Flowline Junction Fitting with Offset Bore and Long-Sweep Curves
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Solution Overview
Problem
Conventional frac systems face challenges with high complexity, assembly time, cost, and reliability due to numerous components and exposed elastomeric seals, which are prone to leaking and erosion from abrasive and corrosive fluids under high pressure.
Innovation Solution
The development of novel frac manifolds and flow lines featuring offset cross junctions with long-sweep curves and flange unions, reducing the number of components and eliminating exposed elastomeric seals, which minimizes turbulence and erosion by directing fluid flow more laminarly and reducing the angle of impact on conduit walls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional frac systems use numerous components with elastomeric seals, then assembly flexibility and connection reliability are improved, but the system complexity increases and leak points multiply
Solution Approach 1:
The patent combines multiple flow lines and junction fittings into a single integrated flow line with integrated junctions formed directly within the flow line body. This merging eliminates the need for separate junction fittings and reduces the number of connections required, thereby reducing system complexity while maintaining connection reliability through the robust flow line construction.
Solution Approach 2:
The flow line is designed with multi-functional integrated junctions that can accommodate multiple feed bores and flow line configurations within a single component. This universal design allows the flow line to perform multiple functions (manifold, junction, and conduit) simultaneously, reducing the number of separate components needed and simplifying the overall system.
2Adaptability or versatility
If conventional junction fittings are used with multiple connections, then flow distribution flexibility is improved, but assembly time and potential leak points increase
Solution Approach 1:
Multiple junction functions are merged into the flow line body itself, with feed bores and connection points integrated directly into the flow line structure. This eliminates the need to assemble multiple separate junction fittings, significantly reducing assembly time while maintaining the flexibility to distribute flow to multiple destinations through the integrated junction design.
Solution Approach 2:
The junctions and feed bores are pre-formed as integral parts of the flow line during manufacturing, rather than requiring field assembly. This preliminary action of creating ready-to-connect junctions reduces on-site assembly time and minimizes the potential for assembly errors or leaks.
3Volume of moving object
If conventional flow lines with sharp turns are used, then space efficiency is improved, but erosion and turbulence increase
Solution Approach 1:
The patent employs long-sweep curved feed bores and smooth transitions within the flow line instead of sharp angles or abrupt direction changes. These curved pathways reduce turbulence and minimize erosion by distributing fluid flow more evenly along the bore walls, while still achieving compact routing through optimized curve geometry that maintains space efficiency.
4Ease of operation
If elastomeric seals are used in unions, then connection ease is improved, but wear resistance and reliability under abrasive conditions worsen
Solution Approach 1:
The patent eliminates elastomeric seals from the high-pressure, high-velocity flow path by using sealless union designs or metal-to-metal sealing surfaces that are resistant to abrasive wear. This extraction of vulnerable elastomeric components from the abrasive environment maintains connection ease through standardized union interfaces while dramatically improving wear resistance and reliability under harsh frac conditions.
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
This design enhances wear resistance, simplifies assembly, reduces leak points, and extends the service life of flow line components by minimizing erosion and turbulence, leading to a more efficient and cost-effective high-pressure fluid transportation system.
Implementation Method 1
directing fluid flow more laminarly
Implementation Method 2
minimizes turbulence and erosion by directing fluid flow more laminarly
Implementation Method 3
minimizes turbulence and erosion by directing fluid flow more laminarly and reducing the angle of impact on conduit walls
Data Source
AI summary
Missile flow lines are incorporated into frac manifolds, especially trailered or skidded frac manifolds. The missiles manifold the discharge from a plurality of pumps and comprise at least two junction fittings joined by spooled pipe. The junction fittings comprise a body having a primary bore and at least two feed bores. The intersections of the feed bores with the primary bore are offset axially from each other along the primary bore. The junction fittings are joined by flange unions to at least one spooled pipe such that the junction fittings and spooled pipe form a conduit including the primary bores. A discharge line from a pump may be joined to each feed union face of the junction fittings by a flange union. Thus, the discharge from the pumps may be manifolded into the conduit.