Hybrid Wellhead Connector Sealing Wafer Design
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Solution Overview
Problem
Current wellhead assemblies face challenges in efficiently converting between drilling and production phases, particularly in ensuring reliable sealing and quick connection/disconnection of components, which affects operational efficiency and safety.
Innovation Solution
A wellhead assembly design featuring a recessed pocket in the wellhead housing that accommodates a drilling adapter for elastomeric sealing during drilling and a sealing wafer for metal-to-metal sealing during production, allowing for easy conversion between phases with threaded and flanged connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a wellhead assembly uses a single sealing mechanism for both drilling and production phases, then the device complexity is reduced, but the reliability of sealing is compromised during phase conversion
Solution Approach 1:
The wellhead assembly dynamically switches between two sealing mechanisms (elastomeric seal for drilling phase, metal seal for production phase) based on operational requirements. The system transitions from a static single-sealing approach to a dynamic multi-sealing configuration, allowing the sealing mechanism to adapt to different operational phases and maintain high reliability throughout.
Solution Approach 2:
The patent changes the sealing material parameter from a single type to two different types (elastomeric and metal) suited for different phases. During drilling operations, elastomeric seals provide flexible sealing, while during production, metal seals provide rigid sealing. This parameter change allows the system to optimize sealing performance for each specific operational phase.
2Reliability
If the wellhead assembly requires complete disassembly for phase conversion, then sealing reliability is improved, but the productivity and operational efficiency decrease
Solution Approach 1:
The wellhead assembly is segmented into modular components that can be independently configured for different phases. The quick-release mechanism allows the drilling adapter to be separated from the wellhead housing without complete disassembly, enabling rapid phase conversion while maintaining reliable connections through the retained flanged interface.
Solution Approach 2:
The drilling adapter is extracted as a removable component that can be quickly detached from the wellhead housing using a quick-release mechanism. This extraction allows the wellhead to be converted to production mode without disassembling the entire assembly, maintaining connection reliability through the permanent flanged interface while dramatically improving conversion efficiency.
3Ease of operation
If elastomeric seals are used for drilling adapter connection, then ease of operation is improved, but the reliability for production phase sealing deteriorates
Solution Approach 1:
The sealing system dynamically switches from elastomeric seals during drilling to metal seals during production. The elastomeric seals provide ease of operation for the drilling adapter connection, while the metal seals provide the reliability needed for production phase sealing. This dynamic switching resolves the contradiction by providing the appropriate sealing type for each operational phase.
Solution Approach 2:
The sealing material parameter is changed from elastomeric to metal based on the operational phase. Elastomeric seals are used during drilling for ease of connection, while metal seals are engaged during production for reliable sealing. This parameter change allows the system to optimize both ease of operation and sealing reliability for different phases.
4Reliability
If metal-to-metal sealing is used for production phase, then sealing reliability is improved, but the ease of manufacture and assembly deteriorates
Solution Approach 1:
The metal seal is pre-installed on the sealing wafer during manufacturing, which is then simply placed into the wellhead housing during phase conversion. This preliminary action prepares the reliable metal-to-metal sealing interface in advance, reducing the complexity of assembly during field operations while maintaining high sealing reliability for the production phase.
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
Enables seamless transition between drilling and production phases with enhanced sealing capabilities, ensuring operational efficiency and safety by facilitating quick connections and preventing fluid leakage.
Implementation Method 1
elastomeric seals can be used to seal the drilling adapter to the wellhead housing
Implementation Method 2
metal seals can be used with the sealing wafer to seal the connection of the wellhead housing to a different component
Implementation Method 3
The drilling adapter can be secured to the wellhead housing with a collar threaded onto a threaded surface of the wellhead housing
Implementation Method 4
a threaded flange is spun onto the threaded surface after removing the drilling adapter and collar to allow a flanged connection with another component
Data Source
AI summary
A wellhead apparatus with a removable sealing wafer is provided. In one embodiment, an apparatus includes a wellhead housing with a pocket formed in its upper end and a wafer installed in the pocket. A flange is coupled to the exterior of the upper end of the wellhead housing, and an additional component is coupled to the wellhead housing via the flange. Further, a first seal is positioned between the wafer and a shoulder of the wellhead housing, and a second seal is positioned between the wafer and the additional component. Additional systems, devices, and methods are also disclosed.