Fracturing Pump Supply Hose Transition for Higher Inlet Flow
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Solution Overview
Problem
Hydraulic fracturing systems face challenges with standard 4-inch diameter fluid supply hoses, which limit fluid inlet to pumps, leading to premature wear and failures due to lower flow rates and pressures, and increasing hose sizes is impractical due to component fitting issues and potential flow rate drops that cause blockages.
Innovation Solution
The development of a hydraulic fracturing system utilizing a 5-inch diameter hose with hybrid 6-inch end connectors, including a specially designed ferrule to maintain standard 6-inch connection types, allowing for increased fluid supply and reducing pressure drop and cavitation, while integrating with existing equipment without significant overhaul.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If standard 4-inch diameter hoses are used, then compatibility with existing fittings is maintained, but fluid flow rate and pressure to pumps are limited
Solution Approach 1:
A transition fitting serves as an intermediary component between the 5-inch hose and existing 4-inch pump fittings. This mediator enables compatibility with existing equipment while allowing the larger diameter hose to provide increased fluid flow rates and pressures without requiring modification of the pump or other existing components.
Solution Approach 2:
The hose diameter parameter is changed from the standard 4 inches to 5 inches to increase fluid flow capacity. This parameter change is made possible by introducing a transition fitting that adapts between the different diameter standards, allowing the system to operate with improved flow characteristics while maintaining interface compatibility.
2Power
If hose size is increased to improve fluid supply, then flow rate and pressure increase, but component fitting compatibility becomes problematic
Solution Approach 1:
The transition fitting acts as an intermediary that bridges the gap between the non-standard 5-inch hose and standard 4-inch pump fittings. This enables the system to achieve higher fluid pressures and flow rates through the larger diameter hose while maintaining adaptability to existing equipment through the standardized connection interface.
3Reliability
If standard hose sizes are used, then equipment compatibility is maintained, but pumps experience premature wear and failures due to lower flow rates
Solution Approach 1:
The transition fitting serves as a simple intermediary component that enables the use of larger diameter hoses without increasing overall system complexity. By adding only this single adaptation component, the system achieves improved reliability through higher flow rates and reduced pump wear, without requiring complex redesign of the entire hose system.
Data Source
AI summary
A hydraulic fracturing system for fracturing a subterranean formation includes an electric powered pump having an inlet and an outlet, the outlet coupled to a well associated with the subterranean formation and powered by at least one electric motor. The system also includes a fluid source, coupled to the inlet of the electric powered pump, the fluid source providing a slurry for injection into the subterranean formation. The system further includes a hose extending between the fluid source and the electric powered pump, the hose being flexible and having a first diameter. The system includes a fitting between the hose and the electric powered pump, the fitting having a first end for receiving the hose at the first diameter and a second end for coupling to the electric powered pump at a second diameter, the second diameter being larger than the first diameter.