Suction Manifold Positioning Mechanism for Safe Transit Repositioning
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Solution Overview
Problem
High pressure pumps used in hydraulic fracturing face challenges with sub-optimal suction piping design, as desirable suction manifolds exceed trailer width, making them illegal for road transit and posing safety risks during removal and reinstallation, often requiring compromise and increased injury risk.
Innovation Solution
A 2-stage positioning mechanism using gas dampers and a linkage system to safely lower and rotate the suction manifold into a road-legal position, ensuring controlled movement and automatic alignment during reinstallation, reducing the risk of injury and damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a well-designed suction manifold is used, then pump performance is improved, but the manifold width exceeds trailer dimensions making it illegal for road transit
Solution Approach 1:
The suction manifold is designed with a movable positioning mechanism that allows it to dynamically change its position between an operational configuration (extending laterally for optimal pump performance) and a transit configuration (retracted within trailer width limits). This dynamic repositioning capability resolves the contradiction by enabling the manifold to achieve both performance optimization and road legality at different times.
Solution Approach 2:
Instead of reducing the manifold width directly, the invention moves the manifold in the vertical dimension (up and down positioning) and longitudinal dimension (forward and backward positioning) to achieve compact packaging for transit while maintaining the full lateral extension capability for operation. This dimensional transformation allows the manifold to exceed width limits during operation but remain within limits during transit.
2Length of moving object
If the suction manifold is removed from the pump for transit, then road legality is achieved, but worker safety risks increase due to heavy manual handling
Solution Approach 1:
The positioning mechanism is designed to be self-operating through gravity and spring-loaded dampers. When the manifold needs to be repositioned for transit or service, the system automatically lowers or raises it without requiring workers to manually lift or support the heavy component. The gravity-assisted movement with controlled damping eliminates the need for human physical intervention during the repositioning process, thereby eliminating worker injury risks associated with heavy manual handling.
Solution Approach 2:
The positioning mechanism acts as an intermediary system between the suction manifold and the trailer frame. This intermediary mechanism bears and controls the weight of the manifold during all movement operations, preventing direct contact between workers and the heavy manifold. The mechanism mediates the force transmission and position control, ensuring that workers never need to manually support or position the heavy component.
3Length of moving object
If the suction manifold is removed and reinstalled manually, then transit compliance is achieved, but equipment damage risk increases due to misalignment
Solution Approach 1:
The positioning mechanism includes self-aligning features that automatically position the suction manifold correctly relative to the pump flange during the lowering operation. Alignment pins, tapered surfaces, or guided mounting interfaces within the mechanism ensure that the manifold settles into the correct position without requiring manual alignment by workers. This self-alignment capability prevents misalignment damage to seals, mating surfaces, and threaded connections that would otherwise occur during manual reinstallation.
Solution Approach 2:
The positioning mechanism pre-establishes the correct alignment and position of the suction manifold before the final mounting operation. By controlling the lowering path and final resting position of the manifold, the mechanism ensures that all mating surfaces, seals, and connection points are properly aligned in advance of the bolting operation. This preliminary positioning action prevents the need for forceful adjustment or realignment during installation, thereby protecting equipment integrity.
4Object-affected harmful factors
If the suction manifold is left in place during transit, then worker safety is improved, but the manifold may damage pump components due to vibration and movement
Solution Approach 1:
The positioning mechanism provides dynamic securing capability that adapts to different transit conditions. During transit, the mechanism can be configured to rigidly secure the manifold to the trailer frame, preventing any movement or vibration that could damage pump components. The same mechanism that enables easy positioning also provides rigid fixation during transport, eliminating the need to choose between leaving the manifold in place (safety) or removing it (component protection).
Solution Approach 2:
The positioning mechanism incorporates vibration isolation and shock absorption features that are activated during transit. These cushioning elements are built into the mounting and positioning system to protect the manifold and pump components from vibration and shock during road transport. By providing beforehand cushioning, the mechanism allows the manifold to remain secured to the pump during transit without risking damage from vibration or movement.
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
Enables the use of properly-designed suction manifolds on hydraulic fracturing pumps, facilitating safe and efficient movement between service and transit positions, reducing worker injury and potential damage to equipment, while ensuring compliance with road dimensions.
Implementation Method 1
Gas dampers are used to ensure that the heavy suction manifold is lowered in a slow, controlled fashion, reducing the potential for worker injury and fatigue
Implementation Method 2
The positioning mechanism permits the suction manifold to fall under the force of gravity when the suction manifold is detached from the pump fluid end
Data Source
AI summary
A positioning mechanism for lowering a suction manifold from an operational position with respect to pump fluid end to a transit and service position includes a linkage base plate configured to be fixedly coupled with a vehicle trailer, a linkage arm pivotally coupled with the linkage base plate and the suction manifold, a primary damper pivotally coupled with the linkage base plate and the linkage arm, a secondary damper pivotally coupled with the linkage base plate and the suction manifold, and a mechanical stop removably coupled with the secondary damper and configured to maintain the secondary damper at a fixed length while the mechanical stop is coupled with the secondary damper. The positioning mechanism permits the suction manifold to fall under the force of gravity when the suction manifold is detached from the pump fluid end, the primary damper is configured to slow the fall of the suction manifold under the force of gravity, and removal of the mechanical stop from the secondary damper permits the secondary damper to shorten from the fixed length to a shorter length under the force of gravity.