Arched Flexible Pipe Connections for High-Pressure Frac Lines
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Solution Overview
Problem
Existing well fracture systems face challenges with rigid pipe connections that cause erosion, corrosion, leaks, and cluttered workspaces due to vibrations and complex arrangements, leading to inefficiencies and safety hazards.
Innovation Solution
The use of self-supporting, arched flexible pipes that form a smooth pathway between pump trucks and manifolds, reducing vibrations and pressure loss while providing a clutter-free workspace by elevating the pipes above ground, allowing flexible pump truck arrangements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid pipe connections are used to deliver high-pressure fluid from pump trucks to manifolds, then structural strength and pressure containment are improved, but pipe erosion, corrosion, and leaks increase due to vibrations and complex arrangements
Solution Approach 1:
The patent replaces rigid pipe connections with flexible hose connections that have a multi-layer construction including an inner tube, reinforcement layers, and an outer cover. This flexible structure absorbs vibrations and movements, preventing the erosion, corrosion, and leaks that plague rigid pipe systems while maintaining the necessary pressure containment for high-pressure fluid delivery.
Solution Approach 2:
The flexible hose employs a composite multi-layer construction with different materials serving specific functions: an inner tube for fluid containment, reinforcement layers (such as braided or woven patterns) for strength and pressure resistance, and an outer cover for protection. This composite structure achieves both the strength needed for pressure containment and the flexibility needed to prevent vibration-induced failures.
2Reliability
If rigid pipes are arranged in complex configurations to connect pump trucks and manifolds, then connection reliability is improved, but workspace clutter and safety hazards increase
Solution Approach 1:
The flexible hose connection allows dynamic positioning of pump trucks relative to the manifold. Instead of requiring fixed, complex rigid pipe arrangements, the flexible hose accommodates movements and repositioning of equipment, enabling workers to clear walkways and improve workspace accessibility while maintaining reliable fluid delivery connections.
3Stress or pressure
If rigid pipe systems are installed to ensure stable high-pressure fluid delivery, then pressure containment is improved, but assembly time and operational efficiency decrease
Solution Approach 1:
The flexible hose connection system is divided into separable components that can be independently handled and connected. The hose assemblies can be pre-prepared and then quickly connected to the manifold and pump trucks using coupling mechanisms, dramatically reducing assembly time compared to welding or flanging rigid pipes, while maintaining the capability to deliver high-pressure fluids.
Data Source
AI summary
A system may a first frac tree having a first inlet, a manifold having a first fluid outlet, and a first flexible pipe. The first flexible pipe may include a first end of the first flexible pipe coupled to the first fluid outlet; a second end of the first flexible pipe is coupled to the first inlet; and a first outer shell rotationally mounted on the manifold, the first outer shell extends from the manifold a length between the first end and the second end. The first outer shell may extend from the manifold a length between the first end and the second end. Additionally, the first outer shell is curved to have a radius to arch the first flexible pipe from the manifold to the frac tree.