Flow Cross Junctions With Removable Adapters for High-Pressure Manifolds
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Solution Overview
Problem
Conventional fluid couplings in hydraulic fracturing manifolds experience frequent failures due to high pressures, vibrations, and erosion, leading to significant delays and increased costs, and the large size and weight of these couplings necessitate bulky and expensive equipment.
Innovation Solution
The development of streamlined flow cross junctions with removable coupling adapters that facilitate quick replacement, reducing downtime and size/weight, and eliminating the need for large flanged connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If large flanged connections are used for fluid couplings, then the manifold can withstand high pressures, but the size and weight of the manifold increases significantly
Solution Approach 1:
The manifold is divided into modular sections with standardized flow cross junctions that can be independently manufactured and assembled. This segmentation allows for optimized wall thicknesses in each module without requiring the entire manifold to be oversized, reducing overall weight while maintaining pressure integrity.
Solution Approach 2:
The design transitions from conventional large flanged connections to a streamlined configuration with reduced dimensional parameters. By optimizing the wall thickness and connection geometry parameters, the manifold achieves adequate pressure withstanding capability with significantly reduced weight.
2Strength
If conventional fluid couplings are used, then connections are structurally robust, but replacement time increases significantly during failures
Solution Approach 1:
The fluid coupling system is segmented into removable coupling adapters that can be quickly detached and replaced without affecting the entire manifold structure. This allows rapid replacement of failed couplings while maintaining the integrity of the remaining system.
Solution Approach 2:
The coupling adapters are designed with dynamic replacement capability, allowing for quick connection and disconnection operations. This enables maintenance personnel to rapidly replace failed couplings without extensive disassembly or specialized tools, reducing downtime while maintaining connection strength.
3Weight of stationary object
If streamlined flow cross junctions are used, then size and weight are reduced, but manufacturing precision requirements increase
Solution Approach 1:
The design employs optimized parameter ranges that balance reduced dimensions with achievable manufacturing tolerances. By carefully selecting wall thickness, bore diameter, and connection interface parameters, the streamlined flow cross junctions achieve weight reduction without requiring excessively tight manufacturing precision.
Solution Approach 2:
The flow cross junctions are designed as standardized modular components with repeating geometric features. This segmentation and standardization allows for optimized manufacturing processes that reduce precision requirements while maintaining the streamlined, lightweight design.
Data Source
AI summary
An embodiment of a manifold of a hydraulic fracturing system includes a flow cross junction including an inlet flow bore. In addition, the manifold includes a coupling adapter including an external shoulder and a connection device. The connection device is to connect to an output of a pump of the hydraulic fracturing system, and the coupling adapter is removably inserted within the inlet flow bore such that the connection device is positioned outside of the inlet flow bore. Further, the manifold includes a retainer ring connected to the flow cross junction and compressed against the external shoulder.