IS22.1172-WO-PCT SCALABLE MANIFOLD ASSEMBLY CROSS-REFERENCE TO RELATED APPLICATION [0001] This application claims priority to and the benefit of U.S. Provisional Patent Application Serial No.63/607,103, titled “Scalable Manifold,” filed December 7, 2023, which is herein incorporated by reference in its entirety for all purposes. BACKGROUND [0002] This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present disclosure, which are described and/or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it may be understood that these statements are to be read in this light, and not as admissions of prior art. [0003] Manifolds have been traditionally engineered-to-order or bespoke solutions for which final design varies from project to project. Having to reengineer these structures for every project introduces design/engineering, manufacturing and supply chain risks and inefficiencies, which could be otherwise prevented if having a more common and repeatable design. However, introducing repeatability on the manifold product line is challenging given the high level of customization and the multitude of functionality options to select from. [0004] Attempts to address this challenge in the art include introducing low functionality/compact designs, but this limits the operability of the system, and any cost savings are negated by a lack of functionality options. SUMMARY [0005] This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining or limiting the scope of the claimed subject matter as set forth in the claims.
IS22.1172-WO-PCT [0006] In an embodiment, a scalable manifold assembly includes a header assembly configured to receive production fluid from one or more wells fluidly coupled to the header assembly and deliver process fluid to the one or more wells fluidly coupled to the header assembly and a frame assembly configured to at least partially surround the header assembly. The header assembly includes one or more header modules, the frame assembly includes one or more frame modules, the header assembly and the frame assembly are integrated together such that the frame assembly supports the header assembly, and a quantity and type of the one or more frame modules corresponds to a quantity and type of the one or more header modules. [0007] In another embodiment, a frame assembly for a scalable manifold assembly includes a plurality of frame modules configured to be integrated with a header assembly of the scalable manifold assembly. The plurality of frame modules includes a lift box module configured to at least partially surround and support one or more header interior modules and a branch core module of the header assembly, one or more header wing modules configured to at least partially surround and support one or more header termination modules of the header assembly, and one or more branch wing modules configured to at least partially surround and support one or more branch termination modules of the header assembly. [0008] In another embodiment, a method of configuring a scalable manifold assembly includes selecting a quantity of header modules configured to collective define a header assembly, wherein the quantity of header modules comprises any combination of one or more header termination modules, branch termination modules, branch core modules, and header interior modules. The method further includes selecting a frame assembly having one or more frame modules and sized to accommodate the selected quantity of header modules, wherein the one or more frame modules comprise any combination of one or more header wing modules, branch wing modules, and lift box modules, and wherein each of the one or more frame modules are associated with a corresponding header module of the header assembly, arranging the header modules in and on the one or more frame modules of the frame assembly, and connecting the header modules to one another with interconnecting piping. BRIEF DESCRIPTION OF THE DRAWINGS [0009] The subject disclosure is further described in the following detailed description, and the accompanying drawings and schematics of non-limiting embodiments of the subject
IS22.1172-WO-PCT disclosure. The features depicted in the figures are not necessarily shown to scale. Certain features of the embodiments may be shown exaggerated in scale or in somewhat schematic form, and some details of elements may not be shown in the interest of clarity and conciseness. These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein: [0010] FIG. 1 shows a schematic view of an embodiment of a subsea production system including a scalable manifold assembly in accordance with the principles described herein; [0011] FIG.2 shows a perspective view of an embodiment of a scalable manifold assembly in accordance with the principles described herein; [0012] FIGS. 3 shows a perspective view of an embodiment of a header assembly of the scalable manifold assembly of FIG.2 in accordance with the principles described herein; [0013] FIG.4 shows a schematic of an embodiment of the scalable manifold assembly of FIG. 2 in accordance with the principles described herein; [0014] FIG.5 shows a perspective view of an embodiment of a frame assembly of the scalable manifold assembly of FIG.2 in accordance with the principles described herein; [0015] FIG.6 shows a schematic view of an embodiment of a frame assembly of the scalable manifold assembly of FIG.2 in accordance with the principles described herein; [0016] FIG. 7A shows a schematic of an embodiment of a frame assembly of a scalable manifold assembly in a stacked configuration in accordance with the principles discussed herein; and [0017] FIG. 7B shows a schematic of an embodiment of a frame assembly of a scalable manifold assembly in a flush configuration in accordance with the principles discussed herein. [0018] FIG. 8A shows a perspective view of an embodiment of a header assembly of a scalable manifold assembly, including six branch termination modules in accordance with the principles described herein; [0019] FIG. 8B shows a perspective view of an embodiment of a frame assembly for the header assembly of FIG.8A, including six slots in accordance with the principles described herein;
IS22.1172-WO-PCT [0020] FIGS. 9A shows a perspective view of an embodiment of a header assembly of a scalable manifold assembly, including eight branch termination modules in accordance with the principles described herein; [0021] FIG. 9B shows a perspective view of a frame assembly for the header assembly of FIG.9A, including eight slots in accordance with the principles described herein; [0022] FIG. 10 shows schematics of various header and frame assembly combinations for a scalable manifold assembly in accordance with the principles described herein. DETAILED DESCRIPTION [0023] One or more specific embodiments of the present disclosure will be described below. The particulars shown herein are by way of example, and for purposes of illustrative discussion of the embodiments of the subject disclosure only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the subject disclosure. In this regard, no attempt is made to show structural details of the subject disclosure in more detail than is necessary for the fundamental understanding of the subject disclosure, the description taken with the drawings making apparent to those skilled in the art how the several forms of the subject disclosure may be embodied in practice. Additionally, in an effort to provide a concise description of these exemplary embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers’ specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure. [0024] When introducing elements of various embodiments of the present invention, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to.” Also, any use of any form of the
IS22.1172-WO-PCT terms “connect,” “engage,” “couple,” “attach,” or any other term describing an interaction between elements is intended to mean either an indirect or a direct interaction between the elements described. In addition, as used herein, the terms “axial” and “axially” generally mean along or parallel to a central axis (e.g., central axis of a body or a port), while the terms “radial” and “radially” generally mean perpendicular to the central axis. For instance, an axial distance refers to a distance measured along or parallel to the central axis, and a radial distance means a distance measured perpendicular to the central axis. The use of “top,” “bottom,” “above,” “below,” and variations of these terms is made for convenience but does not require any particular orientation of the components. [0025] Certain terms are used throughout the description and claims to refer to particular features or components. As one skilled in the art will appreciate, different persons may refer to the same feature or component by different names. This document does not intend to distinguish between components or features that differ in name, but not function. [0026] Hydrocarbon fluids, such as oil and natural gas, may be obtained from subterranean or subsea geologic formations, often referred to as reservoirs, by drilling one or more wells that penetrate the hydrocarbon-bearing geologic formation. In general, various types of infrastructure may be utilized in such an endeavor, such as fluid handling components that operate to transfer fluids from one location to another. In subsea applications, such infrastructure may be positioned underwater and/or along a sea floor to aid in retrieving the hydrocarbon fluids and/or injecting fluids. The fluid handling components may be utilized, for example, to transfer hydrocarbons from the reservoir to a desired location, transfer fluids used in maintaining or operating the infrastructure to respective operating locations, and/or transfer injection fluids (e.g., carbon dioxide, seawater, desired chemical compositions, etc.) into the reservoir. As should be appreciated, pumps/compressors may be utilized to increase the pressure of a process fluid and/or to motivate a flow of the process fluid from one location to another. Such process fluids may include but are not limited to crude oil, hydrocarbon gases (e.g., methane, ethane, propane, butane, etc.), sea water, fresh water, and barrier fluids (e.g., lubricating fluids). [0027] The infrastructure of subsea applications may be positioned along a sea floor to aid in retrieving the hydrocarbon fluids. Furthermore, traditional infrastructure of a subsea station may include a well and a subsea tree, also known as a Christmas tree, that have individualized
IS22.1172-WO-PCT components, which may be implemented independently. For example, a well may generally include multiple valves as well as flowline communication connections to different components of a subsea tree to realize an injection system. Each of the subsea trees may be fluidly coupled to a manifold that may provide an interface between a production pipeline and the subsea tree, thereby enabling hydrocarbon bearing fluids to be delivered to various systems (e.g., surface systems) for production. Unfortunately, traditional manifolds may suffer from various inefficiencies. For example, traditional manifolds may be manufactured and/or produced based on specific design and/or engineering constraints associated with a particular application and may include components that are implemented independently. As such, engineers may be tasked with reengineering such structures and/or components for each new project or application, thereby causing design/engineering, manufacturing, and supply chain risks and inefficiencies. Furthermore, such traditional manifolds may provide limited flexibility with respect to operability and/or functionality of a subsea system. [0028] Accordingly, present embodiments are directed toward a novel approach for the design and manufacture of subsea manifolds. For example, pre-engineered pipe (e.g., header) modules and frame modules may be configured with one another to provide a scalable manifold assembly that enables multiple manifold variations, thereby increasing system functionality and enabling design repeatability. The disclosed scalable manifold assembly (e.g., manifold platform) reduces the engineering effort required during project execution compared to project execution known in the art. For example, various modules may be employed to increase standardization of high level subassemblies rather than using individual components. As used herein, a module may be a physical and/or logical conglomeration of components considered together. In certain embodiments, a module may include a framework, a housing, and/or support structure. Further, in certain embodiments, the module may include piping, flow controls (e.g., valves, pumps, compressors, pressure regulators, etc.), and/or sensors. In the following discussion, the piping may include straight pipe sections (e.g., straight fluid conduit), bent pipe sections or elbows (e.g., curved or arcuate shaped fluid conduit extending over 30, 45, 60, 90, 120, 135, 150, or 180 degrees), fittings, connectors, or any combination thereof. In the following discussion, the valves may include gate valves, ball valves, chokes, butterfly valves, check valves, or any combination thereof. Moreover, in certain embodiments, the module may be described as an assembly, self-
IS22.1172-WO-PCT contained unit, and/or retrievable unit, which may be independent from other modules, and each module may be, at least partially, pre-assembled prior to subsea installation. [0029] The manufacturing repeatability of these different modules reduces manufacturing time associated with a subsea system. Additionally, by implementing different components as modules, certain modules may be interchangeable with other modules based on common structures and/or components and common foundation interfaces. In this way, certain modules may be used for different applications and/or may be reused, thereby reducing cost and lead time associated with a new subsea system. The disclosed scalable, configurable, and modular manifold assemblies enable flexibility in the field layout and system architecture by supporting both horizontal and vertical connection systems and multiple valve actuation types (e.g., hydraulic, electric, manual). The disclosed manifold assemblies leverage pre-engineered solutions that are validated for structural and pressure integrity and remote operated vehicle (ROV) accessibility, which reduces design iterations allowing for up to sixty percent faster product delivery times compared to a standard manifold known in the art. [0030] In the following discussion, the various modules may have at least one, two, or three dimensions in common with other modules. For example, each of the modules may have a common height as well as a common length and/or a common width. The modules may be categorized as different module types, such as header termination modules, upstream modules, downstream modules, branch termination modules, branch core modules, header interior modules, header wing modules, lift box modules, elevated roof modules, controls porch modules, and branch wing modules. Each type of the modules may include a family of modules of different dimensions. In certain embodiments, a family of the modules includes a height (H) that is common for the family; however, the family of modules includes a length (L) and a width (W) that can vary for each module type. For example, if the lift module includes a first length and a first width, then the other module types may include a matching first length and/or a matching first width in addition to a common first height. By further example, if the lift module includes a second length and a second width, then the other module types may include a matching second length and/or a matching second width in addition to a common first height or a common second height. The analogy continues for each variation in length and width. In some embodiments, the lift module is the core building block for the other modules, and generally resides in the center or core of the other modules. Thus, the other types of modules may include matching lengths and/or widths. In
IS22.1172-WO-PCT some embodiments, the modules that couple to sides of the lift module may include fractions of those lengths or widths to enable multiple modules to couple to one side of the lift module, while collectively adding up to the total length and/or total width of the lift module. Thus, the following discussion is intended to cover any commonality of the modules to enable the various modules to couple together with one or more common dimensions. [0031] With the preceding in mind, FIG.1 is a schematic view of a subsea production system 10 that utilizes one or more pumps/compressors and/or other fluid processing machines having sealing assemblies therein, according to an embodiment of the present disclosure. In general, the subsea production system 10 may include electrical or hydraulic lines 12 running to a subsea tree 14 that is coupled to a wellhead 16. The subsea tree 14, the wellhead 16, and/or additional components form a subsea station 18 that extracts formation fluid (e.g., production fluid), such as oil and/or natural gas, from a reservoir below the sea floor 20 through a well 22. The subsea production system 10 may include multiple subsea stations 18 that extract formation fluid from respective wells 22 and/or inject a process fluid into the formation. In some embodiments, formation fluid may flow through jumper cables 24 (e.g., well jumpers, flowlines) from a respective subsea tree 14 to a pipeline manifold 26 (e.g., scalable manifold assembly, integrated manifold header and frame assembly). The pipeline manifold 26 may connect to one or more flowlines 28 to enable the formation fluid to flow from the wells 22 to a surface platform 30. In some embodiments, the surface platform 30 may include a floating production, storage, and offloading unit (FPSO) or a shore-based facility. In addition to the flowlines 28 that carry the formation fluid away from the wells 22 and/or process fluid to the subsea trees 14, the subsea production system 10 may include lines or conduits 32 that supply fluids (e.g., hydraulic control fluids), as well as carry control and data lines to the subsea equipment. In some scenarios, the conduits 32 may connect to a distribution module 34, which in turn couples to the subsea stations 18. In some scenarios, the surface platform 30 may be located a significant distance (e.g., greater than 100 m, greater than 1 km, greater than 10 km, or greater than 60 km) away from the wells 22. The reservoir fluids and operational fluids (e.g., barrier fluids, injections fluids) may flow between the wells 22 and the surface platform 30 via one or more pumps disposed, for example, at the surface platform 30, subsea trees 14, distribution module 34, pipeline manifold 26, etc. [0032] FIG.2 is a perspective view of an embodiment of the scalable manifold assembly 26 (e.g., integrated manifold header and frame assembly) of FIG. 1. To facilitate discussion, the
IS22.1172-WO-PCT scalable manifold assembly 26 and its components may be described with reference to a longitudinal axis 50, a lateral axis 52, and a vertical axis 54. In the illustrated embodiment, the scalable manifold assembly 26 is an arrangement of modules, piping, valves, and/or other components configured to optimize, combine, distribute, control, and/or monitor fluid flow through a subsea production system, such as the subsea production system 10 of FIG.1. In some embodiments, the scalable manifold assembly 26 may be configured to provide an interface between a production pipeline and a well. For example, the scalable manifold assembly 26 may be fluidly coupled to one or more wells via one or more well jumpers (e.g., jumper cables 24, flowlines) and may also be coupled to a surface platform (e.g., remote production platform) via a flowline (e.g., flowline 28). In this way, hydrocarbon-bearing fluid may be delivered from a respective well to the scalable manifold assembly 26 and from the scalable manifold assembly 26 to a production platform, such as the surface platform 30 of FIG.1. [0033] In addition to facilitating the flow of hydrocarbon-bearing fluids (e.g., production fluids) from respective wells to a production platform, the scalable manifold assembly 26 may be configured to facilitate distribution of an injection fluid (e.g., process fluid, gas, chemicals, seawater, frac fluid, etc.) to the various wells coupled thereto. For example, the injection fluid may be delivered to the scalable manifold assembly 26, and the scalable manifold assembly 26 may then direct the injection fluid to a target location (e.g., target well) to facilitate collection of hydrocarbon-bearing fluids. Furthermore, the scalable manifold assembly 26 may be configured to facilitate distribution of electrical and hydraulic systems, provide support and/or protection for various components disposed within the scalable manifold assembly 26, provide attachment points for installation and/or retrieval of the scalable manifold assembly 26, and/or provide a support platform for remote operated vehicles (ROVs) during ROV operations (e.g., inspections), as discussed in greater detail below. [0034] In the illustrated embodiment, the scalable manifold assembly 26 includes a header assembly 100 and a frame assembly 200 configured to be integrated with the header assembly 100. As shown, the header assembly 100 includes two headers 101, and each of the headers 101 may be configured to receive production fluid from one or more wells fluidly coupled to the headers 101 (e.g., via a header module) and deliver the production fluid to a production platform (e.g., the surface platform 30 of FIG.1) and/or other components disposed upstream and/or downstream of the scalable manifold assembly 26 (e.g., an additional production manifold). As noted above, in
IS22.1172-WO-PCT some embodiments, each of the headers 101 may also be configured to deliver process fluid (e.g., injection fluid) to one or more wells to facilitate recovery of hydrocarbon-based fluids from the well. Thus, under certain operating conditions (e.g., production conditions) fluid may flow through the manifold 26 in a first direction from the wells to the manifold 26 and ultimately to a production platform, while in other operating conditions (e.g., injection conditions) fluid may flow through the manifold in a second direction, opposite the first direction, from the manifold 26 to the wells (e.g., based on a positioning and/or orientation of various valves disposed along the header assembly 100). [0035] To facilitate the collection and/or distribution of fluid to and from the manifold 26, the header assembly 100 may include one or more header modules 102 (e.g., piping modules that include various header and branch modules) that collectively define the respective headers 101. For example, the header modules 102 of the header assembly 100 may comprise any combination of one or more header termination modules, branch termination modules, branch core modules, header interior modules, and interconnecting piping. Each of the header modules 102 may include respective components (e.g., straight pipe sections, bent pipe sections, fittings, valves, hub connectors) that enable fluid flow control (e.g., production fluid flow control, process fluid flow control) to and from a well. In the illustrated embodiment, four of the header modules 102 of the header assembly 100 are fluidly coupled to respective subsea stations 18, thereby enabling collection of production fluid from the wells 22 of the subsea stations 18 to the headers 101 and/or delivery of process fluid from the headers 101 to the wells 22 of the subsea stations 18. [0036] The frame assembly 200 may be configured to house, protect, and/or provide structural support for the header assembly 100. To this end, the frame assembly 200 may also include one or more frame modules 202 that define the frame assembly 200. For example, the frame modules 202 of the frame assembly 200 may comprise one or more header wing modules, a lift box module, and one or more branch wing modules. Each of the frame modules 202 may correspond to and/or be associated with a particular header module 102 of the header assembly 100. For example, each of the frame modules 202 of the frame assembly 200 may define a respective volume, slot, or compartment, thereby enabling a particular frame module 202 of the frame assembly 200 to accommodate and/or support a corresponding header module 102 of the header assembly 100. Thus, in certain embodiments, a size, a quantity, a volume, and the like of a particular frame module 202 may be selected based on a size (e.g., length, width) of the corresponding header
IS22.1172-WO-PCT module 102 supported by the particular frame module 202. Each of the frame modules 202 includes a framework of interconnected structural elements, such as ties, struts, beams (e.g., open section beams), columns, tubulars, hollow sections, plates, and diaphragms, made of materials (e.g., carbon or low alloy steel, stainless steel, nickel alloy, composites, etc.) suitable for a subsea environment. The structural elements may be oriented as horizontal structures, vertical structures, and/or angular structures therebetween. The structural elements may have a cross-sectional shape that extends along its longitudinal axis, wherein the cross-sectional shape may include a I-shape, a U-shape, a T-shape, an L-shape, a square shape, or any combination thereof. For example, the beam may be an I-beam. The structural elements may be coupled together to define three- dimensional (3D) frameworks of the frame modules 202 to protect components of the header assembly 100. In some embodiments, the frame modules 202 are open frameworks as illustrated in FIG.2, although the frame modules 202 may include one or more walls, floors, and/or ceilings to partially enclose the components of the header assembly 100. Each of the frame modules 202 may be constructed independently of other frame modules 202, wherein each frame module 202 may couple together the structural elements via fixed joints (e.g., welds) and/or removable joints (e.g., fasteners, bolts, etc.). The frame modules 202 can be used in any combination with one another to build an overall frame assembly 200, such that each frame assembly 200 may have a custom selection of frame modules 202 suitable for a particular application. [0037] In certain embodiments, the frame assembly 200 may include supplemental framework (e.g., an elevated roof, control porches, and/or other miscellaneous equipment) made of structural elements to facilitate collection and/or distribution of fluid to and from one or more wells. The elevated roof may be configured to extend the roof elevation above a threshold height (e.g., above the main structure) to protect taller valves and components having a length or height that is equal to or greater than the threshold height. The control porches may correspond to platforms onto which control modules, such as subsea control modules and electric subsea control modules are mounted. Notably, each of the header modules 102 discussed herein may include standardized, pre-engineered components that facilitate efficient manufacturing and assembly of the header modules 102. Moreover, each of the frame modules 202 of the frame assembly 200 is scalable and may be expanded or reduced to accommodate a corresponding type and quantity of the header modules 102 of the header assembly 100. In certain cases, a single frame assembly 200 may be compatible with various combinations of header modules 102. The frame assembly 200
IS22.1172-WO-PCT and the header assembly 100 are integrated together, such that the frame assembly 200 supports and at least partially surrounds the header assembly 100. Thus, it should be appreciated that while the scalable manifold assembly 26 is illustrated as having two headers 101 delivering and/or collecting fluid to and from four subsea stations 18, in other embodiments, the scalable manifold assembly 26 may include fewer (e.g., one) or more (e.g., three, four, five, or more) headers 101, fewer or more header modules 102, and a corresponding number of frame modules 202 to accommodate the header modules 102. That is, frame modules 202 may be added and/or omitted accordingly based on a number of headers 101 employed by the header assembly 100 and/or a number of header modules 102 employed by the header assembly 100. Similarly, the scalable manifold assembly 26 may be coupled to any number of subsea stations (e.g., less than four, more than four), and a corresponding number of header modules 102 and/or frame modules 202 may be added or omitted accordingly, as described in greater detail below. [0038] FIG.3 is a perspective view of an embodiment of the header assembly 100 of FIG.2 illustrating the headers 101 and the various header modules 102 of the header assembly 100. In the illustrated embodiment, the header assembly 100 includes four branch core modules 104, two header interior modules 106, four header termination modules 108, four branch termination modules 110, and four upstream/downstream header modules 112, among other components. Each header termination module 108 may be fluidly coupled to a respective end of a header interior module 106, and each branch termination module 110 may be fluidly coupled to a corresponding branch core module 104. Each branch core module 104 may be fluidly coupled to each of the header interior modules 106, and may include components that enable selective distribution from the branch core modules 104 to one of, or both of the header interior modules 106, as discussed in greater detail below. [0039] As noted above, one or more of the modules 102 (e.g., header termination modules 108, branch termination modules 110) may be coupled to components of a subsea production system disposed upstream and/or downstream of the scalable manifold assembly 26 (e.g., header assembly 100). For example, each of the branch termination modules 110 may be fluidly coupled to a well (e.g., subsea station 18) disposed upstream of the scalable manifold assembly 26 (e.g., relative to a flow direction of production fluid from a well to a production platform). Further, at least a portion of the header termination modules 108 may be coupled to components disposed upstream of the scalable manifold assembly 26, such as an additional production manifold, a well,
IS22.1172-WO-PCT a tree, an injection fluid source, and the like, while a remaining portion of the header termination modules 108 may be coupled to components disposed downstream of the scalable manifold assembly 26, such as an additional production manifold, a production platform, and the like. Thus, in the illustrated embodiment, production fluid may flow from wells to the branch termination modules 110, from the branch termination modules 110 into the branch core modules 104, and/or from the branch core modules 104 into one of the header interior modules 106. [0040] Each of the header interior modules 106 may be oriented and/or extend in a direction (e.g., horizontal direction) along the longitudinal axis 50, such that as the production fluid is received by one of the header interior modules 106, the production fluid may flow through the header interior modules 106 in a direction 56 along the longitudinal axis 50 toward the header termination modules 108 disposed on a first end 96 of the header assembly 100, and from the header termination modules 108 disposed on the first end 96 to downstream components of a subsea production system (e.g., surface platform). Thus, the header termination modules 108 disposed on a second end 98 of the header assembly 100 may correspond to upstream header termination modules 108, while the header termination modules 108 disposed on the first end 96 of the header assembly 100 may correspond to downstream header termination modules 108. It should be appreciated, however, that in certain embodiments, production fluid may flow through the header interior modules 106 in a direction 58, opposite the direction 56, such that the header termination modules 108 disposed on the second end 98 of the header assembly 100 correspond to downstream header termination modules 108, while the header termination modules 108 disposed on the first end 96 of the header assembly 100 correspond to upstream header termination modules 108. Each of the branch termination modules 108 may include piping, valves, tie-ins, and connectors that enable the branch termination modules 108 to fluidly couple to components disposed upstream and/or downstream of the scalable manifold assembly 26. [0041] In certain embodiments, each of the upstream header modules 112 may include a header isolation valve with an optional pressure and temperature transducer as well as one chemical injection point on either side of the header isolation valve. In other embodiments, each of the upstream header modules 112 may include one pressure and temperature transducer, two chemical injection points, and no header isolation valve. Each of the downstream header modules 112 may include one pressure and temperature transducer and two chemical injection points. However, certain embodiments of the upstream and downstream header modules 112 may include
IS22.1172-WO-PCT any combination of valves, sensors, and chemical injection points, wherein the sensors may include any number of temperature sensors, pressure sensors, flow meters, fluid composition sensors, and vibration sensors. [0042] Further, it should be appreciated that while the discussion herein focuses on a flow direction of production fluid through the scalable manifold assembly 26 (e.g., from wells, through the header assembly 100, and out of the header assembly 100 toward a production platform), in certain embodiments, the flow direction of fluid (e.g., process fluid) through the header assembly 100 may be reversed. That is, in certain embodiments, process fluid (e.g., injection fluid) may be injected into the wells to facilitate collection of production fluid thereafter. Thus, in certain embodiments, the header assembly 100 may be configured to receive process fluid via one or more of the header termination modules 108. The process fluid may flow through a respective header termination module 108 into a header interior module 106, and from the header interior module 106 into one or more of the branch core modules 104. Each of the branch core modules 104 may be configured to distribute the process fluid toward the branch termination module 110 respectively coupled thereto, thereby enabling process fluid to be selectively distributed to wells coupled to the header assembly 100 via the branch termination modules 110. For example, each branch termination module 110 may be fluidly coupled to a respective branch core module 104 such that a quantity of branch core modules 104 employed by the header assembly 100 corresponds to a quantity of branch termination modules 110 employed by the header assembly 100. [0043] As noted above, each of the header modules 102 may include components (e.g., pipes, fittings, blocks, valves) that collectively define the respective header module 102. For example, FIG. 4 illustrates a schematic view of an embodiment of the header assembly 100 having eight branch core modules 104, two header interior modules 106, four header termination modules 108, and eight branch termination modules 110, and the various components of each of the modules 102 employed by the header assembly 100. To simplify the following discussion, FIGS.3 and 4 will be discussed together. Each of the branch core modules 104 may include one or more straight pipe sections 120 extending in respective directions (e.g., horizontal directions) along the lateral axis 52, one or more fittings 122, one or more elbows 124, one or more branch isolation valves 126, one or more header selection valves 128, and associated interconnecting piping sections between the fittings 122, elbows 124, and valves 126, 128, all of which are coupled together via joints. The joints may include removeable joints (e.g., threaded annular joints, bolted flanges,
IS22.1172-WO-PCT etc.), fixed joints (e.g., welded joints), or any combination thereof. The branch isolation valves 126 and the header selection valves 128 may be arranged in valve blocks 129 (e.g., multi-cavity valve blocks, integrated valve blocks) or standalone configurations. [0044] Each of the header interior modules 106 may include straight pipe sections 140 fluidly coupled to one another via one or more fittings 142, and the fittings 142 may be configured to facilitate a fluid coupling between the branch core module 104 and the header interior modules 106 (e.g., facilitate a fluid coupling between the straight pipe sections 140 of the header interior modules 106 and the straight pipe sections 120 of the branch core module 104). Each of the header termination modules 108 may include straight pipe sections 150 (e.g., vertical directions, horizontal directions), bent sections 152, fittings and/or blocks 154, and hub connectors 156 (e.g., flowline inboard hub connectors), and each of the branch termination modules 110 may include straight pipe sections 160, bent sections, fittings, elbows 162, and hub connectors 164 (e.g., flowline inboard hub connectors). In certain embodiments, one or more of the straight pipe sections 160 (e.g., second straight pipe sections 160) of the branch termination modules 110 may be oriented and/or extend in a direction that is crosswise to a direction along which the header interior modules 106 extends. Additionally, in certain embodiments, the fittings and/or blocks 154 may be used in combination with and/or may replace the upstream and downstream header modules 112 discussed above. Thus, in certain embodiments, the fittings and/or blocks 154 may include temperature and pressure transducers, chemical injection points, and/or header isolation valves. [0045] In the illustrated embodiment, the straight pipe sections 150, the bent pipe sections 152, and the fittings and/or blocks 154 of each of the header termination modules 108 enable the respective hub connectors 156 to be oriented in a direction (e.g., vertical direction) along the vertical axis 54. Similarly, the straight pipe sections 160 and the elbows 162 (or alternatively, straight pipe sections, bent pipe sections, and fittings and/or couplings therebetween) of the branch termination modules 110 enable the respective hub connectors 164 to be oriented in a direction (e.g., vertical direction) along the vertical axis 54. However, it should be appreciated that, in certain embodiments, the bent pipe sections 152 of the header termination modules 108 may be omitted, such that the hub connectors 156 are oriented in a direction (e.g., horizontal direction) along the longitudinal axis 50. Similarly, in certain embodiments, the elbows 162 of the branch termination modules 110 (or the bent pipe sections of the branch termination modules 110) may
IS22.1172-WO-PCT be omitted, such that the hub connectors 164 are oriented in a direction (e.g., horizontal direction) along the lateral axis 52. Thus, in certain embodiments, one or more of the hub connectors 156, 164 may be oriented in a vertical direction, while one or more other hub connectors 156, 164 may be oriented in a horizontal direction. [0046] The various straight pipe sections, bent sections, fittings, blocks, elbows, hub connectors, and the like discussed above may enable each of the header modules 102 employed by the header assembly 100 to be fluidly coupled to one another, thereby providing a fluid flow path through the header assembly 100. Furthermore, one or more of the valves discussed above may be controlled or modulated to control a direction of fluid flow through the header assembly 100. For example, during a production process (e.g., during a process in which production fluid is being delivered from a well, through the manifold 26, and to a production platform), production fluid may flow from various wells respectively coupled to each of the branch termination modules 110, through the branch core module 104, into the header interior modules 106, and out of one or more of the header termination modules 110. For example, a respective hub connector 164 of a branch termination module 110 may receive production fluid and may direct the production fluid therethrough in a direction along the vertical axis 54 and into a first straight pipe section 160 of the respective branch termination module 110. The production fluid may then reach an elbow 162 (or a bent pipe section) of the branch termination module 110, thereby redirecting the production fluid along a second straight pipe section 160 of the branch termination module 110 in a direction (e.g., horizontal direction) along the lateral axis 52 toward the branch core module 104. [0047] The second straight pipe section 160 may direct the production fluid toward a valve block 129 of the branch core module 104, which may include one or more of the fittings 122 and/or elbows 124 of the branch core module 104, thereby enabling the branch core module 104 to selectively distribute the production fluid toward the header interior modules 106. For example, the production fluid may travel through the second straight pipe section 160 of a branch termination module 110 in a direction (e.g., horizontal direction, inward direction relative to a central axis 95 of the header assembly 100 that extends along the longitudinal axis 50) along the lateral axis 52 before reaching one or more of the elbows 124 of the branch core module 104. The one or more elbows 124 of the branch core module 104 may redirect the flow of production fluid, such that the production fluid flows in a direction (e.g., horizontal direction) along the longitudinal axis 50 toward a straight pipe section 120 of the branch core module 104. The fittings 122 of the
IS22.1172-WO-PCT branch core module 104 may receive the flow of production fluid and once again redirect the flow of production fluid into the straight pipe sections 120 of the branch core module 104. In turn, the straight pipe sections 120 may direct the production fluid in a direction (e.g., horizontal direction, outward direction relative to the central axis 95) along the lateral axis 52 toward the header interior modules 106. [0048] As noted above, in certain embodiments, the branch core module 104 may include one or more valve blocks 129 that include the fittings 122, the elbows 124, the branch isolation valves 126, and the header selection valves 128. Thus, production fluid may be directed from a branch termination module 110 toward a valve block 129 of branch core module 104, and may travel through components of the valve block 129 (e.g., fittings 122, elbows 124, branch isolation valve 126, header selection valve 128) before being directed toward a header interior module 106 via the straight pipe sections 120 of the branch core module 104. For example, in certain embodiments, the production fluid may reach a valve block 129 and may first travel through a branch isolation valve 126 before reaching one or more of the elbows 124 configured to redirect the flow direction of production fluid toward the straight pipe sections 120 of the branch core module. In other embodiments, the production fluid may be directed through one or more of the elbows 124 to change direction before reaching the branch isolation valve 126. After passing through the branch isolation valve 126 and the one or more elbows 124, the production fluid may reach a fitting 122, which may be configured to direct the flow of production fluid into a respective straight pipe section 120 of the branch core module 104. Thereafter, based on a positioning and/or orientation of the header selection valves 128, the production fluid may be directed in a direction (e.g., horizontal direction, outward direction relative to the central axis 95) along the lateral axis 52 toward one of the header interior modules 106. For example, one of the header selection valves 128 may be controlled to move toward a closed position, while another of the header selection valves may be controlled to move toward an open position, thereby enabling the flow of production fluid through the open header selection valve 128 and toward the corresponding header interior module 106, while limiting flow of production fluid through the closed header selection valve 128. [0049] In certain embodiments, production fluid may also be directed into the header assembly 100 via one or more of the header termination modules 108. For example, components (e.g., manifolds) disposed upstream of the manifold 26 may direct production fluid toward one or more of the hub connectors 156 of the header termination modules 108 (e.g., hub connectors 156
IS22.1172-WO-PCT of the upstream header termination modules 108 disposed on the second end 98 of the header assembly 100). The hub connectors 156 may then direct the production fluid therethrough in a direction along the vertical axis 54 and into a bent pipe section 152 of the respective header termination module 108. The bent pipe section 152 may be coupled to a straight pipe section 150 of the respective branch termination module 108 via a fitting or block 154. Thus, the bent pipe section 152 may be configured to redirect the production fluid, thereby enabling the production fluid to flow in a direction (e.g., horizontal direction) along the longitudinal axis 50 through the straight pipe section 150. The straight pipe section 150 may be fluidly coupled to the header interior module 106 (e.g., via fittings 142), thereby enabling production fluid from components disposed upstream of the manifold 26 to be directed through the manifold 26 and out of the downstream header termination modules 108 toward a production platform. [0050] In certain embodiments, the fittings and/or blocks 154 may be configured to facilitate coupling to other components of a subsea production system. For example, the fittings and/or blocks 154 may include tie-ins, sensors (e.g., temperature transducers, pressure transducers, flow meters, vibration sensors, gas composition sensors, etc.), valves (e.g., header isolation valves), and/or connection points (e.g., chemical injection points). As noted above, it should be appreciated that while the above discussion focuses on production fluid moving in a general direction from wells, through the manifold 26, and out of the manifold assembly 26 toward a production platform, in other embodiments, the flow of fluid (e.g., process fluid) may be reversed such that the process fluid flows through the modules 102 of the manifold assembly 26 in a direction that is opposite the flow direction of production fluid discussed above. For example, process fluid may flow from the header termination modules 108 (e.g., from the blocks 154) to the header interior modules 106, from the header interior modules 106 through the straight pipe sections 120 of the branch core module 104, through the valve blocks 129 and components thereof (e.g., fittings 122, elbows 124, valves 126, 128) of the branch core module 104 to the second straight pipe sections 160 of the branch termination modules 110, through the elbows 162 of the branch termination modules 110 (or the bent pipe sections), through the first straight pipe sections 160 of the branch termination modules 110, through the hub connectors 164, and toward the wells respectively coupled to each of the hub connectors 164. [0051] FIG.5 is a perspective view of an embodiment of the frame assembly 200 of FIG.2 illustrating the various frame modules 202 of the frame assembly 200 that are configured to at least
IS22.1172-WO-PCT partially enclose, support, and/or house components of the header assembly 100 (e.g., header modules 102). In the illustrated embodiment, the frame assembly 200 includes a lift box module 204, two header wing modules 206, and two branch wing modules 208. Additionally, portions of the lift box module 204, the header wing modules 206, and the branch wing modules 208 may collectively define one or more recesses 210, each of which may be configured to receive a control porch module for control components of the scalable manifold assembly 26. [0052] As noted above, each frame module 202 (e.g., lift box module 204, header wing module 206, branch wing module 208) is scalable and may be expanded or reduced to accommodate the type and quantity of the header modules 102 of the header assembly 100. In this way, a single frame assembly 200 may be compatible with various combinations of header modules 102. The frame assembly 200 and the header assembly 100 are integrated together such that the frame assembly 200 supports and at least partially surrounds the header assembly 100. For example, in certain embodiments, each header wing module 206 may provide support connection for one or more header termination modules 108, at least a portion of the header interior modules 106, and the upstream/downstream header modules 112. In certain embodiments, each branch wing module 208 may provide support connection for one or more branch termination modules 110 and at least a portion of the branch core module 104. In certain embodiments, the lift box module 204 interconnects the header wing modules 206 and the branch wing modules 208. Additionally, the lift box module 204 provides an interface between the manifold assembly 26 and the sea floor 20 via a base 212 of the lift box module 204 and may facilitate transport, retrieval, deployment of the scalable manifold assembly via one or more lift points 214 (e.g., lift connectors, padeyes, trunnions, rings, loops, etc.) of the lift box module 204. For example, the lift points 214 may be used as attachment points for cables of a crane, thereby enabling the crane to lift and move the lift box module 204. In certain embodiments, the upstream/downstream header modules 112 may be positioned within the lift box module 204. [0053] In the illustrated embodiment, the lift box module 204 includes six sides that collectively define a volume 216 configured to accommodate and/or support the branch core module 104 and the header interior modules 106. Each of the sides may include one or more structural components (e.g., beams, columns, etc.) that are coupled to one another to collectively define the lift box module 204, and thus, the volume 216. Each of the header wing modules 206 may also include six sides that collectively define a volume 218 of the header wing module 206
IS22.1172-WO-PCT configured to accommodate portions of the header termination modules 108. In certain embodiments, the volume 218 of a header wing module 206 may be further separated via structural components (e.g., beams, columns, etc.) into one or more slots 220 configured to receive and/or support a hub connector 156 of a header termination module 108. Each of the branch wing modules 208 also includes six sides that collectively define a volume 222 of the branch wing module 208 configured to accommodate portions of the branch termination modules 110. In certain embodiments, the volume 222 of a branch wing module 208 may be further separated via structural components (e.g., beams, columns, etc.) into one or more slots 224 configured to receive and/or support a hub connector 164 of a branch termination module 110. In certain embodiments, one or more of the sides of a respective header wing module 206 and/or branch wing module 208 may correspond to a side of the lift box module 204. That is, in certain embodiments, at least a portion of the lift box module 204 may partially define the volumes 218 and 222 of the header wing modules 206 and the branch wing modules 208, respectively. [0054] In certain embodiments, one or more dimensions of each of the header wing modules 206 and the branch wing modules 208 may correspond and/or be common with a dimension of the lift box module 204. For example, a first dimension 226 (e.g., height) of the lift box module 204 may extend in a direction (e.g., vertical direction) along the vertical axis 54. Similarly, a first dimension 228 (e.g., height) of the header wing modules 206, and a first dimension 230 (e.g., height) of the branch wing modules may each also extend in respective directions (e.g., vertical directions) along the vertical axis 54. As shown in FIG.5, each of the first dimensions 226, 228, 230 of the lift box module 204, the header wing modules 206, and the branch wing modules 208 are substantially the same (e.g., identical height accounting for manufacturing tolerances). [0055] Additionally, as shown in FIG. 6, the lift box module 204 may have a second dimension 232 (e.g., length) that extends in a direction (e.g., horizontal direction) along the longitudinal axis 50, and a third dimension 234 (e.g., width) that extends in a direction (e.g., horizontal direction) along the lateral axis 52. Notably, in certain embodiments, at least a portion of each of the header wing modules 206 and branch wing modules 208 may include dimensions that are substantially similar (e.g., identical dimension accounting for manufacturing tolerances) to the second and third dimensions 232, 234 of the lift box module 204. For example, each of the header wing modules 206 may have a second dimension 236 (e.g., length) that extends in a direction (e.g., horizontal direction) along the longitudinal axis 50 and a third dimension 238 (e.g.,
IS22.1172-WO-PCT width) that extends in a direction (e.g., horizontal direction) along the lateral axis 52. In certain embodiments, the third dimension 238 of each of the header wing modules 206 may be substantially similar (e.g., identical dimension accounting for manufacturing tolerances) to the third dimension 234 of the lift box module 204, thereby facilitating a coupling between the lift box module 204 and the header wing modules 206. Similarly, each of the branch wing modules 208 may have a second dimension 240 (e.g., length) that extends in a direction (e.g., horizontal direction) along the longitudinal axis 50, and a third dimension 242 (e.g., width) that extends in a direction (e.g., horizontal direction) along the lateral axis 52. In certain embodiments, the second dimension 240 of each of the branch wing modules 208 may be substantially similar (e.g., identical dimension accounting for manufacturing tolerances) to the second dimension 232 of the lift box module 204, thereby facilitating a coupling between the lift box module 204 and the branch wing modules 208. It should be appreciated that, in certain embodiments, the frame modules 202 of the frame assembly 200 may share fewer than two dimensions without departing from the scope of this disclosure. For example, in certain embodiments, the length 240 of one or more of the branch wing modules 208 may be less than or greater than the length 232 of the lift box module 204 and/or the width 238 of one or more the header wing modules 206 may be less than or greater than the width 234 of the lift box module 204. Nevertheless, each of the modules 202 may be scalable, repeatable, and configurable to couple to one another to define the frame assembly 200, thereby enabling the frame assembly 200 to accommodate and support a variety of configurations of the header assembly 100. [0056] Additionally, it should be appreciated that the dimensions of a particular frame module 202 that define the respective volumes of the frame module 202 (e.g., height 226, length 232, and width 234 of the lift box module 204, height 228, length 236, and width 238 of the header wing modules 206, height 230, length 240, and width 242 of the branch wing modules 208) may be selected based on a size of the corresponding header module 102 supported by the particular frame module 202. For example, the height 226, length 232, and width 234 of the lift box module 204 may be selected based on dimensions (e.g., height, length, and/or width) of the header interior modules 104 and components thereof and/or dimensions of the branch core modules 104 and components thereof. Similarly, the height 228, length 236 and width 238 of the header wing modules 206 may be selected based on dimensions of the header termination modules 108, and the
IS22.1172-WO-PCT height 230, length 240, and width 242 of the branch wing modules 208 may be selected based on dimensions of the branch termination modules 110. [0057] Each of the header modules 102 and the frame modules 202 that collectively define the header assembly 100 and the frame assembly 200 (e.g., collectively define the scalable manifold assembly 26) are scalable, repeatable, and configurable subassemblies that enable the modules 102, 202 to be arranged and/or interconnected in various configurations to support and/or accommodate various field layouts. In certain embodiments, each of the modules 102, 202 may be described with reference to a standard unit of measure (e.g., a 1U basis along a width [W] and a length [L] dimension) such that the modules 102, 202 could correspond to a 1x1 unit, 1x2 unit, 1x3 unit, 1x4 unit, 2x2 unit, 2x3 unit, etc. For example, in an embodiment, the lift box module 204 may be a 2Wx4L unit, each of the header wing modules 208 may be 1Wx4L units, each of the branch core modules 104 may be 2Wx1L units, and each of the branch termination modules 110 may be 1Wx1L units. Further, it should be appreciated that given the scalability, repeatability, and configurability of each of the modules 102, 202 discussed herein, any number of configurations of the manifold assembly 26 are contemplated herein, and are not limited to the illustrated drawings. In certain embodiments, the modules 102, 202 may correspond to blocks that can be arranged, stacked, and/or interconnected in any suitable arrangement to facilitate the collection and/or distribution of fluid (e.g., production fluid, process fluid) to and from a well. [0058] For example, FIGS. 7A and 7B illustrate embodiments of the frame assembly 200 having modules 202 arranged in a stacked configuration (as shown in FIG. 7A) and a flush configuration (as shown in FIG. 7B). Indeed, as noted above, because each of the modules 202 employed by the frame assembly 200 are scalable, repeatable, and configurable to connect to any of the other frame modules 202 employed by the frame assembly 200, numerous different arrangements of the scalable manifold assembly 26 are contemplated herein. [0059] Referring now to FIGS.8A–9B, the scalable manifold assembly 26 of FIG.2 is shown scaled to include additional slots 224 for the additional branch termination modules 110 employed by the header assembly 100. For example, in the embodiments illustrated in FIGS.2 and 3, the scalable manifold assembly 26 includes four branch termination modules 110, and thus, the frame assembly 200 in FIG.5 includes two branch wing modules 208, each having two slots 224 such that the four branch termination modules 110 are supported by the four slots 224. However, the
IS22.1172-WO-PCT header assembly 100 in FIG.8A includes six branch termination modules 110, and thus, the frame assembly 200 in FIG.8B includes two branch wing modules 208, each having three slots 224 such that the six branch termination modules 110 are supported by the six slots 224. Similarly, the header assembly 100 in FIG. 9A includes eight branch termination modules 110, and thus, the frame assembly in FIG. 9B includes two branch wing modules 208, each having four slots 224 such that the eight branch termination modules 110 are supported by the eight slots 224. Thus, as additional branch termination modules 110 are added, the second dimension 232 of the lift box module 204 and/or the second dimension of each of the branch wing modules 208 may be expanded or elongated to accommodate the additional branch termination modules 110. The header wing modules 206 of the frame assemblies 200 illustrated in FIGS.8B and 9B may also be scaled up or down in size to accommodate the header termination modules 108 of the header assembly 100. Thus, while the scalable manifold assembly 26 is shown and described herein as having four, six, or eight slots 224, in other embodiments, the manifold may have two, three, five, seven, nine, ten, or more slots 224. [0060] Figure 10 shows various manifold assemblies 26A–26F having header assemblies 100A–100F and components thereof (e.g., header modules 102, branch core modules 106, header termination modules 108, branch termination modules 110) that are integrated with frame assemblies 200A–200F and components thereof (e.g., frame modules 202, lift box module 204, header wing modules 206, branch wing modules 208), respectively, thereby enabling the manifold assemblies 26A–26F to be both modular and scalable. For example, header assembly 100A comprises two headers and four branch termination modules on a medium sized frame assembly 200A (e.g., medium sized lift box module) without a header isolation valve. The medium sized frame assembly 200A may include two branch wing modules each having a pair of slots (e.g., slots 224) such that the medium sized frame assembly 200A includes four total slots to accommodate the four branch termination modules of the header assembly 100A. [0061] Header assembly 100B comprises two headers and six branch termination modules on a medium sized frame assembly 200B without a header isolation valve. The medium sized frame assembly 200B may include two branch wing modules each having three slots (e.g., slots 224) such that the medium sized frame assembly 200B includes six total slots to accommodate the six branch termination modules of the header assembly 100B. Header assembly 100C comprises two headers and eight branch termination modules on a large sized frame assembly 200C (e.g., large
IS22.1172-WO-PCT sized lift box module) without a header isolation valve. The large sized frame assembly 200C may include two branch wing modules each having four slots (e.g., slots 224) such that the large sized frame assembly 200C includes eight total slots to accommodate the eight branch termination modules of the header assembly 100C. [0062] Header assembly 100D comprises two headers and four branch termination modules on a medium sized frame assembly 200D with a header isolation valve. The medium sized frame assembly 200D may include two branch wing modules each having a pair of slots (e.g., slots 224) such that the medium sized frame assembly 200D includes four total slots to accommodate the four branch termination modules of the header assembly 100D. Header assembly 100E comprises two headers and six branch termination modules a large sized frame assembly 200E with a header isolation valve. The large sized frame assembly 200E may include two branch wing modules each having three slots (e.g., slots 224) such that the large sized frame assembly 200E includes six total slots to accommodate the six branch termination modules of the header assembly 100E. Header assembly 100F comprises two headers and eight branch termination modules on a large sized frame assembly 200F with a header isolation valve. The large sized frame assembly 200F may include two branch wing modules each having four slots (e.g., slots 224) such that the large sized frame assembly includes eight total slots to accommodate the eight branch termination modules of the header assembly 100F. It should be appreciated that portions (e.g., frame modules 202) of the frame assemblies 200 discussed herein (e.g., lift box module 204, header wing module 206, branch wing module 208) may be scaled up, elongated, and expanded or scaled down and reduced as needed to accommodate the quantity, type, location, and size of the header modules 102. [0063] The disclosed scalable manifold combines standard pre-engineered subassemblies or modules with a frame assembly that is sized to fit yet scalable to accommodate more or fewer subassemblies or modules. The piping and frame modules may also be interchangeable and repeatable according to the specified functionality. The disclosed scalable manifold provides flexibility to accommodate various field layout constraints by using common foundation interfaces. The modules may be rearranged to accommodate various field layouts including location of a subsea control module (SCM), stab plates, jumper departure angles. In an embodiment, the SCM may be disposed on the scalable manifold; in another embodiment, the SCM may be disposed on a subsea tree.
IS22.1172-WO-PCT [0064] The scalable manifold also supports header and branch isolation; multiple options for pressure and temperature sensors and chemical injection points; both 10 kilopounds per square inch (ksi) and 15 ksi pressure rated systems; and ten- and twelve-inch header pipe sizes as well as six- and eight-inch branch pipe sizes. In other embodiments, header pipe sizes less than ten inches and greater than twelve inches and branch pipe sizes less than six inches and greater than eight inches may be used. Further, various module designs and configurations may be pre-validated to support typical jumper, lifting and seismic loading conditions, and may also support water injection manifolds. [0065] The subject matter described in detail above may be defined by one or more clauses, as set forth below. [0066] A scalable manifold assembly includes a header assembly configured to receive production fluid from one or more wells fluidly coupled to the header assembly and deliver process fluid to the one or more wells fluidly coupled to the header assembly and a frame assembly configured to at least partially surround the header assembly. The header assembly includes one or more header modules, the frame assembly includes one or more frame modules, the header assembly and the frame assembly are integrated together such that the frame assembly supports the header assembly, a quantity and type of the one or more frame modules corresponds to a quantity and type of the one or more header modules, and each of the one or more frame modules and the one or more header modules are scalable, repeatable, and configurable. [0067] The scalable manifold assembly of the preceding clause wherein the one or more header modules comprise any combination of one or more header termination modules, one or more upstream header modules, one or more downstream header modules, one or more branch termination modules, one or more interior header modules, or one or more branch core modules. [0068] The scalable manifold assembly of any preceding clause, wherein the one or more frame modules comprise any combination of one or more header wing modules, one or more branch wing modules, a control porch module, or a lift box module. [0069] The scalable manifold assembly of any preceding clause, wherein the one or more header wing modules of the frame assembly are configured to at least partially surround and support the one or more header termination modules of the header assembly.
IS22.1172-WO-PCT [0070] The scalable manifold assembly of any preceding clause, wherein the one or more branch wing modules of the frame assembly are configured to at least partially surround and support the one or more branch termination modules of the header assembly. [0071] The scalable manifold assembly of any preceding clause, wherein each of the one or more branch wing modules defines one or more slots configured to receive and support a branch termination module of the one or more branch termination modules. [0072] The scalable manifold assembly of any preceding clause, wherein the lift box module of the frame assembly is configured to at least partially surround and support the one or more header interior modules and the one or more branch core modules of the header assembly. [0073] The scalable manifold assembly of any preceding clause, wherein each of the one or more branch core modules comprises one or more straight pipe sections, one or more fittings, one or more elbows, and one or more valve blocks, and wherein each of the one or more valve blocks comprise a branch isolation valve and one or more header selection valves. [0074] The scalable manifold assembly of any preceding clause, wherein each of the one or more header termination modules comprises one or more straight pipe sections, a bent pipe section, one or more fittings, one or more blocks, and a hub connector, each of the one or more branch termination modules comprises one or more straight pipe sections, one or more elbows, one or more fittings, and a hub connector, and each of the one or more header interior modules comprises one or more straight pipe sections and one or more fittings. [0075] The scalable manifold assembly of any preceding clause, wherein the one or more straight pipe sections of the one or more branch termination modules are oriented crosswise relative to the one or more straight pipe sections of the one or more header interior modules. [0076] The scalable manifold assembly of any preceding clause, wherein the one or more blocks are configured to facilitate one or more connections between one or more sensors, one or more chemical injections points, or any combination thereof. [0077] The scalable manifold assembly of any preceding clause, wherein the frame assembly comprises an elevated roof configured to protect components of the header assembly that extend beyond a threshold height.
IS22.1172-WO-PCT [0078] A frame assembly for a scalable manifold assembly includes a plurality of frame modules configured to be integrated with a header assembly of the scalable manifold assembly. The plurality of frame modules includes a lift box module configured to at least partially surround and support one or more header interior modules and one or more branch core modules of the header assembly, one or more header wing modules configured to at least partially surround and support one or more header termination modules of the header assembly, and one or more branch wing modules configured to at least partially surround and support one or more branch termination modules of the header assembly. [0079] The frame assembly of the preceding clause, wherein a first height and a first length of the lift box module are the same as a respective second height and a respective second length of each of the one or more branch wing modules. [0080] The frame assembly of any preceding clause, wherein a first height and a first width of the lift box module are the same as a respective second height and a respective second width of each of the one or more header wing modules. [0081] The frame assembly of any preceding clause, wherein first dimensions of the lift box module are selected based on second dimensions of the one or more header interior modules and third dimensions of the one or more branch core modules. [0082] The frame assembly of any preceding clause, wherein first dimensions of the one or more header wing modules are selected based on one or more second dimensions of the one or more header termination modules. [0083] The frame assembly of any preceding clause, wherein first dimensions of the one or more branch wing modules are selected based on one or more second dimensions of the one or more branch termination modules. [0084] The frame assembly of any preceding clause, wherein the one or more branch wing modules are configured to define a plurality of slots, wherein each of the plurality of slots is configured to support a particular branch termination module of the one or more branch termination modules, and wherein a quantity of the plurality of slots is selected based on a quantity of the one or more branch termination modules.
IS22.1172-WO-PCT [0085] A method of configuring a scalable manifold assembly includes selecting a quantity of header modules configured to collective define a header assembly, wherein the quantity of header modules comprises any combination of one or more header termination modules, branch termination modules, branch core modules, and header interior modules. The method further includes selecting a frame assembly having one or more frame modules and sized to accommodate the selected quantity of header modules, wherein the one or more frame modules comprise any combination of one or more header wing modules, branch wing modules, and lift box modules, and wherein each of the one or more frame modules are associated with a corresponding header module of the header assembly, arranging the header modules in and on the one or more frame modules of the frame assembly, and connecting the header modules to one another with interconnecting piping. [0086] While the subject disclosure is described through the above embodiments, it will be understood by those of ordinary skill in the art that modification to and variation of the illustrated embodiments may be made without departing from the inventive concepts herein disclosed. Moreover, while some embodiments are described in connection with various illustrative structures, one skilled in the art will recognize that the system may be embodied using a variety of specific structures.