Integrated Manifold Check Valve Assembly for Fracturing Connection Reliability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Hydraulic fracturing systems experience premature failure of fluid connections due to axial loading, radial loading, vibration, and fatigue, particularly at the junctions of hoses or flow lines with check valves, leading to significant downtime and increased costs.
Innovation Solution
Integrated flow junction and check valve assemblies with internally mounted check valves and streamlined designs that reduce the effects of axial and radial loading, vibration, and weight, while allowing for quick connector replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If check valves are connected to the manifold via external hoses or flow lines, then the system can control fluid flow from the manifold to wellbores, but the connections experience axial loading, radial loading, vibration, and fatigue leading to premature failure
Solution Approach 1:
The check valve is integrated directly into the manifold body, merging two previously separate components (manifold and check valve) into a single unified structure. This eliminates the external hose connections that were subject to axial loading, radial loading, vibration, and fatigue, thereby resolving the technical contradiction by removing the vulnerable connection points while maintaining the fluid flow control function.
2Ease of operation
If heavy hoses are used to connect check valves to the manifold, then fluid can be directed away from the manifold, but the hose weight creates additional load on connections requiring separate support structures
Solution Approach 1:
By integrating the check valve directly into the manifold body, the invention eliminates the need for external heavy hoses. The fluid direction control function is maintained through the integrated valve mechanism, while the weight problem is resolved by removing the hose component entirely and replacing it with a lightweight integrated valve structure within the manifold.
3Ease of operation
If check valves are positioned at a distance from the manifold centerline, then fluid flow control is achieved, but the distance increases the effects of axial loading, radial loading, and bending moment on connections
Solution Approach 1:
The integration of the check valve directly into the manifold body eliminates the distance between the valve and manifold centerline. The fluid flow control function is maintained through the integrated valve mechanism, while the connection strength is improved by eliminating the long-distance connections that were subject to axial loading, radial loading, and bending moment effects.
Data Source
AI summary
Embodiments of a manifold of a hydraulic fracturing system include a junction having an inlet flow bore. The junction can include an integrated flow junction and valve check assembly having a body including a central portion and one or more side portions. The central portion can be positioned between a pair of manifold sections of the manifold and attached thereto. The one or more side portions extend radially from the central portion and include an inlet bore through which a pressurized fluid is received and supplied to the manifold. One or more check valves is positioned along the inlet bore so as to be integrated within the body of the junction.