Frac Pump Swap Platform With Guided Conduit Pressure Isolation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Frac pumps require frequent maintenance, leading to downtime due to the need for personnel to enter the high-pressure red zone, which is unsafe and disrupts continuous hydraulic fracturing operations.
Innovation Solution
A system with a platform and conduit configuration that allows pumping units to be swapped outside the red zone, using a conduit system with a pivoting member and valve assembly for safe disconnection and pressure control, along with a controller for automated brake engagement and pressure testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pumping units are swapped during active operations, then operational continuity is improved, but personnel safety deteriorates due to exposure to high-pressure red zone
Solution Approach 1:
The patent introduces a remote operation system with automated valve control and pressure monitoring as an intermediary between operators and the high-pressure frac pump system. This allows pump swapping to be performed remotely without personnel entering the red zone, eliminating safety hazards while maintaining operational continuity.
Solution Approach 2:
The patent replaces manual mechanical operations with automated electronic control systems. Automated valves, pressure sensors, and control systems perform the functions previously requiring manual intervention in the high-pressure zone, enabling safe remote pump swapping while maintaining continuous operations.
2Reliability
If pump swapping is performed frequently for maintenance, then equipment reliability is improved, but operational downtime increases
Solution Approach 1:
The patent enables continuous pump swapping operations where one pump can be replaced while another continues operating. The system maintains continuous fluid flow through automated valve transitions and pressure management, eliminating downtime between pump replacements and ensuring uninterrupted production.
Solution Approach 2:
The patent implements a standby pump system where replacement pumps are pre-positioned and ready. When a pump requires maintenance, the pre-positioned standby unit can be immediately deployed through automated switching mechanisms, eliminating the time required for pump replacement preparations.
3Ease of repair
If manual pump swapping is performed in the red zone, then equipment maintenance is enabled, but operational complexity increases due to safety protocols
Solution Approach 1:
The patent replaces complex manual safety protocols with automated electronic control systems. The automated system manages valve operations, pressure monitoring, and pump switching through centralized control, simplifying the maintenance process while eliminating the need for personnel to navigate complex safety procedures in the red zone.
Data Source
AI summary
Systems and methods of operating a fracturing operation include a platform having an upper surface and a channel, wherein the platform is configured to receive a carrier mounted with a pumping unit; and a conduit configured to transfer fluid to or from a manifold system, the conduit having a first end configured to be connected to the pumping unit. The channel may be configured to receive the conduit when the carrier is at least partially received on the platform. A guide member may be configured to guide the conduit into the channel and include a rounded portion and an abutment surface, wherein the conduit is configured to extend at last partially around the rounded portion, and the carrier is configured to engage the abutment surface. The systems and methods may also include a controller configured to control a braking system of the carrier when the pumping unit is actuated.