Modular Fluid Delivery System With Quick-Connect Manifolds
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Solution Overview
Problem
The management of complex fluid delivery systems in oilfield operations, such as hydraulic fracturing, is hindered by the need for frequent equipment disassembly and reassembly, malfunctions, and time-consuming connections/disconnections, which disrupt operations and are costly.
Innovation Solution
A modular, adjustable fluid delivery system that allows for isolation of components for service or repair while maintaining system operation, featuring a network of pipelines and pump skids with hub connectors for efficient connection and misalignment handling, and a leveling system to manage elevation changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If equipment is used in hydraulic fracturing operations, then fluid delivery function is achieved, but equipment requires frequent disassembly and reassembly which consumes time and manpower
Solution Approach 1:
The system is divided into modular components including pump units, manifold assemblies, and connection interfaces that can be independently assembled and disassembled. Each pump unit can be connected to the manifold through standardized quick-connect interfaces, enabling rapid deployment and reconfiguration without time-consuming welding or bolting operations.
Solution Approach 2:
Connection interfaces and coupling mechanisms are pre-configured and pre-positioned on pump units and manifold assemblies before field deployment. Quick-connect couplings are pre-assembled with sealing elements and alignment features, allowing operators to simply engage connections rather than assembling multiple components on-site, significantly reducing assembly time.
2Productivity
If complex equipment systems are deployed for hydraulic fracturing, then fluid delivery capability is achieved, but system complexity increases requiring more manpower for management
Solution Approach 1:
The manifold assembly is designed as a universal interface that can accommodate multiple pump units of the same or different types through standardized connection ports. The same manifold configuration can serve different well sites and different fracturing operations, reducing the variety of specialized components needed and simplifying inventory management and personnel training.
Solution Approach 2:
Multiple functional components including pressure regulation, flow distribution, and connection interfaces are integrated into a single manifold assembly. This consolidation reduces the number of separate equipment items that need to be managed, tracked, and maintained, thereby reducing overall system complexity despite maintaining full fluid delivery capability.
3Ease of manufacture
If equipment is relocated between well sites for reuse, then cost effectiveness is achieved, but disassembly and reassembly operations are time-consuming
Solution Approach 1:
The system employs dynamic quick-connect interfaces that allow pump units to be rapidly attached and detached from the manifold without permanent installation. Hydraulic connections, mechanical couplings, and alignment features are designed to engage in a single motion, enabling equipment to be quickly relocated between well sites while maintaining sealing integrity and operational readiness.
Solution Approach 2:
All connection interfaces, sealing elements, and alignment features are pre-assembled and pre-positioned during manufacturing or initial setup. This preliminary configuration eliminates the need for complex field assembly operations during relocation, allowing equipment to be moved between well sites in a largely pre-configured state, thereby reducing both time and labor requirements while maintaining cost effectiveness.
4Productivity
If equipment operates continuously in hydraulic fracturing, then production efficiency is achieved, but malfunctions require operation interruption for repair
Solution Approach 1:
The system is segmented into independently replaceable pump units that can be quickly swapped at the manifold interface. If one pump unit malfunctions, it can be rapidly disconnected and replaced with a standby unit without affecting other pump units or requiring interruption of overall system operation, thereby maintaining production efficiency while improving reliability through continuous operation capability.
Solution Approach 2:
The manifold assembly serves as an intermediary hub that decouples individual pump units from the overall fluid delivery system. This intermediary structure allows pump units to be independently maintained, repaired, or replaced without shutting down the entire system, as the manifold can continue to receive and distribute fluid through remaining operational pumps, thus maintaining operational continuity.
Data Source
AI summary
Described herein is a modular, adjustable system for distributing fluids to one or more wellbores. The system is readily configured and assembled at a well site, and allows for one portion of the system to be isolated for service or repair while the remainder of the system continues to operate. The system includes a plurality of pump skids having both a distribution junction in fluid communication with inlets to of plurality of pump trucks and an exit junction in fluid communication with outlets of the plurality of pump trucks.