Flapper Valve Axis Alignment in Frac Head
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Solution Overview
Problem
Hydraulic fracturing processes face challenges due to high-pressure and abrasive frac fluids that wear down components in frac systems, reducing their operational life and requiring frequent maintenance.
Innovation Solution
A flapper valve system integrated within the frac head provides a dual barrier to control fluid flow and protect other valves from pressurized frac fluid, reducing exposure and wear by aligning with different axes in open and closed positions, and is actuated by a controller to manage fluid flow effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a valve is used to control fluid flow in the frac system, then fluid flow control is improved, but the valve is exposed to high-pressure and abrasive frac fluid causing wear and reducing operational life
Solution Approach 1:
The flapper valve is nested within the frac head, positioned inside the fluid pathway. This internal placement allows the flapper valve to control fluid flow to the outlet while being protected from direct exposure to the full force of high-pressure abrasive frac fluid, thereby extending operational life while maintaining control functionality
Solution Approach 2:
The flapper valve acts as an intermediary component between the frac head and the outlet valve. It provides a first barrier that reduces the exposure of downstream components to abrasive frac fluid, while still enabling effective fluid flow control through its positioning and movement mechanism
2Reliability
If multiple valves are used to provide redundant fluid control, then reliability is improved, but device complexity and overall height increase
Solution Approach 1:
The flapper valve is integrated within the frac head structure itself, merging the valve function with the existing frac head component. This consolidation provides redundant fluid control capability without adding separate external valve assemblies, thereby reducing overall device complexity and vertical height while maintaining reliability through dual barrier protection
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 flapper valve system extends the operational life of frac system components, reduces maintenance needs, and lowers the overall height of the frac tree, facilitating assembly and operation while maintaining redundant fluid control.
Implementation Method 1
The flapper valve aligns with a first axis of the outlet and the second inlet in the closed position and aligns with a second axis of the first inlet in the open position
Data Source
AI summary
A frac system including a frac tree. The frac tree includes a frac head. The frac head defines a first inlet, a second inlet, and an outlet. The frac head receives frac fluid through the first inlet and directs the frac fluid to the outlet fluidly coupled to a wellhead. A valve couples to the second inlet of the frac head. A flapper valve is within the frac head. The flapper valve moves between an open position and a closed position to control fluid flow to the valve through the second inlet. The flapper valve aligns with a first axis of the outlet and the second inlet in the closed position and aligns with a second axis of the first inlet in the open position.