"Arteries" and "Veins" of Fracking Operations: A Brief Analysis of High- and Low-Pressure Manifold Systems-Jingzhou Jinxiu Machinery Technology Co., Ltd._Plug valve

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"Arteries" and "Veins" of Fracking Operations: A Brief Analysis of High- and Low-Pressure Manifold Systems

Published time:

2025-11-01

In the vast landscape of oil fracturing operations, dense pipelines function like the human circulatory system, delivering power and media to critical components. Among them, high-pressure and low-pressure manifolds form the core pathways of this system, collectively ensuring the safety and efficiency of fracturing operations. This article briefly introduces the definitions, functions, and applications of these two systems.

I. High-Pressure Manifold: The "Aorta" Delivering Power
Definition
The high-pressure manifold is a piping system composed of high-pressure-rated steel pipes, elbows, tees, plug valves, and other components. It serves as the final "express pathway" between the fracturing fleet and the wellhead, directly withstanding the extreme pressure from the fracturing pump outlet.

Core Functions

Collect and transport high-pressure fluid: Gathers high-pressure fluid from multiple fracturing pumps and delivers it steadily and reliably to the wellhead assembly.

Withstand extreme pressure: During fracturing operations, its working pressure typically ranges from 80 MPa to over 140 MPa, making it one of the highest-pressure components in the entire surface equipment.

Distribute and switch flow paths: Utilizes plug valves to switch flow channels, enabling transitions between different processes such as fracturing and testing.

Applications
The high-pressure manifold is the absolute core of the main fracturing phase. When high-pressure fracturing fluid carrying proppant is pumped at high rates, the entire high-pressure manifold system is subjected to extreme dynamic and static loads. Its performance directly determines the upper limit of operational pressure and job safety.

II. Low-Pressure Manifold: The "Great Vein" Distributing Materials
Definition
The low-pressure manifold is a piping system located between the blender and the fracturing pumps, used to transport and distribute low-pressure mixed fluid. It ensures a stable supply of "raw material" to the fracturing pumps.

Core Functions

Transport and distribute low-pressure fluid: Distributes the low-pressure fracturing fluid (typically <2 MPa) prepared by the blender to the suction ends of the fracturing pumps.

Ensure continuous fluid supply: Through multi-branch design, it guarantees that all fracturing pumps receive sufficient and stable fluid, preventing damage due to cavitation.

Flexible connections: Often uses quick connectors like unions for rapid on-site deployment and disassembly.

Applications
The low-pressure manifold operates continuously throughout the pumping process. It connects the mixing tank, blender, and fracturing pump fleet, forming the "logistical network" for fracturing fluid supply. Its design directly impacts the suction efficiency of the fracturing pumps, thereby influencing the output rate of the entire fleet.

Comparison of High- and Low-Pressure Manifolds

Feature	High-Pressure Manifold	Low-Pressure Manifold
Function	Delivers high-pressure fluid to the wellhead	Distributes low-pressure fluid to fracturing pumps
Pressure Rating	High (typically >80 MPa)	Low (typically <2 MPa)
Key Requirements	Strength, toughness, fatigue resistance, sealing	Flow capacity, flow rate, anti-settling, flexibility
Main Components	Thick-walled steel pipes, live elbows, high-pressure plug valves	Large-diameter steel pipes, low-pressure unions, hoses

As the "vital pathways" of the fracturing surface process, the reliability of high- and low-pressure manifold design and equipment is fundamental to the success of fracturing operations. Key components such as live elbows in the high-pressure manifold, which must maintain sealing and structural integrity under high-frequency vibrations and high-pressure erosion, place extreme demands on materials, forging techniques, and heat treatment technologies.

Understanding the division of labor between high- and low-pressure tubing assemblies helps us more deeply appreciate that a successful fracturing project relies not only on high-powered fracturing trucks, but also on the precision, reliability, and durability of every single connecting component.

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