Segmented Fluid Routing Plug for High-Pressure Pump Wear Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional fluid ends used in hydraulic fracturing operations are prone to structural failures due to high operational pressures, vibrations, and abrasives, leading to fluid leakage and short operational lifespans.
Innovation Solution
The fluid end is configured with multiple sections instead of a single housing, allowing for easier replacement of individual sections and reducing manufacturing costs. Each section has a single horizontal bore, eliminating high-stress areas and intersecting bores, and a fluid routing plug is used to direct fluid flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single housing is used in traditional fluid ends, then the structure can handle high operational pressures, but the structure is prone to wear and failure at high-stress areas and intersecting bores
Solution Approach 1:
The fluid end is divided into multiple sections, each with a single horizontal bore, replacing the traditional single housing with intersecting bores. This segmentation eliminates high-stress areas at bore intersections while maintaining pressure handling capability through the fluid routing plug that connects sections.
2Ease of manufacture
If multiple sections are used instead of a single housing, then manufacturing costs are reduced and replacement is easier, but the device complexity increases
Solution Approach 1:
The fluid end is divided into multiple sections that can be manufactured separately with simpler single bores instead of complex intersecting bores, reducing manufacturing difficulty and cost. The sections are then assembled using the fluid routing plug as a connecting component.
Solution Approach 2:
The fluid routing plug serves multiple functions: it routes fluid between sections, connects the sections together, and eliminates the need for complex intersecting bores. This multi-functionality reduces the overall complexity despite having multiple sections.
3Power
If traditional fluid ends operate at high pressures of 10,000-15,000 psi, then hydraulic fracturing operations are effective, but structural failures occur due to extreme pressures and vibrations
Solution Approach 1:
Dividing the fluid end into multiple sections with single bores eliminates stress concentration at bore intersections, allowing the structure to better withstand high pressures and vibrations without failure.
Solution Approach 2:
The high-pressure operation that previously caused failure at intersecting bores is now beneficial, as the segmented design with fluid routing plug directs pressure flows smoothly through horizontal bores without creating stress concentration points.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design significantly delays or avoids wear and failure points within the fluid end, leading to extended operational lifespans and reduced maintenance needs.
Implementation Method 1
a fluid routing plug is used to direct fluid flow
Data Source
AI summary
A fluid routing plug for use with a fluid end section. The fluid end section being one of a plurality of fluid end sections making up a fluid end side of a high pressure pump. The fluid routing plug is installed within a horizontal bore formed in a fluid end section and is configured to route fluid between an intake and discharge bore. The fluid routing plug comprises a plurality of first and second fluid passages. The first and second passages do not intersect and are offset from one another. The first fluid passages are configured to direct fluid delivered to the horizontal bore from intake bores towards a reciprocating plunger. The second fluid passages are configured to direct fluid pressurized by the plunger towards a discharge bore.