Multipart Frac Head with Replaceable Inlet Ports

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The high maintenance and repair costs of frac heads due to abrasion from pumping abrasive proppant, which requires transportation to a machine shop for refurbishment, and the inability of abrasion-resistant materials to completely eliminate maintenance needs.

Innovation Solution

A multipart frac head design with removable components, such as a bottom leg and inlet ports, that can be replaced in the field, eliminating the need for welding and reducing construction and transportation costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If frac head is constructed with welded inlet ports and abrasion-resistant materials, then abrasion resistance is improved, but maintenance cost and complexity increase due to required transportation to machine shop for refurbishment

Engineering Contradiction:

Improveabrasion resistanceVSAvoidmaintenance complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The frac head is divided into modular components: a body portion and multiple replaceable inlet ports. Each inlet port can be independently removed and replaced without affecting the entire frac head assembly, enabling field maintenance without transportation to machine shops.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The inlet ports are extracted as separate, removable components from the frac head body. This extraction allows the inlet ports to be replaced independently in the field, eliminating the need to transport the entire frac head for routine maintenance.

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If frac head is refurbished by welding new components, then wear resistance is restored, but time and cost increase due to heating, welding, post-heating, and cooling processes

Engineering Contradiction:

Improvewear resistanceVSAvoidrefurbishment time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

Replaceable inlet ports are pre-manufactured with abrasion-resistant properties before being installed in the frac head. This preliminary preparation allows rapid field replacement without time-consuming on-site welding, heating, or post-heating processes.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The inlet ports are designed as replaceable, relatively simple components that can be manufactured more economically and replaced in the field. Rather than investing significant time and resources in refurbishing the entire frac head, operators can replace individual inlet ports as needed.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Strength

If frac head components are welded together, then structural strength is improved, but construction cost increases due to skilled labor, pre-heating, and post-processing requirements

Engineering Contradiction:

Improvestructural strengthVSAvoidconstruction cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The welded mechanical connection between inlet ports and frac head body is replaced with a threaded mechanical fastening system. This substitution eliminates the need for skilled welding, pre-heating, and post-heating processes, significantly reducing construction costs while maintaining structural integrity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The connection method is changed from welding (thermal process) to threading (mechanical process). This parameter change in the joining method eliminates expensive thermal processing steps and skilled labor requirements while achieving sufficient structural strength for frac head operation.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS8113275B2Multipart frac head with replaceable components

Publication Date: 2012.02.14 OIL STATES ENERGY SERVICES LLC

AI summary

A multipart frac head with removable components permits the frac head to be refurbished in the field. A bottom leg and inlet ports of the multipart frac head can be replaced.