Fracking Pump Hot-Swap Connection for Pressurized Manifolds
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Solution Overview
Problem
Current fracking and well workover operations require depressurization of the fracturing manifold to remove or replace pumps, which is time-consuming and poses safety risks to personnel due to the high-pressure environment near the manifold, known as the 'red zone'.
Innovation Solution
A system that allows pumps to be connected and disconnected from the fracturing manifold without depressurizing it, using automated and controlled high-pressure side and low-pressure side connectors and valves, enabling 'hot swapping' of pumps while maintaining system pressure, thus keeping personnel out of the hazardous 'red zone'.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pumps are removed or replaced by depressurizing the fracturing manifold, then personnel safety is improved, but operational time and productivity deteriorate
Solution Approach 1:
The system is divided into multiple isolation zones using segmentable isolation devices (valves and connectors) that can separate the pump being serviced from the pressurized manifold. This allows the manifold to remain pressurized while the specific pump connection is isolated and depressurized, enabling safe pump replacement without shutting down the entire system.
Solution Approach 2:
Hot swap connectors act as intermediary devices between the pressurized manifold and the pump. These connectors include integrated isolation valves and quick-connect mechanisms that mediate the transition from pressurized to depressurized states, allowing pump replacement while maintaining system pressure in the manifold.
2Reliability
If pumps are removed by depressurizing the manifold, then equipment safety is improved, but operational efficiency deteriorates
Solution Approach 1:
Isolation valves are positioned upstream of the pump connection, allowing the pump to be isolated from pressure before disconnection begins. This preliminary isolation action protects equipment from pressure surges during the replacement process while enabling continuous operation of other pumps in the system.
Solution Approach 2:
The system transitions from a static all-or-nothing pressurization state to a dynamic state where individual pump connections can be independently pressurized or depressurized. This dynamic control allows continuous operation of the fracturing system while individual pumps are replaced.
3Ease of operation
If the manifold is depressurized for pump replacement, then connection safety is improved, but operational cost and time increase
Solution Approach 1:
The hazardous pressurized fluid is extracted or isolated from the specific pump connection zone using upstream isolation valves and hot swap connectors. This extraction of pressure from the local connection area while maintaining system pressure eliminates the need for full manifold depressurization and subsequent repressurization cycles.
Solution Approach 2:
The fracturing operation continues uninterrupted in the manifold while individual pumps are replaced. The isolation devices maintain continuous pressure in the manifold, allowing other pumps to continue operating and eliminating the downtime associated with full system depressurization and repressurization.
Data Source
AI summary
A pump connection point to a fracturing manifold includes a valve configured to isolate the fracturing manifold from an outside fluid source. A connector is attached to the valve opposite the well fracturing manifold. A guide is attached to the connector. The guide configured to align a fluid line to mate with the connector.