Modular Frac Manifold Layout for Shorter Hoses and Access
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Solution Overview
Problem
Existing fracturing systems for oil and gas wells face challenges with hose management, as high-pressure hoses on the ground complicate operations and hinder accessibility due to excess length and positioning issues, particularly when equipment is spread out and positioned on trailers, making it difficult for personnel to perform maintenance and access the manifold.
Innovation Solution
A modular system with adjustable and laterally spaced manifolds, including low-pressure and high-pressure manifolds supported by a structural frame and height-adjustable legs, allows for flexible configuration and positioning, reducing hose length and enabling easier access by positioning manifolds directly on the ground or trailers, with connecting spools of varying lengths to accommodate different job site requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If equipment is spread out and positioned on trailers, then coverage area is improved, but hose management becomes complicated and accessibility deteriorates
Solution Approach 1:
The system is divided into multiple modular manifold units that can be independently positioned on trailers or ground. Each manifold unit is self-contained with connection points for hoses, allowing the system to cover a larger area while maintaining manageable hose lengths between each modular unit and the wellhead.
2Length of moving object
If hose length is increased to reach distant equipment, then connectivity is improved, but hose clutter and operational complexity increase
Solution Approach 1:
Instead of using a single long hose from a central manifold, the system uses multiple shorter hoses connecting to distributed modular manifold units. This segmentation reduces hose clutter on the ground while maintaining connectivity to all necessary equipment points.
3Adaptability or versatility
If manifold is positioned on trailers, then mobility is improved, but accessibility for maintenance deteriorates
Solution Approach 1:
The manifold system is designed with dynamic positioning capability, allowing units to be easily moved between trailer-mounted and ground-positioned configurations. This dynamic adaptability enables the system to provide mobility when needed while allowing easy access for maintenance when positioned on the ground.
4Device complexity
If equipment is centralized, then hose management is simplified, but coverage area and adaptability to job site conditions deteriorate
Solution Approach 1:
Each modular manifold unit is designed as a universal component that can function independently or in combination with other units. The standardized connection points and modular design allow the system to adapt to various job site configurations while maintaining simplified hose management through consistent connection interfaces.
Data Source
AI summary
An illustrative modular manifold disclosed herein includes, among other things, a low-pressure manifold comprising a frac fluid outlet valve, wherein a fracturing fluid is adapted to be supplied from the low-pressure manifold via the frac fluid outlet valve to a suction side of a frac pump, and a high-pressure manifold comprising at least one frac fluid inlet valve, wherein the high-pressure manifold is adapted to receive, via the frac fluid inlet valve, a fracturing fluid discharged from the frac pump. In this example, the modular manifold also includes a support structure for mechanically supporting the low- and high-pressure manifolds and a plurality of height-adjustable support legs operatively coupled to the support structure.