Modular Pump Manifold Connection Blocks for Faster Frac Setup
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Solution Overview
Problem
Current pump manifold systems are expensive, complex, heavy, difficult to transport, install, and maintain, requiring extensive personnel and equipment for connection and operation.
Innovation Solution
The design includes a connection block with a first and second end hub, planar faces, and clamps that facilitate easy assembly and disassembly, along with a crane system that is modular and lightweight, allowing for quick setup and reduced equipment needs, featuring quick-detach clamps and a base frame with rollers for mobility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional pump manifold systems are used, then pumping operations can be performed, but the systems are expensive, complex, heavy, and difficult to transport and install
Solution Approach 1:
The pump manifold system is divided into modular connection blocks that can be independently manufactured and assembled. Each connection block contains integrated components (hubs, tubes, shoulders) that are pre-fabricated as discrete units, allowing for simplified manufacturing and easy assembly on-site without requiring complex welding or fabrication operations.
Solution Approach 2:
Multiple functional components are merged into single integrated parts. The connection block combines hubs, tubes, shoulders, and mounting features into one unified component, reducing the total number of parts and simplifying the overall system structure while maintaining all necessary pumping functions.
2Productivity
If traditional pump manifold systems are used, then pumping operations can be performed, but they require extensive personnel and equipment for connection and operation
Solution Approach 1:
Connection blocks are pre-assembled with hubs, tubes, and mounting features already in place during manufacturing. This preliminary assembly eliminates the need for on-site fabrication, welding, or complex alignment operations, allowing rapid installation by simply connecting pre-fabricated modules together.
Solution Approach 2:
The system incorporates movable rollers on the base frame that enable dynamic repositioning and adjustment of the connection blocks during installation and operation. This dynamic capability allows single-operator installation and easy reconfiguration without requiring multiple personnel for positioning and alignment.
3Weight of moving object
If traditional pump manifold systems are used, then pumping operations can be performed, but the systems are heavy and difficult to transport
Solution Approach 1:
The system is segmented into discrete, modular connection blocks that can be transported separately and assembled on-site. This segmentation reduces the weight of individual transport units and allows for flexible shipping arrangements, while the modular nature enables easy reconfiguration at the destination.
Solution Approach 2:
The connection blocks are designed with thin-walled tubular structures that maintain structural integrity while minimizing weight. The hollow tube design provides the necessary strength for pumping operations while dramatically reducing the weight compared to solid construction, improving transportability without sacrificing structural capability.
4Ease of repair
If traditional pump manifold systems are used, then pumping operations can be performed, but they are difficult to maintain
Solution Approach 1:
The modular connection block design allows individual components to be independently accessed, removed, and replaced. If a tube or hub becomes damaged or worn, only that specific component needs to be replaced rather than the entire manifold system, significantly simplifying maintenance while maintaining overall system reliability through quick repairs.
Solution Approach 2:
The system is designed to allow easy replacement of worn or damaged components. Connection blocks can be quickly disconnected and replaced as needed, and removed components can be recovered, refurbished, and reused in future applications, reducing maintenance costs and improving system availability.
Data Source
AI summary
Aspects of the present disclosure relate to connection blocks and pump manifold systems, and related methods, for pumping operations (such as frac operations). In one implementation, a connection block for disposition along a pump manifold of a pump system includes a first end hub having a first tube and a first outer shoulder extending outwardly relative to the first tube. The connection block includes a second end hub opposing the first end hub. The second end hub has a second tube and a second outer shoulder extending outwardly relative to the second tube. The connection block includes one or more faces between the first end hub and the second end hub.