Remote Fluid Connection Lock and Seal for High-Pressure Wellheads
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Solution Overview
Problem
Conventional wellhead connections for pressure control equipment pose safety risks to operators due to high pressures and large diameters, and existing fluid connections struggle to consistently maintain high pressures in larger diameters, especially during hydraulic fracturing operations.
Innovation Solution
A remotely-operated fluid connection assembly with a fluid connection adapter and housing assembly that uses internal working pressure to tighten seals, featuring a tapered lock engagement surface, locking elements, and a high-strength sleeve to enhance seal performance and robustness, while minimizing moving parts and allowing remote operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional hand union or hammer union connections are used for wellhead pressure control equipment, then the connection can be made with simple structure, but the operator is exposed to safety risks including collision with suspended load and pinched or crushed fingers and hands
Solution Approach 1:
The patent replaces manual mechanical operations with automated hydraulic systems. A hydraulic actuator automatically positions and secures the pressure control equipment to the wellhead, eliminating the need for operators to manually handle heavy suspended loads or tighten bolts with knock wrenches. The hydraulic system provides controlled, forceful engagement that safely secures the connection without exposing operators to pinch points or collision risks.
Solution Approach 2:
The connection mechanism is designed to be self-securing through automated hydraulic actuation. Once the pressure control equipment is positioned near the wellhead, the hydraulic system automatically completes the connection by forcing the equipment into engagement and securing it with locking bolts, without requiring continuous manual intervention or exposure to hazardous zones.
2Stress or pressure
If existing fluid connections are designed for higher pressures and larger diameters, then the connection capacity increases, but manufacturing consistency and seal performance become difficult to maintain
Solution Approach 1:
The patent employs a tapered seal interface where the seal surface angle is specifically designed to work with elastomeric seal material. The taper allows the seal to deform and conform to the mating surface under high pressure, creating a reliable seal even at large diameters and pressures up to 15,000 psi. This geometric parameter change enables consistent sealing performance across varying sizes and pressure conditions.
Solution Approach 2:
The seal system combines a rigid tapered metal seal surface with a flexible elastomeric seal element. The elastomer deforms to fill micro-irregularities in the tapered interface, compensating for manufacturing tolerances and ensuring consistent sealing performance. This composite approach allows the connection to maintain reliable seals at larger diameters and higher pressures where rigid seals alone would be difficult to manufacture consistently.
3Strength
If manual bolt tightening with knock wrench and sledgehammer is used, then the connection can be secured sufficiently tight, but the operator is exposed to physical danger and the process is time-consuming
Solution Approach 1:
The patent replaces manual bolt tightening with hydraulic actuation. The hydraulic system applies controlled force to secure the pressure control equipment to the wellhead, achieving sufficient connection strength without requiring operators to strike knock wrenches with sledgehammers. This automated mechanical system both strengthens the connection and eliminates the time-consuming manual tightening process.
Solution Approach 2:
The connection mechanism uses hydraulic pressure to automatically secure the pressure control equipment. Hydraulic actuators provide the force needed to engage locking mechanisms and tighten connections, replacing the need for manual knocking and tightening. This hydraulic system achieves strong, reliable connections quickly and safely without operator exposure to heavy tools or suspended loads.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively retains higher pressures in larger diameters, enhances seal robustness, and addresses safety concerns by enabling remote operation, thus improving personnel safety and performance in high-pressure, high-flow applications like hydraulic fracturing.
Implementation Method 1
The seal is disposed to expand radially and tighten sealing contact in response to internal pressure
Data Source
AI summary
A remotely-operated fluid connection assembly to hold higher internal pressures in larger diameters. The assembly comprises a fluid connection adapter and a fluid connection housing assembly. A first seal section on the housing assembly sealingly contacts a first seal bore on the adapter when the adapter enters the housing assembly. Engagement of an externally-disposed locking ring on locking element outer surfaces causes inner surfaces on the locking elements to retain the adapter to the housing assembly via a lock engagement surface. The first seal section is further disposed to expand radially such that when the first seal section expands radially, the first seal section further tightens sealing contact against the first seal bore. Adapter displacement relative to the housing assembly preferably further tightens the adapter against the locking elements as now restrained by the locking ring.