HOT SWAPPABLE FRACTURING PUMP SYSTEM

Abstract

A method, apparatus, and system according to which a swap station is adapted to communicate pressurized fluid to an oil and gas wellbore.

Description

BACKGROUND

This application is 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

FIG. 1A 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.

FIG. 1B is a diagrammatic illustration of a portion of the hydraulic fracturing system of FIG. 1A, said portion including a hot swappable fracturing pump system, according to one or more embodiments.

FIG. 2A is a perspective view of a swap station and a pump truck of the hot swappable fracturing pump system of FIG. 1B, according to one or more embodiments.

FIG. 2B is another perspective view of the swap station and the pump truck of the hot swappable fracturing pump system of FIG. 1B, according to one or more embodiments.

FIG. 3 is a perspective view of a swap adapter connected to the pump truck of FIGS. 2A and 2B, according to one or more embodiments.

FIG. 4A is a top plan view of an adapter body of the hot swap adapter of FIG. 3, according to one or more embodiments.

FIG. 4B is an elevational view of the adapter body of the swap adapter of FIG. 3, according to one or more embodiments.

FIG. 4C is another elevational view of the adapter body of the swap adapter of FIG. 3, according to one or more embodiments.

FIG. 5A is a perspective view of the swap station of FIGS. 2A and 2B, according to one or more embodiments.

FIG. 5B is another perspective view of the swap station of FIGS. 2A and 2B, according to one or more embodiments.

FIG. 5C is an elevational view of the swap station of FIGS. 2A and 2B, according to one or more embodiments.

FIG. 6A is a perspective view of a grapple assembly of the swap station of FIGS. 5A through 5C, according to one or more embodiments.

FIG. 6B is another perspective view of the grapple assembly of the swap station of FIGS. 5A through 5C, according to one or more embodiments.

FIG. 6C is an elevational view of the grapple assembly of the swap station of FIGS. 5A through 5C, according to one or more embodiments.

FIG. 7A is a perspective view of a lock assembly of the swap station of FIGS. 5A through 5C, according to one or more embodiments.

FIG. 7B is another perspective view of the lock assembly of the swap station of FIGS. 5A through 5C, according to one or more embodiments.

FIG. 7C is an elevational view of the lock assembly of the swap station of FIGS. 5A through 5C, according to one or more embodiments.

FIG. 8 is a flow diagram illustrating a method for using the swap station of FIGS. 2A and 2B, according to one or more embodiments.

FIG. 9A is top plan view illustrating execution of a first step of the method illustrated in FIG. 8, according to one or more embodiments.

FIG. 9B is a perspective view illustrating execution of the first step of the method illustrated in FIG. 8, according to one or more embodiments.

FIG. 9C is a perspective view illustrating execution of a second step of the method illustrated in FIG. 8, according to one or more embodiments.

FIG. 9D is a perspective view illustrating execution of a third step of the method illustrated in FIG. 8, according to one or more embodiments.

FIG. 9E is a top plan view illustrating execution of the third step of the method illustrated in FIG. 8, according to one or more embodiments.

FIG. 9F is a top plan view illustrating execution of the third step of the method illustrated in FIG. 8, according to one or more embodiments.

FIG. 9G is a top plan view illustrating execution of a fourth step of the method illustrated in FIG. 8, according to one or more embodiments.

FIG. 9H is a perspective view illustrating execution of the fourth step of the method illustrated in FIG. 8, according to one or more embodiments.

FIG. 9I is a perspective view illustrating execution of a fifth step of the method illustrated in FIG. 8, according to one or more embodiments.

FIG. 9J is an elevational view illustrating execution of the fifth step of the method illustrated in FIG. 8, according to one or more embodiments.

FIG. 10 is a diagrammatic illustration of a computing node for implementing one or more embodiments of the present disclosure.

DETAILED DESCRIPTION

Referring to FIG. 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 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 Jun. 10, 2019, now published as U.S. Patent Application Publication No. 2020/0386359, the entire disclosure of which is hereby incorporated herein by reference.

Although shown in FIG. 1A 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 FIG. 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.

Referring to FIG. 1B, with continuing reference to FIG. 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, 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.

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 FIG. 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.

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 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.

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 conduit 160b′ also includes a pressure sensor 171′ that detects a discharge pressure exiting the swap station 135bb.

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 FIG. 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′.

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.

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 Ser. No. 17/388,716, filed Jul. 29, 2021, the entire disclosure of which is hereby incorporated herein by reference; U.S. patent application Ser. No. 17/319,854, filed May 13, 2021, the entire disclosure of which is hereby incorporated herein by reference; U.S. patent application Ser. No. 16/855,749, filed Apr. 22, 2020, the entire disclosure of which is hereby incorporated herein by reference.

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 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 185a′). 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.

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 FIG. 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.

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 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.

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 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.

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 FIG. 1B and, therefore, will not be described in further detail.

In one or more embodiments, the swap stations 135aa though 135bc are substantially identical to one another, and, therefore, in connection with FIGS. 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 FIGS. 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.

Referring to FIGS. 2A and 2B, with continuing reference to FIGS. 1A 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 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.

Referring to FIG. 3, with continuing reference to FIGS. 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.

Referring to FIGS. 4A through 4C, with continuing reference to FIG. 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 FIGS. 2A and 2B). Additionally, the discharge conduit 185b is connected to, and extends from, the discharge fitting 270b (as shown in FIGS. 2A and 2B).

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 FIG. 4B, the recess 295a defines a slot 300 and opposing inclined surfaces 305a-b in the adapter 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.

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.

Referring to FIGS. 5A through 5C, with continuing reference to FIGS. 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 component 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 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.

Referring to FIGS. 6A through 6C, with continuing reference to FIGS. 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).

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., 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.

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.

Referring to FIGS. 7A through 7C, with continuing reference to FIGS. 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 favor of another suitable type of linear actuator (e.g., a hydraulic actuator, and electrical actuator, a mechanical actuator, etc.).

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.

Referring to FIGS. 8 and 9A through 9J, with continuing reference to FIGS. 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 FIG. 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 FIGS. 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.

The suction and discharge conduits 185a-b are omitted from view in FIGS. 9A through 9J for clarity. As shown in FIGS. 9A and 9B, at the step 505 of positioning the 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 FIG. 9A, when so positioned, the pump truck 140ba's swap adapter 175 may extend at an angle A1 relative to the suction and discharge flow components 340a-b of the swap station 135ba. As shown in FIG. 9C, at the step 510 of positioning the linear actuators 380a-b of the swap station 135ba into the recesses 295a-b (shown in FIGS. 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 FIG. 9C). More particularly, the inclined surfaces 305a-b and 325a-b (shown in FIGS. 4A through 4C) guide the extended linear actuators 380a-b into the slots 300 (shown in FIGS. 4A through 4C) 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.

As shown in FIGS. 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 FIGS. 6A through 6C) of the linear actuators 380a-b's grapples 430 engage the tapered surfaces 330 (shown in FIG. 4C) of the grappling holds 310a-b, respectively, to straighten the swap adapter 175's adapter body 235 (shown in FIGS. 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 A1 (as indicated by arrows 480 in FIGS. 9D and 9E, and arrows 485 in FIG. 9F). In this manner, the grapple assembly 345 is able to move the adapter body 235 in an angular direction via engagement with the grappling holds 310a-b.

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 FIGS. 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 FIGS. 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 FIGS. 6A through 6C) of the linear actuators 380a-b's grapples 430 engage the tapered surfaces 330 (shown in FIG. 4C) of the grappling holds 310a-b, respectively, to urge the suction and discharge fittings 270a and 275a (shown in FIGS. 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 FIGS. 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.

Finally, as shown in FIGS. 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 FIGS. 91 and 9J) so that: the channel 470 (shown in FIGS. 7A through 7C) of the clamp 440a receives the clamping hold 335a (shown in FIGS. 4A and 4C) of the swap adapter 175, the clamping hold 465aa (shown in FIGS. 7A and 7B) of the suction flow component 340a, and the clamping hold 465ba (shown in FIGS. 7B and 7C) of the discharge flow component 340b; and the channel 470 (shown in FIGS. 7A through 7C) of the clamp 440b receives the clamping hold 335b (shown in FIG. 4C) of the swap adapter 175, the clamping hold 465ab (shown in FIG. 7A) of the suction flow component 340a, and the clamping hold 465bb (shown in FIG. 7C) of the discharge flow component 340b.

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.

Referring to FIG. 10, with continuing reference to FIGS. 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 FIGS. 1A 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.

In one or more embodiments, one or more of the embodiments described above and/or illustrated in FIGS. 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 FIGS. 1A through 9J include respective pluralities of same components.

In one or more embodiments, one or more of the embodiments described above and/or illustrated in FIGS. 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.

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.

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.

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.

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.

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.

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.

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 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.

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 FIGS. 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.

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 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.

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, 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.

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 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.

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 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.

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.

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.

It is understood that variations may be made in the foregoing without departing from the scope of the present disclosure.

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.

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.

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, processes, and/or procedures may be merged into one or more steps, processes and/or procedures.

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.

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.

Claims

1. A system, comprising: a swap station positionable in the vicinity of a hydraulic fracturing missile, the hydraulic fracturing missile comprising suction and discharge manifolds, the swap station comprising: a support frame;suction and discharge flow components mounted on the support frame; andsuction and discharge conduits connected to, and extending from, the suction and discharge flow components, respectively;andsuction and discharge fittings adapted to be mounted on a pump truck;wherein, when the swap station is positioned in the vicinity of the hydraulic fracturing missile: the suction conduit is adapted to be operably coupled to the suction manifold of the hydraulic fracturing missile so that the suction conduit is, or is at least adapted to be, in fluid communication with each of the suction manifold and the suction flow component;the discharge conduit is adapted to be operably coupled to the discharge manifold of the hydraulic fracturing missile so that the discharge conduit is, or is at least adapted to be, in fluid communication with each of the discharge manifold and the discharge flow component; anda hydraulic fracturing pump mounted on the pump truck is positionable in the vicinity of the swap station, opposite the hydraulic fracturing missile;andwherein, when the suction and discharge conduits are operably coupled to the suction and discharge manifolds, respectively, of the hydraulic fracturing missile, the suction and discharge fittings are mounted on the pump truck, and the hydraulic fracturing pump mounted on the pump truck is positioned in the vicinity of the swap station, opposite the hydraulic fracturing missile: the suction flow component is detachably connectable to the suction fitting mounted on the pump truck so that the suction flow component is, or is at least adapted to be, in fluid communication with each of: the hydraulic fracturing pump via the suction fitting; andthe suction manifold of the hydraulic fracturing missile via the suction conduit;andthe discharge flow component is detachably connectable to the discharge fitting mounted on the pump truck so that the discharge flow component is, or is at least adapted to be, in fluid communication with each of: the hydraulic fracturing pump via the discharge fitting; andthe discharge manifold of the hydraulic fracturing missile via the discharge conduit.

2. The system of claim 1, wherein the swap station further comprises: one or more actuators adapted to effect relative movement between the suction flow component of the swap station and the suction fitting, when the suction fitting is mounted on the pump truck, to sealingly engage the suction fitting with the suction flow component; anda lock assembly adapted to secure the suction fitting in sealing engagement with the suction flow component.

3. The system of claim 2, wherein the one or more actuators is, or are, further adapted to effect relative movement between the discharge flow component of the swap station and the discharge fitting, when the discharge fitting is mounted on the pump truck, to sealingly engage the discharge fitting with the discharge flow component; andwherein the lock assembly is further adapted to secure the discharge fitting in sealing engagement with the discharge flow component.

4. The system of claim 3, wherein both the suction fitting and the discharge fitting are part of a swap adapter.

5. The system of claim 1, wherein the swap station further comprises: one or more actuators adapted to effect relative movement between the discharge flow component of the swap station and the discharge fitting, when the discharge fitting is mounted on the pump truck, to sealingly engage the discharge fitting with the discharge flow component; anda lock assembly adapted to secure the discharge fitting in sealing engagement with the discharge flow component.

6. The system of claim 1, further comprising: the hydraulic fracturing missile.

7. The system of claim 1, further comprising: the hydraulic fracturing pump.

8. The system of claim 1, further comprising: the pump truck.

9. A method, comprising: positioning a swap station in the vicinity of a hydraulic fracturing missile, the hydraulic fracturing missile comprising suction and discharge manifolds, the swap station comprising: a support frame;suction and discharge flow components mounted on the support frame; andsuction and discharge conduits connected to, and extending from, the suction and discharge flow components, respectively;operably coupling the suction conduit to the suction manifold of the hydraulic fracturing missile so that the suction conduit is, or is at least adapted to be, in fluid communication with each of the suction manifold and the suction flow component; andoperably coupling the discharge conduit to the discharge manifold of the hydraulic fracturing missile so that the discharge conduit is, or is at least adapted to be, in fluid communication with each of the discharge manifold and the discharge flow component.

10. The method of claim 9, further comprising: positioning a hydraulic fracturing pump mounted on a pump truck in the vicinity of the swap station, opposite the hydraulic fracturing missile;detachably connecting the suction flow component to a suction fitting mounted on the pump truck so that the suction flow component is, or is at least adapted to be, in fluid communication with each of: the hydraulic fracturing pump via the suction fitting; andthe suction manifold of the hydraulic fracturing missile via the suction conduit;anddetachably connecting the discharge flow component to a discharge fitting mounted on the pump truck so that the discharge flow component is, or is at least adapted to be, in fluid communication with each of: the hydraulic fracturing pump via the discharge fitting; andthe discharge manifold of the hydraulic fracturing missile via the discharge conduit.

11. The method of claim 10, wherein detachably connecting the suction flow component to the suction fitting mounted on the pump truck comprises: effecting, using one or more actuators, relative movement between the suction flow component of the swap station and the suction fitting mounted on the pump truck to sealingly engage the suction fitting with the suction flow component; andsecuring, using a lock assembly, the suction fitting in sealing engagement with the suction flow component.

12. The method of claim 11, wherein detachably connecting the discharge flow component to the discharge fitting mounted on the pump truck comprises: effecting, using the one or more actuators, relative movement between the discharge flow component of the swap station and the discharge fitting mounted on the pump truck to sealingly engage the discharge fitting with the discharge flow component; andsecuring, using the lock assembly, the discharge fitting in sealing engagement with the discharge flow component.

13. The method of claim 12, wherein both the suction fitting and the discharge fitting are part of a swap adapter.

14. The method of claim 10, wherein detachably connecting the discharge flow component to the discharge fitting mounted on the pump truck comprises: effecting, using one or more actuators, relative movement between the discharge flow component of the swap station and the discharge fitting mounted on the pump truck to sealingly engage the discharge fitting with the discharge flow component; andsecuring, using a lock assembly, the discharge fitting in sealing engagement with the discharge flow component.

15. A swap station positionable in the vicinity of a hydraulic fracturing missile, the hydraulic fracturing missile comprising suction and discharge manifolds, the swap station comprising: a support frame;suction and discharge flow components mounted on the support frame; andsuction and discharge conduits connected to, and extending from, the suction and discharge flow components, respectively;wherein, when the swap station is positioned in the vicinity of the hydraulic fracturing missile: the suction conduit is adapted to be operably coupled to the suction manifold of the hydraulic fracturing missile so that the suction conduit is, or is at least adapted to be, in fluid communication with each of the suction manifold and the suction flow component;the discharge conduit is adapted to be operably coupled to the discharge manifold of the hydraulic fracturing missile so that the discharge conduit is, or is at least adapted to be, in fluid communication with each of the discharge manifold and the discharge flow component; anda hydraulic fracturing pump mounted on a pump truck is positionable in the vicinity of the swap station, opposite the hydraulic fracturing missile.

16. The swap station of claim 15, wherein, when the suction and discharge conduits are operably coupled to the suction and discharge manifolds, respectively, of the hydraulic fracturing missile, and the hydraulic fracturing pump mounted on the pump truck is positioned in the vicinity of the swap station, opposite the hydraulic fracturing missile: the suction flow component is detachably connectable to a suction fitting mounted on the pump truck so that the suction flow component is, or is at least adapted to be, in fluid communication with each of: the hydraulic fracturing pump via the suction fitting; andthe suction manifold of the hydraulic fracturing missile via the suction conduit;andthe discharge flow component is detachably connectable to a discharge fitting mounted on the pump truck so that the discharge flow component is, or is at least adapted to be, in fluid communication with each of: the hydraulic fracturing pump via the discharge fitting; andthe discharge manifold of the hydraulic fracturing missile via the discharge conduit.

17. The swap station of claim 16, further comprising: one or more actuators adapted to effect relative movement between the suction flow component of the swap station and the suction fitting mounted on the pump truck to sealingly engage the suction fitting with the suction flow component; anda lock assembly adapted to secure the suction fitting in sealing engagement with the suction flow component.

18. The swap station of claim 17, wherein the one or more actuators is, or are, further adapted to effect relative movement between the discharge flow component of the swap station and the discharge fitting mounted on the pump truck to sealingly engage the discharge fitting with the discharge flow component; andwherein the lock assembly is further adapted to secure the discharge fitting in sealing engagement with the discharge flow component.

19. The swap station of claim 18, wherein both the suction fitting and the discharge fitting are part of a swap adapter.

20. The swap station of claim 16, further comprising: one or more actuators adapted to effect relative movement between the discharge flow component of the swap station and the discharge fitting mounted on the pump truck to sealingly engage the discharge fitting with the discharge flow component; anda lock assembly adapted to secure the discharge fitting in sealing engagement with the discharge flow component.