Swiveling Fluid Routing System for Frac Well Isolation
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Solution Overview
Problem
Hydraulic fracturing operations face inefficiencies and equipment failures due to the complex layout of zipper manifolds, which require frequent valve operations, leading to increased maintenance and the risk of valve failure, as well as the need for extensive frac iron that can be prone to turbulence and abrasive effects.
Innovation Solution
A fluid routing system with a swiveling conduit that allows for selective connection to a single well while isolating others, reducing the number of valves and eliminating the need for extensive piping, thereby minimizing pressure control equipment and footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a zipper manifold with multiple valves is used to direct high-pressure fluid to multiple wells, then fluid can be routed to different wells, but the repeated opening and closing of valves leads to valve failure and increased maintenance
Solution Approach 1:
The system divides the fluid distribution function into separate dedicated lines for each well, with each line having its own isolation valve. This segmentation eliminates the need for a complex manifold with multiple valves that must be repeatedly operated, thereby reducing valve failure risk while maintaining the ability to route fluid to different wells.
Solution Approach 2:
The system uses dynamic isolation valves on individual lines that can be opened or closed independently to control fluid flow to specific wells. This dynamic control approach replaces the static manifold configuration, allowing flexible well selection without repeatedly operating manifold valves, thus improving valve reliability.
2Area of stationary object
If a zipper manifold is located near the missile far from the wells, then the layout is compact, but the amount of frac iron required increases and the piping becomes muddled with many turns and bends
Solution Approach 1:
The system relocates the fluid distribution function from a centralized manifold near the missile to individual connection points at each well location. This dimensional redistribution of equipment eliminates the need for extensive piping with multiple turns and bends, simplifying the overall system layout while maintaining compactness through strategic positioning of simplified components.
3Power
If multiple high-pressure fracturing pumps are combined in a manifold to provide sufficient fluid volume and pressure, then the pumping capacity is adequate, but the complex manifold layout increases the risk of turbulence and abrasive effects on the piping
Solution Approach 1:
The system segments the high-pressure fluid delivery into separate dedicated lines, with each line receiving pressurized fluid directly from the pumps. This segmentation eliminates the complex manifold routing that causes turbulence and abrasion, while maintaining adequate fluid delivery capacity through direct, streamlined pathways to each well.
Data Source
AI summary
The application is directed to a system for conveying fluid to one or more downstream locations including a plurality of downstream locations severally. The system includes one or more upstream fluid sources, a fluid routing system in fluid communication with the one or more upstream fluid sources via an upstream fluid line and each of the downstream locations via separate downstream fluid lines. The fluid routing system includes fluid connections corresponding to each of the downstream fluid lines and is operationally configured to fluidly connect with a particular fluid connection while remaining fluidly disconnected from the remaining fluid connections.