Fracture Fluid Manifold Assembly With API 6A Metal-Sealed Connections
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Solution Overview
Problem
Conventional manifold skids for hydraulic fracturing face issues with high-pressure fluid causing binding and failure due to expansion, hammering, and vibrations, leading to safety hazards and increased rigging complexity.
Innovation Solution
A manifold skid design featuring studded or flanged iron connections and open-faced connections made to API 6A standards, eliminating elastomeric seals and using alloy steel ring gaskets for robust sealing, which reduces vibrations and enhances reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional high-pressure piping systems with multiple integral connections are used, then fluid delivery capability is achieved, but binding and failure occur due to expansion, hammering, and vibrations
Solution Approach 1:
The patent combines multiple separate piping components into a single integrated manifold assembly with a common base plate. This merging eliminates numerous individual connections between piping components, thereby reducing the sources of vibrations and hammering while maintaining high-pressure fluid delivery capability.
Solution Approach 2:
The manifold assembly is segmented into distinct functional zones (low-pressure inlets, high-pressure outlets, pump connections) all mounted on a common base plate. This segmentation allows each zone to be optimized independently while the common base plate provides structural stability to reduce vibrations.
2Productivity
If multiple integral connections between piping components are used, then fluid distribution is achieved, but rigging up time and complexity increase significantly
Solution Approach 1:
The manifold integrates multiple piping functions (fluid distribution, pressure regulation, pump connections) into a single pre-assembled unit. This merging reduces the number of field assembly steps from multiple individual connections to simple connection points, dramatically reducing rigging up time and complexity.
Solution Approach 2:
The manifold assembly is pre-assembled and pre-tested at the factory with all internal piping and connections already in place. This preliminary action transfers complex assembly work from the field to the manufacturing environment, where it can be performed more efficiently and with better quality control.
3Reliability
If elastomeric seals are used in high-pressure connections, then sealing is achieved, but binding and failure occur under high pressure
Solution Approach 1:
The patent changes the material parameter of the sealing element from elastomeric (flexible) to metal (rigid). This parameter change enables the seal to withstand high-pressure conditions without binding or failing, as metal maintains its structural integrity under high stress where elastomeric materials would deform or rupture.
Data Source
AI summary
Disclosed is a flanged manifold frack delivery system, or manifold assembly, for distributing fluids to a well wherein the assembly comprises at least one high pressure output studded or flanged connection in the absence of rubber seals. The high-pressure connection consists of cross-blocks and spools connected in series to each other. Described is a combination of high and low-pressure conduit configurations disposed along the length of the chassis; the high-pressure conduit assembly is made up using studded or flanged iron connections terminating at the opposite end to the low-pressure inlet with a studded or flanged iron connection so that a spool can be attached at the height of the well head to route the fluid to the well head. The assembly may be pre-fabricated to the user's needs and assembled on site, or may be mobile and delivered to the desired site for use.