Modular Fracturing Blender Layout for Rapid Component Swaps
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing hydraulic fracturing systems face inefficiencies due to fixed component positions, leading to costly downtime and potential well contamination when components fail, and lack flexibility to adapt to changing job requirements.
Innovation Solution
A modular blender system with independently operable units mounted on frames, allowing easy swapping and reconfiguration of components to meet operational needs, and a controller for managing component communication and redundancy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If fixed component positions are used in traditional blender systems, then structural stability is maintained, but operational flexibility and response to component failures are reduced
Solution Approach 1:
The blender system is divided into modular components (hopper, conveyors, blending units, pumps) that can be independently positioned and reconfigured on the trailer frame. Each component is mounted on separate frames or skids with adjustable positioning mechanisms, allowing segments to be moved and reassembled in different configurations based on operational needs or failure conditions.
Solution Approach 2:
The system incorporates dynamically adjustable component positions through hydraulic or mechanical positioning systems. Components can be moved from fixed positions to alternative locations on the trailer, enabling the system to adapt its configuration in response to changing operational requirements or component failures during fracturing operations.
2Reliability
If traditional fixed-position components are used, then manufacturing and assembly are simplified, but downtime during component failure or maintenance increases
Solution Approach 1:
The system pre-positions multiple components and backup units on the trailer frame before deployment. Alternative conveyors, blending units, and pumps are staged in ready-to-deploy positions, allowing quick substitution if a primary component fails or requires maintenance, thereby minimizing downtime and maintaining continuous operation capability.
Solution Approach 2:
The modular design allows failed or maintenance-required components to be quickly disconnected and replaced with backup units. The removed components can be recovered, transported to a service location, and repaired or replaced offline while the main system continues operation with alternative components, reducing overall system downtime.
3Adaptability or versatility
If components are mounted in fixed positions on the blender, then installation is simplified, but adaptability to changing job requirements is reduced
Solution Approach 1:
The trailer frame is designed with universal mounting locations and standardized connection interfaces that allow the same component to be positioned in multiple locations depending on the job requirements. The hopper, conveyors, and pumps can be repositioned to different sides or locations on the trailer to accommodate various operational configurations and access requirements for different well sites.
Solution Approach 2:
The system employs intermediary positioning mechanisms such as adjustable skids, hydraulic lifts, and modular frame sections that facilitate easy repositioning of heavy components. These intermediaries reduce the physical effort required to move components between positions, enabling operators to reconfigure the system for different job requirements without excessive manual labor.
4Productivity
If traditional blender designs are used, then initial setup is straightforward, but response to component failures and maintenance needs is delayed
Solution Approach 1:
Components are segmented into independently accessible modules mounted on separate frames. Each module (hopper, conveyor, blending unit, pump) can be accessed, removed, or replaced independently without disturbing other system components, significantly improving ease of repair and maintenance while maintaining high operational efficiency through quick component swaps.
Solution Approach 2:
The system incorporates intermediary access mechanisms such as removable panels, adjustable positioning systems, and modular connection interfaces that facilitate rapid access to components for maintenance or replacement. These intermediaries enable operators to quickly service components in the field without complex disassembly procedures, improving both ease of repair and operational efficiency.
Data Source
AI summary
A multi-blender system for blending liquid and solid particulates together to prepare a fracturing fluid, the blender system can include a plurality of independently operable blender units each having components that can operate with either blender unit. Each component may be a modular blender component mounted to respective independent frames. The independent frames are configured to be independently removable, replaceable and movable to multiple positions in the blender system. In some aspects the multi-blender system can operate at different sand concentrations, instantaneously adjust flow rate to one or more of the components in either blender unit, provide control redundancy, and may continue to operate despite a failure of one of the major components.