Curved Manifold Header Outlets for Erosion-Resistant Wellsite Flow
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Solution Overview
Problem
Conventional manifolds in hydraulic fracturing systems experience premature wear due to turbulent flow and erosive wear at sharp fluid flow changes, leading to pipe leaks and increased maintenance costs, particularly at joints where the direction of fluid flow changes sharply.
Innovation Solution
The manifold header design includes an inlet with multiple outlets, each featuring an entrance section matching the inner surface profile, an outlet port perpendicular to the manifold axis, and a transition section with a radius of curvature to reduce turbulence and internal erosion, allowing for smoother fluid flow and extended service life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional manifolds with welded-on outlets are used, then the manifold can redirect viscous fracturing fluid at high pressure, but the piping experiences turbulent flow and erosive wear at sharp direction changes, leading to premature wear
Solution Approach 1:
The patent applies curvature by designing outlets with a rounded entrance section that smoothly transitions into the manifold body, replacing sharp angular joints with curved surfaces. This curvature eliminates turbulent flow separation at sharp edges, reducing erosive wear while maintaining high-pressure fluid redirection capability
Solution Approach 2:
The patent implements local quality by providing different geometric characteristics at different locations: the outlet entrance section has a specific curved profile matched to the manifold inner surface, while the outlet port maintains perpendicular orientation. This localized geometric optimization addresses wear at critical junctions without compromising overall manifold function
2Reliability
If reinforcing plates are added at joints and spools to prevent wear, then wear resistance improves, but the plates are costly and difficult to install due to weight and intricate positioning
Solution Approach 1:
The patent merges the outlet structure with the manifold body by integrally forming the outlet from the manifold material, eliminating separate reinforcing plates and spools. This integration simplifies manufacturing and installation while providing continuous wear resistance throughout the fluid path, as the outlet and manifold become a single monolithic component
Solution Approach 2:
The patent extracts the problematic sharp-cornered joint geometry from the design and replaces it with a smoothly curved transition zone. By removing the geometric feature that causes turbulence and wear (the sharp corner), the need for additional reinforcing elements is eliminated
3Reliability
If the joint connection is sanded for a smoother joint, then wear rate decreases, but the manifolds still incur premature wear
Solution Approach 1:
The patent applies curvature at the outlet entrance to create a smooth, continuous surface that guides fluid flow without sharp transitions. This geometric curvature is more effective than sanding because it fundamentally changes the flow pattern from turbulent to laminar, preventing wear at its source rather than merely smoothing the surface
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 design reduces internal erosion and extends the service life of the manifold header by minimizing turbulence and wear, thereby reducing maintenance and replacement costs while maintaining efficient fluid distribution.
Implementation Method 1
The piping within the manifold must redirect the viscous fracturing fluid at high contact angles and high pressure, resulting in turbulent flow
Implementation Method 2
The piping within the manifold is particularly eroded at junctions where the direction of fluid flow changes sharply
Data Source
AI summary
A pumping system for pumping a fluid for a wellsite. The pumping system includes a manifold assembly and pumping systems in fluid communication with the manifold header. The manifold assembly includes a manifold header that includes a manifold header body and outlets. The manifold header body includes an inlet to receive the fluid and an interior bore. Each outlet includes an entrance section shaped to have a profile that is approximately the same as a profile of an inner surface of the manifold header body, an outlet port shaped to flow the fluid approximately perpendicular to a longitudinal axis of the manifold header body, and a transition section shaped to have a radius of curvature that transitions from the profile of the entrance section to the outlet port and reduces internal erosion of the outlet due to the fluid flowing from the manifold header and through the outlet port.