Modular Fracturing Manifold With Movable Flow Lines
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Solution Overview
Problem
Conventional hydraulic fracturing systems are overly complex, leading to excessive setup time, labor costs, limited adjustability, safety risks due to potential leak points, and decreased pumping efficiency, particularly in challenging environments such as continuous duty operations and extended-reach lateral wells.
Innovation Solution
A modular pressurization manifold system with movable flow lines and skids, allowing for adjustable connections between pumps and wellbores, and a zipper manifold to efficiently convey pressurized fluid to multiple wellbores, reducing complexity and enhancing adjustability and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional frac iron is used to connect pumps, manifolds, and wellbores, then fluid communication is established, but setup time and labor costs increase excessively
Solution Approach 1:
The patent combines multiple separate frac iron components (pump connections, manifold connections, wellbore connections) into an integrated modular system where the manifold assembly serves as a central hub that consolidates multiple connection points and functions into a single deployable unit, reducing the number of separate assembly operations required
Solution Approach 2:
The system is divided into modular components (manifold assembly, pump units, wellbore connections) that can be independently prepared and then quickly assembled together, allowing for pre-fabrication of sub-assemblies that reduce on-site setup time while maintaining reliable fluid communication pathways
2Adaptability or versatility
If conventional frac iron with multiple connection points is used, then fluid distribution to multiple wellbores is achieved, but the number of leak points and safety risks increase
Solution Approach 1:
Multiple fluid distribution functions are merged into a single integrated manifold assembly with standardized connection interfaces, reducing the total number of separate connection points and potential leak locations while maintaining the ability to distribute fluid to multiple wellbores through the consolidated structure
Solution Approach 2:
The manifold assembly is designed as a universal platform that can handle multiple wellbore connections and fluid distribution paths through standardized interfaces, reducing the need for specialized connection points for each wellbore and thereby reducing overall leak potential while maintaining versatility
3Reliability
If conventional frac iron with fixed connections is used, then pump fluid communication is established, but adjustability and pumping efficiency decrease
Solution Approach 1:
The manifold assembly incorporates movable or adjustable connection elements that allow the system to adapt pump configurations and fluid pathways dynamically, enabling optimization of pumping efficiency for different operational scenarios while maintaining reliable fluid communication through the standardized interface design
Data Source
AI summary
An apparatus according to which a subterranean formation in which a wellbore extends is hydraulically fractured, the apparatus comprising first and second manifolds, the first manifold including first and second flow lines adapted to be in fluid communication with first and second pumps, respectively, the first pump being adapted to pressurize fluid received from the first flow line, and the second pump being adapted to pressurize fluid received from the second flow line, and the second manifold including a third flow line adapted to convey pressurized fluid from the first and second pumps to the wellbore to hydraulically fracture the subterranean formation in which the wellbore extends. The apparatus is adapted to be connected to another apparatus used to hydraulically fracture the subterranean formation in which the wellbore extends by moving one, or both, of the first and second flow lines relative to the third flow line.