Wellsite Fluid Manifold Layout to Cut Hose Length and Rig-Up Time
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Solution Overview
Problem
The existing systems for distributing natural gas, diesel, and frac fluid at a wellsite are inefficient, leading to long rig-up times and safety risks due to the extensive use of hoses, which occupy space and increase the weight and complexity of equipment.
Innovation Solution
A fluid distribution unit and method that positions natural gas, diesel, and frac fluid pipes in a configuration where they are at least partially above or between the upstream and downstream frac pipes, reducing the length and number of hoses needed, and utilizing a single control unit to manage the distribution of these fluids to dual-fuel engines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If trailers and long hoses are used to distribute natural gas and diesel to engines, then fluid distribution can be achieved, but rig-up time increases and safety risks increase
Solution Approach 1:
The patent combines multiple fluid distribution functions (natural gas, diesel, and frac fluid distribution) into a single integrated manifold system. This merging eliminates the need for separate trailers and multiple long hoses, directly reducing rig-up time while maintaining all necessary distribution capabilities to the engines.
Solution Approach 2:
The patent repositions the fluid distribution system by placing manifolds at the wellsite location rather than using remote trailers. This spatial reconfiguration reduces the length of hoses needed and consolidates equipment in a more efficient location, thereby reducing setup time and improving safety.
2Adaptability or versatility
If multiple separate systems are used for frac fluid, natural gas, and diesel distribution, then all fluids can be distributed, but device complexity increases
Solution Approach 1:
The patent integrates three separate fluid distribution systems (frac fluid, natural gas, and diesel) into a unified manifold system. This consolidation maintains the ability to distribute all required fluids while reducing overall system complexity by eliminating redundant components and simplifying the architectural structure.
Solution Approach 2:
The manifold system is designed to perform multiple functions simultaneously - distributing frac fluid to pump units, natural gas to engines, and diesel to engines - through a single integrated structure. This multi-functionality reduces the need for separate specialized systems while maintaining full operational capability.
3Reliability
If long hoses are used to reach engines from trailers, then fluid delivery is possible, but safety risks increase due to tripping hazards and equipment failure
Solution Approach 1:
The patent extracts the fluid distribution function from remote trailers and relocates it to on-site manifolds positioned near the engines. This extraction eliminates the need for long connecting hoses, removing tripping hazards and potential failure points while maintaining reliable fluid delivery to the engines.
Solution Approach 2:
The patent introduces compact manifolds as intermediary distribution points between the fluid sources and engines. These manifolds are positioned optimally to minimize hose length and eliminate safety hazards, serving as intermediate nodes that maintain fluid delivery while improving safety.
Data Source
AI summary
A fluid distribution unit includes a first upstream frac pipe configured to receive a frac fluid and to distribute the frac fluid to a plurality of pump units at a first pressure. The fluid distribution unit also includes a downstream frac pipe configured to receive the frac fluid from the pump units at a second pressure that is greater than the first pressure. The frac fluid at the second pressure is directed into a wellbore. The fluid distribution unit also includes a natural gas pipe configured to receive natural gas from a gas source and to distribute the natural gas to the pump units. The fluid distribution unit also includes a diesel pipe configured to receive diesel from a diesel source and to distribute the diesel to the pump units.