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 McIntyre Benjamin Graham
Zachary Vick
 HALLIBURTON HT-2000 FRAC PUMP
VALVE SEAT MODIFICATION PROJECT

A project approved for AME 4553: Senior Design Practicum by

The University of Oklahoma

School of Aerospace and Mechanical Engineering
Spring 2011

BY

______________________________________ __________
Gerardo Conanan, Team Accountant Date

______________________________________ __________
Jason Edwards, Team Public Relations Liaison Date

______________________________________ __________
Benjamin Graham, Team Integrator Date

______________________________________ __________
Zachary Vick, Team Leader Date

ii
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 this
document 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. In
addition, 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
project. And finally, this report describes the team organization of the student team.

iii
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

iv
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

v
List of Tables
Table 1: Tasks and Subtasks ....................................................................................................10

vi
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 on
realistic 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 skills
including 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.

1
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. This
displacement 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. This
presents 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 known
that 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
valve seat are of little consequence, the properties of metal surrounding the valve seat are quite
important. An untrained individual might excessively heat the surrounding metals, causing
undesirable changes to material properties of these metals.

Due to the previously described barriers to on-site replacement of valve seats, the pump must
be moved to an offsite location where the valve seats can be removed by one trained in the
process. This causes delays on the well site that can lead to unnecessary expenses and
possibly client dissatisfaction with Halliburton services.

Valve seat failure is defined here as either displacement of the valve seat from its designed
position, or the inability of the valve seat to form an adequate seal with the valve plug. The first
failure mode has essentially been eliminated by the change in seat geometry described earlier.
However, the frequency of the second failure mode is such that the inability to replace the valve
seats in the field causes excess nonproductive time on the well site. The challenges described
here are such that it has become apparent that a method for on-site valve seat removal is
required.

2
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 the
Capstone project.

3
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.

4
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
well practiced in the process and we are confident that this process produces optimal results in
a time-efficient manner.

To better summarize the steps in our technical approach and to clarify our iterative process of
concept selection, we have created the flow chart given in the figure on the following page.
These steps are reflected in our Gantt chart, which can be viewed in the Schedule section of
this report.

5
 Create Plan of Action Final Report

Use techniques such Function

Generate Structures and Morphological
Charts to generate a number
Concepts of possible solutions. Manufacture a prototype of
Manufacture the selected concepts and
test comparing
and Test experimental results to
Prototype analytical and
computational.

Select the most promising

concepts for refinement.
Select
Promising
Concepts
Develop a report and
Mid-Semester presentation describing
project status and
Report remaining tasks.

Refine concepts based Create manufacturer

on results of numerical ready engineering
and analytical drawings.
Refine calculations. Decide whether to
Concepts Detailed Create Prototype Determine whether
the sponsor wishes a
Design prototype to
manufactured

Figure 1: Flow Chart for Technical Approach

6
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 equations
relate 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.

Figure 2: Numerical Technique

Equation (1) and Equation (2) were modified to reduce the number of variables present in the
code by restating the displacements in term of the original geometry and the radius of fit. For
each of the thin, constant radii cylinders, the pressure was multiplied by the differential surface
area to find a differential normal force. These differential forces were multiplied by a coefficient
of friction and summed using a left-hand Riemann Summation. This provided a total pulling
force required to remove the valve seat. We used a step size of 0.01 in. for a 1.25 in. valve seat
height, which resulted in 125 grid points. For more information, view the Mathcad code found in
Appendix C of this report.

7
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 valve
seat 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.

Figure 3: Radial Stresses Acting in a Press Fit

8
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 to
analytical answers to verify the results of the computer simulations.

Figure 4: Radial Displacement Acting in a Press Fit

9
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
Research and Generate Questions for Generate list of questions based on
2 6 days All
Halliburton findings
3 Thanksgiving Break 4 days All Review finding during the break
Travel to Duncan, OK to discuss
4 Meet with Halliburton 1 day All
answers to questions with Halliburton
Main focus of Fall 2010 semester,
5 Plan of Action 14 days All create strategic plan for project
execution during Spring of 2011
Addressed to sponsor and introducing
6 Cover Letter 6 days Jason Edwards the plan of action, original signature of
the team communicator
Project title, submitted to, submitted by
7 Cover Page 6 days Benjamin Graham
Halliburton, and date.
Typewritten names and original
8 Signature Page 6 days Zachary Vick
signature of each team member.
Summarize the important aspects of the
9 Executive Summary 4 days All
plan
Introduce the problem, provide
10 Introduction/Background 6 days Jason Edwards background information, and explain the
need to solve it.
Identify the nature and function of the
11 Desired End Product 6 days Benjamin Graham
end product desired.
List detailed design and function
12 Design Requirements 6 days Benjamin Graham
requirements and specifications.
Describe overall approach for the
problem. Identify major steps, and
13 Technical Approach 6 days Jason Edwards
develop a flow chart or sequence of
operation.
The Statement of Work to perform the
project is to be clearly laid out using
tasks and subtasks. The objectives and
requirements of all tasks and subtasks
14 Work Statement 4 days All are to be clearly stated. Divide up
technical responsibilities across entire
team by assigning task leadership and
task personnel evenly over all tasks and
subtasks.
Identify duration of each major task
15 Schedule 6 days Zachary Vick
using a Gantt chart
List items to be purchased and
16 Budget Statement 6 days Gerardo Conanan
approximate cost. Justify the budget.

10
 Identify/list facilities and resources
required for project completion. These
17 Facilities and Resources 6 days Gerardo Conanan include space, computer resources,
machining facilities, and other project
specific needs.

List team structure and posts taken by

each team member. Describe functions
18 Team Organization 6 days Gerardo Conanan
and products of each post taken by
each team member.

19 Christmas Break 22 days All

Theory was covered in previous
20 Review Press Fit Theory 22 days All courses. This information should be
reviewed by all team members.
This information should be reviewed by
21 Review Halliburton Provided Documents 22 days All
all team members.
This information was not covered in
22 Investigate Reciprocating Pump Theory 22 days All previous courses. This information
should be investigated.
23 Generate Concepts 9 days All
Team members should generate
24 Individually Generate Ideas 3 days All
original concepts.
The team will meet to compile and
25 Team Meeting, Idea Swap 3 days All
compare concepts generated
The team will agree upon most suitable
26 Select Best Concepts 3 days All
concepts for further refinements.
27 Refine Concepts 20 days All
Allows quantitative descriptions of
28 CAD Modeling 15 days Gerardo Conanan qualitative concepts for analysis using
FEA and CFD.
Allows the concepts to be analyzed for
29 FEA Analysis 15 days Jason Edwards
failure and deformation.
These will be used to verify results from
30 Theoretical Calculations 15 days Zachary Vick
FEA and CFD analysis.
This process included a compilation and
31 Concept Compilation 5 days Benjamin Graham comparison of the results for various
concept analyses.
32 Mid-Term Report 6 days All
Project title, submitted to, submitted by
33 Cover Page 6 days Benjamin Graham
Halliburton, and date.
Typewritten names and original
34 Signature Page 6 days Zachary Vick
signature of each team member.
Summarize the important aspects of the
35 Executive Summary 4 days All
plan
This details the goals needed for project
36 Goals 3 days All completion during the second half of the
semester.
Details the required tasks required to
37 Strategic Plan 3 days All complete the project on time and under
budget.
Introduce the problem, provide
38 Introduction/Background 6 days Jason Edwards background information, and explain the
need to solve it.
Identify the nature and function of the
39 Desired End Product 6 days Benjamin Graham
end product desired.

11
 List detailed design and function
40 Design Requirements 6 days Benjamin Graham
requirements and specifications.
Describe overall approach for the
problem. Identify major steps, and
41 Technical Approach 6 days Jason Edwards
develop a flow chart or sequence of
operation.
Identify duration of each major task
42 Schedule 6 days Zachary Vick
using a Gantt chart
List items to be purchased and
43 Budget Statement 6 days Gerardo Conanan
approximate cost. Justify the budget.
Identify/list facilities and resources
required for project completion. These
44 Facilities and Resources 6 days Gerardo Conanan include space, computer resources,
machining facilities, and other project
specific needs.
List team structure and posts taken by
each team member. Describe functions
45 Team Organization 6 days Gerardo Conanan
and products of each post taken by
each team member.
Presentation presenting current
46 Mid-Term Presentation 6 days All progress and strategic plan to all
parties.
Current progress and strategic is
47 Mid-Term Design Review 3 days All
reviewed by advisor and Halliburton.
48 Further Refine Concepts 20 days All
Allows quantitative descriptions of
49 CAD Modeling 15 days Gerardo Conanan qualitative concepts for analysis using
FEA and CFD.
Allows the concepts to be analyzed for
50 FEA Analysis 15 days Jason Edwards
failure and deformation.
These will be used to verify results from
51 Theoretical Calculations 15 days Zachary Vick
FEA and CFD analysis.
This process included a compilation and
52 Concept Compilation 5 days Benjamin Graham comparison of the results for various
concept analyses.
53 Detailed Design 6 days All
Produce detailed engineering drawings
54 Engineering Drawings 6 days All
required for product prototype.
55 Product Prototyping 6 days All To be discussed with Halliburton.
56 Final Report Rough Draft 6 days All
Project title, submitted to, submitted by
57 Cover Page 6 days Benjamin Graham
Halliburton, and date.
Typewritten names and original
58 Signature Page 6 days Zachary Vick
signature of each team member.
Summarize the important aspects of the
59 Executive Summary 4 days All
plan
This details the goals needed for project
60 Goals 3 days All completion during the second half of the
semester.
Details the required tasks required to
61 Strategic Plan 3 days All complete the project on time and under
budget.

Introduce the problem, provide

62 Introduction/Background 6 days Jason Edwards background information, and explain the
need to solve it.

12
 Identify the nature and function of the
63 Desired End Product 6 days Benjamin Graham
end product desired.
List detailed design and function
64 Design Requirements 6 days Benjamin Graham
requirements and specifications.
Describe overall approach for the
problem. Identify major steps, and
65 Technical Approach 6 days Jason Edwards
develop a flow chart or sequence of
operation.
Identify duration of each major task
66 Schedule 6 days Zachary Vick
using a Gantt chart
List items to be purchased and
67 Budget Statement 6 days Gerardo Conanan
approximate cost. Justify the budget.
Identify/list facilities and resources
required for project completion. These
68 Facilities and Resources 6 days Gerardo Conanan include space, computer resources,
machining facilities, and other project
specific needs.
List team structure and posts taken by
each team member. Describe functions
69 Team Organization 6 days Gerardo Conanan
and products of each post taken by
each team member.
Presentation presenting final progress
70 Final Presentation 6 days All
and strategic plan to all parties.
Final product is reviewed by advisor and
71 Final Design Review 3 days All
Halliburton.
Final report is edited as per instruction
72 Edit Final Report 3 days All
from advisor review.
Prepare poster for poster fair
73 Prepare Poster/Final Prototype 14 days All
presentation.
74 Completion of Project Deliverables 1 day All Submit all deliverables.

13
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.

14
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 seat
c. 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
shrink fit simulations.
b. ANSYS Workbench will be utilized to find estimated pulling force as well as verify
SolidWorks Simulation results.

17
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 tool
in 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.

18
Facilities and Resources
There are many facilities and resources that will need to be utilized to accomplish certain tasks
of 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 Lab
The 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. For
example, the team’s weekly progress reports and the electronic
record of all purchases and expenditures will be written in word.

For the distribution of documents, all documents will be saved as

PDFs. All word files will be stored the individual parties.

Microsoft PowerPoint This program will be used to create sides that will assist in the oral
presentation of the project.

Microsoft Project This program was used to create the Gantt Chart used in this
document.

Adobe Reader This program provides the ability to view all the documents that are
saved as PDFs.

Various Testing Any other software, provided by the University of Oklahoma, that
Software will assist in the analysis of the project (such as Finite Element
Analysis) will be used as seen fit.

19
 Internet – Email Email will be the main source of communication between parties.

Internet – Project’s This website provides the ability for all parties associated with the
Website project 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 despite
the 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: bmays@ou.edu
Greg Machinist
Williams Phone: (405) 325-4337
Email: gww@ou.edu

In addition to providing the assistance and knowledge of the building parts, Mr. Billy Mays will
also provide our team with a locker. A key to the team’s locker will be checked out through the
AME Office with approval from Mr. Mays.

20
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 capstone
program 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. To
make sure that all financial matters are capable and accounted for, he will be responsible of
making or authorizing all purchase orders.

The role of Team Public Relations Liaison was appointed to Jason Edwards. He will be in
charge of the information communication to all parties. During all collaborations, he is
responsible for making sure that the team and its facilities are maintaining elite appearance.
This will be done by exposing and promoting various aspects of the team’s progression of the
project. To capitalize on this responsibility, Jason has already created a Team Project Website
that can be accessed by all parties associated with the project. This website provides the ability
to view the current status of the project, the history of the project, and the future plans for the
project, excluding all proprietary information. Also, a discussion board was included in the
website to produce another source of communication.

With this team’s structure and capabilities, a successful outcome of the project can be
predicted.

21
References
[1] Edwards, K., & Mckee, R. (1991). Fundamentals of Mechanical Component Design. New
York: 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.

22
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 remove
the 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
locking? Does this refer to the press-fit itself or is there some other mechanism for
locking the seat in place?
Answer: This mechanism is referring to the press fit which locks the valve seat in place.
There is no other locking mechanism present.

7. Question: Could we obtain a sample of the valve seat material, or a valve seat that has
not been pressed into the pump housing?
Answer: Halliburton has provided us with both new and worn valve seats.

8. Question: What are the pump operating conditions? (pressures, temperatures, flowrates,
etc.)
Answer: The pump has a max operating pressure of 20,000psi and a maximum flow rate
of 23.9bpm. Other conditions are expected in the email delivery of technical information.

I
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 pressure
and 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 Duncan
Manufacturing 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 forces
required 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
place; the normal operation loads from the pump will complete the press-fit. We do not
have information on the current manufacturing processes at this point.

14. Question: Could we witness the process of valve seat removal with heat and hydraulic
seat puller, as described in project description?
Answer: We were able to witness a valve seat removal in progress. All team members
were present for the demonstration which was described to Dr. Chang. Photographs of
this process are expected from Halliburton via email.

15. Question: If no, could we have technical data from valve seat removal including heating
temperature and force required for removal?
Answer: No formal technical data exists. This process is performed by experienced by
technicians based purely on past experience removing valve seats.

II
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-2000
pump 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 readily
available 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.

21. Question: Is it important to keep broken valve seat intact when removing?
Answer: No, the worn valve seat is not reused or recycled in any way.

22. Question: What are the preferred software packages for document/file submission
(SolidWorks, ANSYS, MS Excel, etc.)?
Answer: SolidWorks is the preferred medium for CAD models while Microsoft Excel is
acceptable for calculations.

23. Question: What are material properties of the valve seat, fluid end, and jaw of the pulling
tool?
Answer: Justin Hurst will converse with Halliburton metallurgist and reply with specific
values.

III
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.

IV
Appendix B: Associated Photographs

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

Figure 6: Valve, Valve Seat, Valve Seat Retainer Exploded

V
Figure 7: Valve Seat Retainer Top View

Figure 8: Valve Seat Retainer Side View

VI
Figure 9: Valve Seat Side View

Figure 10: Valve Seat Top View

VII
Figure 11: Valve Plunger

VIII
Figure 12: Valve Seat and Valve Seat Retainer, Worn

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
Appendix C: Mathcad Code

XVI
 Discharge Valve Seat Press Fit Calculator
riVS  roVS  riFE 
0 0 0
Program Description
0 1.75 0 2.537 0 2.526
1 1.75 1 2.538 1 2.526
2 1.75 2 2.538 2 2.527 This section of the Mathcad Worksheet defines the inner and
3 1.75 3 2.539 3 2.527 outer radii of the valve seat as a function of vertical location
4 1.75 4 2.539 4 2.528 from the bottom of the valve seat. The inner radius of the
5 1.75 5 2.54 5 2.529 fluid end is defined similarly. Every value in the matrixes
6 1.75 6 2.541 6 2.529 represents a the i-th value of the height. For instance, the
7 1.75 7 2.541 7 2.53 zero-th location in the matrix represent a height of zero. The
8 1.75 8 2.542 8 2.53 first location in the matrix represents the radius at a height of
9 1.75 9 2.543 9 2.531
(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
10 1.75 10 2.543 10 2.532
continues to the final height of 1.25 in, giving 126 data point
11 1.75 11 2.544 11 2.532
for each radius.
12 1.75 12 2.544 12 2.533
13 1.75 13 2.545 13 2.534
14 1.75 14 2.546 14 2.534
15 1.75 15 2.546 15 2.535
16 ... 16 ... 16 ...

XVII
 This portion of the Mathcad Worksheet defines constants that
Constants: OutRadiusFE  4.5 will be used throughout the calculations. Notably, the outer
Evs  29000000 Efe  Evs radius of the fluid end is approximated as a constant. The
material properties of the valve seat and fluid end are
vs  0.285 fe  vs defined. These include Young's modulus and Poisson's ratio.
Also, the coefficient of friction between the press-fit interface
  0.15   3.142 is defined, and pi is also defined.

Solve Block: Given

( OutRadiusVS  R)  Evs  

 R2  InRadiusVS2 
  

This portion of the Mathcad Worksheet in the solve block that
solves for the radius of fit, rf, and the pressure of fit, pf, provided
( R P) 
 2 2
 R  InRadiusVS   vs
 with the constants: inner radius of the valve seat, outer radius of
the valve seat, inner radius of the fluid end, and outer radius of
( R  InRadiusFE)  Efe 
 
 OutRadiusFE2  R2 
 
 the fluid end. These equation are merely an application of
( R P) 
 2 
2
 OutRadiusFE  R 
fe

Lame's thick-walled pressure vessel theory and were obtained
from Fundamentals of Machine Elements by Bernard J.
Hamrock, Steven R. Schmidt, Bo O. Jacobson. This section
SOLVEInRadiusVS
( OutRadiusVSInRadiusFERP)  Find(RP) also defines the function SOLVE() that finds the radius and
pressure of fit if given the required geometry.

XVIII
Solution Loop: pfmatrix  i  0
while i  126
  roVSi  riFEi 

ans  SOLVEriVS roVS riFE 
  10000
 i i i 2 
pfout  ans
i 1 These two while loops define two matrices, pfmatrix
i i 1 which holds the values of the pressure of fit as a
i  51 if i 36
function of vertical location from the bottom of the valve
seat, and rfmatrix which holds the values of the radius
pfout
of fit as a function of vertical location from the bottom of
the valve seat. It accomplishes this by calling the
rfmatrix  i0
function SOLVE() and passing it geometry from the
while i  126
matrices defined at the top of the worksheet.
  roVSi  riFEi 

ans  SOLVEriVS roVS riFE 
  pfmatrix
 i i i 2 i

rfout  ans
i 0

ii 1
i  51 if i 36
rfout

XIX
Solution: 0 0
0 2.530842597063938 0 2.77·10 4
1 2.531469417071638 1 2.77·10 4
2 2.532096235730838 2 2.77·10 4
3 2.532723053043068 3 2.77·10 4
4 2.533349869009858 4 2.769·104
This section of the worksheet displays the the
5 2.533976683632733 5 2.769·104
radius of fit and pressure of fit matrices. This
6 2.534603496913217 6 2.769·104
rfmatrix  pfmatrix 
is the solution to the previously displayed
7 2.535230308852835 7 2.769·104
solution loop.
8 2.535857119453107 8 2.769·104
9 2.536483928715551 9 2.769·104
10 2.537110736641684 10 2.769·104
11 2.537737543233022 11 2.769·104
12 2.538364348491078 12 2.769·104
13 2.538991152417364 13 2.769·104
14 2.539617955013388 14 2.769·104
15 ... 15 ...

Force  i0
df  0
while i  125 It then solves for the required pulling force by summing:
ans  2   rfmatrix  0.01 pfmatrix  
i i
(the differential pressures) x (the differential areas) x (the
df  df  ans coefficient of static friction)
i i 1
df up the entire height of the valve seat. Mathematically, this
can be written as:

4
Force  6.072 10

XX