High-Pressure Fracturing Connector With Remote Sealing Plug Isolation
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Solution Overview
Problem
The increasing number of fracing stages in hydraulic fracturing operations leads to excessive wear and maintenance of valves in zipper manifolds, posing safety risks and downtime due to the harsh conditions and high frequency of valve operations, which can result in accidents and inefficiencies.
Innovation Solution
The introduction of a jumper manifold that replaces dual isolation valves with a jumper and sealing plugs, allowing for remote operation and elimination of valves, ensuring safe and reliable high-pressure connections without the need for frequent maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dual isolation valves are used in zipper manifolds for high-pressure fracing operations, then flow control and isolation capability are improved, but valve wear and maintenance frequency increase significantly due to harsh conditions and high operation frequency
Solution Approach 1:
The patent removes the dual isolation valves from the system entirely and replaces them with a jumper manifold configuration using sealing plugs. This extraction of the problematic valve components eliminates the source of wear and maintenance requirements while maintaining the necessary isolation capability through alternative means (sealing plugs that can be remotely set and are not subject to the same wear mechanisms).
Solution Approach 2:
The patent replaces the mechanical valve system with a jumper and sealing plug system that can be operated remotely without mechanical valve components. The sealing plugs are set remotely via wireline or coiled tubing, eliminating the need for frequent mechanical valve operations that lead to wear and downtime.
2Stress or pressure
If dual isolation valves are used in zipper manifolds, then pressure control is improved, but safety risks increase due to valve wear and potential failure under harsh conditions
Solution Approach 1:
By removing the dual isolation valves and replacing them with sealing plugs in a jumper manifold configuration, the patent eliminates the mechanical components that are prone to failure under harsh fracing conditions. The sealing plugs provide pressure control without the wear and potential failure modes associated with mechanical valves.
Solution Approach 2:
The sealing plugs used in the jumper manifold are simpler, more robust components that can be replaced if necessary without the complex maintenance requirements of valves. They are designed to withstand the harsh conditions without the wear mechanisms that affect mechanical valves.
3Adaptability or versatility
If frequent valve operations are performed to handle increasing number of fracing stages, then operational flexibility is improved, but valve wear accelerates leading to more maintenance requirements
Solution Approach 1:
The patent removes the mechanical valves that are subject to wear from frequent operations and replaces them with a jumper manifold system using sealing plugs. This eliminates the wear mechanism while maintaining the ability to handle multiple fracing stages through remote operation of the plugs.
Solution Approach 2:
The patent replaces the mechanical valve system with a jumper and sealing plug system that can be operated remotely via wireline or coiled tubing. This substitution eliminates the mechanical wear that occurs with frequent valve operations while maintaining full operational flexibility for handling increasing numbers of fracing stages.
4Adaptability or versatility
If traditional zipper manifold with valves is used, then flow distribution to multiple wells is achieved, but system complexity and maintenance requirements increase
Solution Approach 1:
The patent removes the complex valve system from the zipper manifold and replaces it with a simpler jumper and sealing plug configuration. This extraction eliminates the mechanical complexity of valves while maintaining the multi-well flow distribution capability through alternative means.
Solution Approach 2:
The patent replaces the mechanical valve system with a jumper manifold using sealing plugs that can be set remotely. This substitution simplifies the overall system by eliminating mechanical valves and their associated complexity, while maintaining the ability to distribute flow to multiple wells through the jumper configuration.
Data Source
AI summary
A connector system for use during hydraulic fracturing operations includes a first connector having a bore and an annular interface defined by a plurality of surfaces disposed at selected angles with respect to each other. A second connector has an annular interface defined by a plurality of surfaces disposed at selected angles to each other. The plurality of surfaces of the annular interface of the first connector are adapted to engage the plurality of surfaces of the annular interface of the second connector to form a seal.