FIELD OF THE DISCLOSURE

This subject matter of the present disclosure relates to fluid delivery systems, and in particular to a manifold fracture delivery system for delivery of fluids under high-pressure.

BACKGROUND OF THE DISCLOSURE

Hydraulic fracturing, or “fracking,” is the process of injecting a fluid into a wellbore at high pressure to fracture rock formations and facilitate release of trapped hydrocarbons within the formation. Fracking operations typically use manifold trailers or trailer-mounted skids that have a piping system attached thereon to deliver the pressurized fluids to the wellhead at surface.

During fracking operations, for example, a blender initially mixes the chemicals, proppant (e.g., sand), and carrier fluid for the fracking operation into a slurry. A low-pressure side of the piping system receives the slurry from the blender at a low pressure and routes the slurry to a manifold skid or trailer. From the skid or trailer, the slurry is distributed to a plurality of pumps, which pressurize the slurry to a high-pressure—e.g., up to about 20,000 psi. The pumps return the pressurized slurry to a high-pressure side of the manifold skid or trailer, which then routes the pressurized slurry to the wellhead.

As an example, US 2013/0284455 is directed to a delivery system for fracture applications. US 2014/0231554 is directed to a manifold trailer with multiple articulating arm assemblies. U.S. Pat. No. 8,474,521 is directed to an adjustable modular skid system for manifolds with a plurality of skid modules having a frame to support oil field fluid components.

Conventional manifold skids or trailers include multiple high-pressure piping systems that have multiple discharge points. Rigging up the conventional manifold skid or trailer can require operators to assemble high-pressure flowline iron known as integral iron, which includes piping components, such as tubular connectors, tubular swivel connectors, valves, and piping joints between the manifold skid or trailer and the pumps. These elements couple with other piping preinstalled in parallel along the length of the manifold skid or trailer. The high-pressure flowline integral iron is stacked horizontally and vertically on the manifold skid or trailer to form multiple manifolds.

High-pressure fluid flowing through the high-pressure flowline integral iron can cause the piping components to expand and hammer, which may cause binding and/or failure of one or more of the integral connections between the piping components. Further, the high-pressure fluid flowing through the high-pressure flowline integral iron may pulsate and hammer, which causes vibrations that may induce cracks or failures and contribute to a safety hazard to personnel in one or more of the integral connections between piping components and/or the piping components themselves in the event of failure. Finally, in the case of a component replacement, rig up time and complexity is increased significantly due to the numerous connections between the various piping components of the high-pressure flowline integral iron.

As an example,FIG.1Ais a perspective view of a typical manifold skid or trailer10according to the prior art as used within the industry. The typical manifold trailer10has a base12having a rack14on which multiple conduits30a-band40a-bare supported. Headers20a-bhave multiple low-pressure fluid inlets22for connection to a source of fluid (e.g., fracture slurry). The headers20a-bconnect to low-pressure conduits30a-bthat run along the length of the rack14. Often, and as shown here, two low pressure conduits30a-brun parallel to one another above two high-pressure conduits40a-b, which also run along the rack14. The low-pressure conduits30a-bhave a series of low pressure outlets32to connect to inlets of external pumps (not shown). The low-pressure outlets32typically have 1502 wing-type connections or similar.

On the high-pressure side, each of the outlets of the external pumps (not shown) connect into the high-pressure conduits40a-bvia an inlet assembly50, which is shown in closer detail inFIG.1B. Ends of the high-pressure conduits40a-bhave connections42, which can be 1502 wing-type connections or similar for connecting to downstream components, such as wellhead connections, conduits on another manifold trailer, etc. The inlet assemblies50has piping made up of a series of connections52a-c(e.g., 1502 wing type connections or similar) with swivels54to allow for movement of the inlet assemblies50. All of the connections for the swivels54and for the 1502 wing type connections42,52a-chave elastomers and gaskets that are prone to leaking and failure.

FIG.1Bis a close-up perspective view ofFIG.1A, illustrating a high-pressure inlet assembly50. The high-pressure conduit40has branched inlet piping45from the conduit40. The swivel54connects to the branched piping45via connections54a, such as 1502 wing type connections or similar, and the swivel54has piping with similar connections54b-c. The high-pressure conduit40has end connections42, such as 1502 wing type connections or similar, for connection to the wellhead, zipper manifold, etc. It is known in the industry that when the assembly described inFIGS.1A-1Bis under high pressure, a water hammer effect occurs that can cause very damaging vibration through the high-pressure conduits40a-b.

The subject matter of the present disclosure is directed to overcoming, or at least reducing the effects of, one or more of the problems set forth above.

SUMMARY OF THE DISCLOSURE

Disclosed herein is a manifold skid having at least one single, high-pressure studded or flanged iron connection output, studded or flanged iron connections, and open-faced connections, that are made to American Petroleum Institute (API)6A standards. Both studded or flanged connections may be used with the manifold skid of the present disclosure, and particularly for the connections of the high-pressure conduit.

Disclosed herein is a manifold skid having at least one single, high-pressure output studded or flanged connection. Iron may be used as the studded or flanged metal connection but other metals are acceptable, e.g., aluminum, cast, stainless steel, or any metal that can withstand pressure ratings up to about 22500 psi.

A manifold assembly is connectable to pumps that pressurize fluid from a low-pressure source for delivery to a high-pressure destination. The assembly comprises: a first chassis, a first conduit, and a second conduit. The first chassis has a length. The first conduit is supported on the first chassis and is disposed along the length. The first conduit has at least one first inlet and first outlets. The at least one first inlet is configured to receive the fluid at low-pressure, and the first outlets are configured to deliver the fluid at low-pressure to the pumps.

The second conduit is supported on the first chassis and is disposed along the length adjacent the first conduit. The second conduit has second inlets and a second outlet. The second conduit has at least two connection blocks and at least two spools connected in line with one another along the length of the chassis. Each of the at least two connection blocks has one of the second inlets and has at least one port side. Each of the second inlets is configured to receive the fluid at high-pressure from one of the pumps. The at least two spools are connected to the port sides of the at least two connection blocks for delivering the fluid at high pressure to the second outlet of the second conduit. The second outlet is configured to deliver the fluid at high-pressure to the destination.

The second conduit can be supported a height above the first conduit. The first conduit can comprise a header in fluid communication with the first conduit. The header can have a plurality of the at least one first inlet. The at least one first outlets can comprise a valve configured to open and close fluid communication therethrough. The first conduit can comprise a plurality of the at least one first outlet disposed at spaced intervals along both sides of the length of the first conduit.

The first conduit can comprise at least one port configured to connect in fluid communication with another conduit. The at least one of the connection blocks can have no elastomeric seal. At least one of the connection blocks can comply with API6A standards.

The second conduit can comprise a plurality of the at least one connection block and a plurality of the at least one spool. Each of the connection blocks can have one of the second inlets, and each of the connection blocks can have one of the port sides connected to one of the spools.

The at least one connection block can comprise two of the at least one second inlet on first opposing sides thereof. The two second inlets can communicate with one another inside the at least one connection block.

The at least one connection block can comprise two of the at least one port side on second opposing sides thereof. The two port sides can communicate with one another and with the two second inlets inside the at least one connection block.

The second inlet can comprise a bonnet and a ring gasket. The bonnet can be connected with a plurality of studs and bolts to the port side of the connection block. The ring gasket can seal the bonnet to the port side. The bonnet can have a female member of a hammer union for coupling with a male member of the hammer union from one of the pumps.

The at least one spool can comprise a flanged end connected with a plurality of studs and bolts to the at least one port side of the at least one connection block.

The flanged end can define a circumferential groove in a face thereof. The at least one connection block can define a corresponding circumferential groove in a face thereof circumscribing the at least one port side, and a gasket can be sandwiched between the circumferential grooves.

The assembly can further comprise a third conduit supported on the first chassis and disposed along the length adjacent the first conduit. The third conduit can have at least one third inlet and at least one third outlet. The at least third first inlet can be configured to receive the fluid at low-pressure, and the at least one third outlet can be configured to deliver the fluid at low-pressure to at least one of the pumps.

The assembly can further comprise sing a third conduit supported on the first chassis and disposed along the length adjacent the second conduit. The third conduit can have at least one third inlet and at least one third outlet, and the third conduit can have at least one connection block and at least one spool. The at least one connection block can have the at least one third inlet and can have at least one port side. The at least one third inlet can be configured to receive the fluid at high-pressure from at least one other of the pumps. The at least one spool can be connected to the at least one port side of the at least one connection block for delivering the fluid at high pressure to the at least one third outlet of the third conduit. The at least one third outlet can be configured to deliver the fluid at high-pressure to the destination.

The at least second and third outlets of the first and second conduits can combine to a common outlet. The second and third conduits can run parallel to one another along the length of the first chassis.

The assembly can further comprise a second chassis supporting additional ones of the first and second conduits. The additional one of the first conduit can be disposed in line with, and connected in fluid communication with, the first conduit of the first chassis. The additional one of the second conduit can be disposed in line with, and connected in fluid communication with, the second conduit of the first chassis.

A manifold assembly is connectable to fracturing pumps that pressurize treatment fluid from a low-pressure source for delivery to a high-pressure destination associated with a wellbore. The assembly comprises a chassis and at least one conduit. The chassis has a length. The at least one conduit is supported on the chassis and is disposed along the length.

The at least one conduit has inlets and at least one outlet, and the at least one conduit has at least two connection blocks and at least two spools. Each of the at least two connection blocks has one of the inlets, and each of the inlets is configured to receive the fluid at high-pressure from one of the fracturing pumps. Ends of one of the spools interconnects the at least two of the connection blocks in fluid communication. The at least one outlet of the at least one conduit comprises the other of the spools configured to deliver the fluid at high pressure to the destination associated with the wellbore.

A method of pressurizing fluid from a low-pressure source with pumps for delivery to a high-pressure destination comprises: receiving the fluid at low pressure from the low-pressure source at at least one first inlet of a first conduit; conveying the fluid along a first length of the first conduit to a plurality of first outlets spaced along the first length of the first conduit and configured to deliver the fluid at low-pressure to a corresponding one of the pumps; receiving the fluid at high pressure from the pumps at second inlets in connection blocks interconnected by spools of a second conduit; and conveying the fluid along a second length of the second conduit along the connection blocks interconnected by the spool to a second outlet configured to deliver the fluid at high-pressure to the destination.

The method can further comprise initially blending components of the fluid from the low-pressure source. The method can further comprise pumping the fluid from each of the first outlets with corresponding ones of the pumps; and discharging the pumped fluid at high pressure to one of the second inlets.

The foregoing summary is not intended to summarize each potential embodiment or every aspect of the present disclosure.

