Modular Hydraulic Fracturing Manifolds With Integrated Intensifiers
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Solution Overview
Problem
Existing hydraulic fracturing spreads require numerous high-pressure connections, large footprints, and extensive maintenance, posing safety concerns and inefficiencies.
Innovation Solution
A hydraulic fracturing spread system utilizing manifold assemblies with integrated pressure intensifier pumps that reduce high-pressure connections and consolidate equipment, using low-pressure hydraulic oil to drive oil-hydraulic pumper units and intensifier units, thereby increasing fracturing fluid pressure efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If individual pumping units on truck trailers are used to pump fracturing fluid, then the fracturing fluid can be pumped at high pressure, but the number of high-pressure connections increases and the spread footprint increases
Solution Approach 1:
The patent combines multiple individual pumping units into a single integrated pumping system. Instead of using twelve separate truck-mounted pumps each requiring high-pressure connections to the manifold, the invention uses one pumping unit that pumps fluid through low-pressure hydraulic lines to drive multiple intensifier pumps within a single manifold assembly. This merging eliminates numerous high-pressure connections while maintaining the required high-pressure output capability.
Solution Approach 2:
The patent introduces low-pressure hydraulic oil as an intermediary medium to transfer power from the pumping unit to the intensifier pumps. Instead of directly connecting high-pressure fracturing fluid lines from multiple pumps to the manifold, the system uses low-pressure hydraulic oil to drive the intensifier mechanisms, which then generate the required high pressure. This intermediary approach reduces the number and pressure level of connections required.
2Power
If individual pumping units on truck trailers are used, then high pressure pumping is achieved, but the spread requires a large footprint
Solution Approach 1:
The patent consolidates multiple truck-mounted pumping units into a single integrated manifold assembly with intensifier pumps. Instead of requiring space for twelve separate trucks and their associated equipment, the invention combines all pumping functions into one location, dramatically reducing the spread footprint while maintaining the capability to deliver high-pressure fracturing fluid to the wellbore.
3Adaptability or versatility
If numerous high-pressure connections are used in the spread, then individual pumping units can operate independently, but maintenance requirements increase and safety concerns arise
Solution Approach 1:
The patent uses low-pressure hydraulic oil as an intermediary to drive the intensifier pumps, eliminating the need for numerous high-pressure connections between individual pumping units and the manifold. By reducing the pressure level of the hydraulic lines and connections, the system minimizes safety hazards and maintenance requirements associated with high-pressure connections while maintaining operational flexibility through the intensifier mechanism.
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
Reduces the number of high-pressure connections, decreases the spread's footprint, enhances safety by minimizing maintenance downtime, and improves operational efficiency.
Implementation Method 1
The hydraulic oil is then sent from the oil-hydraulic manifolds to oil-hydraulic pumper units, which increase the pressure of the hydraulic oil
Implementation Method 2
The fracturing fluid is then sent to high-pressure fracturing fluid manifolds positioned on the manifold assemblies, where the pressure is increased to the desired pressure or PSI
Data Source
AI summary
A hydraulic fracturing spread system has modular high-pressure fracturing fluid manifold assemblies which couple to form a large trunk line for collecting and conveying high pressure fracturing fluid toward the well bore. Oil-hydraulic intensifier pump units integrated with the modular manifold assemblies increase the fracturing fluid pressure into the trunk line. The manifold assemblies may be configured differently from one to the other and coupleable horizontally and/or vertically.