Adjustable Fracturing Tree Layout for Straight-Flow Frac Iron
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Solution Overview
Problem
Conventional hydraulic fracturing systems are overly complex, leading to excessive setup time, labor costs, safety risks due to potential leak points, and decreased pumping efficiency, particularly in extreme conditions and for multiple extended-reach lateral wells.
Innovation Solution
An adjustable fracturing system featuring a fracturing tree with a straight fluid flow path and a zipper module that allows for swiveling and height adjustment of fluid conduits and blocks to align fluid passages, reducing complexity and enhancing connectivity between components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional frac iron is used to connect fracturing components, then connectivity between components is achieved, but device complexity increases and setup time increases
Solution Approach 1:
The system is divided into modular components (fracturing tree, zipper module, fluid conduit) that can be independently assembled and connected, replacing the monolithic conventional frac iron system. Each module has standardized connection interfaces that simplify assembly procedures.
Solution Approach 2:
The zipper module incorporates swivelable blocks and adjustable-height components that can be dynamically repositioned during setup and operation. This dynamic adjustability allows the system to adapt to different well configurations without requiring complete reassembly, significantly reducing setup time.
2Reliability
If conventional frac iron with multiple connection points is used, then connectivity is achieved, but safety risks increase due to potential leak points
Solution Approach 1:
Multiple connection functions are merged into integrated components. The zipper module combines multiple connection points into a single modular unit with unified sealing, reducing the total number of potential leak points while maintaining all necessary connectivity options.
Solution Approach 2:
The system incorporates redundant sealing mechanisms and pressure-relief features in advance of potential failure points. The integrated modular connections include built-in safety features that prevent catastrophic failures before they occur, cushioning against potential safety risks.
3Productivity
If conventional frac iron configuration is used, then component connection is achieved, but pumping efficiency decreases
Solution Approach 1:
The fluid conduit and zipper module are designed with dynamic positioning capabilities, allowing optimal alignment with the fracturing tree and wellbore orientation. This dynamic configuration minimizes flow resistance and maximizes pumping efficiency by eliminating unnecessary bends and misalignments in the fluid path.
Solution Approach 2:
The system utilizes vertical stacking of modular components in the height dimension, allowing horizontal fluid flow paths to be maintained while accommodating different wellhead positions. This dimensional arrangement optimizes fluid flow dynamics by keeping conduits as straight as possible.
Data Source
AI summary
A method and apparatus according to which a hydraulic fracturing fluid is communicated to a wellhead, the apparatus including a fracturing tree connected to the wellhead and into which the hydraulic fracturing fluid is adapted to flow, a fluid conduit connected to the fracturing tree and through which the hydraulic fracturing fluid is adapted to flow before flowing into the fracturing tree, the fluid conduit defining a straight fluid flow path, and a zipper module connected to the fluid conduit and out of which the hydraulic fracturing fluid is adapted to flow before flowing through the fluid conduit. The hydraulic fracturing fluid flows along the straight fluid flow path of the fluid conduit upon flowing out of the zipper module, and continues to so flow along the straight fluid flow path until the hydraulic fracturing fluid flows into the fracturing tree.