High-Pressure Flowline Union Sealing for Faster Field Assembly
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Solution Overview
Problem
Existing frac systems and high-pressure fluid transportation systems face challenges in efficiently and reliably connecting and disconnecting components, particularly in harsh environments with abrasive and corrosive fluids, leading to increased time, cost, and safety hazards.
Innovation Solution
The development of novel unions and flowline components that utilize high-yield steel, rotatable flanges, and advanced seal assemblies, allowing for quicker and more reliable connection and disconnection of components under high pressure and flow rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If conventional unions are used to connect flowline components, then the system can be assembled and disassembled, but the process requires significant time and exposes workers to safety hazards in harsh environments
Solution Approach 1:
The union is divided into separate male and female halves that can be independently positioned on flowline components. The male half attaches to one component while the female half attaches to the other, allowing gradual assembly without requiring complete disassembly of the entire system. This segmentation enables workers to connect components in manageable sections, reducing overall assembly time and minimizing exposure to hazardous environments.
Solution Approach 2:
The male and female union halves are pre-assembled with seals and connection mechanisms before being brought to the work site. This preliminary preparation allows for rapid field assembly where the pre-configured union halves can be quickly attached to flowline components without requiring complex on-site assembly procedures, thereby reducing assembly time and operational complexity.
2Productivity
If traditional connection methods are used, then components can be joined, but the process is complex and requires multiple steps
Solution Approach 1:
The sealing function and connection function are merged into a single integrated union assembly. The seal is incorporated within the union body itself rather than requiring separate sealing components and procedures. This merging of functions simplifies the connection process to a single operational step where the union is attached and sealing occurs simultaneously, eliminating multiple discrete steps and improving assembly efficiency.
Solution Approach 2:
The union design incorporates multiple functions within a single component structure: mechanical connection, sealing, and pressure containment. This multi-functionality eliminates the need for separate specialized components for each function, reducing the overall complexity of the connection system while maintaining high productivity through streamlined assembly operations.
3Reliability
If standard seals are used in high-pressure flowlines, then sealing is provided, but the seals may fail under extreme pressure and abrasive conditions
Solution Approach 1:
The sealing system uses composite construction combining metal backup rings with elastomeric seal elements. The metal backup ring provides structural support and pressure distribution while the elastomeric material provides the actual sealing function. This composite approach allows the seal to withstand extreme pressures and abrasive fluid conditions by distributing stresses across materials with complementary properties, significantly improving seal reliability in harsh environments.
Solution Approach 2:
The seal assembly includes a metal backup ring positioned behind the elastomeric seal element to provide structural support and prevent seal extrusion under high pressure. This backup structure acts as a cushion that distributes the extreme pressure loads before they reach the sealing element, protecting the seal from failure due to pressure spikes and abrasive conditions, thereby enhancing reliability in advance of potential failures.
Data Source
AI summary
A union is used to join mating high pressure flow line components. The union comprises an abutment, an annular gland, a seal assembly, and a plurality of threaded connectors. The abutment is between bearing surfaces on the mating components. The gland is formed by alignment of rabbets on the mating components and extends axially across and radially inward of the bearing surface. The seal assembly is carried in the gland and comprises first and second elastomeric seals on each side of a metal backup ring. The threaded connectors extend through holes in the mating components and apply axial load to the abutment to form the union.