Adjustable Flowline Lug Connections for Faster Frac Piping
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Solution Overview
Problem
Existing oil and gas production systems face challenges with cluttered work sites due to numerous small bore flowlines, potential leak points, and cumbersome piping configurations, particularly in hydraulic fracturing operations, which are time-consuming and hazardous.
Innovation Solution
The implementation of adjustable flowline connections using a lug system that allows for axial movement and adjustment of large bore flowlines, eliminating the need for traditional threaded or stud connections, reducing clutter and potential leak paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If numerous small bore flowlines are used to connect to the wellhead at a manifold, then fluid distribution capability is improved, but work site clutter and potential leak points increase
Solution Approach 1:
The flowline connection system is segmented into modular components: a manifold body with multiple ports, individual flowline segments with connectors, and lug-based coupling mechanisms. This segmentation allows flexible configuration to distribute fluid to multiple wells while maintaining a organized, less cluttered worksite compared to traditional numerous small bore lines.
Solution Approach 2:
The connector design uses axial movement and rotation in three-dimensional space to achieve connection and locking. The lug system allows the flowline segments to be positioned and secured through axial displacement followed by rotational locking, adding spatial dimensions to the connection process and reducing the need for complex alignment procedures that would increase worksite clutter.
2Strength
If traditional threaded or stud connections are used for flowlines, then connection strength is improved, but installation time and operational complexity increase
Solution Approach 1:
The connector transitions from a static threaded connection to a dynamic two-stage connection process: first axial movement to engage the lugs, then rotational movement to lock the lugs into position. This dynamic connection mechanism is faster than traditional threading while maintaining connection strength through the interlocking lug design that resists both axial and rotational forces.
Solution Approach 2:
The invention extracts the threading operation entirely from the connection process, replacing it with a lug-based mechanical interlock system. This removal of the time-consuming threading step significantly reduces installation time while the lug geometry and locking mechanism preserve the necessary connection strength for high-pressure flowline applications.
3Stability of the object's composition
If hard piping is used for frac trees arranged proximate one another, then structural stability is improved, but adaptability to different tree configurations decreases
Solution Approach 1:
The flowline connection system incorporates dynamic adjustment capabilities through axial movement and rotational locking of the lug connectors. This allows the piping configuration to be adapted to different tree arrangements and spacing while maintaining structural stability under operating conditions. The connectors can be positioned and locked in various orientations to accommodate different wellhead configurations.
Solution Approach 2:
The manifold and connector design serves multiple functions: it distributes fluid to multiple wells, accommodates different tree configurations through adjustable connector positioning, provides stable high-pressure connections, and enables quick reconfiguration between different well patterns. This multi-functionality replaces the need for multiple specialized hard piping configurations.
4Reliability
If multiple flowline segments are connected to reduce clutter, then leak points are reduced, but connection complexity increases
Solution Approach 1:
The lug-based connector uses a simple two-stage dynamic connection process (axial engagement followed by rotational locking) that reduces connection complexity compared to traditional multi-component flanged or threaded connections. This simplified process makes it easier to create multiple secure connections, thereby reducing the total number of potential leak points while maintaining connection reliability.
Data Source
AI summary
A tubular connection system includes a connector coupled to a tubular segment, the connector having a first bore with a first bore diameter and a mating connector coupled to the connector, the mating connector having a second bore with a second bore diameter. The connector includes a plurality of connector lugs extending into the first bore. The connector also includes a plurality of gaps, respective gaps of the plurality of gaps are arranged between adjacent connector lugs of the plurality of connector lugs in a first alternating pattern. The plurality of connectors lugs are arranged in connector lug rows. The mating connector includes a plurality of mating lugs radially outward. The mating connector also includes a plurality of openings, respective openings of the plurality of openings are arranged between adjacent mating lugs of the plurality of mating lugs. The plurality of mating lugs are arranged in mating lug rows.