Swirl-Flow Manifold Coupling for Fracturing Fluid Vibration Control
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Solution Overview
Problem
High-pressure fracturing operations face challenges in effectively dissipating fluid energy, suspending proppants, and draining fracturing fluids from manifold assemblies, leading to vibration, reduced proppant effectiveness, and potential damage to equipment due to residual fluids.
Innovation Solution
The use of a manifold coupling design with oriented inlet passages that promote swirling of fracturing fluid, enhancing energy dissipation and proppant suspension, and improving drainage by configuring the inlet passages to intersect with the manifold passage in a manner that encourages turbulent flow and efficient fluid movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-pressure fracturing fluid is pumped into the formation at high flow rates, then the formation fractures and creates additional flow paths for hydrocarbons, but pressure builds rapidly causing formation failure and vibration
Solution Approach 1:
The patent converts the harmful pressure oscillations and vibrations generated by multiple pumps into beneficial swirling flow patterns. The manifold coupling design directs the pulsating fluid flows from multiple pumps to create controlled swirler flow, which dissipates energy and reduces harmful vibrations while maintaining high-pressure fracturing capability for hydrocarbon production.
2Productivity
If multiple hydraulic fracturing pumps operate simultaneously to supply high-pressure fracturing fluid, then productivity increases, but large pressure oscillations and vibrations are generated in the manifold
Solution Approach 1:
The patent transforms the destabilizing pressure oscillations from multiple pumps into a useful swirling flow regime. The manifold coupling geometry converts the pulsating flows into coordinated swirler flow patterns that dissipate energy and stabilize the system, turning what would be harmful vibrations into beneficial flow characteristics that enhance proppant suspension and energy dissipation.
Solution Approach 2:
The patent merges the outputs from multiple hydraulic fracturing pumps through a specially designed manifold coupling. The coupling combines the individual pump flows in a way that creates a unified swirling flow pattern in the manifold passage, allowing multiple pumps to operate simultaneously while their combined effect produces stable, controlled flow rather than chaotic oscillations.
3Reliability
If proppants are suspended in the fracturing fluid slurry, then fracture conductivity is maintained, but proppant suspension becomes difficult at high flow rates and long distances from the wellbore
Solution Approach 1:
The patent converts the high-velocity, turbulent flow conditions that would normally cause proppant settling into beneficial swirling flow patterns. The swirler flow created by the manifold coupling generates centrifugal forces and enhanced mixing that actively suspend proppants throughout the fracturing fluid, maintaining fracture conductivity even at high flow rates and distances from the wellbore.
4Productivity
If the manifold assembly is designed for high-pressure operation, then fracturing fluid delivery is effective, but complete drainage of residual fluids becomes difficult
Solution Approach 1:
The patent applies drainage ports at the top of the manifold assembly rather than at the bottom, inverting the conventional drainage approach. The swirler flow pattern created during operation naturally directs residual fluids toward the top-mounted drainage ports, allowing complete and easy drainage of the manifold assembly after high-pressure fracturing operations without requiring complex drainage systems.
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
This design reduces vibration, enhances proppant suspension, and facilitates complete drainage of fracturing fluids, improving the efficiency and longevity of fracturing operations by minimizing equipment damage and weight imbalances during transport.
Implementation Method 1
The first and second inlet passages may be oriented and/or configured such that fracturing fluid entering the manifold assembly via the first and second inlet passages promotes swirling of the fracturing fluid downstream of the manifold coupling
Implementation Method 2
enhancing energy dissipation and proppant suspension, and improving drainage by configuring the inlet passages to intersect with the manifold passage in a manner that encourages turbulent flow
Data Source
AI summary
Methods, systems, and devices to enhance fracturing fluid delivery to subsurface formations to enhance hydrocarbon production from the subsurface formations may include providing a manifold coupling having a manifold coupling passage with a manifold coupling axis. The manifold coupling may include a first inlet passage positioned to provide fluid flow between a first fracturing fluid output and the manifold coupling passage, and a second inlet passage positioned opposite the first inlet passage to provide fluid flow between a second fracturing fluid output and the manifold coupling passage. The first inlet passage may have a first inlet passage cross-section at least partially defining a first inlet axis extending transverse relative to the manifold coupling axis. The second inlet passage may have a second inlet passage cross-section at least partially defining a second inlet axis extending transverse relative to the manifold coupling axis and not being co-linear with the first inlet axis.