Fracturing Pump Hot Swapping at Pressurized Manifold Connections
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current fracking 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 need for manual handling in the 'red zone' under high pressure conditions.
Innovation Solution
A system allowing 'hot swapping' of pumps without depressurizing the manifold, using automated connection points with high and low pressure valves and sensors, enabling pumps to be connected and disconnected while the system is still pressurized, and controlled by a controller to ensure safe operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pumps are removed or replaced by depressurizing the manifold, then personnel safety is improved, but operational time and productivity are reduced
Solution Approach 1:
The manifold is segmented into multiple isolated connection points, each with its own isolation valves. This allows individual pump connections to be depressurized and serviced while other sections of the manifold remain pressurized and operational, enabling continuous production while maintaining safety during pump changes
Solution Approach 2:
Automated quick-connect couplings serve as intermediaries between pumps and the manifold. These automated connection devices eliminate the need for manual handling in the red zone, allowing safe hot-swapping of pumps while maintaining system pressure and continuous operation
2Productivity
If pumps are hot swapped without depressurizing, then productivity and operational time are improved, but system complexity and device complexity increase
Solution Approach 1:
The manifold system is divided into independent zones with individual isolation valves at each connection point. This segmentation allows controlled depressurization of only the specific section being serviced, rather than the entire system, reducing the complexity of pressure management while enabling hot-swapping
Solution Approach 2:
The system incorporates automated quick-connect couplings that can connect and disconnect pumps without manual intervention in the high-pressure zone. The automated coupling mechanism self-regulates the connection process, reducing operational complexity despite the advanced hardware required
3Ease of operation
If manual handling is required in the red zone, then ease of operation is maintained, but safety and harmful factors increase
Solution Approach 1:
Automated quick-connect couplings act as intermediaries that perform the connection and disconnection operations remotely or automatically, eliminating the need for personnel to manually handle equipment in the high-pressure red zone. This maintains operational capability while removing personnel from the hazardous environment
Solution Approach 2:
Manual mechanical handling operations are replaced with automated coupling mechanisms controlled from a safe distance. The automated system performs the mechanical connection and disconnection tasks that previously required personnel to be in the dangerous high-pressure zone
4Reliability
If the entire manifold is depressurized for pump changes, then safety is improved, but energy consumption and loss of energy increase
Solution Approach 1:
The manifold is divided into independent pressurized zones with individual isolation valves at each pump connection point. Only the specific zone being serviced needs to be depressurized, while other zones maintain pressure and continue operation, significantly reducing the total energy that must be repressurized after maintenance
Data Source
AI summary
A system that permits fracturing pumps such as, for example, at least first and second fracturing pumps, each carried on a truck, to be connected to, and disconnected from, respective connection points on a fracturing manifold while fracturing fluid in the fracturing manifold is at pressure, in certain instances at or near fracturing pressure, and/or while other(s) of the fracturing pumps are being operated to pump fracturing fluid.