Central Pump Area Layout for Hot-Swapping Fracturing Pumps
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Solution Overview
Problem
In unconventional reservoirs, maintaining high pressure pumps for hydraulic fracturing and injection operations results in significant downtime, increasing operational costs and reducing production efficiency due to the need for frequent maintenance shutdowns.
Innovation Solution
A pumping system and method for hot swapping pumps at a well site, allowing continuous operations by isolating, disconnecting, and replacing pumps using a pump swap tool and isolation devices, with automated or semi-automated processes to minimize downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pumps are maintained using traditional shutdown methods, then pump reliability is improved, but productivity deteriorates due to operational downtime
Solution Approach 1:
The system segments the pump maintenance process by isolating individual pumps from the manifold using isolation devices, allowing one pump to be maintained while others continue operating. This divides the system into independent operational units that can be serviced separately without shutting down the entire system.
Solution Approach 2:
The system performs preliminary actions by pre-positioning replacement pumps and preparing isolation devices before maintenance is needed. The isolation devices are already installed and configured, allowing for rapid pump replacement without extensive preparation during the maintenance window.
2Reliability
If pumps are maintained frequently, then reliability is improved, but loss of time increases due to maintenance windows
Solution Approach 1:
The system maintains continuous useful action by ensuring that while one pump is being maintained, other pumps continue to perform the pumping function. The manifold is designed to redistribute flow among remaining operational pumps, eliminating idle time and maintaining production continuity throughout the maintenance process.
Solution Approach 2:
The isolation devices serve as intermediaries between the pumps and the manifold, enabling rapid disconnection and reconnection of pumps during maintenance. These intermediary components facilitate quick pump swaps by providing pre-configured connection points that eliminate the need for complex disassembly and reassembly operations.
3Device complexity
If pumps are arranged in a compact configuration, then device complexity is reduced, but ease of operation deteriorates due to limited access for pump swapping
Solution Approach 1:
The system addresses accessibility issues by transitioning from a two-dimensional compact layout to a three-dimensional configuration using vertical manifolds and elevated pump positions. This dimensional change allows pumps to be arranged in a space-efficient manner while maintaining adequate access through vertical clearance and side-approach pathways for maintenance personnel and equipment.
Data Source
AI summary
The disclosure presents systems and methods for hot swapping pumps at a wellsite while minimizing the impact to the pumping operations. As one pump is swapped out, such as for maintenance, the remaining pumps in the set of pumps at the wellsite can continue pumping operations. In some aspects, the pumps can be arranged around a central open area where the manifold pipes are located on the outside perimeter. This arrangement allows for a pump moving apparatus to remove and locate pumps at various positions around the perimeter while minimizing movement and minimizing the time the pump moving apparatus spends off of matting. The pump moving apparatus can be shielded with a protective barrier to protect the equipment or user from discharges from other pumps that are under high pressure.