Threaded Plug with Displaceable Flange for Hammer Union Thread Protection
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Solution Overview
Problem
Hammer union joints in hydraulic fracturing systems are prone to high-pressure failure due to thread damage and lack of reliable metal-to-metal seals, posing risks to workers and environmental contamination.
Innovation Solution
A threaded plug with a cylindrical body, circumferential screw threads, a hand grip, and a downwardly obliquely oriented displaceable flange is used to protect the threads of the hammer union nut and male sub, maintaining engagement and providing a seal to prevent damage and leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If hammer unions are used to join pipe sections, then assembly speed increases and cost decreases compared to flanged connections, but reliability deteriorates due to thread damage and lack of metal-to-metal seals under high pressure
Solution Approach 1:
The patent applies preliminary action by providing protective caps that are pre-installed on hammer union fittings before they are put into service. These caps protect the threaded surfaces and sealing surfaces from damage during storage, handling, and installation. The caps are removed only when the fitting is ready to be assembled, ensuring the surfaces remain intact and undamaged throughout the preliminary period.
Solution Approach 2:
The patent uses protective caps as intermediary elements that temporarily cover and protect the vulnerable threaded and sealing surfaces of hammer union fittings. These caps act as mediators between the fitting and the environment, preventing direct contact between damaging elements (debris, moisture, improper handling) and the critical surfaces, thereby maintaining reliability without compromising the speed of assembly.
2Productivity
If hammer unions are subjected to repeated use and handling, then productivity increases through multiple assemblies, but thread damage occurs reducing reliability and increasing maintenance needs
Solution Approach 1:
Protective caps are installed on hammer union fittings before they enter service, preventing thread damage during storage and handling. This preliminary protection ensures that when the fitting is eventually assembled, the threads are intact and undamaged, maintaining manufacturing precision across multiple uses.
Solution Approach 2:
The protective caps serve as a cushioning barrier that absorbs potential damage before it can reach the critical threaded surfaces. By placing this protective layer in advance, the patent prevents thread damage that would otherwise occur during repeated handling and storage, thereby preserving thread integrity for multiple assembly cycles.
3Reliability
If protective devices are added to hammer unions, then thread protection improves, but device complexity increases
Solution Approach 1:
The patent employs simple, inexpensive protective caps that can be easily manufactured and discarded or reused. These caps are basic plastic or rubber components that provide effective thread protection without adding mechanical complexity. Their simplicity means they can be easily replaced if needed, and they don't require complex installation or maintenance procedures.
Solution Approach 2:
The protective caps are made from flexible materials such as plastic or rubber that can conform to the shape of the hammer union fitting. This flexibility allows the caps to provide comprehensive protection for threaded and sealing surfaces without requiring precise machining or complex structural designs, thereby maintaining simplicity while improving reliability.
Data Source
AI summary
A threaded plug for use in connection with a hammer union is provided, the plug comprising a plug body cylindrical in configuration, the plug body having circumferential screw threads about at least a portion of the longitudinal extent of the body, a hand grip suitable for installing the thread plug accessible at an upper end, and the upper end having extending from the periphery thereof a downwardly obliquely oriented displaceable flange member. An assembly is also provided comprising the threaded plug installed on a nut of a hammer union and maintaining the nut in engagement with a male sub of a hammer union to provide protection of the screw threads of the nut and the end of the male sub.