Fracturing System Guide Rail for Automated Hydraulic-End Replacement
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Solution Overview
Problem
The manual replacement of hydraulic ends in plunger pumps is labor-intensive and time-consuming, often leading to safety risks due to limited space and high-pressure environments, with potential device failures going undetected during wellsite operations.
Innovation Solution
A fracturing system incorporating a guide rail and intelligent working apparatus with a main-body driving mechanism, enabling automated inspection and maintenance of fracturing devices and pipelines, including a robotic arm for component replacement and real-time monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual replacement of hydraulic end is performed through multi-person collaboration, then the replacement can be completed, but the replacement cycle becomes long and personal operation intensity increases
Solution Approach 1:
The intelligent working apparatus autonomously performs inspection, diagnosis, and replacement operations on the fracturing device without requiring multi-person manual collaboration. The apparatus independently navigates to the device, identifies issues, and executes maintenance tasks, eliminating the need for human operators to directly handle heavy components in confined spaces.
Solution Approach 2:
The patent replaces the manual mechanical replacement process with an automated intelligent working apparatus equipped with robotic manipulators. The apparatus uses automated positioning, gripping, and assembly mechanisms to perform hydraulic end replacement, substituting human labor with robotic systems that can operate more efficiently and safely.
2Ease of repair
If manual replacement is performed in limited device replacement space, then the hydraulic end can be replaced, but safety accidents such as injuries to personnel may occur
Solution Approach 1:
The intelligent working apparatus autonomously performs all replacement operations without human intervention in the immediate work zone. The system independently completes tasks such as positioning, disassembly, and assembly of hydraulic components, eliminating personnel exposure to high-pressure hazards and confined space risks.
Solution Approach 2:
The robotic manipulators and end effectors serve as intermediaries between the control system and the hydraulic components. These robotic elements handle all physical interactions with high-pressure pipes and heavy components, acting as a safe intermediary that protects human operators from direct exposure to dangerous conditions.
3Reliability
If personnel conduct inspection in high-pressure dangerous region, then real-time device status can be monitored, but device failures cannot be discovered and repaired immediately due to safety constraints
Solution Approach 1:
The patent replaces human inspectors with an intelligent working apparatus equipped with sensors, cameras, and diagnostic tools. This robotic system can safely enter high-pressure zones to perform visual inspection, measure parameters, and detect anomalies in real-time without exposing personnel to danger, enabling immediate response to detected failures.
Solution Approach 2:
The intelligent working apparatus autonomously performs both inspection and repair functions. When a failure is detected through onboard sensors and diagnostic equipment, the system automatically initiates repair procedures without requiring human intervention or withdrawal from the hazardous environment, thereby eliminating response time delays.
4Ease of repair
If heavy replacement device is used in limited device replacement space, then the hydraulic end can be replaced, but safety accidents may occur
Solution Approach 1:
The intelligent working apparatus is divided into modular components including base units, robotic manipulators, and tool modules. This segmentation allows the system to perform heavy replacement tasks using distributed, lighter-weight components rather than requiring a single heavy device, reducing safety hazards while maintaining replacement capability.
Data Source
AI summary
This application provides a fracturing system includes: a fracturing device having a hydraulic end; a high/low-pressure manifold skid including a main pipeline extending along a first direction and a main pipeline support for bearing the main pipeline; a guide rail; an intelligent working apparatus including a main body mounted on the guide rail; and a main-body driving mechanism. The fracturing device is located on at least one side of the high/low-pressure manifold skid in a second direction perpendicular to the first direction. The main pipeline is connected to the hydraulic end of the fracturing device. The guide rail is located on the high/low-pressure manifold skid and extends along the first direction. The main-body driving mechanism is connected to the main body of the intelligent working apparatus and configured to drive the main body of the intelligent working apparatus to move at least along the guide rail.