Integrated Pump Manifold Assembly for Hydraulic Fracturing
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Solution Overview
Problem
Conventional manifold and pump assemblies in hydraulic fracturing require separate transportation and assembly at the frac site, leading to increased labor, rig-up time, and equipment footprint, with diesel engines limiting pump size and efficiency.
Innovation Solution
An integrated pump and manifold assembly mounted on a single support structure, utilizing electric motors for power and reducing the number of trailers and equipment, with linear pumps allowing for smaller footprint and modular design for customization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If separate pump units and manifold assemblies are transported on multiple trailers to the frac site, then the equipment can be delivered to the site, but the number of trailers and equipment footprint increase significantly
Solution Approach 1:
The patent combines the manifold assembly and pump units into a single integrated unit mounted on one trailer. The manifold is mounted on a support structure with pump units positioned adjacent to it, integrating previously separate components into one cohesive system that reduces the number of trailers needed and minimizes on-site equipment footprint.
2Power
If conventional diesel engines power the pump units, then the pumps can operate, but the pump size and efficiency are limited
Solution Approach 1:
The patent replaces diesel engines with electric motors to power the pump units. Electric motors provide higher power output and efficiency while eliminating the mechanical complexity of diesel engine systems. The electric motors are mounted on the same support structure and directly drive the pump units through integrated drive mechanisms.
3Adaptability or versatility
If pump units and manifold assemblies are assembled at the frac site using frac iron and piping, then the system can be configured for operation, but labor and rig-up time increase
Solution Approach 1:
The patent integrates the pump units and manifold assembly into a pre-configured unit before transportation to the frac site. The pump units are mounted adjacent to the manifold on the same support structure with pre-established fluid connections, eliminating the need for on-site assembly with frac iron and piping while maintaining configuration flexibility for different wellhead arrangements.
4Ease of manufacture
If multiple separate components are used for pump and manifold assembly, then the system can be transported, but the number of trailers and transportation complexity increase
Solution Approach 1:
The patent merges the manifold assembly and multiple pump units into a single integrated unit that mounts on one trailer. The support structure accommodates the manifold with pump units positioned adjacent to it, creating a unified system that reduces transportation complexity while maintaining modular design principles for ease of manufacture and deployment.
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
This solution reduces setup time, labor, and equipment footprint, increases efficiency, and safety, while enabling larger pump units and higher pressures with reduced environmental impact and compliance with road regulations.
Implementation Method 1
The one or more frac pumps are configured to be in fluid communication with the high pressure discharge line and to output a high pressure fluid to the high pressure discharge line through the frac pump outlet of each of the one or more frac pumps
Data Source
AI summary
An integrated pump and manifold assembly includes a support structure, a manifold assembly mounted on the support structure, and one or more frac pumps. The manifold assembly includes one or more low pressure lines and a high pressure discharge line including a discharge outlet configured to fluidly couple to a wellhead. The one or more frac pumps are each mounted on the support structure and include a frac pump inlet and a frac pump outlet. The one or more frac pumps are configured to be in fluid communication with the one or more low pressure lines and the high pressure discharge line. The one or more low pressure lines, the high pressure discharge line, and the one or more frac pumps are integrated as a single unit and mounted on the support structure.