Fluid Manifold Flow-Altering Assemblies for Standing Wave Disruption

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Solution Overview

Problem

Hydraulic fracturing systems experience significant vibration and premature component failure due to pressure pulsations and standing wave resonance in the fluid manifold, which are caused by the operation of positive displacement pumps.

Innovation Solution

Implementing flow altering assemblies in the fluid manifold to create velocity and pressure differentials, disrupt standing wave formation, and alter the natural frequency of the system to prevent resonance and vibration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If positive displacement pumps are used to pump fracturing fluid at high pressure and high flow rate, then productivity is improved, but pressure pulsations and standing wave resonance are generated causing vibration and component wear

Engineering Contradiction:

Improvefracturing fluid flow rateVSAvoidcomponent wear and failure

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

A flow altering assembly is introduced as an intermediary device in the fluid manifold. This assembly includes a flow altering element positioned to intercept pressure waves and standing waves generated by the positive displacement pumps, converting harmful acoustic energy into beneficial flow disruption that prevents resonance while maintaining high productivity

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The flow altering assembly converts harmful pressure pulsations and standing wave resonance into beneficial flow disruption. By strategically positioning the flow altering element, the system transforms the acoustic energy that causes vibration and component wear into a mechanism that disrupts standing wave formation, thereby protecting components while maintaining pump productivity

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Reliability

If flow altering assemblies are installed in the fluid manifold to reduce vibration, then reliability is improved, but device complexity increases

Engineering Contradiction:

Improvecomponent wear and failureVSAvoidmanifold structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The flow altering assembly is designed as a segmented, modular component that can be independently installed in the fluid manifold. The assembly consists of discrete elements including a flow altering element with specific geometric features that can be positioned at optimal locations without requiring complete manifold redesign, thereby limiting the increase in device complexity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The flow altering element is positioned at specific locations within the fluid manifold where standing waves and pressure pulsations are most problematic. Rather than modifying the entire manifold system, the solution applies local flow alteration at critical points, minimizing overall device complexity while effectively addressing vibration issues

Inventive Principle:

Principle #3Local quality

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

Reduces the likelihood of premature component wear and failure by minimizing the impact of pressure pulsations and standing waves, thereby enhancing the durability and efficiency of the hydraulic fracturing system.

Implementation Method 1

the devices and methods may result in creating a velocity differential and/or a pressure differential in the flow of fracturing fluid through the fluid manifold

Methodology Applied

Scientific EffectPressure differential: Pressure Gradient

Implementation Method 2

pressure pulsations and resonance in the form of standing waves may be generated by operation of the fracturing pumps

Methodology Applied

Scientific EffectAcoustic resonance: Resonance

Implementation Method 3

the devices and methods may result in at least partially reflecting pressure waves back upstream

Methodology Applied

Scientific EffectWave reflection: Reflection

Data Source

PatentUS12378864B2Systems and methods to reduce acoustic resonance or disrupt standing wave formation in a fluid manifold of a high-pressure fracturing system

Publication Date: 2025.08.05 BJ ENERGY SOLUTIONS LLC

AI summary

An example fluid manifold, for a fracturing system, includes one or more spool sections and a flow passage at least partially defined by the spool sections that extends along a longitudinal axis. In addition, the manifold includes a first flow altering assembly positioned along the flow passage and including a diverter surface positioned to divert fluid radially away from the axis. Further, the manifold includes a second flow altering assembly positioned along the flow passage and spaced from the first flow altering assembly. The second flow altering assembly includes an annular flange and a flow altering tube extending axially from the annular flange such that the annular flange and the flow altering tube define an annular cavity that extends radially between the flow altering tube and an inner wall of the flow passage and that extends axially along the flow altering tube to the annular flange.