Modular Well Manifold Blocks for Faster Custom Assembly
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Solution Overview
Problem
Existing hydrocarbon well manifolds are bespoke and require lengthy production times due to numerous custom parts, leading to high costs and inefficiencies in delivery and assembly.
Innovation Solution
A modular manifold system composed of standardized building blocks, including flow-line, header, and branch configuration blocks, allowing for pre-stocking and flexible assembly to meet specific client requirements, with features like double barrier valves and ROV-compatible connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If bespoke manifolds are manufactured according to customer specifications, then the manifold can be adapted to specific requirements, but the production period and delivery time increase significantly
Solution Approach 1:
The manifold is divided into standardized modular blocks (header blocks, flowline blocks, branch blocks) that can be pre-manufactured and stocked. Each block type serves specific functions and can be combined in different configurations to meet customer requirements, eliminating the need for complete bespoke manufacturing while maintaining adaptability.
Solution Approach 2:
The standardized blocks are designed with universal connection interfaces and features that allow them to serve multiple functions and be used in various manifold configurations. For example, header blocks can accommodate different numbers of branch connections, and flowline blocks can be arranged in series to create manifolds of different sizes, all using the same basic block types.
2Adaptability or versatility
If bespoke manifolds with high number of parts are manufactured, then specific customer requirements are met, but the cost increases
Solution Approach 1:
By segmenting the manifold into standardized blocks, the system reduces the total number of unique parts required. Each block type can be manufactured in volume and stocked, achieving economies of scale. The modular approach allows customization through configuration rather than through unique part design, significantly reducing per-unit costs.
Solution Approach 2:
The standardized blocks can be reused across different manifold projects and configurations. Unused blocks from one project can be recovered and used in future projects, further reducing material costs and waste. This reuse capability makes the system economically advantageous for companies with multiple manifold requirements.
3Reliability
If double barrier philosophy is implemented with redundant valves, then safety and reliability are improved, but the number of parts and system complexity increase
Solution Approach 1:
The double barrier valve system is integrated into the standardized block design itself rather than being added as separate external components. The redundant valves are incorporated within the block housing with integrated mounting and connection features, reducing the overall number of discrete parts while maintaining the safety functionality.
Solution Approach 2:
The standardized blocks are designed with universal features that accommodate double barrier valves in a standardized manner. The same block design can be used whether or not double barrier protection is required, with the valve integration being a standard option rather than a custom modification, thereby maintaining reliability without proportionally increasing complexity.
Data Source
AI summary
The present invention relates to a header configuration block for a hydrocarbon well comprising a header configuration block housing having a plurality of transversal bores each in fluid connection with a discrete longitudinal main bore. At least one cut off valve is located in each transversal bore. A first connecting surface is parallel to and similar with a second connecting surface, whereby the first connecting surface and the second connecting surface are adapted to be connected to at least one further similar header configuration block. The invention also relates to a manifold branch configuration block and a well fluid manifold assembled of header configuration blocks, branch configuration blocks and flow line configuration blocks.