Modular Pump Manifolds for Fracturing Without Full Shutdown
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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 management of individual pump manifolds, enabling simultaneous maintenance and reactivation during active fracturing stages, using low-pressure and high-pressure manifolds, and a bleed-off/prime-up manifold for safe and efficient pump maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If a pump is shut down for maintenance during active fracturing operations, then pump maintenance can be performed, but the entire fracing stage must be stopped leading to nonproductive time
Solution Approach 1:
The system divides the fracing operation into multiple independent pump manifolds (first modular pump manifold, second modular pump manifold, etc.) that can operate independently. When one manifold requires maintenance, only that specific manifold is isolated while others continue operating, allowing pump maintenance without stopping the entire fracing stage.
Solution Approach 2:
The system implements dynamic isolation capabilities where individual pump manifolds can be isolated from the main high-pressure manifold while others remain connected and operational. This allows the system to transition from all-pumps-operating to selective-pumps-operating mode without complete shutdown.
2Productivity
If high pressure is maintained in the fracing system during active operations, then fracturing fluid can be pumped into the formation, but pump maintenance and access cannot be performed safely
Solution Approach 1:
The system segments the high-pressure system into isolated manifold sections. Each manifold can be individually isolated and depressurized while maintaining pressure in other sections, enabling safe pump access and maintenance in the isolated section without affecting the overall fracturing operation.
Solution Approach 2:
The main high-pressure manifold acts as an intermediary that can selectively connect or disconnect individual pump manifolds. This allows pressure to be maintained in the main manifold and operational manifolds while isolated manifolds are depressurized for safe maintenance.
3Productivity
If proppant accumulates in pumps during operation, then pumping continues, but pump performance deteriorates and maintenance is delayed
Solution Approach 1:
The system enables preliminary isolation of pump manifolds before performance deterioration becomes critical. By monitoring and selectively isolating manifolds, maintenance can be performed proactively on individual pumps while others continue operating, preventing performance degradation from affecting the entire system.
Solution Approach 2:
The system maintains continuous fracturing operations through multiple parallel pump manifolds. While one manifold is isolated for maintenance or flushing, other manifolds continue pumping, ensuring uninterrupted useful action in the overall fracing operation.
4Power
If multiple pumps operate simultaneously in a single manifold, then pumping capacity increases, but isolation and maintenance of individual pumps becomes difficult
Solution Approach 1:
Instead of attempting to isolate individual pumps within a manifold, the system segments at the manifold level. Each modular pump manifold contains multiple pumps that operate together as a unit, and the entire manifold can be isolated from the main system. This reduces isolation complexity compared to individual pump isolation while maintaining high pumping capacity through parallel manifolds.
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.