Fluid Manifold Flow-Altering Assemblies for Standing Wave Disruption

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Solution Overview

Problem

Hydraulic fracturing systems experience significant vibration and premature component failure due to pressure pulsations and standing wave resonance in the fluid manifold, which are caused by the operation of positive displacement pumps.

Innovation Solution

Implement flow altering assemblies in the fluid manifold to create velocity and pressure differentials, alter the natural frequency, and partially reflect pressure waves, reducing the likelihood of resonance and vibration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If positive displacement pumps are used to pump fracturing fluid at high pressure and flow rate, then productivity is improved, but acoustic resonance and standing wave formation occur causing vibration and component failure

Engineering Contradiction:

Improvefracturing fluid pumping rateVSAvoidcomponent service life

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

A flow altering assembly is introduced as an intermediary device in the fluid manifold. This assembly includes a flow altering element positioned to intercept pressure waves and standing waves generated by the positive displacement pumps, converting harmful acoustic energy into useful flow energy that maintains productivity while reducing vibration and preventing component failure.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The flow altering assembly converts the harmful pressure pulsations and standing waves (acoustic resonance) generated by the pumps into beneficial flow energy. The device captures the acoustic energy that would otherwise cause vibration and component failure, and redirects it to enhance fluid flow through the manifold, thereby maintaining high productivity while eliminating the harmful effects.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Reliability

If flow altering assemblies are installed in the fluid manifold, then acoustic resonance and vibration are reduced, but device complexity increases

Engineering Contradiction:

Improvecomponent service lifeVSAvoidmanifold structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The flow altering assembly is designed to perform multiple functions simultaneously: it acts as a flow distributor, a pressure wave interceptor, a standing wave disruptor, and a flow energy converter. By consolidating these functions into a single multi-functional device, the complexity increase is minimized while achieving comprehensive vibration reduction and reliability improvement.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The flow altering element changes key flow parameters including velocity distribution, pressure wave characteristics, and flow direction. By strategically positioning the element and designing its geometry, the device modifies flow parameters to disrupt standing wave formation and convert acoustic energy, achieving vibration reduction without requiring complex active control systems.

Inventive Principle:

Principle #35Parameter changes

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

Reduces the likelihood of premature component wear and failure by minimizing acoustic resonance and standing wave formation in the fluid manifold.

Implementation Method 1

the devices and methods may result in creating a velocity differential and/or a pressure differential in the flow of fracturing fluid through the fluid manifold

Methodology Applied

Scientific EffectPressure differential: Pressure Gradient

Implementation Method 2

pressure pulsations and resonance in the form of standing waves may be generated by operation of the fracturing pumps

Methodology Applied

Scientific EffectAcoustic resonance: Resonance

Implementation Method 3

the devices and methods may result in at least partially reflecting pressure waves back upstream

Methodology Applied

Scientific EffectPressure wave reflection: Reflection

Data Source

PatentUS20260009316A1Systems and methods to reduce acoustic resonance or disrupt standing wave formation in a fluid manifold of a high-pressure fracturing system

Publication Date: 2026.01.08 BJ ENERGY SOLUTIONS LLC

AI summary

An example fluid manifold, for a fracturing system, includes one or more spool sections and a flow passage at least partially defined by the spool sections that extends along a longitudinal axis. In addition, the manifold includes a first flow altering assembly positioned along the flow passage and including a diverter surface positioned to divert fluid radially away from the axis. Further, the manifold includes a second flow altering assembly positioned along the flow passage and spaced from the first flow altering assembly. The second flow altering assembly includes an annular flange and a flow altering tube extending axially from the annular flange such that the annular flange and the flow altering tube define an annular cavity that extends radially between the flow altering tube and an inner wall of the flow passage and that extends axially along the flow altering tube to the annular flange.