manifold body configured to be operatively coupled to each fluid end module, the manifold body providing a first end, a second end, a discharge bore extending between the first and second ends, and one or more discharge inlets that fluidly communicate with the discharge bore, and a ring joint gasket arranged between each discharge inlet of the discharge manifold and a corresponding discharge outlet of the one or more fluid end modules.