Modular Manifold Assembly With Flexible Conduits for Fluid End Alignment
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Solution Overview
Problem
Existing manifold assemblies for high-pressure fluid ends in hydraulic fracturing operations face challenges with misalignment during connection, leading to increased stress and reduced operating life due to the rigidity of metal conduits, which complicates and prolongs the attachment process.
Innovation Solution
A manifold assembly with a flexible conduit system that includes upper and lower suction and discharge conduits attached to manifolds, allowing for easier alignment and attachment to the fluid end, and featuring a frame with adjustable side posts and blocks to secure the manifolds in position, reducing the risk of misalignment and stress on the fluid end.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid metal conduits are used to connect manifolds to fluid ends, then structural strength and pressure resistance are improved, but misalignment during connection occurs leading to increased stress and prolonged attachment time
Solution Approach 1:
The system is divided into rigid manifold components and flexible conduit components. The flexible conduits act as independent segments that can accommodate misalignment, separating the rigid structural elements from the alignment-sensitive connection elements.
Solution Approach 2:
The physical state of the conduits is changed from rigid to flexible by using elastomeric material. This parameter change allows the conduits to deform and accommodate misalignment during attachment while maintaining structural integrity under pressure.
2Strength
If rigid metal conduits are used to connect manifolds to fluid ends, then structural strength is improved, but stress on fluid end increases due to misalignment
Solution Approach 1:
The conduits are changed from rigid metal to flexible elastomeric material, allowing them to deform and absorb misalignment stresses without transmitting them to the fluid end, thereby eliminating the harmful stress factor while maintaining pressure containment capability.
Solution Approach 2:
The flexible conduit acts as an intermediary element between the rigid manifold and the fluid end. It mediates the connection by absorbing misalignment through its flexibility, preventing direct stress transmission to the fluid end while maintaining the structural connection.
3Stress or pressure
If rigid metal conduits are used, then pressure resistance is improved, but ease of operation deteriorates due to alignment difficulties
Solution Approach 1:
The mechanical property of the conduits is changed from rigid to flexible, enabling them to bend and conform during attachment operations. This allows operators to easily connect manifolds to fluid ends without precise alignment while maintaining the ability to withstand high operating pressures.
Solution Approach 2:
Flexible elastomeric conduits are used instead of rigid metal pipes. These flexible shells can deform during connection to accommodate misalignment, making the operation easier, while their elastomeric nature provides sufficient pressure resistance for hydraulic fracturing applications.
4Ease of operation
If flexible conduits are used to reduce misalignment stress, then ease of operation is improved, but structural strength may be compromised
Solution Approach 1:
The conduits are constructed from composite materials, specifically elastomeric materials that combine flexibility with high tensile strength and pressure resistance. This allows the conduits to be flexible enough for easy connection while maintaining the structural strength needed to withstand high-pressure hydraulic fracturing operations.
Solution Approach 2:
The material properties of the conduits are optimized to achieve a balance between flexibility and strength. The elastomeric material parameters are selected to provide sufficient elongation for alignment accommodation while maintaining adequate tensile strength and pressure containment capability for the application.
Data Source
AI summary
A manifold assembly configured for use with a fluid end used in oil and gas operations. The manifold assembly comprises upper and lower manifolds supported on side posts such that the manifolds and posts define a central opening. In operation, the fluid end is positioned within the central opening such that the manifold assembly surrounds the fluid end. The manifold assembly is not attached to the fluid end other than flexible conduits interconnecting the fluid and the manifolds. The manifold assembly is modular and when assembled, may be moved together as a single unit.