Lower Stress, Longer Life a Winning Formula for TLS 10 Fluid Ends

January 1, 2013

Gardner Denver recently unveiled its latest innovation in fluid ends featuring its proprietary Falcon Technology.

In its new TLS 10 fluid ends, Gardner Denver’s application of Falcon Technology includes the development of a twist-in retainer that does not require special alignment to the valve cover, as the gun-sight design of its counterpart does, but maintains compatibility with both. The result is lower stress while extending the life of the fluid end.

Fluids ends, the most critical parts of well-service pumps, are subjected to extreme stress and, as a result, are the most common source of failure. According to Gregory Hash, Gardner Denver’s director of engineering, the TLS 10 fluid end was a timely solution for a customer that had experienced early failures with the fluid ends on their pressure pumps, with expensive delays compounded by long lead times for replacement fluid ends. 

In response to the customer’s needs, “We were able to build a better mousetrap,” Hash said.

The company’s TLS 10 carbon steel fluid end, based on test results using Gardner Denver’s refined finite-element stress analysis techniques and backed by 40 years of experience in fluid-end design, has been proven to last up to three times longer within well-service pumps  than fluid ends made by their competitors. Gardner Denver also credits its Falcon Technology with making the TLS 10 fluid ends more user-friendly.

The TLS 10 fluid end is also available in stainless steel, where performance test results show it has four to six times the life of carbon steel versions from Gardner Denver’s competitors. Hash said a growing number of GD’s customers have opted for stainless steel fluid ends in spite of their higher initial cost due to the expected lower cost of ownership over the life of the fluid end. This has affirmed Gardner Denver’s commitment to improving its aftermarket service.

Based on the success of the TLS 10, Gardner Denver is integrating its Falcon Technology throughout its fluid-end lines. At the same time, the company has expanded its production facilities in Tulsa, Oklahoma; Fort Worth, Texas; and Altoona, Pennsylvania to accommodate increased aftermarket demand.

In total, Gardner Denver has increased its dedicated aftermarket space from 42,000 square feet to more than 200,000 combined square feet. In Oklahoma, the Tulsa plant underwent two transformations over a two-year period, doubling its footprint from 40,000 square feet to today’s 80,000 square feet. As a result, Gardner Denver’s pressure pumping and fluid-end capacity increased fourfold. Moreover, the expanded facility lowers cost and significantly reduces lead times for customers.

 In Texas, Gardner Denver has expanded and modernized its Fort Worth facility to house 70,000 square feet of aftermarket services. To design the aftermarket facility, Gardner Denver personnel joined forces with select customers in a shared team effort.   Gardner Denver chose to build its newest facility in Altoona in order to respond to the company’s rapid growth in the pressure pumping industry. The 70,000-square-foot operation will manufacture fluid ends and repair pressure pumps, by providing on-site service to its customers in the Marcellus and Utica Shale region.

 All three facilities feature efficient layouts and are equipped with state-of-the-art machines for greater capacity and flexibility. In addition, work cells at the facilities follow lean principles to improve workflow, resulting in quicker service time and less downtime for customers.

“We have invested heavily in the aftermarket to provide better support to our customers,” Hash said.

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