Segmented Fluid End Structure for High-Pressure Wear Reduction
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Solution Overview
Problem
Conventional fluid ends used in hydraulic fracturing operations experience frequent structural failures due to high operational pressures and abrasive conditions, leading to premature wear and leakage, which necessitates frequent replacement.
Innovation Solution
The fluid end is designed with multiple sections that can be replaced individually, eliminating stress points and allowing for the use of lower-strength, less costly materials, and features improved fluid routing and sealing mechanisms to reduce stress and extend lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If conventional fluid ends are used with high operational pressures, then high-pressure performance is achieved, but structural failures occur frequently due to stress and abrasion
Solution Approach 1:
The fluid end is divided into multiple separate sections (e.g., first section, second section, third section) that can be individually replaced. This segmentation eliminates stress concentration points at single-weld locations and allows selective replacement of worn sections without replacing the entire fluid end, thereby maintaining reliability under high pressure while reducing failure frequency.
Solution Approach 2:
Different sections of the fluid end can be manufactured from different materials optimized for their specific functions. For example, sections exposed to abrasive proppants can use more abrasion-resistant materials, while other sections use cost-effective materials. This local optimization improves overall reliability without requiring high-strength materials throughout the entire component.
2Reliability
If high-strength materials are used to prevent structural failures, then reliability improves, but manufacturing costs increase
Solution Approach 1:
By segmenting the fluid end into replaceable sections, the patent allows use of lower-strength, more cost-effective materials for sections not subject to high stress or abrasion. Only critical sections require high-strength or specialized materials, significantly reducing overall manufacturing cost while maintaining reliability where needed.
Solution Approach 2:
The segmented design enables replacement of only the worn or failed section rather than the entire fluid end. This approach uses cost-effective materials for individual sections that can be economically replaced when needed, rather than investing in expensive high-strength materials for the entire component.
3Strength
If the fluid end is designed as a single integrated component, then structural strength is maintained, but replacement frequency increases due to complete unit replacement
Solution Approach 1:
The fluid end is divided into multiple sections connected by coupling mechanisms (e.g., couplings with seals, flanged connections). Each section maintains structural integrity through proper connection design, while the segmented architecture enables replacement of individual sections rather than the complete unit, reducing replacement frequency and downtime.
Solution Approach 2:
The design allows recovery and retention of functional sections when only one section becomes worn or failed. Instead of discarding the entire fluid end, only the damaged section is replaced while reusable sections are retained, improving productivity by reducing replacement frequency.
4Stress or pressure
If conventional sealing mechanisms are used, then fluid sealing is achieved, but leakage occurs frequently under high-pressure and abrasive conditions
Solution Approach 1:
Different sealing mechanisms can be applied at different locations based on specific requirements. For example, packed boxes with multiple packing rings can be used at plunger rod connections where abrasion is severe, while simpler seals are used elsewhere. This localized optimization improves sealing reliability under high pressure and abrasive conditions.
Solution Approach 2:
The sealing design incorporates features that anticipate and prevent failure under high-pressure and abrasive conditions. Multiple packing rings, pre-compression springs, and protective shields are positioned beforehand to cushion against pressure spikes and abrasive particles, preventing leakage before it occurs.
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.