Adjustable Frac Flow Line Sealing for Gap-Free High-Pressure Connections
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Solution Overview
Problem
Flow lines connecting frac equipment in wellbore operations often fail due to gaps at connection points, leading to pressure loss and leakage, especially when the equipment arrangement is not precisely known, causing productivity losses and environmental risks.
Innovation Solution
The development of adjustable and customizable flow lines with features such as axially translatable pipe bodies, metal and elastomer seals, and adjustable flanges allows for precise fitting and robust connections, capable of withstanding high pressures and erosive materials, and can be customized to fit varying equipment arrangements without precise measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pre-sized flow lines are used to connect frac equipment, then the flow lines can withstand high pressures and erosive materials, but gaps may occur at connection points due to imprecise equipment location and orientation
Solution Approach 1:
The flow line incorporates an adjustable length mechanism that allows the connection to adapt dynamically to varying distances and orientations between frac equipment. This dynamic adjustment capability eliminates gaps at connection points while maintaining the structural integrity needed to withstand high pressures and erosive materials.
Solution Approach 2:
The flow line design allows for changing the length parameter to match the actual distance between connection points on frac equipment. By adjusting this parameter, the system accommodates imprecise equipment location and orientation without creating gaps, thereby maintaining connection reliability under harsh operating conditions.
2Reliability
If adjustable flow lines with axially translatable pipe bodies are used, then precise fitting and robust connections can be achieved, but the device complexity increases
Solution Approach 1:
The flow line is divided into modular sections with flanges and connection components that can be independently adjusted. This segmentation allows for precise fitting through axial translation of pipe bodies while keeping each component relatively simple in design, balancing connection robustness with structural complexity.
3Manufacturing precision
If customizable flow lines are used to fit varying equipment arrangements, then connection precision improves, but the ease of manufacture decreases
Solution Approach 1:
The flow line design uses standardized flange connections and modular components that can be configured for different equipment arrangements. This universal design approach allows precise fitting to various configurations while maintaining manufacturing simplicity through repeated use of standard parts and assembly procedures.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides reliable, long-lasting connections that prevent pressure loss and leakage, reducing equipment damage and environmental risks, while allowing for efficient assembly and reducing the need for frequent replacements, thus enhancing wellbore operation productivity.
Implementation Method 1
a metal seal positioned between an outer surface of inner pipe body and an inner surface of the outer pipe body
Implementation Method 2
one or more elastomer seals positioned between the first pipe body and the second pipe body
Implementation Method 3
one or more threaded rods configured to secure the first flange to the second flange
Data Source
AI summary
An adjustable flow line may include an outer pipe body having a first flange, an inner pipe body partially disposed within the outer pipe body and axially translatable with respect to the outer pipe body, a metal seal positioned between an outer surface of inner pipe body and an inner surface of the outer pipe body, a sleeve positioned around the inner pipe body and outside of the outer pipe body, and a second flange positioned around the inner pipe body, wherein when connected to the first flange. The sleeve may be axially translatable with respect to the inner pipe body. The second flange may axially secure the sleeve with respect to the outer pipe body and cause the sleeve to energize the metal seal.