Offset Cross Junctions in Frac Manifold Missiles
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Solution Overview
Problem
Conventional frac systems face challenges with complex assembly, high leakage rates, and costly maintenance due to the harsh conditions of abrasive and corrosive fluids under high pressure, leading to inefficiencies and safety concerns in fracturing operations.
Innovation Solution
The development of novel missile flow lines with offset cross junctions and larger diameters, along with a single, straight missile design for frac manifolds, which reduces vibration and turbulence, and incorporates features like long-sweep curves and thick walls to minimize erosion and corrosion, facilitating easier assembly and longer service life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional frac systems use multiple pumps and complex flow line assemblies, then pumping capacity is increased, but device complexity and assembly difficulty increase significantly
Solution Approach 1:
The patent combines multiple pump discharge lines into a single missile flow line assembly. The manifold structure integrates multiple feed bores that converge into one primary bore, allowing multiple pumps to discharge through a unified flow path rather than requiring separate complex assemblies for each pump.
Solution Approach 2:
The missile flow line serves multiple functions: it acts as a manifold for multiple pumps, provides erosion-resistant flow paths through its geometric design, and functions as a single replaceable assembly unit. This multi-functionality reduces the number of separate components needed in the system.
2Ease of manufacture
If conventional flow lines use sharp turns and standard diameter pipes, then manufacturing is simpler, but erosion from abrasive fluids increases significantly
Solution Approach 1:
The missile flow line incorporates long-sweep curves with a sweep ratio of at least 1.25, replacing sharp angular turns with gradual curved transitions. This geometric modification reduces turbulence and prevents abrasive proppant-laden fluids from impacting the flow line walls at high velocities, thereby minimizing erosion while maintaining manufacturability.
3Ease of manufacture
If conventional junction fittings have feed bores intersecting at right angles, then manufacturing is easier, but vibration and turbulence increase
Solution Approach 1:
The junction fittings feature feed bores that intersect the primary bore at angles other than right angles, and the intersections are offset axially from each other. This asymmetric configuration prevents symmetric flow patterns that cause vibration and turbulence, while the axial offset spacing allows turbulence from one feed bore to subside before the next feed bore introduces additional fluid.
4Area of stationary object
If conventional missiles use smaller diameters to fit in standard manifolds, then space utilization is better, but leakage rates increase under high pressure
Solution Approach 1:
The patent specifies that the missile inner diameter should be about equal to or greater than the liner inner diameter, representing a parameter change from conventional smaller diameters. This larger diameter design, combined with the offset cross junction geometry, reduces velocity and pressure concentration points that lead to leakage, while the overall compact missile structure maintains space efficiency.
5Loss of substance
If conventional systems use thin-walled flow lines, then material cost and weight are reduced, but service life decreases due to corrosion and erosion
Solution Approach 1:
The missile flow line incorporates thick walls specifically in the regions where erosion and corrosion are most likely to occur, such as near the feed bore intersections and along the primary bore. This localized thickening provides enhanced protection against abrasive fluids and chemical corrosion, extending service life without unnecessarily increasing material cost and weight throughout the entire structure.
Data Source
AI summary
Missile flow lines are incorporated into frac manifolds, especially trailered or skidded frac manifolds. The missiles manifold the discharge from a plurality of pumps and comprise at least two junction fittings joined by spooled pipe. The junction fittings comprise a body having a primary bore and at least two feed bores. The intersections of the feed bores with the primary bore are offset axially from each other along the primary bore. The junction fittings are joined by flange unions to at least one spooled pipe such a that the junction fittings and spooled pipe form a conduit including the primary bores. A discharge line from a pump may be joined to each feed union face of the junction fittings by a flange union. Thus, the discharge from the pumps may be manifolded into the conduit.