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Halliburton Valve Seat Modification Project:Mid-Term Progress Report

AME 4553: Senior Design Practicum

March 8, 2011

Submitted to: Submitted by:

Dr. Kuang-Hua Chang Gerardo Conanan

Mr. Justin Hurst Jason Edwards

Mr Jason McInt re Benjamin Graham



Mr Jason McIntyre Benjamin Graham

HALLIBURTON HT-2000 FRAC PUMPVALVE SEAT MODIFICATION PROJECT

A project approved for AME 4553: Senior Design Practicum by

The University of OklahomaSchool of Aerospace and Mechanical Engineering

Spring 2011

BY

______________________________________ __Gerardo Conanan, Team Accountant Date

______________________________________ __Jason Edwards, Team Public Relations Liaison Date



Executive Summary

This report provides all parties with the strategic plan that this team intends to follow in

completion of this Capstone Project. This lists the major milestones required for project

completion and stresses the importance of the process used in concept generation and design.

This also includes a description of tasks that have been undertaken and the tasks that we are

planning on accomplishing in the near future.

In this report, the reader will find a detailed description of the problem statement and the

importance of addressing this issue for both Halliburton and the industry. Also included in thisdocument is a description of the design requirements for the final deliverable. This is a list of the

characteristics that the final product must exhibit to be considered a successful solution to the

issue at hand.

To create the desired product with the characteristics specified, we have created a technical

approach that documents our process and approach to this project. This section contains both a

written description, and more helpfully, a visual representation in the form of a flow chart. Inaddition, a description of the theoretical theories used to confirm the various simulations ran for

the problem at hand was provided.

In order to complete the project, a list of tasks and subtasks was compiled that steps through

the design process. Each task was then assigned to individual team member based on skill set

and strengths. These tasks were then scheduled such that preexisting deadlines will be met.

In accordance with the predetermined schedule and the evolving obstacles faced on a week-to-

week basis, a descriptions of the tasks completed and to be completed has been provided.

This report also details a cost estimate and resources necessary for the completion of the

j A d fi ll hi d ib h i i f h d



Contents

Executive Summary ................................................................................................................... iii List of Figures ............................................................................................................................. v List of Tables ............................................................................................................................. vi Goals ......................................................................................................................................... 1 Introduction/Background ............................................................................................................ 2 Desired End Product .................................................................................................................. 3 Design Requirements................................................................................................................. 4 Technical Approach ................................................................................................................... 5 Work Statement ........................................................................................................................10 Schedule ...................................................................................................................................14 Strategic Plan ...........................................................................................................................17 Facilities and Resources ...........................................................................................................19

CAD Lab ................................................................................................................................19 AME Machine Shop ...............................................................................................................20

Team Organization ...................................................................................................................21 References ...............................................................................................................................22 Appendix A: Technical Questions (March 8, 2011) ...................................................................... I Appendix B: Associated Photographs ........................................................................................ V Appendix C: Mathcad Code .................................................................................................... XVI



List of Figures

Figure 1: Flow Chart for Technical Approach ............................................................................. 6 Figure 2: Numerical Technique .................................................................................................. 7 Figure 3: Radial Stresses Acting in a Press Fit ........................................................................... 8 Figure 4: Radial Displacement Acting in a Press Fit ................................................................... 9 Figure 5: Valve, Valve Seat, and Valve Seat Retainer ................................................................ V Figure 6: Valve, Valve Seat, Valve Seat Retainer Exploded ....................................................... V Figure 7: Valve Seat Retainer Top View.................................................................................... VI Figure 8: Valve Seat Retainer Side View................................................................................... VI Figure 9: Valve Seat Side View ................................................................................................ VII Figure 10: Valve Seat Top View ............................................................................................... VII Figure 11: Valve Plunger ......................................................................................................... VIII Figure 12: Valve Seat and Valve Seat Retainer, Worn .............................................................. IX Figure 13: Valve Seat Worn ...................................................................................................... IX Figure 14: Valve Seat Removal with Heating 1 .......................................................................... X Figure 15: Valve Seat Removal with Heating 2 ......................................................................... XI

Figure 16: Valve Seat Removal with Heating 3 ........................................................................ XII Figure 17: Removed Valve Seat and Fluid End ....................................................................... XIII Figure 18: Pulling Tool Assembly ............................................................................................ XIV Figure 19: Pulling Tool Components ........................................................................................ XV



List of Tables

Table 1: Tasks and Subtasks ....................................................................................................10



Goals

The following presents the goals our Capstone Team wishes to achieve in this project:

1. Provide Halliburton with reasonable and feasible solutions to the problem at hand.

Multiple possible solutions will be presented to allow Halliburton flexibility in selecting a

final solution.

2. From the process of working with a leading entity in the energy field, the Capstone Team

wishes to increase our experience in a professional work environment while working onrealistic engineering problems

3. Through creating a final report and presentation, the Capstone Team wishes to convey

the importance of our Team’s work and the achievements accomplished through this

project.

4. The Capstone Team wishes to further develop our engineering problem solving skillsincluding the use of new software, reinforcement of engineering theory, and team

building skills.

5. Finally, the Capstone Team wished to broaden their experiences by introducing

ourselves to new technologies such as 3D printing and more in depth computer software

usage.



Introduction/Background

The Halliburton HT-2000 pump is a 2000 horsepower horizontal triplex pump used for fracturing

wells. This pump utilizes a two valve seat and plug configurations to control the pumping fluids

during the pumping process. At any given time during the pumping process, one of these valves

will be closed and the other open. This forces the pumped fluid to flow in the desired direction.

Due to the pressures that this valve seat must withstand (3000 psi), the valve seat geometry

utilizes a tapered press-fit design. This design was implemented in the 1960s-1970s to replace

the previous valve seat, which was often displaced by the large pump out forces. Thisdisplacement of the valve seat effectively caused pump failure. The replacement geometry has

solved this problem by allowing the valve seat to withstand the high pump out forces, but at the

cost of preventing field replacement of the valve seat.

The method of removing the previous valve seat utilized a hydraulic jack. This valve seat could

be removed in the field with only minor inconveniences. The new valve seat geometry, however,

requires that the inner portion of the valve seat be heated with a blowtorch prior to removal. Thispresents a number of problems for in-field valve seat replacement. The first problem presented

by this method of valve seat removal is the method of heating the valve seat. The blowtorch

necessarily utilizes an open flame. Due to the environment of a well site, using this method to

remove the valve seats would be quite dangerous and is prohibited. See Appendix B for picture

of new and used valve components.

Furthermore, the physics of the heating and cooling processes that occur within metals when

the heating is done by an untrained individual can create potential problems. It is well knownthat heating and cooling metals effects the grain sizes of the metals, these grain sizes then have

a significant impact on the material properties of the metal. While the properties of the damaged

l f li l h i f l di h l i



Desired End Product

Halliburton has requested that the Capstone team investigate different seat designs via

computer aided design (CAD) modeling, performing press fit calculations, and possible

prototype component development. The desired end product can include either a new valve

seat design or a new tool that would allow valve seats to be pulled easily in the field. This

should be possible without external heating which may alter the material properties of the

surrounding pump casing. The team is not limited to doing just one of these approaches. We will

attempt to solve the problem from both sides, possibly providing two alternate solutions.

Redesigning the removal tool would not require any modifications to the existing pump design.

This would avoid replacing all existing valve seat that are currently being used on field sites. A

new removal tool will need to be cheap and rugged enough to bring out to the field and work

with preexisting tooling. A new valve seat design should allow the seat to be removed in the

field without any additional tools using applying heat in the shop.

A final report will be submitted to Halliburton, the project sponsor, at the completion of theCapstone project.



Design Requirements

The redesigned valve seat and/or removal tool should allow Halliburton personnel to replace the

valve seat on site. The removal tool should contain the following characteristics.

Cost effectiveness : The removal tool should be inexpensive to produce and have a

sufficiently long life to justify its cost.

Durability : The removal tool will be used in a harsh working environment. Abrasive

materials such as sand, mud and various other factors will be present, and the tool will

be used repeatedly. Portability : The tool will need to be easily brought on site and stored by field personnel.

Ease of Use : Similar tools are already in use by field personnel. The tool should not

require additional training and should function with preexisting attachments.

Functionality : The tools should satisfy all required geometry such that both suction and

discharge valve seats can be removed.

Any recommended modification to the valve seat should provide the following requirements.

Usage : The valve seat should be able to withstand pump out forces.

Life : It should have at least the same life cycle as the current design.

Maintenance : The valve seat should be easily removed with the existing hydraulic ram or

other tools readily available on site.

Installation : Installation and removal of the valve seat should not cause additional

damage to the surrounding pump casing. Functionality : The valve seat cannot affect pump performance including operating

pressures and flow rates.

Cost effectiveness: The valve seat cost should be comparable to the current design



Technical Approach

In preparation for the start of the project in January 2011 and in tandem with the project

schedule, we have identified a list of crucial technical tasks that must be completed over the

course of the project. The major steps in our technical approach are as follows.

1. Create Plan of Action:

Develop a strategic approach for the project that can be followed of the course of

its execution.

2. Generate Concepts:Generate possible solutions to the valve seat problem based on initial research.

3. Refine Concepts:

Select the most promising concepts and further refine them so they can be

analyzed using FEA and/or CFD software.

4. Further Concept Refinement and Selection:

Select one or two concepts as potential solutions and refine the design with

further testing, analysis, and refinement as necessary.5. Detailed Design:

Create detailed engineering drawings showing the final concept geometry. These

should be sufficiently detailed to be sent to manufacturing upon completion for

prototyping.

6. Manufacture and Test Prototype:

If the sponsor desires it, we will manufacture a prototype and test it under realistic

conditions. This will likely require the use of sponsor facilities.

For concept selection, we utilize an iterative process that maximizes the options available while

minimizing excess delays due to major late stage changes in the concept design. Our team is

ll i d i h d fid h hi d i l l i



6

Create Plan of Action

Generate

Concepts

Select

Promising

Concepts

Refine

Concepts Detailed

Design

Manufacture

and Test

Prototype

Decide whether to

Create Prototype

Final Report

Mid-Semester

Report

Use techniques such Function

Structures and Morphological

Charts to generate a number

of possible solutions.

Select the most promising

concepts for refinement.

Develop a report and

presentation describing

project status and

remaining tasks.

Manufacture a prototype of

the selected concepts and

test comparing

experimental results to

analytical and

computational.

Determine whether

the sponsor wishes a

prototype to

manufactured

Create manufacturer

ready engineering

drawings.

Refine concepts based

on results of numerical

and analytical

calculations.

Figure 1: Flow Chart for Technical Approach



As the valve seat is pressed into the fluid end, utilizing an interference fit to withstand pump out

forces, press fit theory was reviewed for this application. Press fit theory is merely a specific

application of Lame’s thick-walled, cylindrical pressure vessel theory. The following equationsrelate the displacement of the hub and shaft in relation to the radial stress due to the pressure of

fit.

( ) (1)

(

) (2)

These equations are only valid for shafts and hubs with constant inner and outer radii. In the

valve seat and fluid end geometry, both the “hub” and “shaft” have variable inner and outer radii.

Therefore, in order to solve for pulling forces, these equations were numerically applied at many

locations along the height of the valve seat and fluid end section. Each of these height locations

was considered as a very thin, constant radii cylinder. A pressure and radius of fit were found

for each location. The following figure depicts the concept in an exaggerated form.



Additionally, finite element analysis (FEA) can be used to simulate press fits. Software such as

SolidWorks and ANSYS Workbench can be used to run press fit simulations, and the results of

these can be used to analyze the system. The radial stresses on the outer surface of the valveseat represent the pressure of fit. The displacement of the outer surface of the valve seat

represents the radius of fit.

The following figure illustrates how FEA can be used to obtain the pressure of fit. This figure

shows the predicted radial stress distribution in the valve seat due to a press fit. The FEA

software can average the radial stresses acting at nodes on the outer surface of the valve seat.

This can be used to find the pulling force required.



The following figure illustrates how FEA can be used to obtain the radius of fit. This figure shows

the predicted radial displacements that occur during the press fit. The predicted displacements

can be used to find the deformed radius, or the radius of fit. These can be compared toanalytical answers to verify the results of the computer simulations.

Figure 4: Radial Displacement Acting in a Press Fit



Work Statement

The following table details the required tasks and subtasks necessary for the completion of the

project. This ensures fair distribution of all responsibilities and required workload among team

members. During our analysis, we tried to take into account the difficulty of the task being

performed rather than relying solely on the time required to completed the task.

Table 1: Tasks and Subtasks

Task Name Duration Responsible Party Description

1 Receive Capstone Assignment 1 day All Received assignment from AME 4163

2Research and Generate Questions forHalliburton

6 days AllGenerate list of questions based onfindings

3 Thanksgiving Break 4 days All Review finding during the break

4 Meet with Halliburton 1 day AllTravel to Duncan, OK to discussanswers to questions with Halliburton

5 Plan of Action 14 days AllMain focus of Fall 2010 semester,create strategic plan for projectexecution during Spring of 2011

6 Cover Letter 6 days Jason Edwards Addressed to sponsor and introducingthe plan of action, original signature ofthe team communicator

7 Cover Page 6 days Benjamin Graham Project title, submitted to, submitted byHalliburton, and date.

8 Signature Page 6 days Zachary Vick Typewritten names and originalsignature of each team member.

9 Executive Summary 4 days All Summarize the important aspects of theplan

10 Introduction/Background 6 days Jason Edwards Introduce the problem, providebackground information, and explain theneed to solve it.

11 Desired End Product 6 days Benjamin Graham Identify the nature and function of theend product desired.



17 Facilities and Resources 6 days Gerardo Conanan

Identify/list facilities and resourcesrequired for project completion. Theseinclude space, computer resources,

machining facilities, and other projectspecific needs.

18 Team Organization 6 days Gerardo Conanan

List team structure and posts taken byeach team member. Describe functionsand products of each post taken byeach team member.

19 Christmas Break 22 days All

20 Review Press Fit Theory 22 days All Theory was covered in previouscourses. This information should be

reviewed by all team members.

21 Review Halliburton Provided Documents 22 days All This information should be reviewed byall team members.

22 Investigate Reciprocating Pump Theory 22 days All This information was not covered inprevious courses. This informationshould be investigated.

23 Generate Concepts 9 days All

24 Individually Generate Ideas 3 days All Team members should generateoriginal concepts.

25 Team Meeting, Idea Swap 3 days All The team will meet to compile andcompare concepts generated

26 Select Best Concepts 3 days All The team will agree upon most suitableconcepts for further refinements.

27 Refine Concepts 20 days All

28 CAD Modeling 15 days Gerardo Conanan Allows quantitative descriptions ofqualitative concepts for analysis usingFEA and CFD.

29 FEA Analysis 15 days Jason Edwards Allows the concepts to be analyzed for

failure and deformation.

30 Theoretical Calculations 15 days Zachary Vick These will be used to verify results fromFEA and CFD analysis.

31 C t C il ti 5 d B j i G hThis process included a compilation and

i f th lt f i



40 Design Requirements 6 days Benjamin Graham List detailed design and functionrequirements and specifications.

41 Technical Approach 6 days Jason Edwards

Describe overall approach for theproblem. Identify major steps, anddevelop a flow chart or sequence ofoperation.

42 Schedule 6 days Zachary Vick Identify duration of each major taskusing a Gantt chart

43 Budget Statement 6 days Gerardo Conanan List items to be purchased andapproximate cost. Justify the budget.


Identify/list facilities and resourcesrequired for project completion. Theseinclude space, computer resources,

machining facilities, and other projectspecific needs.



46 Mid-Term Presentation 6 days AllPresentation presenting currentprogress and strategic plan to allparties.

47 Mid-Term Design Review 3 days AllCurrent progress and strategic is

reviewed by advisor and Halliburton.

48 Further Refine Concepts 20 days All

49 CAD Modeling 15 days Gerardo Conanan Allows quantitative descriptions ofqualitative concepts for analysis usingFEA and CFD.

50 FEA Analysis 15 days Jason Edwards Allows the concepts to be analyzed forfailure and deformation.

51 Theoretical Calculations 15 days Zachary Vick These will be used to verify results fromFEA and CFD analysis.

52 Concept Compilation 5 days Benjamin Graham This process included a compilation andcomparison of the results for variousconcept analyses.

53 Detailed Design 6 days All



63 Desired End Product 6 days Benjamin Graham Identify the nature and function of theend product desired.

64 Design Requirements 6 days Benjamin Graham

List detailed design and function

requirements and specifications.

65 Technical Approach 6 days Jason Edwards

Describe overall approach for theproblem. Identify major steps, anddevelop a flow chart or sequence ofoperation.

66 Schedule 6 days Zachary Vick Identify duration of each major taskusing a Gantt chart

67 Budget Statement 6 days Gerardo Conanan List items to be purchased andapproximate cost. Justify the budget.


Identify/list facilities and resources

required for project completion. Theseinclude space, computer resources,machining facilities, and other projectspecific needs.



70 Final Presentation 6 days AllPresentation presenting final progressand strategic plan to all parties.

71 Final Design Review 3 days All Final product is reviewed by advisor andHalliburton.

72 Edit Final Report 3 days AllFinal report is edited as per instructionfrom advisor review.

73 Prepare Poster/Final Prototype 14 days AllPrepare poster for poster fairpresentation.

74 Completion of Project Deliverables 1 day All Submit all deliverables.



Schedule

The tasks required for the completion of this project were discussed in detail in the previous

section. The responsible parties were also identified.

In this section, the process and the sequence of events needed to complete the project are

highlighted. Estimated time requirements are also provided for each task and subtasks. The

estimated time requirements given in the previous section were superimposed over predefined

deadlines to create the following schedule.



Strategic Plan

In accordance with the schedule previously displayed, by this point in the progress, many of the

tasks have been completed. The following tasks have been completed as planned.

Generate Concepts:

The following concepts were generated in order to meet design requirements:

1. Diminish the taper design on the existing pump to decrease interference fit

a. Decrease outer radius uniformly, keeping the current taper angle

b. Decrease the taper angle, removing material from the top of the valve seatc. Increase the taper angle, removing material from the bottom of the valve seat

2. Add material to the pulling tool in locations of high stress concentrations, decreasing the

possibility of failure of the pulling tool

3. Design “heating cap” out of heat resistant and heavy material to heat the valve seat

without applying heat to the fluid end and without the use of an open flame

Refine Concepts:

The generated concepts were presented to our Capstone advisor and to our sponsors for

approval.

Create Analysis Tools:

The following tools were created to analysis of the press fit system.

1. Analytical can be completed with the use of a variable radius Mathcad worksheet press

fit calculator. This sheet was coded as discussed in the Technical Approach section.

2. FEA software packages were learned.a. SolidWorks Simulations Add-In tool was investigated and used to predict failure

modes in both the valve seat and pulling tool. This include static simulations and

h i k fi i l i



Plan Forward:

Using the foundation created during the first portion of this project, we are ready to begin testing

our generated concepts. This included creating new geometry for the valve seat and pulling toolin SolidWorks. These new geometries can be tested using the same methods and procedures

discussed earlier. Our testing criteria for new designs includes the following.

Valve Seat Criteria:

Anticipating pulling force for removal must be:

Greater than 36 thousand pounds to avoid being pumped out

Less than 60 thousand pounds to avoid failure of the pulling tool

Pulling Tool Criteria:

The new pulling tool geometry must meet the following criteria:

Be able to withstand 60 thousand pounds of pulling force

Be compatible with the current valve seat and fluid end geometries

Additionally, once the concepts have been tested and completely defined, new CAD models

should be produced as well as detailed engineering drawings for submission to Halliburton.

These models will also be used during the 3D printing process in order to create physical

representations our designs.



Facilities and Resources

There are many facilities and resources that will need to be utilized to accomplish certain tasksof the project. The University of Oklahoma’s Computer Aided Design Laboratory (CAD) and the

Aeronautical and Mechanical Engineering (AME) Machine Shop located in Felgar are the main

facilities that contain the resources that our team will use for this project.

CAD LabThe Cad Lab located in Felgar Room 146 contains all the computer software that will be used

for this project. A list of these programs and their relationship to the project is described below.

SolidWorks The current parts of the HT-2000 Pump were developed in

SolidWorks. Therefore, our team must use this program to view

and analyze the parts provided to us by Halliburton. Also, to stay

consistent, we are going to use this program to develop new

design possibilities for the components.

In addition to developing the parts, various functions of this

program can be used to test the applicability of the new design,

such as motion works.

Microsoft Excel This program will be used to store and analyze various data points

collected from experimental analysis.

Microsoft Word All documents for this project will be created in this program. Forexample, the team’s weekly progress reports and the electronic

record of all purchases and expenditures will be written in word.



Internet – Email Email will be the main source of communication between parties.

Internet – Project’sWebsite

This website provides the ability for all parties associated with theproject to get up to speed quickly since the site will contain the

current status of the project, the history of the project, and the

future plans for the project, excluding all proprietary information.

There will also be a discussion board on the website for another

source of communication.

Team’s Shared Drive This is the main drive that will be used to store all of our team

documents. Also, this will be the method of transferring documents

between Dr. Chang and the project team.

AME Machine Shop

The AME Machine Shop, located in the basement of Felgar Hall, will be the main source for

tools, devices, and machines that will be needed to create any part or component desired for

the project. All reasonable construction of parts can be accomplished through the shop despitethe inexperience of operating certain machines. Mr. Billy Mays and Mr. Greg Williams, along

with the Shop Team, will provide assistance and knowledge for any machine available in the

shop. These two men’s contact information is listed below.

Billy Mays AME Shop Supervisor

Phone: (405) 325-4337

Email: [email protected]

Greg

Williams

Machinist

Phone: (405) 325-4337

Email: [email protected]



Team Organization

Each member of the team was assigned a specific role for the Senior Design Practicum Project.Each role consisted of specific responsibilities that would need to be accomplished throughout

the duration of the project to ensure successful results.

The role of Team Leader was appointed to Zachary Vick. He will be in charge of managing the

progression of the project, the execution of the project, and the coordination of comprehension

of the project status for all parties involved with the project. In regards to the completion of the

project, he will be responsible for making sure that all the engineering principles and capstoneprogram policies are followed. Also he will establish goals and develop plans to achieve them.

In regards to the project’s sponsor, he will be responsible for making sure that all legal matters

are taken into account and followed.

The role of Team Integrator was appointed to Benjamin Graham. He will be in charge of

documenting the progression of the project by assembling a report containing all written inputs

from team members. In regards to the success of the project, he will be responsible for ensuring

high-quality material from all the team members. This will guarantee great documentation of the

progression of the project. In regards to all the parties involved with the project, he will be

responsible for ensuring quick and timely communication from the project team. This will

guarantee that the status of the project is always dynamic.

The role of Team Accountant was appointed to Gerardo Conanan. He will be in charge of

making sure that the project is delivered within the specified budget constraints by recording all

purchases and expenditures electronically and providing budget statements for all reports. Tomake sure that all financial matters are capable and accounted for, he will be responsible of

making or authorizing all purchase orders.



References

[1] Edwards, K., & Mckee, R. (1991). Fundamentals of Mechanical Component Design . NewYork: McGraw-Hill.

[2] “Student Handbook AME 4553.” Web. 09 Dec. 2010.

<http://www.coe.ou.edu/ame/capstone/student_handbook.htm>

[3] Maddox, W. E. Mechanical Research and Development. (1966). “Tapered Valve Seat for

3-3/8” HT-400.” Halliburton Company .

[4] Maddox, W. E. Mechanical Research and Development. (1968). “Tapered Valve Seat for

HT-400 Pumps.” Halliburton Company .

[5] Morris, R. Mechanical Research and Development. (1970). “No. 5, No. 4, and No. 3 HT-400

Frac Valves.” Halliburton Company .



Appendix A: Technical Questions (March 8, 2011)

1. Question: Is the seat shape the same as given by Halliburton Patent # 5,226,445? If so,would it be acceptable for us to change this shape in the new design?

Answer: This patent application does apply to this pump; however, the seat geometry

has undergone significant changes since the patent application.

2. Question: Would it be acceptable to recommend changes to other pump components

other than the valve seat (casing, plug, etc.)?

Answer: Changes should only be made to the valve seat itself or the tool used to removethe valve seat.

3. Question: Could we obtain all available information on the HT-2000 pump? (data sheets,

pump spec sheets, pump performance curves, part engineering drawings, etc.)

Answer: Halliburton has agreed to provide us with this information. They will send it

electronically via email.

4. Question: What are the materials used in the pump? (valve seat, pump housing, valve

head, etc.)?

Answer: The seat material is carburized AISI 4130 while the fluid end material is AISI

4330.

5. What are the component dimensions?

Answer: These dimensions will be emailed to the team by Halliburton in the CAD model

and the associated engineering drawings.

6. Question: The valve seats “utilize a locking taper press-fit design.” What is meant by

l ki ? D hi f h fi i lf i h h h i f



9. Question: What sorts of loads are typically acting on the valve seat during normal

operation? Is the seat experiencing impact loading?

Answer: The types of loads experienced by the valve seat were described as pressureand impact loading. The pressure on the valve seat is approximately 3000psi.

10. Question: We assume that cyclic loading is a major factor here. What is the expected life

of this product?

Answer: This largely depends on the fluid pumped, but the typical operating time

between seat changes was stated as 20-30 hours.

11. Question: What is the pumps main purpose? Is it used for frac-ing, cementing, or

pumping drilling mud? (The main concern here is erosion of valve seat from pumping

fluid.)

Answer: This pump is used solely for frac-ing purposes.

12. Question: Could we visit a manufacturing and assembly facility in order to see pumps

manufactured/assembled, esp. the current press-fit process for seating the valve seat?

(Online research found that these pumps may be manufactured in the DuncanManufacturing Center in Duncan, OK.)

Answer: We were able to visit the pump manufacturing center in Duncan, OK and were

allowed to see the valve seat removal process. The current press-fit process consists of

lightly hammering the valve seat in place, the normal operation loads from the pump will

complete the press-fit.

13. Question: If no, could we have the technical data from the press-fit, including forcesrequired for installation? Could we also have a detailed description of the manufacturing

processes used in the production of this part?

Answer: The current press-fit process consists of lightly hammering the valve seat in



16. Question: The purpose of the project is to provide a valve seat design that could be

easily pulled in the field. Is this this is due to valve seat failure or need to remove the

valve seat to repair other components of the pump?Answer: This is due entirely to erosion of the valve seat from the pumped fluid causing

valve seat failure.

17. Question: If due to valve seat failure, could we have copies of failure reports, pictures of

failed valve seats, or samples of failed valve seats?

Answer: We were able to obtain both picture of the failed valve seats and samples of

failed valve seats as well as those of new valve seats.

18. Question: If due to valve seat failure, what are the typical failure modes? Is vibration an

issue? (Seats can crack from thermal stress, thermal shock, or mechanical stress. The

seats may also be eroded by the pumping fluid.)

Answer: This is due entirely to erosion of the valve seat from the pumped fluid causing

valve seat failure.

19. Question: Could we ask operations personnel for experiences working with the HT-2000pump and their thoughts on the valve seat removal process?

Answer: We were able to speak with shop technicians experienced in the valve seat

removal process. Due to the complete lack of technical data on the process, the

information provided here was completely qualitative.

20. Question: The project description asks for a valve seat that could easily be removed by

operations personnel without needing heat or additional tools. What tools are readilyavailable to operations personnel?

Answer: Halliburton desires a valve seat or new tool that can be used to remove the

valve seat using the hydraulic ram



24. Question: What are the pulling capabilities of the tool?

Answer: The ram is rated for 60 tons. The limit is the failure of the jaws.

25. Question: How is the pulling tool assembled and used?

Answer: Justin Hurst will investigate providing the Capstone Team with a video of the

pulling tool in use and possibly a SolidWorks assembly.



Appendix B: Associated Photographs

Figure 5: Valve, Valve Seat, and Valve Seat Retainer



Figure 7: Valve Seat Retainer Top View



Figure 9: Valve Seat Side View



Figure 12: Valve Seat and Valve Seat Retainer, Worn



Figure 14: Valve Seat Removal with Heating 1



Figure 16: Valve Seat Removal with Heating 3



Figure 19: Pulling Tool Components



Appendix C: Mathcad Code



XVII

Discharge Valve Seat Press Fit Calculator

Program Description

This section of the Mathcad Worksheet defines the inner and

outer radii of the valve seat as a function of vertical location

from the bottom of the valve seat. The inner radius of the

fluid end is defined similarly. Every value in the matrixes

represents a the i-th value of the height. For instance, the

zero-th location in the matrix represent a height of zero. The

first location in the matrix represents the radius at a height of

(1 x 0.01) in. The second location location in the matrix

represents the radius at a height of (2 x 0.01) in. This

continues to the final height of 1.25 in, giving 126 data pointfor each radius.

riVS

0

0

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

1.75

1.75

1.75

1.75

1.75

1.75

1.75

1.75

1.75

1.75

1.75

1.75

1.75

1.75

1.75

1.75

...

roVS

0

0

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

2.537

2.538

2.538

2.539

2.539

2.54

2.541

2.541

2.542

2.543

2.543

2.544

2.544

2.545

2.546

2.546

...

riFE

0

0

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

2.526

2.526

2.527

2.527

2.528

2.529

2.529

2.53

2.53

2.531

2.532

2.532

2.533

2.534

2.534

2.535

...



XVIII

This portion of the Mathcad Worksheet defines constants that

will be used throughout the calculations. Notably, the outer

radius of the fluid end is approximated as a constant. The

material properties of the valve seat and fluid end are

defined. These include Young's modulus and Poisson's ratio.

Also, the coefficient of friction between the press-fit interface

is defined, and pi is also defined.

Constants:

Solve Block:

This portion of the Mathcad Worksheet in the solve block that

solves for the radius of fit, rf , and the pressure of fit, pf , providedwith the constants: inner radius of the valve seat, outer radius of

the valve seat, inner radius of the fluid end, and outer radius of

the fluid end. These equation are merely an application of

Lame's thick-walled pressure vessel theory and were obtained

from Fundamentals of Machine Elements b y Bernard J.

Hamrock, Steven R. Schmidt, Bo O. Jacobson. This section

also defines the function SOLVE() that finds the radius and

pressure of fit if given the required geometry.

OutRadiusFE 4.

Evs

2900000 Efe

Evs

vs

0.28 fe

vs

0.1 3.142

Given

OutRadiusVS R( ) Evs

R P( )R

2

InRadiusVS

2

R

2InRadiusVS

2

vs

R InRadiusFE( ) Efe

R P( )

OutRadiusFE2

R2

OutRadiusFE2

R2

fe

SOLVEInRadiusVS OutRadiusVS InRadiusFE R P( ) Find R P( )



XIX

Solution Loop:

These two while loops define two matrices, pfmatrix

which holds the values of the pressure of fit as a

function of vertical location from the bottom of the valve

seat, and rfmatrix which holds the values of the radius

of fit as a function of vertical location from the bottom of

the valve seat. It accomplishes this by calling the

function SOLVE() and passing it geometry from the

matrices defined at the top of the worksheet.

pfmatrix i 0

an s S OLV EriVSi

roVSi

riFEi

roVSi

riFEi

2 10000

pf outi

ans1

i i 1

i 51 i 36if

i 126while

pf out

rfmatrix i 0

ans SOLV EriVSi

roVSi

riFEi

roVSi

riFEi

2 pfmatrix

i

rf outi

ans0

i i 1

i 51 i 36if

i 126while

rf out



XX

Solution:

This section of the worksheet displays the theradius of fit and pressure of fit matrices. This

is the solution to the previously displayed

solution loop.

It then solves for the required pulling force by summing:

(the differential pressures) x (the differential areas) x (the

oefficient of static friction)

up the entire height of the valve seat. Mathematically, this

an be written as:

rfmatrix

0

0

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

2.530842597063938

2.531469417071638

2.532096235730838

2.532723053043068

2.533349869009858

2.533976683632733

2.534603496913217

2.535230308852835

2.535857119453107

2.536483928715551

2.537110736641684

2.537737543233022

2.538364348491078

2.538991152417364

2.539617955013388

...

pfmatrix

0

0

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

42.77·10

42.77·10

42.77·10

42.77·10

42.769·10

42.769·10

42.769·10

42.769·10

42.769·10

42.769·10

42.769·10

42.769·10

42.769·10

42.769·10

42.769·10

...

Force i 0

df 0

ans 2 rfmatrixi

0.01 pfmatrixi

df df ans

i i 1

i 125while

df

Force 6.072 104