Fracturing Pump Inlet Hose Transition for Higher Slurry Flow
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Solution Overview
Problem
Hydraulic fracturing systems face challenges with standard 4-inch diameter fluid flow lines that limit fluid inlet to pumps, leading to premature wear and failures due to lower flow rates and pressures, and increasing hose sizes is impractical due to component fitting issues and potential blockages.
Innovation Solution
The development of a hydraulic fracturing system using a 5-inch diameter hose with hybrid 6-inch end connectors, allowing for increased fluid flow and pressure while maintaining standard 6-inch component compatibility, and incorporating a fitting system that transitions between 5-inch and 6-inch diameters to prevent particulate dropouts and reduce pressure drops.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If standard 4-inch diameter fluid flow lines are used, then component compatibility is maintained, but fluid inlet to pumps is limited causing lower flow rates and pressures
Solution Approach 1:
A hybrid fitting system acts as an intermediary between the 5-inch hose and 6-inch pump components. The fitting includes a 5-inch receptacle that receives the hose and internally transitions to a 6-inch outlet that couples to standard 6-inch pump components, enabling compatibility without requiring pump modification
Solution Approach 2:
The system changes the diameter parameter of the flow line from the standard 4-inch to 5-inch to increase fluid capacity. This parameter change is made possible by the hybrid fitting that accommodates the larger diameter while maintaining interface compatibility with existing 6-inch pump components
2Quantity of substance
If hose sizes are increased to improve fluid flow, then flow rates increase, but component fittings on the pump create compatibility problems and potential blockages
Solution Approach 1:
The hybrid fitting serves as a mediator that reconciles the size mismatch between the 5-inch hose and 6-inch pump components. It provides a smooth internal transition that prevents particulate dropout and blockages while maintaining ease of operation with standard pump interfaces
3Reliability
If standard 4-inch flow lines are used, then system compatibility is maintained, but pumps experience premature wear and failures due to lower flow rates and pressures
Solution Approach 1:
Increasing the flow line diameter from 4-inch to 5-inch changes the flow parameters (rate and pressure) to levels that prevent pump wear and failure. The hybrid fitting makes this parameter change feasible without requiring complete system redesign
Solution Approach 2:
The hybrid fitting enables the 5-inch hose integration with existing 6-inch pump components, creating a reliable connection that maintains improved flow rates and pressures while preserving pump equipment life
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system achieves higher fluid flow rates and pressures, reducing cavitation and equipment wear, while integrating seamlessly with existing systems without the need for costly overhauls, thereby prolonging equipment life and improving operational efficiency.
Implementation Method 1
The hose being flexible and having a first diameter... allowing for increased fluid flow and pressure
Implementation Method 2
a fitting system that transitions between 5-inch and 6-inch diameters to prevent particulate dropouts and reduce pressure drops
Implementation Method 3
the electric powered pump configured to pump fluid into a wellbore associated with the well at a high pressure so that the fluid passes from the wellbore into the subterranean formation and fractures the subterranean formation
Data Source
AI summary
A hydraulic fracturing system for fracturing a subterranean formation includes an electric powered pump having an inlet and an outlet, the outlet coupled to a well associated with the subterranean formation and powered by at least one electric motor. The system also includes a fluid source, coupled to the inlet of the electric powered pump, the fluid source providing a slurry for injection into the subterranean formation. The system further includes a hose extending between the fluid source and the electric powered pump, the hose being flexible and having a first diameter. The system includes a fitting between the hose and the electric powered pump, the fitting having a first end for receiving the hose at the first diameter and a second end for coupling to the electric powered pump at a second diameter, the second diameter being larger than the first diameter.