Frac Adapter Couples Frac Tree to Wellhead
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Solution Overview
Problem
The high-pressure requirements during hydraulic fracturing of wells necessitate wellhead equipment rated for pressures exceeding typical production pressures, leading to increased costs due to the need for expensive, high-pressure-rated components that are only temporarily used.
Innovation Solution
A frac adapter that couples a frac tree to the wellhead, allowing for high-pressure fracturing operations without requiring the entire wellhead to be rated for the high pressures, thereby enabling the use of lower-pressure-rated equipment for production, and is designed to withstand pressures up to 10,000 or 20,000 psi.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-pressure-rated wellhead equipment is used to withstand fracturing pressures, then safety and reliability are improved, but equipment cost and complexity increase
Solution Approach 1:
The wellhead system is divided into two separate components: a high-pressure-rated frac adapter for fracturing operations and a lower-pressure-rated wellhead for production operations. This segmentation allows each component to be optimized for its specific pressure requirement, improving safety during fracing while reducing overall equipment complexity and cost.
Solution Approach 2:
The frac adapter serves as an intermediary component that temporarily connects the frac tree to the wellhead during fracturing operations. It mediates between the high-pressure fracturing fluid and the lower-pressure-rated wellhead, protecting the wellhead from excessive pressure while allowing high-pressure operations to proceed safely.
2Reliability
If high-pressure-rated wellhead equipment is used to withstand fracturing pressures, then safety is improved, but equipment cost increases
Solution Approach 1:
The wellhead system is divided into two separate components: a high-pressure-rated frac adapter for fracturing operations and a lower-pressure-rated wellhead for production operations. This segmentation allows each component to be optimized for its specific pressure requirement, improving safety during fracing while reducing overall equipment complexity and cost.
Solution Approach 2:
The frac adapter is designed as a temporary, disposable component that is used only during fracturing operations and then removed. This allows the use of high-pressure-rated material only where absolutely necessary, rather than requiring expensive high-pressure-rated equipment throughout the entire wellhead system, thereby reducing overall equipment cost.
3Strength
If the entire wellhead system is rated for high pressures, then pressure containment is improved, but operational efficiency decreases due to unnecessary over-engineering
Solution Approach 1:
The frac adapter incorporates high-pressure containment capability only at the specific location where fracturing fluid enters the system. The rest of the wellhead system can be designed for lower pressure ratings, optimizing the distribution of strength properties to match actual operational requirements and improving overall operational efficiency.
Solution Approach 2:
The system transitions dynamically between two operational states: during fracturing operations, the high-pressure-rated frac adapter is installed to withstand high pressures; during production operations, the frac adapter is removed and a lower-pressure-rated wellhead is used. This dynamic configuration optimizes pressure containment only when needed, improving operational efficiency.
Data Source
AI summary
There is provided a frac adapter configured to couple a frac tree to a wellhead component. The frac adapter may couple the frac tree to a casing head without a tubing head, thereby enabling the well to be fractured before the tubing head is installed. As a result, the tubing head used in well production may be pressure-rated for production pressures rather than for fracing pressures. The frac adapter may be coupled to or integral with the frac tree. In addition, a union-nut coupling may be employed to quickly and easily assemble and disassemble the frac adapter from the wellhead component, such as the casing head. The union-nut coupling may further enable the components to be pressure-tested before the fracturing process is initiated.