Hybrid Flow Line Fitting for Fracturing Pump Cavitation Control
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Solution Overview
Problem
Hydraulic fracturing systems face challenges with standard 4-inch diameter fluid flow lines, 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 blockages.
Innovation Solution
The development of a hydraulic fracturing system using a 5-inch diameter hose with hybrid 6-inch end connectors, allowing for increased fluid flow and pressure while maintaining standard 6-inch component compatibility, reducing cavitation and blockages by ensuring fluid velocity above threshold levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If standard 4-inch diameter flow lines are used, then component compatibility is maintained, but fluid inlet to pumps is limited causing premature wear and failures
Solution Approach 1:
A hybrid adapter assembly serves as an intermediary component between the 4-inch flow line and 6-inch pump inlet. The adapter includes a 4-inch female coupling that receives the standard flow line and a 6-inch male coupling that connects to the pump, enabling compatibility between non-matching components while maintaining standard flow line usage
Solution Approach 2:
The system changes the diameter parameter of the flow path by using an adapter that transitions from 4-inch to 6-inch diameter. This parameter change allows the pump to receive sufficient fluid inlet while maintaining compatibility with existing 4-inch flow lines through the adapter interface
2Productivity
If hose size is increased to improve fluid flow, then flow rates increase, but component fitting compatibility becomes problematic
Solution Approach 1:
The hybrid adapter assembly provides multi-functionality by serving as both a size transition component and a compatibility interface. It enables the system to use standard 4-inch flow lines while achieving 6-inch pump inlet requirements, making the solution universally applicable to existing fracturing equipment
Solution Approach 2:
The adapter acts as a mediator between components of different sizes, allowing the system to maintain standard component specifications while achieving improved fluid flow through the 6-inch pump inlet
3Productivity
If flow rate is increased to reduce operational time, then productivity improves, but particulate dropout and blockages occur
Solution Approach 1:
The system changes the flow rate parameter to an optimal range by enabling 6-inch pump inlet through the hybrid adapter. This allows the pump to operate at higher flow rates while maintaining sufficient velocity to prevent particulate dropout, thus improving productivity without sacrificing reliability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system provides improved fluid supply to fracturing pumps, reducing cavitation and prolonging equipment life by maintaining flow rates above thresholds that prevent particulate dropouts, while integrating seamlessly with existing equipment without costly overhauls.
Implementation Method 1
maintaining flow rates above thresholds that prevent particulate dropouts
Implementation Method 2
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
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.