Compact Dual Header Manifold Layout with Hot Isostatic Pressing
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Solution Overview
Problem
Traditional hydrocarbon production manifolds are bespoke, time-consuming, and costly due to numerous parts and welding processes, requiring complex manufacturing and long delivery times, which limits design flexibility and increases costs.
Innovation Solution
A compact dual header manifold utilizing HIP'ed valve bodies, pipes, and fittings, integrated with three-way directional valves, manufactured through hot isostatic pressing, allowing for a one-piece design with minimal machining, reducing parts count and assembly time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional welded manifold designs are used, then structural strength and reliability are achieved, but manufacturing complexity and production time increase significantly
Solution Approach 1:
The patent merges multiple separate components (headers, valves, piping) into a single integrated manifold body manufactured by hot isostatic pressing. This consolidation eliminates the need for welding multiple parts together, reducing manufacturing complexity while maintaining structural integrity through the monolithic HIP'ed structure.
Solution Approach 2:
The patent replaces the mechanical welding process with hot isostatic pressing. Instead of joining parts through welding (which requires rigid control and certification), the entire manifold is formed as one piece through HIP, eliminating welding-related complexity and certification requirements while preserving reliability.
2Adaptability or versatility
If bespoke welded manifold designs are used, then specific customer requirements are met, but delivery time and cost increase
Solution Approach 1:
The patent creates a universal manifold platform that can serve multiple customer requirements through configuration variations rather than complete redesigns. The HIP manufacturing process allows the same base design to be adapted for different well counts and specifications, reducing delivery time while maintaining design adaptability.
Solution Approach 2:
The patent uses parameter changes in the HIP manufacturing process (temperature, pressure, time, material composition) to produce different manifold configurations from the same design framework. This allows rapid adaptation to customer specifications without extending delivery schedules.
3Strength
If traditional forged and welded construction is used, then structural integrity is achieved, but hydrogen-induced stress cracking risk increases
Solution Approach 1:
The patent replaces the forged-welded construction process with hot isostatic pressing. The HIP process creates a dense, homogeneous microstructure without welding seams or heat-affected zones that are susceptible to hydrogen-induced stress cracking. The resulting monolithic structure maintains structural integrity while eliminating the cracking risk associated with traditional welding.
4Ease of operation
If multiple separate components are used, then assembly flexibility is maintained, but assembly time and parts count increase
Solution Approach 1:
The patent combines multiple separate components (headers, valves, piping sections) into a single integrated manifold body. This eliminates the need for assembly of numerous parts, dramatically improving assembly productivity. The monolithic HIP'ed structure provides all necessary flow paths and connections internally, requiring no field assembly.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a cost-effective, compact, and flexible hydrocarbon production manifold with reduced delivery schedules and simplified engineering, enhancing design freedom and reducing hydrogen-induced stress cracking risks.
Implementation Method 1
During hot isostatic pressing, fine metal powder is provided in a capsule/casting. The capsule is heated to an elevated temperature and isostatic gas pressure is applied.
Implementation Method 2
The capsule is heated to an elevated temperature and isostatic gas pressure is applied.
Data Source
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AI summary
The present invention relates to a dual header oil and gas industry hydrocarbon production manifold 1. A plurality of three-way directional valves 2 separate fluid flow between a well side of manifold 1 and a pipeline side of the manifold 1. Two headers 9, 10 include header bodies and header flow paths and a pipeline side couplings 7. Each of two elbow pipes 12, provide a flow path between one of the headers 9, 10, and a port on one of the plurality of three-way valves 2. At least one T-pipe 13, provides a flow path between one of the headers 9, 10, and a port on two of the plurality of three-way valves. 2. A manifold body or any of its main parts may be hipped. A layout with such a manifold is also disclosed.