End-User Feedback

• Well service company maintenance personnel state that carbon steel manifolds are working okay. Leaks along the weld seams are a regular nuisance, and repair consists of re-welding and/or use of rubber washers with screws.
• Sand dropout causing flow restrictions is common, and some manifold designs last longer than others. End-users reported that 600-800 hours in service is considered a very good performance.
• Lab tests and field trials were recommended per the following application parameters:
  • Low temperature with CO2 at -30°F
  • ASTM spec calls for -62°F
  • The maximum working pressure is 350 PSIG, and test pressure should be 11/2 times working pressure or 525 PSIG
  • Acidizing well treatments use Hydrochloric (HCL) and Hydrofluoric (HFL) acids in (concentrations ranging from 15-28%

Facts

• The Fluid End (FE) is a main consumable of the High Horsepower (HHP) pump used in hydraulic fracturing operations.
• Current life span of a FE ranges from 200 to 1,400 hours.
• Fundamental root causes of FE failure:
  • Cracking of the cross bores
  • Cracking of the valve seat deck
  • Corrosion pitting
  • Cavitation, pump damage due to flow restrictions
• End-user cost for 3-Port FE on a HHP pump ranges from $25K to $60K, and the price is dependent on the brand and/or the material of the FE.
• End-user cost for the 5-port FE on an HHP pump ranges from $55K to $130K, and the price is dependent on the brand and/or material of the FE.

Dixon Solution

The focus was to eliminate flow restrictions and welds when designing intake manifolds. Combine iron manufacturing technology with flow geometry to eliminate welds (7-18 seams). Minimize sand dropout existing in the suction manifolds used today. Include user-friendly inspection ports.

• Designed and patented 3-port and 5-port intake manifolds for HHP pumps.
• Lab tests completed for pressure (350 PSI) and cold (-62°F).
• All new manifold assemblies are pressure tested to 700 PSIG.
• Lab test are available by contacting [email protected].