Modular Pump Manifolds for Continuous Fracturing Maintenance
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Solution Overview
Problem
Current hydraulic fracturing operations face challenges with nonproductive time due to pump malfunctions, proppant/sand accumulation, and the inability to isolate and maintain pumps during active fracturing stages, leading to reduced productivity and increased costs.
Innovation Solution
A modular manifold system that allows for flushing, isolation, and pressure testing of pumps while other manifolds are active, enabling simultaneous maintenance and quick reintegration of pumps into the fracturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pumps are used during active fracturing operations, then fracturing fluid can be pumped into the formation, but pump malfunctions and proppant accumulation occur leading to nonproductive time
Solution Approach 1:
The system divides the pumping operation into multiple independent manifolds (first manifold, second manifold, third manifold) that can operate independently. When one manifold requires maintenance or experiences pump failure, other manifolds can continue operating, segmenting the system to maintain overall productivity while addressing individual pump reliability issues.
Solution Approach 2:
The system enables quick isolation and replacement of malfunctioning pumps within manifolds. Failed pumps can be rapidly discarded from service, replaced with standby pumps, and the recovered manifold quickly reintegrated into active fracturing operations, minimizing nonproductive time.
2Reliability
If pumps are isolated for maintenance during active fracturing stages, then pump reliability can be maintained, but continuous fracturing operations are interrupted
Solution Approach 1:
The manifold system segments the fracturing operation into independent units. Maintenance can be performed on one manifold while other manifolds continue active fracturing stages, eliminating the need to interrupt overall operations and reducing nonproductive time.
Solution Approach 2:
The system maintains continuous fracturing operations by enabling parallel maintenance activities. While one manifold is isolated for pump maintenance, flushing, or pressure testing, other manifolds continue their useful action of pumping fracturing fluid, ensuring uninterrupted overall productivity.
3Stress or pressure
If multiple pumps are used to create high pressure, then fracturing pressure can be achieved, but system complexity increases with multiple hoses and piping
Solution Approach 1:
The system merges multiple pumps and their associated piping into integrated manifold assemblies. Each manifold combines pumps, high-pressure hoses, and piping into a single modular unit, reducing the overall complexity of managing multiple separate pump systems while maintaining the capability to generate high fracturing pressure.
Solution Approach 2:
The manifolds are designed as universal, multi-functional units that can perform pumping, isolation, maintenance, and pressure generation functions. This multi-functionality reduces the need for specialized equipment and simplifies system management compared to having separate dedicated systems for each function.
Data Source
AI summary
An illustrative modular manifold system includes, among other things, two or more modular pump manifolds, a low-pressure header, and a main high-pressure manifold. Modular pump manifolds may include a low-pressure manifold for supplying fracturing fluid or water to pumps, a high-pressure manifold for supplying fracturing fluid or water to one or more wells and a bleed-off / prime-up manifold. Each modular pump manifold of the modular manifold system is configured to be fluidly isolatable from the other modular pump manifolds. Each isolated modular pump manifold is configured to be flushed with water, bled off and primed up independently of the other modular pump manifolds. After the bleed off, maintenance procedures may be performed on pumps associated with the isolated modular pump manifold. The modular pump manifolds that are not isolated may continue in active fracing stage operations while a modular pump manifold is isolated.