Modular Fracturing Manifold Layout for Faster Wellsite Setup
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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 trucks on rails, allowing for adjustable connections between manifolds and pumps, and a zipper manifold to efficiently convey pressurized fluid to multiple wellbores, reducing complexity and enhancing flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional frac iron is used to connect pumps, manifolds, and fracturing trees, then the system can deliver hydraulic fracturing fluid, but the setup time and labor costs increase excessively
Solution Approach 1:
The system is divided into modular components: pump units with integrated flow lines, manifolds with standardized connections, and fracturing trees. Each module can be independently assembled and connected, reducing overall setup time and complexity while maintaining full functionality for fluid delivery.
2Reliability
If conventional frac iron with multiple connection points is used, then fluid can be conveyed to multiple wellbores, but safety risks increase due to potential leak points
Solution Approach 1:
Multiple flow lines and connection points are merged into integrated manifold structures with centralized sealing systems. The manifold design consolidates numerous potential leak points into fewer, more controllable sealing locations, improving safety while maintaining the ability to service multiple wellbores simultaneously.
3Adaptability or versatility
If conventional frac iron with fixed connections is used, then the system structure is stable, but adjustability is limited
Solution Approach 1:
The connection system incorporates movable and adjustable components including telescopic flow lines, articulating joints, and reconfigurable manifold connections. These dynamic elements allow the system to adapt to different wellbore configurations and operational requirements while maintaining structural stability through controlled movement and positioning.
4Productivity
If conventional frac iron is used in extended-reach lateral wells, then fluid can be delivered to distant wellbores, but pumping efficiency decreases
Solution Approach 1:
The system utilizes optimized hydraulic flow line design with appropriate diameter selections, smooth internal surfaces, and minimized bends or restrictions. The manifold configuration and flow line routing are designed to reduce pressure losses and maintain pumping efficiency even when conveying fluid over extended distances to lateral wellbores.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system decreases setup time and labor costs, reduces safety risks, and increases pumping efficiency, thereby improving the effectiveness of hydraulic fracturing operations in various environments.
Implementation Method 1
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
Implementation Method 2
a 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
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.