Modular Fracturing Component Exchange With Quick-Connect Couplers
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Solution Overview
Problem
Hydraulic fracturing operations face significant downtime and inefficiencies due to the complex and cumbersome process of replacing or servicing large, heavy components, which requires disconnecting numerous electrical and fluid connections, leading to prolonged interruptions.
Innovation Solution
The implementation of exchangeable fracturing component sections with quick-connect electrical and fluid couplers, allowing for rapid disconnection and connection of components, including a section frame, electrical assembly, and fluid assembly, to facilitate efficient component replacement and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If traditional component replacement methods are used, then components can be replaced, but the process is complex and time-consuming due to numerous electrical and fluid connections
Solution Approach 1:
The fracturing component is divided into modular sections with standardized interfaces. Each section can be independently replaced by disconnecting and reconnecting at the modular interfaces, eliminating the need to service individual components within the section and significantly reducing replacement time.
Solution Approach 2:
Quick-connect couplers serve as intermediary devices between component sections. These couplers enable rapid connection and disconnection of hydraulic lines and electrical connections, acting as a mediator that simplifies the replacement process and eliminates complex manual disconnection procedures.
2Loss of time
If components are designed for rapid exchange, then downtime is reduced, but the device complexity increases due to quick-connect mechanisms
Solution Approach 1:
Multiple connection functions (hydraulic lines, electrical connections, and mechanical mounting) are merged into a single integrated quick-connect interface. This consolidation reduces the number of separate mechanisms needed and simplifies the overall device while enabling rapid exchange.
Solution Approach 2:
The quick-connect interfaces are designed with universal compatibility across different component sections. The standardized interfaces can handle multiple connection types (hydraulic, electrical, mechanical) through a single universal coupling mechanism, reducing complexity through standardization.
Data Source
AI summary
Systems and methods for exchanging fracturing components of a hydraulic fracturing unit and may include an exchangeable fracturing component section to facilitate quickly exchanging a fracturing component of a hydraulic fracturing unit. The fracturing component section may include a section frame including a base, and a fracturing component connected to the base. The fracturing component section also may include a component electrical assembly and a component fluid assembly connected to the section frame. The fracturing component section further may include a coupling plate connected to the section frame. The fracturing component section also may include one or more of a plurality of quick-connect electrical couplers or a plurality of quick-connect fluid couplers connected to a coupling plate. The quick-connect electrical and fluid couplers may be positioned to receive respective electrical and fluid connections of the component electrical and fluid assemblies and connect to other portions of the hydraulic fracturing unit.