Quick-Connect Coupler for Frac Tree Header Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing hydraulic fracturing operations face inefficiencies in fluid transfer systems, particularly in the connection and control of fluid flow between frac trees and headers, leading to complex and time-consuming assembly and disassembly processes.
Innovation Solution
A fluid transfer system featuring a valve tree with a master valve, a header, and a coupler with a fixed length and flow control valve, utilizing quick connect connectors for efficient coupling and decoupling, enabling rapid installation and removal of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional connection methods are used between valve trees and headers, then the system can maintain structural integrity, but the assembly and disassembly processes become complex and time-consuming
Solution Approach 1:
The connection system is divided into modular components: valve trees, couplers with quick connect connectors, and headers. This segmentation allows independent assembly and disassembly of each module, simplifying the overall connection process while maintaining structural integrity through standardized interfaces.
Solution Approach 2:
A coupler with quick connect connectors serves as an intermediary component between the valve tree and header. This mediator enables rapid connection and disconnection without complex assembly procedures, directly addressing the contradiction by providing both ease of operation and controlled complexity through a specialized intermediate device.
2Productivity
If traditional fluid transfer systems are used, then system stability is maintained, but operational efficiency is reduced due to time-consuming assembly and disassembly
Solution Approach 1:
The quick connect connectors are pre-configured with alignment features and sealing mechanisms that prepare the connection interface in advance. This preliminary preparation eliminates the need for complex alignment and sealing procedures during actual assembly, significantly reducing installation time while maintaining connection reliability.
Solution Approach 2:
The coupler acts as a pre-assembled intermediary unit that bridges the valve tree and header. By preparing this connection interface in advance with integrated quick connect mechanisms, the system achieves rapid deployment without compromising the stability and reliability of the fluid transfer connection.
3Loss of time
If quick connect connectors are implemented for rapid assembly, then installation time is reduced, but access to master valves for maintenance may be restricted
Solution Approach 1:
The system is segmented into independently connectable modules with the coupler serving as a removable intermediate component. This segmentation allows the coupler to be quickly disconnected, providing direct access to master valves for maintenance while enabling rapid reconnection to restore operational status, thus balancing quick installation with ease of repair.
Data Source
AI summary
A fluid transfer system includes a valve tree, the valve tree having a master valve having a flow axis and a header. The fluid transfer system further includes a coupler disposed between, connected to, and in fluid communication with, the valve tree and the header. The coupler has a fixed length and includes a coupler multi-path flow connector in fluid communication with the valve tree. The coupler also includes a flow control valve having a flow axis, the flow control valve directly coupled to the coupler multi-path flow connector and in fluid communication with the header.