Note: Descriptions are shown in the official language in which they were submitted.
P12231CA00
HOT SWAPPABLE FRACTURING PUMP SYSTEM
Cross Reference to Related Applications
[0001] This application claims the benefit of U.S. Patent Application No.
17/548,087,
filed December 10, 2021, which is a continuation-in-part ("CIP") of U.S.
Patent Application
No. 16/436,189, filed June 10, 2019, the entire disclosures of which are
hereby
incorporated herein by reference.
[0002] This application also claims the benefit of U.S. Patent Application No.
17/872,516, filed July 25, 2022, which is a continuation of U.S. Patent
Application No.
17/548,087, filed December 10, 2021, which is a continuation-in-part ("CIP")
of U.S.
Patent Application No. 16/436,189, filed June 10, 2019, the entire disclosures
of which
are hereby incorporated herein by reference.
Background
[0003] This application related generally to oil and gas hydraulic fracturing
operations
and, more particularly, to a hydraulic fracturing system including a hot
swappable
fracturing pump system.
Brief Description of the Drawings
[0004] Figure lA is a diagrammatic illustration of a hydraulic fracturing
system operable
to hydraulically fracture one or more oil and gas wells, according to one or
more
embodiments.
[0005] Figure 1B is a diagrammatic illustration of a portion of the hydraulic
fracturing
system of Figure 1A, said portion including a hot swappable fracturing pump
system,
according to one or more embodiments.
[0006] Figure 2A is a perspective view of a swap station and a pump truck of
the hot
swappable fracturing pump system of Figure 1B, according to one or more
embodiments.
[0007] Figure 2B is another perspective view of the swap station and the pump
truck of
the hot swappable fracturing pump system of Figure 1B, according to one or
more
embodiments.
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[0008] Figure 3 is a perspective view of a swap adapter connected to the pump
truck of
Figures 2A and 2B, according to one or more embodiments.
[0009] Figure 4A is a top plan view of an adapter body of the hot swap adapter
of Figure
3, according to one or more embodiments.
[0010] Figure 4B is an elevational view of the adapter body of the swap
adapter of Figure
3, according to one or more embodiments.
[0011] Figure 4C is another elevational view of the adapter body of the swap
adapter of
Figure 3, according to one or more embodiments.
[0012] Figure 5A is a perspective view of the swap station of Figures 2A and
2B,
according to one or more embodiments.
[0013] Figure 5B is another perspective view of the swap station of Figures 2A
and 2B,
according to one or more embodiments.
[0014] Figure 5C is an elevational view of the swap station of Figures 2A and
2B,
according to one or more embodiments.
[0015] Figure 6A is a perspective view of a grapple assembly of the swap
station of
Figures 5A through 5C, according to one or more embodiments.
[0016] Figure 6B is another perspective view of the grapple assembly of the
swap
station of Figures 5A through 5C, according to one or more embodiments.
[0017] Figure 6C is an elevational view of the grapple assembly of the swap
station of
Figures 5A through 5C, according to one or more embodiments.
[0018] Figure 7A is a perspective view of a lock assembly of the swap station
of Figures
5A through 5C, according to one or more embodiments.
[0019] Figure 7B is another perspective view of the lock assembly of the swap
station
of Figures 5A through 5C, according to one or more embodiments.
[0020] Figure 7C is an elevational view of the lock assembly of the swap
station of
Figures 5A through 5C, according to one or more embodiments.
[0021] Figure 8 is a flow diagram illustrating a method for using the swap
station of
Figures 2A and 2B, according to one or more embodiments.
[0022] Figure 9A is top plan view illustrating execution of a first step of
the method
illustrated in Figure 8, according to one or more embodiments.
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[0023] Figure 9B is a perspective view illustrating execution of the first
step of the
method illustrated in Figure 8, according to one or more embodiments.
[0024] Figure 9C is a perspective view illustrating execution of a second step
of the
method illustrated in Figure 8, according to one or more embodiments.
[0025] Figure 9D is a perspective view illustrating execution of a third step
of the method
illustrated in Figure 8, according to one or more embodiments.
[0026] Figure 9E is a top plan view illustrating execution of the third step
of the method
illustrated in Figure 8, according to one or more embodiments.
[0027] Figure 9F is a top plan view illustrating execution of the third step
of the method
illustrated in Figure 8, according to one or more embodiments.
[0028] Figure 9G is a top plan view illustrating execution of a fourth step of
the method
illustrated in Figure 8, according to one or more embodiments.
[0029] Figure 9H is a perspective view illustrating execution of the fourth
step of the
method illustrated in Figure 8, according to one or more embodiments.
[0030] Figure 91 is a perspective view illustrating execution of a fifth step
of the method
illustrated in Figure 8, according to one or more embodiments.
[0031] Figure 9J is an elevational view illustrating execution of the fifth
step of the
method illustrated in Figure 8, according to one or more embodiments.
[0032] Figure 10 is a diagrammatic illustration of a computing node for
implementing
one or more embodiments of the present disclosure.
Detailed Description
[0033] Referring to Figure 1A, in an embodiment, a hydraulic fracturing system
100 for
hydraulically fracturing wells 105A through 105C+n is illustrated, which
hydraulic
fracturing system 100 includes: a blender 110 adapted to mix fluid from a
fluid source 115
with sand from a sand source 120 to produce hydraulic fracturing fluid; a
suction manifold
125 adapted to receive the hydraulic fracturing fluid from the blender 110; a
discharge
manifold 130; a plurality of swap stations 135aa though 135bc, each adapted to
communicate the hydraulic fracturing fluid from the suction manifold 125 to a
corresponding pump truck 140aa through 140bc, and, after pressurization by the
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corresponding pump truck 140aa through 140bc, to communicate the pressurized
hydraulic fracturing fluid from the corresponding pump truck 140aa through
140bc to the
discharge manifold 130; and a zipper manifold 145 adapted to communicate the
pressurized hydraulic fracturing fluid from the discharge manifold 130 to a
plurality of
hydraulic fracturing legs (or "frac legs") 150A through 150C+n, each of which
is adapted
to communicate the pressurized hydraulic fracturing fluid from the zipper
manifold 145 to
a corresponding one of the wells 105A through 105C+n. In one or more
embodiments,
each of the swap stations 135aa through 135bc is or includes one or more
components
shown and described in the '189 Application, filed June 10, 2019, now
published as U.S.
Patent Application Publication No. 2020/0386359, the entire disclosure of
which is hereby
incorporated herein by reference.
[0034] Although shown in Figure lA as including the swap stations 135aa
through 135ac
and the corresponding pumps trucks 140aa through 140ac, the hydraulic
fracturing
system 100 may additionally (or alternatively) include one or more additional
swap
stations between the swap stations 135ab and 135ac, together with one or more
additional corresponding pump trucks between the pump trucks 140ab and 140ac.
Likewise, although shown in Figure 1A as including the swap stations 135ba
through
135bc and the corresponding pumps trucks 140ba through 140bc, the hydraulic
fracturing
system 100 may additionally (or alternatively) include one or more additional
swap
stations between the swap stations 135bb and 135bc, together with one or more
additional corresponding pump trucks between the pump trucks 140bb and 140bc.
[0035] Referring to Figure 1B, with continuing reference to Figure 1A, in an
embodiment,
the hydraulic fracturing system 100 includes a hot swappable fracturing pump
system
155, which hot swappable fracturing pump system 155 includes the swap stations
135ba
and 135bb, and the corresponding pump trucks 140ba and 140bb. The swap station
135ba is connected to, and adapted to be in fluid communication with, the
suction
manifold 125 via a suction conduit 160a. The suction conduit 160a includes a
valve 165
that controls the communication of fluid between the suction manifold 125 and
the swap
station 135ba. In one or more embodiments, the valve 165 is a gate valve.
Additionally,
the suction conduit 160a may include another valve such as, for example, a
check valve,
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in addition to the valve 165. Likewise, the swap station 135ba is connected
to, and
adapted to be in fluid communication with, the discharge manifold 130 via a
discharge
conduit 160b. The discharge conduit 160b includes a pair of valves 170a-b that
control
the communication of fluid between the swap station 135ba and the discharge
manifold
130. In one or more embodiments, the valves 170a-b are gate valves.
Additionally, the
discharge conduit 160b may include another valve such as, for example, a check
valve,
in addition to the valves 170a-b. Alternatively, in one or more embodiments,
one of the
valves 170a-b is a check valve. The discharge conduit 160b also includes a
pressure
sensor 171 that detects a discharge pressure exiting the swap station 135ba.
[0036] The pump truck 140ba includes a swap adapter 175 and a fracturing pump
180.
The fracturing pump 180 is connected to, and adapted to be in fluid
communication with,
the swap adapter 175 via a suction conduit 185a. Likewise, the fracturing pump
180 is
connected to, and adapted to be in fluid communication with, the swap adapter
175 via a
discharge conduit 185b. In one or more embodiments, the suction conduit 185a,
the
discharge conduit 185, or both is/are or include(s) flexible conduit(s) (e.g.,
flexible
hose(s)). In addition, or instead, the suction conduit 185a, the discharge
conduit 185, or
both may be or include rigid conduit(s), swivel(s) (e.g., chiksan swivel
joints), both rigid
conduit(s) and swivel(s), the like, or any combination thereof. The swap
adapter 175 of
the pump truck 140ba is detachably connectable to the swap station 135ba, as
shown in
Figure 1B; when so detachably connected: fluid communication is established
between
the suction conduit 160a and the suction conduit 185a; and fluid communication
is
established between the discharge conduit 185b and the discharge conduit 160b.
In one
or more embodiments, the swap adapter 175 includes, or is part of, the swap
station
135ba.
[0037] The hot swappable fracturing pump system 155 also includes a primer
tank 190
connected to, and adapted to be in fluid communication with, the suction
conduit 160a (at
a location between the swap station 135ba and the valve 165) via a primer
conduit 195a.
The primer conduit 195a includes a primer pump 200, a pressure sensor 205, and
a valve
210. The primer pump 200 is adapted to pump fluid from the primer tank 190 to
the
suction conduit 160a via the primer conduit 195a. The pressure sensor 205
detects a
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discharge pressure exiting the primer pump 200. The valve 210 controls the
communication of fluid between the primer tank 190 and the suction conduit
160a (via the
primer conduit 195a). In one or more embodiments, the valve 210 is a gate
valve.
Additionally, the primer conduit 195a may include another valve such as, for
example, a
check valve, in addition to the valve 210. Likewise, the primer tank 190 is
connected to,
and adapted to be in fluid communication with, the discharge conduit 160b (at
a location
between the swap station 135ba and the valves 170a-b) via a primer conduit
195b. The
primer conduit 195b includes a pair of valves 215a-b that control the
communication of
fluid between the discharge conduit 160b and the primer tank 190 (via the
primer conduit
195b). In one or more embodiments, the valves 215a-b are gate valves.
Additionally, the
primer conduit 195b may include another valve such as, for example, a check
valve, in
addition to the valves 215a-b. Alternatively, in one or more embodiments, one
of the
valves 215a-b is a check valve. Although the hot swappable fracturing pump
system 155
is described as including the primer tank 190 and the primer pump 200, the
primer tank
190, the primer pump 200, or both may instead be omitted in favor of an
existing fluid
vessel (and, optionally, an associated pump or valve) on the well site, to
which existing
fluid vessel the primer fluid conduits 195a-b are connected.
[0038] The swap station 135bb is connected to, and adapted to be in fluid
communication with, the suction manifold 125 via a suction conduit 160a'. The
suction
conduit 160a' includes a valve 165' that controls the communication of fluid
between the
suction manifold 125 and the swap station 135bb. In one or more embodiments,
the valve
165' is a gate valve. Additionally, the suction conduit 160a' may include
another valve
such as, for example, a check valve, in addition to the valve 165'. Likewise,
the swap
station 135bb is connected to, and adapted to be in fluid communication with,
the
discharge manifold 130 via a discharge conduit 160b'. The discharge conduit
160b'
includes a pair of valves 170a-b' that control the communication of fluid
between the swap
station 135bb and the discharge manifold 130. In one or more embodiments, the
valves
170a-b' are gate valves. Additionally, the discharge conduit 160b' may include
another
valve such as, for example, a check valve, in addition to the valves 170a-b'.
Alternatively,
in one or more embodiments, one of the valves 170a-b' is a check valve. The
discharge
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conduit 160b' also includes a pressure sensor 171' that detects a discharge
pressure
exiting the swap station 135bb.
[0039] The pump truck 140bb includes a swap adapter 175' and a fracturing pump
180'.
The fracturing pump 180' is connected to, and adapted to be in fluid
communication with,
the swap adapter 175' via a suction conduit 185a'. Likewise, the fracturing
pump 180' is
connected to, and adapted to be in fluid communication with, the swap adapter
175' via
a discharge conduit 185b'. The swap adapter 175' of the pump truck 140bb is
detachably
connectable to the swap station 135bb, as shown in Figure 1B; when so
detachably
connected: fluid communication is established between the suction conduit
160a' and the
suction conduit 185a'; and fluid communication is established between the
discharge
conduit 185b' and the discharge conduit 160b'.
[0040] The primer tank 190 of the hot swappable fracturing pump system 155 is
also
connected to, and adapted to be in fluid communication with, the suction
conduit 160a'
(at a location between the swap station 135bb and the valve 165') via the
primer conduit
195a and a primer conduit 195a'. The primer conduit 195a' includes a valve
210'. The
primer pump 200 is adapted to pump fluid from the primer tank 190 to the
suction conduit
160a' via the primer conduit 195a and the primer conduit 195a'. The valve 210'
controls
the communication of fluid between the primer tank 190 and the suction conduit
160a'
(via the primer conduit 195a and the primer conduit 195a'). In one or more
embodiments,
the valve 210' is a gate valve. Additionally, the primer conduit 195a' may
include another
valve such as, for example, a check valve, in addition to the valve 210'.
Likewise, the
primer tank 190 is connected to, and adapted to be in fluid communication
with, the
discharge conduit 160b' (at a location between the swap station 135bb and the
valves
170a-b') via the primer conduit 195 and a primer conduit 195b'. The primer
conduit 195b'
includes a pair of valves 215a-b' that control the communication of fluid
between the
discharge conduit 160b' and the primer tank 190 (via the primer conduit 195b
and the
primer conduit 195b'). In one or more embodiments, the valves 215a-b' are gate
valves.
Additionally, the primer conduit 195b' may include another valve such as, for
example, a
check valve, in addition to the valves 215a-b'. Alternatively, in one or more
embodiments,
one of the valves 215a-b' is a check valve.
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[0041] A controller 220 is adapted to send control signals to, and receive
feedback (e.g.,
position feedback) from, the swap station 135ba, the valve 165, the valve
170a, the valve
170b, the fracturing pump 180, the primer pump 200, the valve 210, the valve
215a, the
valve 215b, the swap station 135bb, the valve 165', the valve 170a', the valve
170b', the
fracturing pump 180', the valve 210', the valve 215a', the valve 215b', or any
combination
thereof. Additionally, the controller 220 is adapted to receive pressure
readings from the
pressure sensor 171, the pressure sensor 205, the pressure sensor 171', or any
combination thereof. In one or more embodiments, the controller 220 is or
includes a
non-transitory computer readable medium and one or more processors adapted to
execute instructions stored on the non-transitory computer readable medium. In
one or
more embodiments, the controller 220 is located on-site at the well site. For
example, the
controller 220 may be part of the swap station 135ba. For another example, the
controller
220 may be part of the swap station 135bb. For yet another example, the
controller 220
may be part of the primer pump 200. Alternatively, the controller 220 may be
located
remotely from the well site. In one or more embodiments, the controller 220
includes a
plurality of controllers. In one or more embodiments, the controller 220
includes a plurality
of controllers, with one or more controllers located on-site at the well site
(e.g., as part of
the swap station 135ba, the swap station 135bb, the primer pump 200, or any
combination
thereof) and/or one or more other controllers located remotely from the well
site. In one
or more embodiments, the controller 220 is, includes, or is part of, one or
more controllers,
sub-controllers, nodes, components, systems, etc. described and illustrated in
one or
more of the following applications: U.S. Patent Application No. 17/388,716,
filed July 29,
2021, the entire disclosure of which is hereby incorporated herein by
reference; U.S.
Patent Application No. 17/319,854, filed May 13, 2021, the entire disclosure
of which is
hereby incorporated herein by reference; U.S. Patent Application No.
16/855,749, filed
April 22, 2020, the entire disclosure of which is hereby incorporated herein
by reference.
[0042] In a first operational state or configuration of the hot swappable
fracturing pump
system 155: the pump truck 140ba is not connected to the swap station 135ba
via the
swap adapter 175; the pump truck 140bb is connected to the swap station 135bb
via the
swap adapter 175'; and the fracturing pump 180' of the pump truck 140bb draws
fluid
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from the suction manifold 125 and discharges pressurized fluid to the
discharge manifold
130. More particularly, the valves 210' and 215a-b' are closed and the valve
165' is
opened to permit fluid to be drawn from the suction manifold 125 by the
fracturing pump
180' (via the suction conduit 160a', the valve 165', the swap station 135bb,
the swap
adapter 175', and the suction conduit 1850. Additionally, the valves 170a-b'
are opened
to permit pressurized fluid to be discharged into to the discharge manifold
130 by the
fracturing pump 180' (via the discharge conduit 185b', the swap adapter 175',
the swap
station 135bb, the discharge conduit 160b', and the valves 170a-b'). The
valves 165,
170a-b, 210, and 215a-b corresponding to the swap station 135ba are closed in
the first
operational state or configuration.
[0043] Subsequently, in a second operational state or configuration of the hot
swappable fracturing pump system 155: the pump truck 140ba is connected to the
swap
station 135ba via the swap adapter 175, as shown in Figure 1B; and the
fracturing pump
180 is primed by the primer pump 200 using fluid from the primer tank 190.
More
particularly, the valve 210 is opened to permit the primer pump 200 to supply
fluid from
the primer tank 190 to the fracturing pump 180 (via the primer conduit 195a,
the valve
210, the suction conduit 160a, the swap station 135ba, the swap adapter 175,
and the
suction conduit 185a). Additionally, the valves 215a-b are opened to permit
circulation of
fluid from the fracturing pump 180 back to the primer tank 190 during the
priming process
(via the discharge conduit 185b, the swap adapter 175, the swap station 135ba,
the
discharge conduit 160b, the primer conduit 195b, and the valves 215a-b). While
the hot
swappable fracturing pump system 155 transitions from the first operational
state or
configuration to the second operational state or configuration, the fracturing
pump 180' of
the pump truck 140bb continues to draw fluid from the suction manifold 125 and
discharge
pressurized fluid to the discharge manifold 130, as described above.
[0044] Subsequently, in a third operational state or configuration of the hot
swappable
fracturing pump system 155, once the fracturing pump 180 is fully primed (as
confirmed
by pressure readings from the pressure sensors 171 and 205), the fracturing
pump 180
of the pump truck 140ba is brought on line to draw fluid from the suction
manifold 125
and discharge pressurized fluid to the discharge manifold 130. More
particularly, the
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valve 165 is opened and the valve 210 is closed to permit the fracturing pump
180 to draw
fluid from the suction manifold 125 (via the suction conduit 160a, the valve
165, the swap
station 135bb, the swap adapter 175, and the suction conduit 185a). In one or
more
embodiments, the valve 165 is opened before the valve 210 is closed. In one or
more
embodiments, the valves 165 and 210 are simultaneously opened and closed,
respectively. Additionally, the valves 170a-b are opened and the valves 215a-b
are
closed to permit the fracturing pump 180 to discharge pressurized fluid to the
discharge
manifold 130 (via the discharge conduit 185, the swap adapter 175, the swap
station
135ba, the discharge conduit 160b, and the valves 170a-b). In one or more
embodiments,
the valves 170a-b are opened before the valves 215a-b are closed. In one or
more
embodiments, the valves 170a-b and 215a-b are simultaneously opened and
closed,
respectively. While the hot swappable fracturing pump system 155 transitions
from the
second operational state or configuration to the third operational state or
configuration,
the fracturing pump 180' of the pump truck 140bb continues to draw fluid from
the suction
manifold 125 and discharge pressurized fluid to the discharge manifold 130, as
described
above.
[0045] Finally, in a fourth operational state or configuration of the hot
swappable
fracturing pump system 155, the fracturing pump 180' of the pump truck 140bb
is brought
off line for maintenance and/or repair. More particularly, the fracturing pump
180' is
ramped down, the valves 170a-b' are closed, and the valves 215a-b' are opened
to bleed
off residual pressure in the discharge conduits 160b' and 185b' to the primer
tank 190.
Additionally, the valve 165' is closed, and, optionally, the valve 210' is
opened to bleed
off residual pressure in the suction conduits 160a' and 185a' to the primer
tank 190. Once
the residual pressure in the discharge conduits 160b' and 185b' and,
optionally, the
suction conduits 160a' and 185a', is bled off to the primer tank 190, the
valves 210' and
215a-b' are closed and the swap adapter 175' of the pump truck 140bb is
disconnected
from the swap station 135bb. While the hot swappable fracturing pump system
155
transitions from the third operational state or configuration to the fourth
operational state
or configuration, the fracturing pump 180 of the pump truck 140ba continues to
draw fluid
from the suction manifold 125 and discharge pressurized fluid to the discharge
manifold
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130, as described above. A replacement pump truck substantially identical to
the pump
truck 140bb with a replacement fracturing pump substantially identical to the
fracturing
pump 180' may subsequently be connected to the swap station 135bb, via a
replacement
swap adapter substantially identical to the swap adapter 175', and brought on
line in a
manner similar to that described above with respect to the pump truck 135ba
and the
fracturing pump 180.
[0046] Although described as including the swap stations 135ba and 135bb, and
the
corresponding pump trucks 140ba and 140bb, the hot swappable fracturing pump
system
155 may additionally or alternatively include any other combination of the
swap stations
135aa through 135bc, and the corresponding pump trucks 140aa and 140bc,
together
with the primer tank 190, the primer pump 100, corresponding conduits
substantially
identical to the conduits 160a-b and 195a-b (or 195a-b'), corresponding valves
substantially identical to the valves 165, 170a-b, 210, and 215a-b (or 165',
170a-b', 210',
and 215a-b'), and corresponding pressure sensors substantially identical to
the pressure
sensors 171 (or 171') and 205. The operation of the various corresponding
components
of such a system would be substantially identical to that described above with
respect to
the hot swappable fracturing pump system 155 shown in Figure 1B and,
therefore, will
not be described in further detail.
[0047] In one or more embodiments, the swap stations 135aa though 135bc are
substantially identical to one another, and, therefore, in connection with
Figures 2A, 2B,
and 5A through 7C, only the swap station 135ba will be described in detail
below;
however, the description below applies equally to the swap stations 135aa
through 135ac,
135bb, and 135bc. Additionally, in one or more embodiments, the pump trucks
140aa
through 140bc are substantially identical to one another, and, therefore, in
connection
with Figures 2A, 2B, 3, and 4A through 4C, only the pump truck 140ba will be
described
in detail below; however, the description below applies equally to the pump
trucks 140aa
through 140ac, 140bb, and 140bc.
[0048] Referring to Figures 2A and 2B, with continuing reference to Figures lA
and 1B,
in an embodiment, the suction conduit 185a and the discharge conduit 185b are
connected to, and extend from the swap adapter 175, which swap adapter 175 is
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connected to the pump truck 140ba. The swap station 135ba is supported by a
skid 225.
A chock assembly 230 is connected to, and extends from, the skid 225 along the
ground.
The chock assembly 230 assists a driver of the pump truck 140ba in backing the
pump
truck 140ba into a position relative to the swap station 135ba, in which
position the swap
station 135ba is capable of grappling the swap adapter 175, as will be
described in further
detail below.
[0049] Referring to Figure 3, with continuing reference to Figures 2A and 2B,
in an
embodiment, the swap adapter 175 of the pump truck 140ba includes an adapter
body
235 and an adapter frame 240. The adapter frame 240 is generally rectangular
in shape.
The adapter body 235 is suspended within the adapter frame 240 by a suspension
assembly 245. In one or more embodiments, the suspension assembly 245 includes
a
plurality of lines 250, each of which is connected at one end to the adapter
body 235,
extends through a corresponding pulley 255 anchored to the adapter frame 240,
and is
connected at the other end to a spring 260, or springs 260, anchored to the
adapter frame
240. In addition, or instead, the adapter body 235 may be suspended within the
adapter
frame 240 by another suitable suspension assembly.
[0050] Referring to Figures 4A through 4C, with continuing reference to Figure
3, the
adapter body 235 includes an adapter plate 265, suction fittings 270a-b, and
discharge
fittings 275a-b. The adapter plate 265 is generally rectangular in shape and
defines
opposing side portions 280a-b, opposing widthwise edge portions 285a-b, and
opposing
lengthwise edge portions 290a-b. Both the suction fitting 270a and the
discharge fitting
275a extend from the side portion 280a of the adapter plate 265. Likewise,
both the
suction fitting 270b and the discharge fitting 275b extend from the side
portion 280b of
the adapter plate 265. The suction conduit 185a is connected to, and extends
from, the
suction fitting 270a (as shown in Figures 2A and 2B). Additionally, the
discharge conduit
185b is connected to, and extends from, the discharge fitting 270b (as shown
in Figures
2A and 2B).
[0051] A recess 295a is formed widthwise into the lengthwise edge portion 290a
of the
adapter plate 265, proximate the widthwise edge portion 285a. As shown in
Figure 4B,
the recess 295a defines a slot 300 and opposing inclined surfaces 305a-b in
the adapter
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plate 265, which opposing inclined surfaces 305a-b extend from the slot 300
toward the
lengthwise edge portion 290a. A grappling hold 310a is connected to, and
extends from,
the side portion 280b of the adapter plate 265 proximate the recess 295a. A
recess 315
is formed into the grappling hold 310a. The recess 315 defines a slot 320 and
opposing
inclined surfaces 325a-b in the grappling hold 310a, which opposing inclined
surfaces
325a-b extend from the slot 320. The grappling hold 310a also includes a
tapered (e.g.,
frustoconical) surface 330 adjacent the slot 320. The grappling hold 310a is
connected
to the side portion 280b of the adapter plate 265 in a manner that aligns the
slot 320 and
the opposing inclined surfaces 325a-b of the grappling hold 310a with the slot
300 and
the opposing inclined surfaces 305a-b, respectively, of the adapter plate 265.
Similarly,
a recess 295b is formed widthwise into the lengthwise edge portion 290a of the
adapter
plate 265, proximate the widthwise edge portion 285b. The recess 295b is
substantially
identical to the recess 295a, and, therefore, will not be described in further
detail.
Additionally, a grappling hold 310b is connected to, and extends from, the
side portion
280b of the adapter plate 265 proximate the recess 295b. The grappling hold
310b is
substantially identical to the grappling hold 310a, and, therefore, will not
be described in
further detail.
[0052] A clamping hold 335a is connected to, and extends from, the side
portion 280b
of the adapter plate 265 along the lengthwise edge portion 290a. Likewise, a
clamping
hold 335b is connected to, and extends from, the side portion 280b of the
adapter plate
265 along the lengthwise edge portion 290b.
[0053] Referring to Figures 5A through 5C, with continuing reference to
Figures 2A and
2B, in an embodiment, the swap station 135ba includes a suction flow component
340a,
a discharge flow component 340b, a grapple assembly 345, a lock assembly 350,
and a
support frame 355. The suction flow component 340a and the discharge flow
flock 340b
are anchored to the support frame 355 using a support bracket 360. The suction
conduit
160a is connected to, and extends from, the suction flow component 340a.
Likewise, the
discharge conduit 160b is connected to, and extends from, the discharge flow
component
340b. The grapple assembly 345 is also connected to the support frame 355. A
plurality
of guide rods 365 are also connected to the support frame 355 to guide the
grapple
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assembly 345 within a range of motion (e.g., a vertical range of motion). The
lock
assembly 350 is anchored to the support frame 355 proximate the suction flow
component
340a and the discharge flow bock 340b, and is adapted to engage the suction
flow
component 340a and the discharge flow component 340b to thereby secure the
suction
fitting 270a and the discharge fitting 275a of the swap adapter 175 to the
suction flow
component 340a and the discharge flow component 340b, respectively, of the
swap
station 135ba.
[0054] Referring to Figures 6A through 60, with continuing reference to
Figures 5A
through 5C, in an embodiment, the grapple assembly 345 includes a support
frame 370,
a pair of linear (e.g., vertical) actuators 375a-b, and a pair of linear
(e.g., horizontal)
actuators 380a-b. The controller 220 is adapted to send control signals to,
and receive
feedback (e.g., position feedback) from, the linear actuators 375a-b and the
linear
actuators 380a-b. The support frame 370 includes a pair of support members
385a-b
and a pair of support members 390a-b. In one or more embodiments, the support
members 385a-b are spaced apart in a parallel relation. The support members
390a-b
are each connected at one end to the support member 385a and at the other end
to the
support member 385b. In one or more embodiments, the support members 390a-b
are
spaced apart in a parallel relation. A plurality of guide holes 395 are formed
through the
support members 390a-b. The guide holes 395 each receive one of the guide rods
365
therethrough to guide the grapple assembly 345 within a range of motion (e.g.,
a vertical
range of motion).
[0055] The linear actuator 375a is connected to, and extends perpendicularly
from, the
support member 385a. In one or more embodiments, the linear actuator 375a is
or
includes a hydraulic piston 400 having a cylinder 405 and a rod 410 extending
from the
cylinder 405 and movable relative thereto to actuate the linear actuator 375a.
More
particularly, the cylinder 405 of the linear actuator 375a is connected to the
support frame
355 of the swap station 135ba, and the rod 410 of the linear actuator 375a is
connected
to the support member 385a of the grapple assembly 345. Although described as
being
or including the hydraulic piston 400 having the cylinder 405 and the rod 410,
the linear
actuator 375a may instead be or include another suitable type of linear
actuator (e.g.,
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another hydraulic actuator, a mechanical actuator, an electrical actuator,
etc.). The linear
actuator 380a is connected to, and extends in a parallel relation with, the
support member
385a, opposite the linear actuator 375a. In one or more embodiments, the
linear actuator
380a is or includes a hydraulic piston 415 including a cylinder 420 and a rod
425
extending from the cylinder 420 and movable relative thereto to actuate the
linear actuator
380a. The linear actuator 380a also has a grapple 430 at a distal end of the
rod 425, said
grapple 430 including a tapered (e.g., frustoconical) surface 435. Although
described as
being or including the hydraulic piston 415 having the cylinder 420 and the
rod 425, the
linear actuator 380a may instead be or include another suitable type of linear
actuator
(e.g., another hydraulic actuator, a mechanical actuator, an electrical
actuator, etc.)
having the grapple 430 connected at a distal end thereof.
[0056] Similarly, the linear actuator 375b is connected to, and extends
perpendicularly
from, the support member 385b. The linear actuator 375b is substantially
identical to the
linear actuator 375a, and, therefore, will not be described in further detail.
The linear
actuator 380b is connected to, and extends in a parallel relation with, the
support member
385b, opposite the linear actuator 375b. The linear actuator 380b is
substantially identical
to the linear actuator 380a, and, therefore, will not be described in further
detail.
[0057] Referring to Figures 7A through 7C, with continuing reference to
Figures 5A
through 5C, the lock assembly 350 includes a pair of clamps 440a-b and a pair
of linear
(e.g., vertical) actuators 445a-b. In one or more embodiments, the linear
actuators 445a-
b each are or includes a threaded rod 450 threadably engaging the clamps 440a-
b. As a
result, when rotated in one angular direction, the threaded rods 450 move the
clamps
440a-b closer together. Conversely, when rotated in the other angular
direction, the
threaded rods 450 moves the clamps 440a-b farther apart. The linear actuator
445b is
substantially identical to the linear actuator, and, therefore, will not be
described in further
detail. In one or more embodiments, the lock assembly 350 also includes a
motor 455
adapted to rotate the linear actuators 445a-b using a chain or belt 460.
Although
described as including the motor 455, the chain or belt 460, and the linear
actuators 445a-
b, each being or including the threaded rod 450 to move the clamps 440a-b
closer
together, and farther apart, one or both of the linear actuators 445a-b may be
omitted in
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favor of another suitable type of linear actuator (e.g., a hydraulic actuator,
and electrical
actuator, a mechanical actuator, etc.).
[0058] The suction flow component 340a defines opposing clamping holds 465aa-
ab,
and the discharge flow component 340b defines opposing clamping holds 465ba-
bb. The
clamps 440a-b each define a channel 470 adapted to secure the suction fitting
270a and
the discharge fitting 275a of the swap adapter 175 to the suction flow
component 340a
and the discharge flow component 340b, respectively, of the swap station
135ba. More
particularly, when the clamps 440a-b are moved closer together: the channel
470 of the
clamp 440a is adapted to receive the clamping hold 335a of the swap adapter
175, the
clamping hold 465aa of the suction flow component 340a, and the clamping hold
465ba
of the discharge flow component 340b; and the channel 470 of the clamp 440b is
adapted
to receive the clamping hold 335b of the swap adapter 175, the clamping hold
465ab of
the suction flow component 340a, and the clamping hold 465bb of the discharge
flow
component 340b.
[0059] Referring to Figures 8 and 9A through 9J, with continuing reference to
Figures
1A through 7C, in an embodiment, a method for connecting the swap adapter 175
of the
pump truck 140ba to the swap station 135ba is generally referred to by the
reference
numeral 500. As shown in Figure 8, the method 500 includes: at a step 505,
positioning
the pump truck 140ba in the vicinity of the swap station 135ba; at a step 510,
positioning
the linear actuators 380a-b of the swap station 135ba into the recesses 295a-
b,
respectively, of the pump truck 140ba's swap adapter 175; at a step 515,
engaging the
grapples 430 of the linear actuators 380a-b with the grappling holds 310a-b,
respectively,
of the pump truck 140ba's swap adapter 175; at a step 520, retracting the
linear actuators
380a-b to sealingly engage the suction and discharge fittings 270a and 275a
(shown in
Figures 4A and 4B) of the pump truck 140ba's swap adapter 175 with the suction
and
discharge flow components 340a-b, respectively, of the swap station 135ba; and
at a step
525, securing the adapter body 235 of the pump truck 140ba's swap adapter 175
to the
suction and discharge flow components 340a-b of the swap station 135ba.
[0060] The suction and discharge conduits 185a-b are omitted from view in
Figures 9A
through 9J for clarity. As shown in Figures 9A and 9B, at the step 505 of
positioning the
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pump truck 140ba in the vicinity of the swap station 135ba, the pump truck
140ba is
backed into engagement with the chock assembly 230. In one or more
embodiments, as
in Figure 9A, when so positioned, the pump truck 140ba's swap adapter 175 may
extend
at an angle Al relative to the suction and discharge flow components 340a-b of
the swap
station 135ba. As shown in Figure 90, at the step 510 of positioning the
linear actuators
380a-b of the swap station 135ba into the recesses 295a-b (shown in Figures 4A
through
4C), respectively, of the pump truck 140ba's swap adapter 175, the extended
linear
actuators 380a-b are lowered into the recesses 295a-b, respectively, of the
pump truck
140ba's swap adapter 175 by extending the linear actuators 375a-b (as
indicated by
arrows 475 in Figure 9C). More particularly, the inclined surfaces 305a-b and
325a-b
(shown in Figures 4A through 4C) guide the extended linear actuators 380a-b
into the
slots 300 (shown in Figures 4A through 40) during the lowering of the extended
linear
actuators 380a-b into the recesses 295a-b, respectively, of the pump truck
140ba's swap
adapter 175. In this manner, the grapple assembly 345 is able to move the
adapter body
235 in a first horizontal direction via engagement with the inclined surfaces
305a-b and
325a-b as the extended linear actuators 380a-b are lowered into the recesses
295a-b,
respectively. Additionally, once the extended linear actuators 380a-b have
"bottomed
out" in the respective slots 300 of the recesses 295a-b, further lowering of
the extended
linear actuators 380a-b moves the adapter body 235 in a vertical (e.g.,
downward)
direction.
[0061] As shown in Figures 9D through 9F, at the step 515 of engaging the
grapples
430 of the linear actuators 380a-b with the grappling holds 310a-b,
respectively, of the
pump truck 140ba's swap adapter 175, the tapered surfaces 435 (shown in
Figures 6A
through 6C) of the linear actuators 380a-b's grapples 430 engage the tapered
surfaces
330 (shown in Figure 40) of the grappling holds 310a-b, respectively, to
straighten the
swap adapter 175's adapter body 235 (shown in Figures 3 and 4A through 4C)
relative to
the suction and discharge flow components 340a-b, thereby compensating for any
angular offset between the adapter body 235 and the suction and discharge flow
components 340a-b, as defined by the angle Al (as indicated by arrows 480 in
Figures
90 and 9E, and arrows 485 in Figure 9F). In this manner, the grapple assembly
345 is
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able to move the adapter body 235 in an angular direction via engagement with
the
grappling holds 310a-b.
[0062] During execution of the step 515, the suspension assembly 245 of the
swap
adapter 175 allows the adapter body 235 to "float" relative to the adapter
frame 240, while
the adapter frame 240 remains fixed to the pump truck 140ba. As shown in
Figures 9G
and 9H, at the step 520 of retracting the linear actuators 380a-b to sealingly
engage the
suction and discharge fittings 270a and 275a (shown in Figures 4A and 4B) of
the pump
truck 140ba's swap adapter 175 with the suction and discharge flow components
340a-
b, respectively, of the swap station 135ba, the tapered surfaces 435 (shown in
Figures
6A through 6C) of the linear actuators 380a-b's grapples 430 engage the
tapered surfaces
330 (shown in Figure 4C) of the grappling holds 310a-b, respectively, to urge
the suction
and discharge fittings 270a and 275a (shown in Figures 4A and 4B) of the pump
truck
140ba's swap adapter 175 into sealing engagement the suction and discharge
flow
components 340a-b, respectively, of the swap station 135ba (as indicated by
arrows 490
in Figures 9G and 9H). In this manner, the grapple assembly 345 is able to
move the
adapter body 235 in a second horizontal direction via engagement with the
grappling
holds 310a-b. During execution of the step 520, the suspension assembly 245 of
the
swap adapter 175 allows the adapter body 235 to "float" relative to the
adapter frame 240,
while the adapter frame 240 remains fixed to the pump truck 140ba.
[0063] Finally, as shown in Figures 91 and 9J, at the step 525 of securing the
adapter
body 235 of the pump truck 140ba's swap adapter 175 to the suction and
discharge flow
components 340a-b of the swap station 135ba, the clamps 440a-b are moved
closer
together (as indicated by arrows 495 in Figures 91 and 9J) so that: the
channel 470 (shown
in Figures 7A through 7C) of the clamp 440a receives the clamping hold 335a
(shown in
Figures 4A and 4C) of the swap adapter 175, the clamping hold 465aa (shown in
Figures
7A and 7B) of the suction flow component 340a, and the clamping hold 465ba
(shown in
Figures 7B and 7C) of the discharge flow component 340b; and the channel 470
(shown
in Figures 7A through 7C) of the clamp 440b receives the clamping hold 335b
(shown in
Figure 4C) of the swap adapter 175, the clamping hold 465ab (shown in Figure
7A) of the
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suction flow component 340a, and the clamping hold 465bb (shown in Figure 7C)
of the
discharge flow component 340b.
[0064] In one or more embodiments, the operation of the hydraulic fracturing
system
100, the hot swappable fracturing pump system 155, or both, and/or the
execution of the
method 500 allow(s) for one or more hydraulic fracturing pumps (e.g., the
hydraulic
fracturing pump 175 of the pump truck 140ba) to be swapped out for a
replacement
hydraulic fracturing pump while one or more other hydraulic fracturing pumps
(e.g., the
hydraulic fracturing pump 175' of the pump truck 140bb) remain operational,
drawing fluid
from the suction manifold 125 and providing pressurized fluid to the discharge
manifold
130.
[0065] Referring to Figure 10, with continuing reference to Figures 1A through
9J, an
illustrative node 1000 for implementing one or more of the embodiments of one
or more
of the controller(s) (e.g., the controller 220), element(s), apparatus,
system(s) (e.g., the
hydraulic fracturing system 100 and/or the hot swappable fracturing pump
system 155),
method(s) (e.g., the method 500), step(s), and/or sub-step(s), or any
combination thereof,
described above and/or illustrated in Figures lA through 9J is depicted. The
node 1000
includes a microprocessor 1000a, an input device 1000b, a storage device
1000c, a video
controller 1000d, a system memory 1000e, a display 1000f, and a communication
device
1000g all interconnected by one or more buses 1000h. In one or more
embodiments, the
storage device 1000c may include a hard drive, CD-ROM, optical drive, any
other form of
storage device and/or any combination thereof. In one or more embodiments, the
storage
device 1000c may include, and/or be capable of receiving, a CD-ROM, DVD-ROM,
or any
other form of non-transitory computer-readable medium that may contain
executable
instructions. In one or more embodiments, the communication device 1000g may
include
a modem, network card, or any other device to enable the node 1000 to
communicate
with other node(s). In one or more embodiments, the node and the other node(s)
represent a plurality of interconnected (whether by intranet or Internet)
computer systems,
including without limitation, personal computers, mainframes, PDAs,
smartphones and
cell phones.
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[0066] In one or more embodiments, one or more of the embodiments described
above
and/or illustrated in Figures 1A through 9J include at least the node 1000
and/or
components thereof, and/or one or more nodes that are substantially similar to
the node
1000 and/or components thereof. In one or more embodiments, one or more of the
above-described components of the node 1000 and/or the embodiments described
above
and/or illustrated in Figures 1A through 9J include respective pluralities of
same
components.
[0067] In one or more embodiments, one or more of the embodiments described
above
and/or illustrated in Figures 1A through 9J include a computer program that
includes a
plurality of instructions, data, and/or any combination thereof; an
application written in, for
example, Arena, HyperText Markup Language (HTML), Cascading Style Sheets
(CSS),
JavaScript, Extensible Markup Language (XML), asynchronous JavaScript and XML
(Ajax), and/or any combination thereof; a web-based application written in,
for example,
Java or Adobe Flex, which in one or more embodiments pulls real-time
information from
one or more servers, automatically refreshing with latest information at a
predetermined
time increment; or any combination thereof.
[0068] In one or more embodiments, a computer system typically includes at
least
hardware capable of executing machine readable instructions, as well as the
software for
executing acts (typically machine-readable instructions) that produce a
desired result. In
one or more embodiments, a computer system may include hybrids of hardware and
software, as well as computer sub-systems.
[0069] In one or more embodiments, hardware generally includes at least
processor-
capable platforms, such as client-machines (also known as personal computers
or
servers), and hand-held processing devices (such as smart phones, tablet
computers, or
personal computing devices (PCDs), for example). In one or more embodiments,
hardware may include any physical device that is capable of storing machine-
readable
instructions, such as memory or other data storage devices. In one or more
embodiments, other forms of hardware include hardware sub-systems, including
transfer
devices such as modems, modem cards, ports, and port cards, for example.
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[0070] In one or more embodiments, software includes any machine code stored
in any
memory medium, such as RAM or ROM, and machine code stored on other devices
(such
as floppy disks, flash memory, or a CD-ROM, for example). In one or more
embodiments,
software may include source or object code. In one or more embodiments,
software
encompasses any set of instructions capable of being executed on a node such
as, for
example, on a client machine or server.
[0071] In one or more embodiments, combinations of software and hardware could
also
be used for providing enhanced functionality and performance for certain
embodiments
of the present disclosure. In an embodiment, software functions may be
directly
manufactured into a silicon chip. Accordingly, it should be understood that
combinations
of hardware and software are also included within the definition of a computer
system
and are thus envisioned by the present disclosure as possible equivalent
structures and
equivalent methods.
[0072] In one or more embodiments, computer readable mediums include, for
example,
passive data storage, such as a random-access memory (RAM) as well as semi-
permanent data storage such as a compact disk read only memory (CD-ROM). One
or
more embodiments of the present disclosure may be embodied in the RAM of a
computer
to transform a standard computer into a new specific computing machine. In one
or more
embodiments, data structures are defined organizations of data that may enable
an
embodiment of the present disclosure. In an embodiment, a data structure may
provide
an organization of data, or an organization of executable code.
[0073] In one or more embodiments, any networks and/or one or more portions
thereof
may be designed to work on any specific architecture. In an embodiment, one or
more
portions of any networks may be executed on a single computer, local area
networks,
client-server networks, wide area networks, internets, hand-held and other
portable and
wireless devices and networks.
[0074] In one or more embodiments, a database may be any standard or
proprietary
database software. In one or more embodiments, the database may have fields,
records,
data, and other database elements that may be associated through database
specific
software. In one or more embodiments, data may be mapped. In one or more
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embodiments, mapping is the process of associating one data entry with another
data
entry. In an embodiment, the data contained in the location of a character
file can be
mapped to a field in a second table. In one or more embodiments, the physical
location
of the database is not limiting, and the database may be distributed. In an
embodiment,
the database may exist remotely from the server, and run on a separate
platform. In an
embodiment, the database may be accessible across the Internet. In one or more
embodiments, more than one database may be implemented.
[0075] In one or more embodiments, a plurality of instructions stored on a non-
transitory
computer readable medium may be executed by one or more processors to cause
the
one or more processors to carry out or implement in whole or in part one or
more of the
embodiments of one or more of the controller(s) (e.g., the controller 220),
element(s),
apparatus, system(s) (e.g., the hydraulic fracturing system 100 and/or the hot
swappable
fracturing pump system 155), method(s) (e.g., the method 500), step(s), and/or
sub-
step(s), or any combination thereof, described above and/or illustrated in
Figures 1A
through 9J. In one or more embodiments, such a processor may include one or
more of
the microprocessor 1000a, any processor(s) that are part of the components of
the
hydraulic fracturing system 100 and/or the hot swappable fracturing pump
system 155,
such as, for example, the controller 220, and/or any combination thereof, and
such a
computer readable medium may be distributed among one or more components of
the
system. In one or more embodiments, such a processor may execute the plurality
of
instructions in connection with a virtual computer system. In one or more
embodiments,
such a plurality of instructions may communicate directly with the one or more
processors,
and/or ay interact with one or more operating systems, middleware, firmware,
other
applications, and/or any combination thereof, to cause the one or more
processors to
execute the instructions.
[0076] A system has been disclosed according to one or more embodiments of the
present disclosure. The system generally includes: a discharge manifold
adapted to be
pressurized by at least a first fracturing pump; a first swap adapter
connected to a second
fracturing pump via a first suction conduit and a first discharge conduit; and
a swap station
connected, via a second suction conduit, to a suction manifold, and, via a
second
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discharge conduit, to the discharge manifold; wherein the first swap adapter
is adapted
to be connected to the swap station while the discharge manifold is
pressurized by at
least the first fracturing pump; and wherein, after the first swap adapter is
connected to
the swap station, and while the discharge manifold remains pressurized by at
least the
first fracturing pump, the second fracturing pump is adapted to: draw fluid
from the suction
manifold via the second suction conduit, the swap station, the first swap
adapter, and the
first suction conduit; and discharge pressurized fluid to the discharge
manifold via the first
discharge conduit, the first swap adapter, the swap station, and the second
discharge
conduit. In one or more embodiments, before connecting the first swap adapter
to the
swap station, and while the discharge manifold remains pressurized by at least
the first
fracturing pump, a second swap adapter is adapted to be disconnected from the
swap
station; and the second swap adapter is connected to a third fracturing pump
via a third
suction conduit and a third discharge conduit. In one or more embodiments, the
swap
station includes a grapple assembly adapted to connect the first swap adapter
to the swap
station by moving the first swap adapter into sealing engagement with the swap
station.
In one or more embodiments, the grapple assembly is adapted to move the first
swap
adapter into sealing engagement with the swap station by moving the first swap
adapter
in a vertical direction. In one or more embodiments, the grapple assembly is
adapted to
move the first swap adapter into sealing engagement with the swap station by
moving the
first swap adapter in a first horizontal direction, a second horizontal
direction, or both. In
one or more embodiments, the grapple assembly is adapted to move the first
swap
adapter into sealing engagement with the swap station by moving the first swap
adapter
in an angular direction. In one or more embodiments, the swap station further
includes a
lock assembly adapted to secure the first swap adapter in sealing engagement
with the
swap station. In one or more embodiments, the first swap adapter is connected
to, and
extends from, a pump truck; and the second fracturing pump is supported on the
pump
truck.
[0077] A method has also been disclosed according to one or more embodiments
of the
present disclosure. The method generally includes: connecting a first swap
adapter to a
swap station while a discharge manifold is pressurized by at least a first
fracturing pump,
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wherein the first swap adapter is connected to a second fracturing pump via a
first suction
conduit and a first discharge conduit, wherein the swap station is connected
to a suction
manifold via a second suction conduit, and wherein the swap station is
connected to the
discharge manifold via a second discharge conduit; and after connecting the
first swap
adapter to the swap station, and while the discharge manifold remains
pressurized by at
least the first fracturing pump: drawing fluid from the suction manifold,
using the second
fracturing pump, via the second suction conduit, the swap station, the first
swap adapter,
and the first suction conduit; and discharging pressurized fluid into the
discharge
manifold, using the second fracturing pump, via the first discharge conduit,
the first swap
adapter, the swap station, and the second discharge conduit. In one or more
embodiments, the method further includes: before connecting the first swap
adapter to
the swap station, and while the discharge manifold remains pressurized by at
least the
first fracturing pump, disconnecting a second swap adapter from the swap
station,
wherein the second swap adapter is connected to a third fracturing pump via a
third
suction conduit and a third discharge conduit. In one or more embodiments,
connecting
the first swap adapter to the swap station includes moving the first swap
adapter into
sealing engagement with the swap station while the first swap adapter remains
connected
to the second fracturing pump via the first suction conduit and the first
discharge conduit.
In one or more embodiments, moving the first swap adapter into sealing
engagement with
the swap station includes moving the first swap adapter in a vertical
direction. In one or
more embodiments, moving the first swap adapter into sealing engagement with
the swap
station includes moving the first swap adapter in a first horizontal
direction, a second
horizontal direction, or both. In one or more embodiments, moving the first
swap adapter
into sealing engagement with the swap station includes moving the first swap
adapter in
an angular direction. In one or more embodiments, connecting the first swap
adapter to
the swap station further includes securing the first swap adapter in sealing
engagement
with the swap station. In one or more embodiments, the first swap adapter is
connected
to, and extends from, a pump truck; and the second fracturing pump is
supported on the
pump truck.
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[0078] A system has also been disclosed according to one or more embodiments
of the
present disclosure. The system generally includes: means for connecting a
first swap
adapter to a swap station while a discharge manifold is pressurized by at
least a first
fracturing pump, wherein the first swap adapter is connected to a second
fracturing pump
via a first suction conduit and a first discharge conduit, wherein the swap
station is
connected to a suction manifold via a second suction conduit, and wherein the
swap
station is connected to the discharge manifold via a second discharge conduit;
and means
for, after connecting the first swap adapter to the swap station, and while
the discharge
manifold remains pressurized by at least the first fracturing pump: drawing
fluid from the
suction manifold, using the second fracturing pump, via the second suction
conduit, the
swap station, the first swap adapter, and the first suction conduit; and
discharging
pressurized fluid into the discharge manifold, using the second fracturing
pump, via the
first discharge conduit, the first swap adapter, the swap station, and the
second discharge
conduit. In one or more embodiments, the system includes means for, before
connecting
the first swap adapter to the swap station, and while the discharge manifold
remains
pressurized by at least the first fracturing pump, disconnecting a second swap
adapter
from the swap station, wherein the second swap adapter is connected to a third
fracturing
pump via a third suction conduit and a third discharge conduit. In one or more
embodiments, means for connecting the first swap adapter to the swap station
includes
means for moving the first swap adapter into sealing engagement with the swap
station
while the first swap adapter remains connected to the second fracturing pump
via the first
suction conduit and the first discharge conduit. In one or more embodiments,
means for
moving the first swap adapter into sealing engagement with the swap station
includes
means for moving the first swap adapter in a vertical direction. In one or
more
embodiments, means for moving the first swap adapter into sealing engagement
with the
swap station includes means for moving the first swap adapter in a first
horizontal
direction, a second horizontal direction, or both. In one or more embodiments,
means for
moving the first swap adapter into sealing engagement with the swap station
includes
means for moving the first swap adapter in an angular direction. In one or
more
embodiments, means for moving the first swap adapter into sealing engagement
with the
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swap station includes means for moving the first swap adapter in one or more
of the
following: a vertical direction; a first horizontal direction; a second
horizontal direction; an
angular direction. In one or more embodiments, means for connecting the first
swap
adapter to the swap station further includes means for securing the first swap
adapter in
sealing engagement with the swap station. In one or more embodiments the first
swap
adapter is connected to, and extends from, a pump truck; and the second
fracturing pump
is supported on the pump truck.
[0079] An apparatus has also been disclosed according to one or more
embodiments
of the present disclosure. The apparatus generally includes: a non-transitory
computer
readable medium; and a plurality of instructions stored on the non-transitory
computer
readable medium and executable by one or more processors, wherein, when the
instructions are executed by the one or more processors, the following steps
are
executed: connecting a first swap adapter to a swap station while a discharge
manifold is
pressurized by at least a first fracturing pump, wherein the first swap
adapter is connected
to a second fracturing pump via a first suction conduit and a first discharge
conduit,
wherein the swap station is connected to a suction manifold via a second
suction conduit,
and wherein the swap station is connected to the discharge manifold via a
second
discharge conduit; and after connecting the first swap adapter to the swap
station, and
while the discharge manifold remains pressurized by at least the first
fracturing pump:
drawing fluid from the suction manifold, using the second fracturing pump, via
the second
suction conduit, the swap station, the first swap adapter, and the first
suction conduit; and
discharging pressurized fluid into the discharge manifold, using the second
fracturing
pump, via the first discharge conduit, the first swap adapter, the swap
station, and the
second discharge conduit. In one or more embodiments, when the instructions
are
executed by the one or more processors, the following step is also executed:
before
connecting the first swap adapter to the swap station, and while the discharge
manifold
remains pressurized by at least the first fracturing pump, disconnecting a
second swap
adapter from the swap station, wherein the second swap adapter is connected to
a third
fracturing pump via a third suction conduit and a third discharge conduit. In
one or more
embodiments, connecting the first swap adapter to the swap station includes
moving the
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first swap adapter into sealing engagement with the swap station while the
first swap
adapter remains connected to the second fracturing pump via the first suction
conduit and
the first discharge conduit. In one or more embodiments, moving the first swap
adapter
into sealing engagement with the swap station includes moving the first swap
adapter in
a vertical direction. In one or more embodiments, moving the first swap
adapter into
sealing engagement with the swap station includes moving the first swap
adapter in a first
horizontal direction, a second horizontal direction, or both. In one or more
embodiments,
moving the first swap adapter into sealing engagement with the swap station
includes
moving the first swap adapter in an angular direction. In one or more
embodiments,
connecting the first swap adapter to the swap station further includes:
securing the first
swap adapter in sealing engagement with the swap station. In one or more
embodiments,
the first swap adapter is connected to, and extends from, a pump truck; and
the second
fracturing pump is supported on the pump truck.
[0080] A swap station has also been disclosed according to one or more
embodiments
of the present disclosure. The swap station generally includes: suction and
discharge
flow components, wherein the suction flow component is adapted to be
connected, via a
first suction conduit, to a suction manifold, and wherein the discharge flow
component is
adapted to be connected, via a first discharge conduit, to a discharge
manifold, said
discharge manifold being adapted to be pressurized by at least a first
fracturing pump;
and a grapple assembly adapted to connect a swap adapter to the suction and
discharge
flow components while the discharge manifold is pressurized by at least the
first fracturing
pump by moving the swap adapter into sealing engagement with the suction and
discharge flow components, wherein the swap adapter is connected to a second
fracturing pump via a second suction conduit and a second discharge conduit.
In one or
more embodiments, after the swap adapter is connected to the suction and
discharge
flow components, and while the discharge manifold remains pressurized by at
least the
first fracturing pump, the second fracturing pump is adapted to: draw fluid
from the suction
manifold via the second suction conduit, the swap station, the swap adapter,
and the first
suction conduit; and discharge pressurized fluid to the discharge manifold via
the first
discharge conduit, the swap adapter, the swap station, and the second
discharge conduit.
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In one or more embodiments, the swap station further includes a lock assembly
adapted
to secure the swap adapter in sealing engagement with the swap station. In one
or more
embodiments, the grapple assembly is adapted to move the swap adapter into
sealing
engagement with the swap station by moving the swap adapter in one or more of
the
following: a vertical direction; a first horizontal direction; a second
horizontal direction; an
angular direction. In one or more embodiments, swap station further includes:
the suction
manifold; the first suction conduit via which the suction flow component is
adapted to be
connected to the suction manifold; the discharge manifold; and the first
discharge conduit
via which the discharge flow component is adapted to be connected to the
discharge
manifold. In one or more embodiments, the swap station further includes the
swap
adapter; the second fracturing pump; the second suction conduit via which the
swap
adapter is connected to the second fracturing pump; and the second discharge
conduit
via which the swap adapter is connected to the second fracturing pump.
[0081] It is understood that variations may be made in the foregoing without
departing
from the scope of the present disclosure.
[0082] In several embodiments, the elements and teachings of the various
embodiments may be combined in whole or in part in some (or all) of the
embodiments. In
addition, one or more of the elements and teachings of the various embodiments
may be
omitted, at least in part, and/or combined, at least in part, with one or more
of the other
elements and teachings of the various embodiments.
[0083] Any spatial references, such as, for example, "upper," "lower,"
"above," "below,"
"between," "bottom," "vertical," "horizontal," "angular," "upwards,"
"downwards," "side-to-
side," "left-to-right," "right-to-left," "top-to-bottom," "bottom-to-top,"
"top," "bottom,"
"bottom-up," "top-down," etc., are for the purpose of illustration only and do
not limit the
specific orientation or location of the structure described above.
[0084] In several embodiments, while different steps, processes, and
procedures are
described as appearing as distinct acts, one or more of the steps, one or more
of the
processes, and/or one or more of the procedures may also be performed in
different
orders, simultaneously and/or sequentially. In several embodiments, the steps,
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processes, and/or procedures may be merged into one or more steps, processes
and/or
procedures.
[0085] In several embodiments, one or more of the operational steps in each
embodiment may be omitted. Moreover, in some instances, some features of the
present
disclosure may be employed without a corresponding use of the other
features. Moreover, one or more of the above-described embodiments and/or
variations
may be combined in whole or in part with any one or more of the other above-
described
embodiments and/or variations.
[0086] Although several embodiments have been described in detail above, the
embodiments described are illustrative only and are not limiting, and those
skilled in the
art will readily appreciate that many other modifications, changes and/or
substitutions are
possible in the embodiments without materially departing from the novel
teachings and
advantages of the present disclosure. Accordingly, all such modifications,
changes,
and/or substitutions are intended to be included within the scope of this
disclosure as
defined in the following claims. In the claims, any means-plus-function
clauses are
intended to cover the structures described herein as performing the recited
function and
not only structural equivalents, but also equivalent structures. Moreover, it
is the express
intention of the applicant not to invoke 35 U.S.C. 112(f) for any
limitations of any of the
claims herein, except for those in which the claim expressly uses the word
"means"
together with an associated function.
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