Curved Manifold Header Outlets for Erosion-Resistant Wellsite Flow
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Solution Overview
Problem
Conventional manifolds in hydraulic fracturing systems experience premature wear due to turbulent flow and erosive wear at sharp fluid flow changes, leading to pipe leaks and increased maintenance costs, particularly at the joint between the outlet and the manifold header.
Innovation Solution
The manifold header design includes an inlet with multiple outlets featuring an entrance section matching the inner surface profile, an outlet port perpendicular to the manifold axis, and a transition section with a radius of curvature, reducing turbulence and internal erosion by smoothing fluid flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional manifolds with welded-on outlets are used, then the manifold can redirect high-pressure fracturing fluid, but the piping experiences premature erosive wear at junctions where fluid flow changes direction sharply
Solution Approach 1:
The patent applies curvature by designing outlets with a rounded, curved transition section instead of sharp angles. The outlet includes a curved surface that gradually transitions from the manifold body to the outlet port, eliminating sharp corners where turbulent flow and erosive wear occur. This curved geometry allows fluid to change direction smoothly, reducing turbulence and preventing premature wear at the joint between the outlet and manifold header.
2Object-affected harmful factors
If reinforcing plates are added at joints and spools, then wear resistance improves, but installation becomes difficult and costly due to weight and intricate positioning
Solution Approach 1:
The patent merges the outlet structure with the manifold body by integrally forming the outlet from the manifold material. The outlet is not a separate component requiring installation but is instead formed as part of the manifold casting or machining process. This integration eliminates the need for separate reinforcing plates and complex positioning, while the curved geometry of the integrated outlet provides inherent wear resistance throughout the fluid path.
3Object-affected harmful factors
If joints are sanded for smoother surface, then wear rate decreases, but premature wear still occurs at the manifold
Solution Approach 1:
The patent addresses wear rate by implementing a curved transition section in the outlet geometry. Instead of merely sanding the joint surface to reduce roughness, the curved design fundamentally changes the flow pattern by eliminating sharp corners and abrupt direction changes. This curvature ensures smooth fluid transition, significantly reducing turbulence and erosive forces that cause wear, thereby providing superior and more reliable wear prevention compared to surface finishing alone.
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
This design extends the service life of the manifold header by minimizing internal erosion and preventing premature wear, thereby reducing maintenance and replacement costs.
Implementation Method 1
The piping within the manifold must redirect the viscous fracturing fluid at high contact angles and high pressure, resulting in turbulent flow and subjecting the manifold to erosive wear
Data Source
AI summary
A pumping system for pumping a fluid for a wellsite. The pumping system includes a manifold assembly and pumping systems in fluid communication with the manifold header. The manifold assembly includes a manifold header that includes a manifold header body and outlets. The manifold header body includes an inlet to receive the fluid and an interior bore. Each outlet includes an entrance section shaped to have a profile that is approximately the same as a profile of an inner surface of the manifold header body, an outlet port shaped to flow the fluid approximately perpendicular to a longitudinal axis of the manifold header body, and a transition section shaped to have a radius of curvature that transitions from the profile of the entrance section to the outlet port and reduces internal erosion of the outlet due to the fluid flowing from the manifold header and through the outlet port.