Swivel Zipper Module for Straight-Flow Fracturing Trees
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Solution Overview
Problem
Conventional hydraulic fracturing systems are overly complex, leading to excessive setup time, labor costs, safety risks, and decreased pumping efficiency due to their limited adjustability and potential leak points, which can decrease the effectiveness of fracturing operations, especially in extreme conditions and for extended-reach lateral wells.
Innovation Solution
The introduction of a system featuring a fracturing tree with a straight fluid flow path and a zipper module that allows for adjustable and swiveling connections between fluid conduits and fracturing trees, enabling efficient alignment and alignment of fluid passages to reduce turbulence and wear, thereby simplifying setup and enhancing operational efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional frac iron is used to connect fracturing trees and manifolds, then the system can deliver hydraulic fracturing fluid, but the setup time and labor costs increase excessively
Solution Approach 1:
The system is divided into modular components (fracturing trees, manifolds, zipper modules, fluid conduits) that can be independently assembled and configured. This segmentation allows for rapid setup by connecting pre-fabricated modules rather than assembling complex conventional frac iron systems from multiple small components.
Solution Approach 2:
The zipper module incorporates swivelable connections that allow dynamic adjustment of fluid conduit orientations. This dynamic capability enables quick adaptation to different wellhead positions and configurations without requiring time-consuming repositioning or reconfiguration of rigid conventional piping systems.
2Reliability
If conventional frac iron with multiple connections is used, then the system can communicate fluid between components, but the number of potential leak points increases
Solution Approach 1:
Multiple connection functions are merged into the zipper module, which integrates swivelable joints, fluid conduits, and alignment mechanisms into a single unified component. This consolidation reduces the total number of separate connections and potential leak points compared to conventional frac iron systems that require multiple separate couplings and joints.
Solution Approach 2:
The fluid conduit acts as an intermediary element that provides a sealed, continuous pathway for hydraulic fracturing fluid between the fracturing tree and manifold. This intermediary conduit eliminates the need for multiple exposed connection points, reducing leak potential while maintaining fluid communication.
3Productivity
If conventional frac iron with complex piping is used, then the system can deliver fluid, but the pumping efficiency decreases
Solution Approach 1:
The fluid conduit is designed with smooth, curved transitions rather than sharp angles or multiple bends typical of conventional piping. This streamlined geometry reduces turbulence and pressure losses, improving pumping efficiency while simplifying the overall piping configuration.
Solution Approach 2:
The zipper module serves multiple functions simultaneously: it provides fluid conduit connection, enables swivelable orientation adjustment, and ensures proper alignment between components. This multi-functionality eliminates the need for separate alignment devices and complex piping arrangements, reducing overall system complexity while maintaining efficient fluid delivery.
Data Source
AI summary
A system for supplying fracturing fluid to a fracturing tree coupled to a wellhead comprising: a zipper module having a lower block with a first opening configured to receive the fracturing fluid, the lower block being independently rotatable at a swivel assembly around a vertical axis relative to the lower block; an upper block with a second opening configured to dispel the fracturing fluid, the upper block being independently rotatable at a swivel connection around the vertical axis; an internal flow path between the upper block and the lower block; and a fluid conduit between the zipper module and the fracturing tree comprising at least one pipe, wherein the at least one pipe defines a first straight flow path between the zipper module and the fracturing tree.