Modular Fracturing Manifold Layout for Flexible Flow Rates
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Solution Overview
Problem
Conventional hydraulic fracturing manifolds lack modularity in junctions and fracturing head configuration, leading to limitations in setup and teardown times, structural size, and weight restrictions, as well as inefficiencies in fluid flow rates and pressures.
Innovation Solution
A modular hydraulic fracturing manifold system that includes a trailer chassis with adjustable junctions and a fracturing head, allowing configuration between multiple positions, where the fracturing head can be moved between configurations by decoupling and re-coupling with additional junctions on a transportation skid, optimizing fluid flow and reducing the need for multiple fracturing heads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional fixed-configuration fracturing manifold is used, then the structure is simple and easy to manufacture, but the setup and teardown times are long and the system cannot adapt to different flow rate requirements
Solution Approach 1:
The fracturing manifold is divided into modular segments including a first plurality of junctions, a second plurality of junctions, and coupling mechanisms. These segments can be independently configured and assembled in different arrangements to create various flow paths and junction configurations, enabling adaptability without requiring complete system replacement.
Solution Approach 2:
The manifold incorporates movable and reconfigurable components such as adjustable junction positions and reconfigurable flow paths. The system can dynamically change its configuration during operation or between jobs by repositioning junctions and adjusting flow paths, transforming a static structure into a dynamic, adaptable system.
2Adaptability or versatility
If multiple fracturing heads are provided for different configurations, then the system can handle various flow rates, but the overall weight and cost increase
Solution Approach 1:
The manifold is designed with universal, multi-functional junctions and flow paths that can serve multiple purposes. The same physical infrastructure (trailer chassis, conduit system, junctions) can be configured to deliver different flow rates by adjusting the arrangement and connectivity of components, eliminating the need for separate fracturing heads for different flow rate requirements.
3Productivity
If the fracturing head is fixed at one end of the trailer, then the manufacturing is simple, but the system cannot optimize fluid flow for different configurations
Solution Approach 1:
The manifold configuration extends beyond a single linear arrangement by incorporating multiple dimensions of junction placement and flow path routing. The system can utilize vertical, horizontal, and diagonal flow paths through the trailer chassis, creating optimized fluid flow configurations that adapt to different operational requirements without increasing manufacturing complexity.
Data Source
AI summary
A fracturing manifold system including a first plurality of junctions mounted on a support structure and fluidly connected via conduit, individual ones of the first plurality of junctions configured to receive fracturing fluid from at least one fracturing pump and the first plurality of junctions including a first terminal junction. The fracturing manifold system further includes a fracturing head fluidly connected to the first plurality of junctions. The fracturing manifold system is configurable between a first configuration in which the fracturing head is mounted at a location proximate an end of the support structure and a second configuration in which an additional junction is mounted on the first support structure at the location, the additional junction is fluidly connected to the first plurality of junctions, a second plurality of junctions is fluidly connected to the additional junction, and the fracturing head is fluidly connected to the second plurality of junctions.