traditional welded pipe manifold application

Case Study

Pump Cavitation Got You Down? One-Piece Suction Manifolds

End-User Feedback
  • Sand dropout causes flow restrictions, and pump cavitation is common.
  • Traditional welded pipe manifolds create turbulence causing excessive abrasion on internal walls.
  • Leaks along the weld seams are a regular nuisance.
  • Acidizing well treatments attack weld seems.
  • CO2 transfers at -30°F temperatures and can cause performance issues.
  • Repairs consist of re-welding and/or using rubber washers with screws.

Within the fracturing operation, there are multiple scenarios where down-time and pump failure can be avoided.

Fig. 1

Welded Pipe Manifold
Traditional welded pipe manifold.

Fig. 2

Sand Dropout In Manifold
Sand dropout and internal weld erosion.

Dixon innovation was demonstrated when developing the one-piece suction manifold that feeds slurry into high-pressure pumps. The manifold design was the result of hydraulic fracturing companies experiencing pump cavitation due to proppant dropout causing destructive flow restrictions.

End-user input is invaluable, and the feedback has helped guide us to an economical solution.

Dixon Solution

The Dixon design combines unique flow geometry with one-piece iron manufacturing technology to increase flow, and eliminate 7-18 leak-prone weld seams. The 3-port and 5-port suction manifolds have been lab and field-tested, and the flow profile simulation demonstrates the differences between the welded pipe and Dixon manifolds.

Flow Profile