Modular High Pressure Manifold for Hydraulic Fracturing
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Solution Overview
Problem
Conventional manifold systems used in hydraulic fracturing operations are often too large and costly for operations requiring fewer than ten or twelve fracturing pumps, leading to wasted resources and complex maintenance processes, as entire manifolds need to be removed for repairs or inspections.
Innovation Solution
A modular manifold system comprising multiple sub-assemblies with adjustable pump counts, allowing for flexible configuration to match the number of fracturing pumps in use, with remote operation of valves and a dedicated high pressure bypass line for efficient fluid management and simplified maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional manifold system designed for ten or twelve stations is used, then the manifold can handle operations with the full number of fracturing pumps, but the system becomes unnecessarily large and costly when fewer pumps are required
Solution Approach 1:
The manifold system is divided into multiple independent sub-assemblies, each capable of handling a specific number of pump stations (e.g., 2-station, 4-station, 6-station sub-assemblies). These sub-assemblies can be selectively combined to match the actual number of fracturing pumps in use, eliminating the need to deploy a complete 10- or 12-station manifold when fewer pumps are required. This segmentation allows the system to be scaled precisely to operational needs.
2Reliability
If a complete manifold system is used for operations requiring fewer pumps, then full operational capability is available, but maintenance requires removal of the entire manifold unit
Solution Approach 1:
By dividing the manifold into modular sub-assemblies, maintenance can be performed on individual sub-assemblies independently. When a sub-assembly requires repair or inspection, only that specific module needs to be removed and replaced, rather than the entire manifold system. This significantly reduces maintenance downtime and complexity while maintaining full operational capability through selective deployment of functional sub-assemblies.
3Ease of repair
If a modular sub-assembly system is implemented, then maintenance can be simplified through individual replacement, but the system complexity increases due to multiple components
Solution Approach 1:
The modular sub-assemblies are designed with standardized interfaces and universal components that can be used across different configurations. A 2-station sub-assembly, for example, uses the same basic building blocks as a 4-station or 6-station sub-assembly, just arranged differently or combined with additional modules. This universality reduces the actual complexity by allowing the same component library to serve multiple functions and configurations, rather than requiring entirely different systems for each size.
Data Source
AI summary
The present application is directed to a manifold system for low pressure and high pressure fluids. The manifold system may include one or more manifold sub-assemblies that may be assembled together, separated apart and replaced as desired. In oil and gas hydraulic fracturing operations, each manifold sub-assembly includes two or more low pressure fluid lines and two or more high pressure fluid lines for fluidly communicating with hydraulic fracturing pumps. High pressure fluid may exit the manifold system via a single line or multiple lines.