Close-Coupled Frac Fluid Layout With Large-Bore Pump Feed
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Solution Overview
Problem
Current frac operations face challenges with the messy, unorganized, and potentially dangerous web of fluid and power lines across the frac site, which creates logistical issues, tripping hazards, and obstructs operations.
Innovation Solution
A close coupled fluid processing system that enables direct large bore connections between the fluid preparation system and the fluid distribution system, along with features for 3-axis alignment, angular alignment accommodation, cross communication, and automated connection systems to reduce the need for multiple hoses and manifolds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple individual fluid supply lines are used to connect each pump to the fluid preparation system, then flexibility of pump locations is improved, but the complexity and safety hazards of the system increase due to the web of lines across the site
Solution Approach 1:
The patent combines multiple individual fluid supply lines into a single large bore fluid connection that serves multiple pressurization units. The fluid distribution system includes a manifold structure that distributes fluid to multiple pumps through one consolidated connection point, eliminating the need for separate lines from the preparation system to each pump.
Solution Approach 2:
The system segments the fluid distribution function into two parts: a single large bore connection for the main fluid supply, and then individual distribution lines from the manifold to each pressurization unit. This segmentation allows the main connection to be simplified while maintaining flexibility at the point of use.
2Adaptability or versatility
If multiple individual fluid supply lines are used to connect each pump, then flexibility of pump locations is improved, but the system becomes more dangerous and obstructive on the frac site
Solution Approach 1:
Multiple fluid lines are merged into a single large bore connection, eliminating the messy web of hoses across the frac site. This consolidation removes tripping hazards and obstructions while maintaining the ability to service multiple pumps through the unified connection system.
3Device complexity
If large bore connections are used between fluid preparation system and fluid distribution system, then the web of lines is reduced, but alignment and connection reliability become more challenging
Solution Approach 1:
The patent introduces alignment features and connection mechanisms as intermediaries between the large bore connections. These include alignment rods, positioning fixtures, and automated connection systems that guide and secure the large diameter pipes together, making the connection process reliable despite the size and rigidity of the components.
Solution Approach 2:
The system replaces manual alignment and connection operations with automated mechanical systems. Automated positioning devices and mechanical alignment features eliminate the need for complex manual procedures, ensuring consistent and reliable connections between large bore pipes.
4Ease of operation
If traditional fluid manifolds with multiple human handleable supply lines are used, then fluid routing to selected pumps is enabled, but the lines create obstacles and are exposed to puncture or damage
Solution Approach 1:
The patent consolidates multiple exposed supply lines into a single large bore protected connection. The fluid distribution manifold is positioned and connected through one robust line, reducing the surface area exposed to potential damage while maintaining the ability to route fluid to selected pumps through the manifold's distribution network.
Data Source
AI summary
A close coupled processing system may include a fluid processing system for producing frac fluid for frac operations, a fluid distribution system for distributing the frac fluid to a plurality of pressurization units, and a large bore fluid connection connecting the fluid processing system and the fluid distribution system.