Dynamic Manifold Locking System for Hot Fracking Connections
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Solution Overview
Problem
Conventional fracking operations require shutting down and depressurizing the manifold to disconnect and reconnect pumping units, posing safety risks to field personnel and potentially compromising the integrity of the downhole fracking stage, leading to inefficiencies and additional costs.
Innovation Solution
The Dynamic Manifold Locking System (DMLS) enables remote-controlled, high-pressure connections and disconnections between pumping units and a pressurized manifold, using a stinger assembly and hot connector assembly with locking elements and a universal positioning system for remote alignment and operation, allowing for safe and efficient switching without interrupting fluid flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional manual connection arrangements are used to disconnect and reconnect pumping units, then field personnel can perform the connection tasks, but safety risks to field personnel and potential compromise of downhole fracking stage integrity occur due to required shutdown and depressurization
Solution Approach 1:
The patent replaces manual mechanical connection operations with an automated robotic system. The robotic arm with specialized end effectors performs the connection and disconnection of pumping units to the manifold without human personnel needing to enter the high-pressure zone. This substitution eliminates safety risks to field personnel while maintaining the ability to perform connection tasks, and crucially allows operations to proceed without shutdown and depressurization, preserving downhole fracking stage integrity.
2Ease of operation
If the manifold is shut down and depressurized to enable disconnection and reconnection of pumping units, then manual connection operations can be performed safely, but fluid flow is interrupted and additional costs are incurred
Solution Approach 1:
The patent enables continuous fluid flow through the manifold during pumping unit connections and disconnections. The automated robotic system performs these operations while the manifold remains pressurized and fluid flow is maintained. This eliminates the need to shut down and depressurize the system, thereby maintaining productivity and avoiding interruptions to the fracking operation while still enabling safe connection operations through automation.
3Object-affected harmful factors
If field personnel are restricted from entering the high-pressure red zone during fluid transfer, then safety is improved, but manual connection and disconnection of pumping units becomes impossible
Solution Approach 1:
The patent introduces a robotic system as an intermediary between the control operators and the high-pressure connection zone. The robotic arm with specialized end effectors acts as the mediator that physically performs the connection and disconnection tasks in the high-pressure red zone, while human personnel remain safely outside this zone providing remote control. This intermediary solution maintains field personnel safety while enabling connection operations to proceed.
4Adaptability or versatility
If pumping units are disconnected mid-stage to replace failed or maintenance-required units, then operational flexibility is improved, but safety risks and operational interruptions increase with conventional methods
Solution Approach 1:
The patent enables pumping unit replacements to occur without interrupting the fracking fluid flow through the manifold. The automated robotic system performs disconnection and reconnection operations while the system remains pressurized and operational. This eliminates the time loss associated with shutdown and depressurization procedures, allowing failed or maintenance-required pumping units to be replaced efficiently while maintaining continuous productive operation of the fracking stage.
Data Source
AI summary
A Dynamic Manifold Locking System (DMLS) enables remote-controlled disconnections and reconnections of pumping units from a pressurized (“hot”) fracking fluid manifold while the manifold remains pressurized and serving a well. The DMLS's connector assemblies integrate high-pressure and low-pressure connections, and remote testing of those connections, in order to enable the disconnections and reconnections of pumping units while the manifold remains pressurized. A Universal Positioning System (UPS) enables remote alignment and connection of two fluid connector assemblies integrated into the DMLS.