U.S. patent application number 14/472931 was filed with the patent office on 2016-03-03 for frac head apparatus.
The applicant listed for this patent is Sean THOMAS. Invention is credited to Sean THOMAS.
Application Number | 20160060997 14/472931 |
Document ID | / |
Family ID | 55401920 |
Filed Date | 2016-03-03 |
United States Patent
Application |
20160060997 |
Kind Code |
A1 |
THOMAS; Sean |
March 3, 2016 |
FRAC HEAD APPARATUS
Abstract
A frac head apparatus has a body with an internal bore extending
therethrough, a first flow bore formed through the body so as to
have an inner end opening to the internal bore of the body and an
outer end opening to an outer side of the body, and a second flow
bore formed through the body so as to have an inner end opening to
the internal bore of the body and an outer end opening at an outer
side of the body. The inner end of the first and second flow bores
are positioned at different levels within the body. Each of the
first and second flow bores has a longitudinal axis offset from and
not intersecting a longitudinal axis of the internal bore of the
body such that a fluid flow through the flow bores is directed
toward a wall of the internal bore offset from an opposite side of
the wall of the internal bore from the inner ends of the flow
bores.
Inventors: |
THOMAS; Sean; (Aledo,
TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
THOMAS; Sean |
Aledo |
TX |
US |
|
|
Family ID: |
55401920 |
Appl. No.: |
14/472931 |
Filed: |
August 29, 2014 |
Current U.S.
Class: |
166/88.4 |
Current CPC
Class: |
E21B 43/267 20130101;
E21B 33/068 20130101 |
International
Class: |
E21B 33/068 20060101
E21B033/068; E21B 43/00 20060101 E21B043/00 |
Claims
1. A frac head apparatus comprising: a body having an internal bore
extending therethrough, said internal bore having an inlet at an
upper end thereof and an outlet at a lower end thereof; a first
flow bore formed through said body so as to have an inner end
opening to said internal bore of said body and an outer end opening
at an outer side of said body, said first flow bore angling through
said body such that said inner end is at a level lower than said
outer end; and a second flow bore formed through said body so as to
have an inner end and an outer end, said inner end of said second
flow bore being positioned opposite said inner end of said first
flow bore, said second flow bore angling through said body such
that said inner end of said second flow bore is at a level lower
than said outer end of said second flow bore, said inner end of
said first flow bore being at a level different than a level of
said inner end of said second flow bore.
2. The frac head apparatus of claim 1, said first flow bore having
a longitudinal axis offset and not intersecting a longitudinal axis
of said internal bore of said body such that a flow through said
first flow bore is directed toward a wall of said inner bore offset
from an opposite side of said wall of said internal bore.
3. The frac head apparatus of claim 1, said second flow bore
angling through said body at an angle relative to the longitudinal
axis of said internal bore, said angle of said second flow bore
being similar to an angle at which said first flow bore extends
relative to the longitudinal axis of said internal bore.
4. The frac head apparatus of claim 2, said second flow bore having
a longitudinal axis offset from and not intersecting the
longitudinal axis of said internal bore of said body such that a
fluid flow through said second flow bore is directed toward said
wall of said internal bore offset from an opposite side of said
wall of said internal bore.
5. The frac head apparatus of claim 4, said longitudinal axis of
said first flow bore being in parallel planar relationship to a
longitudinal axis of said second flow bore.
6. The frac head apparatus of claim 1, said inner end of said
second flow bore positioned at a level above said inner end of said
first flow bore.
7. The frac head apparatus of claim 1, further comprising: a third
flow bore formed through said body so as to have an inner end and
an outer end, said inner end of said third flow bore opening to
said internal bore of said body in a location circumferentially
between said inner ends of said first and second flow bores, said
third flow bore angling through said body such that said inner end
of said third flow bore is at a level lower than a level of said
outer end of said third flow bore.
8. The frac head apparatus of claim 7, further comprising: a fourth
flow bore formed through said body so as to have an inner end and
an outer end, said inner end of said fourth flow bore opening to
said internal bore of said body in a location circumferentially
between inner ends of said first and second flow bores and
generally opposite to said inner end of said third flow bore, said
fourth flow bore angling through said body such that said inner end
of said fourth flow bore is at a level lower than a level of said
outer end of said fourth flow bore.
9. The frac head apparatus of claim 8, said third flow bore angling
through said body at an angle relative to the longitudinal axis of
said internal bore of said body, said fourth flow bore angling
through said body at an angle relative to the longitudinal axis of
said internal bore of said body, said angle of said third flow bore
being similar to said angle of said fourth flow bore.
10. The frac head apparatus of claim 8, said inner end of said
third flow bore being diametrically opposite said inner end of said
fourth flow bore.
11. The frac head at apparatus of claim 8, said inner ends of said
first flow bore, said second flow bore, said third flow bore and
said fourth flow bore being at different levels relative to the
longitudinal axis of said internal bore of said body.
12. The frac head apparatus of claim 9, said third flow bore having
a longitudinal axis offset and not intersecting the longitudinal
axis of said internal bore of said body such that a fluid flow
through said third flow bore is directed toward the wall of said
internal bore offset from an opposite side of said wall of said
internal bore from said inner end of said third flow bore.
13. The frac head apparatus of claim 12, said fourth flow bore
having a longitudinal axis offset from and not intersecting the
longitudinal axis of said internal bore of said body such that a
fluid flow through said fourth flow bore is directed to said wall
of said internal bore offset from an opposite side of said wall of
said internal bore from said inner end of said fourth flow
bore.
14. The frac head apparatus of claim 13, said longitudinal axis of
said third flow bore being in parallel planar relationship to the
longitudinal axis of said fourth flow bore.
15. A frac head apparatus comprising: a body having an internal
bore extending therethrough, said internal bore having an inlet at
an upper end thereof and an outlet at a lower end thereof; a first
flow bore formed through said body so as to have an inner end
opening to said internal bore of said body and an outer end opening
at an outer side of said body, said first flow bore angling through
said body such that said inner end is at a level lower than said
outer end, said first flow bore having a longitudinal axis offset
and not intersecting a longitudinal axis of said internal bore of
said body such that a fluid flow through said first flow bore is
directed toward a wall of said internal bore offset from an
opposite side of said internal bore from said inner end of said
first flow bore; and a second flow bore formed through said body so
as to have an inner end and an outer end, said inner end of said
second flow bore being positioned opposite said inner end of said
first flow bore, said second flow bore angling through said body
such that said inner end of said second flow bore is at a level
lower than said outer end of said second flow bore, said second
flow bore having a longitudinal axis offset from and not
intersecting the longitudinal axis of said internal bore of said
body such that a fluid flow through said second flow bore is
directed toward said wall of said internal bore offset from an
opposite side of said wall of said internal bore from said inner
end of said second flow bore.
16. The frac head apparatus of claim 15, said second flow bore
angling through said body at an angle relative to the longitudinal
axis of said internal bore, said angle of said second flow bore
being similar to an angle at which said first flow bore extends
relative to the longitudinal axis of said internal bore.
17. The frac head apparatus of claim 16, further comprising: a
third flow bore formed through said body so as to have an inner end
and outer end, said inner end of said third flow bore opening to
said internal bore of said body in a location circumferentially
between said inner ends of said first and second flow bores, said
third flow bore angling through said body such that said inner end
of said third flow bore is at a level lower than a level of said
outer end of said third flow bore; and a fourth flow bore formed
through said body so as to have an inner end and an outer end, said
inner end of said fourth flow bore opening to said internal bore of
said body in a location circumferentially between said inner ends
of said first and second flow bores and generally opposite to said
inner end of said third flow bore, said fourth flow bore angling
through said body such that said inner end of said fourth flow bore
is at a level lower than a level of said outer end of said fourth
flow bore.
18. The frac head apparatus of claim 15, said inner end of said
second flow bore positioned at a level above said inner end of said
first flow bore.
19. A frac head apparatus comprising: a body having an internal
bore extending therethrough, said internal bore having an inlet at
an upper end thereof and an outlet at a lower end thereof; a first
flow bore formed through said body so as to have an inner end
opening to said internal bore of said body and an outer end opening
at an outer side of said body, said first flow bore angling through
said body such that said inner end is at a level lower than said
outer end; a second flow bore formed to said body so as to have an
inner end and an outer end, said inner end of said second flow bore
being positioned opposite said inner end of said first flow bore,
said second flow bore angling through said body such that said
inner end of said second flow bore is at a level below said outer
end of said second flow bore; a third flow bore formed through said
body so as to have an inner end and an outer end, said inner end of
said third flow bore opening to said internal bore of said body in
a location circumferentially between said inner ends of said first
and second flow bores, said third flow bore angling through said
body such that said inner end of said third flow bore is at a level
lower the level of said outer end of said third flow bore; and a
fourth flow bore formed through said body so as to have an inner
end and an outer end, said inner end of said fourth flow bore
opening to said internal bore of said body in a location
circumferentially between said inner ends of said first and second
flow bores and generally opposite said inner end of said third flow
bore, said fourth flow bore angling through said body such that
said inner end of said fourth flow bore is at a level lower than a
level of said outer end of said fourth flow bore.
20. The frac head apparatus of claim 19, said inner ends of said
first flow bore and second flow bore and said third flow bore and
said fourth flow bore being positioned at different levels within
said body.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
[0003] NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT Not
applicable.
[0004] INCORPORATION-BY-REFERENCE OF MATERIALS SUBMITTED ON A
COMPACT DISC
[0005] Not applicable.
BACKGROUND OF THE INVENTION
[0006] 1. Field of the Invention
[0007] The present invention relates to frac head apparatus. More
particular, the present invention relates to frac head apparatus
whereby a cyclonic flow of fluid is induced into the internal bore
of the frac head. More particular, the present invention relates to
frac heads having a plurality of flow bores cooperative at the
internal bore of the frac head.
[0008] 2. Description of Related Art Including Information
Disclosed Under 37 CFR 1.97 and 37 CFR 1.98.
[0009] Well fracturing operations are well known in the oil and gas
drilling industries for increasing the flow capacity of a well.
During a typical well fracturing operation, large amounts of
abrasive and/or acidic fluids (i.e. slurries of sand, water, and
various chemicals) are pumped down the well by high-pressure pumps.
The high-pressure fluids (and sometimes gels) are intended to
fracture the formation, thereby improving the permeability and flow
capacity of the hydrocarbons. A frac head is typically connected to
the wellhead (or above the wellhead). Multiple fluid lines connect
the frac head to corresponding high-pressure pumps (typically pump
trucks). The frac head acts as a manifold to collect and redirect
fluid from the multiple fluid lines down through the well head into
the wellbore.
[0010] Because of the abrasive and corrosive nature of the
fracturing fluids, the interior bore of the frac head can be
subject to extreme erosion. Such erosion is costly in that it can
severely limit the useful service life of the frac head. The frac
head wall typically needs to be sufficiently thick to support
pressures of up to about 15,000 p.s.i., fluid velocities of 200
ft/min or more, and fluid flow rates of 100 gallons per second or
more. Eroded frac heads can sometimes be repaired, but are often
simply scrapped. Due to the high fluid pressures, frac head erosion
also potentially poses a serious safety concern. Frac head ruptures
are known in the process of fracturing.
[0011] Numerous approaches have been taken in the past to address
frac head erosion. For example, frac heads have been fabricated
from thick-walled steel and/or with high-strength construction
materials. The inner surface of the frac head has also been lined
with various erosion resistant materials. Unfortunately, these
approaches have met with minimal success, most likely due, in part,
to the extremely high pressures and fluid flow rates.
[0012] The frac head is a common upper wellhead stationary inlet
and outlet multi-bore flow manifold that is used when injecting
fluids or materials within the internal bore of a traditional
petrochemical oil or gas well, as well as being additionally
applied toward the internal self-propelled petrochemical fluid. A
traditional frac head manifold is commonly used to provide service
toward all fluidous flow transfer operations or motion-induced
material flow transfers within the internal bore and/or flow path
of a wellhead Christmas tree assembly. The frac head is a wellhead
assembly designed for typical positioning above the upper C section
of a fully assembled wellhead assembly in order for the frac head
to be positioned generally above all of the critical wellhead
safety control devices and safety regulatory systems, such as those
devices which control, monitor, adjust and regulate all open flow
line bores and closed flow line bores. These items are commonly
known as the lower hydraulic-actuated gate valves, the lower
manually-actuated gate valves, and any pilot-operated automatic
actuated gate valve assemblies. The wellhead assembly configuration
can include various configurations of wellhead casing heads, casing
hangers, casing spools, tubing heads, tubing hangers, tubing
spools, height riser spools, adapter spools, crossover adapters,
test adapters, and the integral main bore section.
[0013] The most common types of damaging effects generated by near
continuous abrasive flow cavitation toward a common frac head are
abrasive internal wall material washout within the entire length of
the internal bore or along the affixed flow line components. These
can continuously degrade during service applications so as to
thereby produce a gradual product failure and deterioration. This
can ultimately result in various product failure conditions. These
failure conditions can include decreases in the upstream accessory
flow line wall thickness, high pressure and high volume abrasive
deformation of the internal wall thickness, and deformation of the
internal wall surface integrity. This can develop a condition, as a
result of the initial internal cavitation and internal flow
washout, wherein the actual washout generated by the internal
cavitation activities of the flow process begin to develop a
significant compounding effect toward the wall thickness washout
and material destruction.
[0014] The most common damaging effects generated by near
continuous non-abrasive flow cavitation include non-abrasive
internal component damage with the entire upstream sectional
lengths of the internal bore of the flow line or the affixed flow
line components. These can continuously degrade during service
application so as to eventually produce product failure and
deterioration. This can ultimately result in various degrees of
product failure conditions which include damage to internal
upstream flow line elastomer seals, seal kits, seal gaskets,
0-rings and other elastomer or wearable flow line components.
[0015] When traditional frac heads are utilized as a means of
wellhead flow injection or flow outlet, the frac head is configured
in a manner consistent with the fluid flow or material flow mass
volumes which are internally directed in a standard uniform fashion
in which the internal fluid flow or material flow is firstly
injectably directed toward the center axis point of the internal
bore in which there is an opposing or near directly center axis
point of the internal bore horizontally-aligned bore section which
creates a situation in which each of the independent injection flow
bores are directly facing one another on an equal horizontal axis
alignment plane from the center point of the internal axis of the
internal bore. As such, all of the pressurized injected fluids or
flow materials create a bullhead-type direct flow mass flow volume
compression interference with one another at the point of injection
into the internal bore of the frac head. This can generate a higher
rate of injection mass flow cavitation and a lessening of the inlet
mass flow pulsation dampening effects. As a result, a less
consistently smooth fluid flow occurs. This is due to the fact that
the traditional frac head is configured in a manner in which all of
the flow bores are manufactured in a simple equal horizontal
alignment around the internal diameter circumference of the frac
head and at the outer diameter circumference of the frac head. This
produces a flow process resulting from the colliding effect of the
injected fluid flow or material flow. An aggressively forceful and
highly pressurized direct alignment collision with these fluid
flows occurs at the initial point of confluence at or near the
vertical center axis of the internal bore section of the frac head.
This collision can be deleterious to the optimum operating
conditions of the frac head.
[0016] Standard frac heads are all manufactured with the individual
flow bores being aligned generally in a near radially equal
horizontal center axis around the outer diameter of the frac head
as well as a near radially equal horizontal center axis around the
inside diameter of the internal bore of the frac head. The flow
bores are thus positioned in nearly equally opposing relationship
in the flow bore. An example of this is when traditional frac heads
are equipped with an industry-standard four side outlets or a more
expensive version equipped with six side outlets. These side
outlets are known as the inlet and outlet flow bores. Each flow
bore will continuously generate a tremendous amount of undesirable
confluence and flow turbulence. This results in a significant
internal washout effect to the internal bore of the frac head as
well as washout of the wellhead components which are positioned and
affixed below and above the frac head. Premature product failure of
the traditional frac head is generated by these various forms of
destructive fluid flow. Traditional frac heads are configured to
provide the means for inlet injection and outlet exhaustion of
fluid flow or material flow volumes to create a near-centrally
located point of confluence of all of the available flow bores.
This can create damaging effects toward the entire internal bore
when the traditional frac head is utilized for the purpose of inlet
injection of fluid flow. Traditional frac heads are designed with
the individual flow bores in an angular configuration in which the
independent flow bores are all generally configured to match the
same angle of flow bore alignment. These angles of flow bore
alignment are typically machined within a traditional frac head at
three principal degrees of angle from the vertical center point of
the internal bore. These angles can be configured at 90.degree.,
45.degree. and 30.degree. off the center point axis of the internal
bore the frac head. These various degrees of angle do not eliminate
the destructive high-pressure injection of fluid and do not
eliminate the washout or damaging abrasive cavitation.
[0017] In the past, various patents have issued with respect to
such frac heads in an effort to minimize the destructive effect
caused by fluid injection. For example, U.S. Pat. No. 7,478,673,
issued on Jan. 20, 2009 to M. D. Boyd, describes a frac head that
includes a mixing chamber located in an internal bored downstream
of an intercept between the side ports in the internal bore and
upstream of a tapered vortex portion of the bore. The tapered
vortex reduces the diameter of the bore from a first diameter to a
second diameter. The length of the mixing chamber (along the
longitudinal axis of the frac head) is greater than the first
diameter. The ratio of the first diameter to the second diameter is
greater than 1.5.
[0018] U.S. Pat. No. 7,828,153, issued on Nov. 9, 2010 to McGuire
et al., describes a multipart frac head with replaceable components
which permit the frac head to be refurbished in the field. A bottom
leg of the multipart frac head is replaceable. The inlet ports of
the frac head are also replaceable.
[0019] U.S. Pat. No. 8,016,031, issued on Sep. 13, 2011 to B.
McGuire, shows an erosion resistant frac head having a conversion
chamber. The frac head also includes an expansion chamber and a
mixing chamber so as to provide improved resistance to erosion
caused by abrasive frac fluids pumped through the frac head. A
bottom leg of the erosion resistant frac head maybe replaced in the
field.
[0020] U.S. Patent Application Publication No. 2013/0075079,
published a Mar. 28, 2013 to D. L. Artherholt, describes a frac
head having a sacrificial wash ring. The sacrificial wash ring is
located above a mixing chamber so as to protect the frac head body
from erosion caused by abrasive frac fluids pumped through the
head.
[0021] It is an object of the present invention to provide a frac
head apparatus that improves overall cycle durability.
[0022] It is another object of the present invention to provide a
frac head apparatus that allows for improved long-lasting
performance of the upstream components.
[0023] It is another object of the present invention to provide a
frac head apparatus that provides a less restrictive flow
process.
[0024] It is another object of the present invention to provide a
frac head apparatus that has a smoother inlet injection flow.
[0025] It is a further object of the present invention to provide a
frac head apparatus that reduces damaging effects caused by
abrasive and non-abrasive flow processes, cavitation, and back
pressure to upstream components.
[0026] It is another object of the present invention to provide a
frac head apparatus that generates an injection-based cyclonic flow
effect.
[0027] It is another object of the present invention to provide a
frac head apparatus that reduces vibratory cavitation washout.
[0028] It is another object of the present invention to provide a
frac head apparatus that reduces premature product failure.
[0029] It is another object of the present invention to provide a
frac head apparatus that is more cost effective.
[0030] It is still a further object of the present invention to
provide a frac head apparatus that allows for the option of
alternating or eliminating the use of more expensive
quinteplex-type injection pumps.
[0031] It is still a further object of the present invention to
provide a frac head apparatus that makes available the use of
cheaper triplex injection pumps.
[0032] It is still a further object the present invention to
provide a frac head apparatus that serves to maintain bore wall
thickness and reduce material washout.
[0033] These and other objects and advantages of the present
invention will become apparent from a reading of the attached
specification and appended claims.
BRIEF SUMMARY OF THE INVENTION
[0034] The present invention is a frac head apparatus that includes
a body having an internal bore extending therethrough with an inlet
at an upper end thereof and an outlet at a lower end thereof. A
first flow bore is formed through the body so as to have an inner
end opening to the internal bore of the body and an outer end
opening at an outer side of the body. The first flow bore angles
through the body such that the inner end is at a level lower than
the outer end. A second flow bore is formed through the body so as
to have an inner end and an outer end. The inner end of the second
flow bore is positioned opposite the inner end of the first flow
bore. The second flow bore angles through the body such that the
inner end of the second flow bore is at a level lower than the
outer end of the second flow bore. In one embodiment, the inner end
of the first flow bore is at a level different than the inner end
of the second flow bore.
[0035] The first flow bore has a longitudinal axis offset from and
not intersecting a longitudinal axis of the internal bore of the
body such that a fluid flow through the first flow bore is directed
toward a wall of the internal bore offset from an opposite side of
the wall of the internal bore from the inner end of the first flow
bore. The second flow bore extends angularly through the body at an
angle relative to the longitudinal axis of the internal bore. The
angle of the second flow bore is similar to the angle at which the
first flow bore extends relative to the longitudinal axis of the
internal bore. The second flow bore has a longitudinal axis offset
from and not intersecting the longitudinal axis of the internal
bore of the body such that a fluid flow through the second flow
bore is directed to the wall of the internal bore offset from an
opposite side of the wall of the internal bore from the inner end
of the second flow bore. The longitudinal axis of the first flow
bore is in parallel planar relationship to a longitudinal axis of
the second flow bore. The inner end of the second flow bore is
positioned at a level above the inner end of the first flow
bore.
[0036] A third flow bore is formed through the body so as to have
an inner end and an outer end. The inner end of the third flow bore
opens to the internal bore of the body of location
circumferentially between the inner ends of the first and second
flow bores. The third flow bore angles through the body such that
the inner end of the third flow bore is at a level lower than a
level of the outer end of the third flow bore. A fourth flow bore
is formed to the body so as to have an inner end and an outer end.
The inner end of the fourth flow bore opens to the internal bore of
the body in a location circumferentially between the inner ends of
the first and second flow bores and located generally opposite to
the location of the inner end of the third flow bore. The fourth
flow bore extends through the body such that the inner end of the
third flow bore is at a level lower than a level of the outer end
of the third flow bore. The third flow bore angles through the body
at an angle relative to the longitudinal axis of the internal bore
of the body. The fourth flow bore also angles through the body at
an angle relative to the longitudinal axis of the internal bore of
the body. The angle of the third flow bore is similar to the angle
of the fourth flow bore. The inner end of the third flow bore is
diametrically opposite the inner end of the fourth flow bore.
[0037] In the present invention, the inner ends of the first,
second, third and fourth flow bores are at different levels
relative to the longitudinal axis of the internal bore of the body.
The third flow bore has a longitudinal axis offset from and not
intersecting the longitudinal axis of the internal bore of the body
such that a fluid flow through the third flow bore is directed
toward the wall of the internal bore offset from an opposite side
of the wall of the internal bore from the inner end of the third
flow bore. Similarly, the fourth flow bore has longitudinal axis
offset and not intersecting the longitudinal axis of the internal
bore of the body such that a fluid flow through the fourth flow
bore is directed toward the wall of the internal bore offset from
an opposite side of the wall of the internal bore from the inner
end of the fourth flow bore. In an embodiment of the present
invention, the longitudinal axis of the third flow bore is in
parallel planar relationship to the longitudinal axis of the fourth
flow bore.
[0038] This foregoing Section is intended to describe, with
particularity, the preferred embodiments of the present invention.
It is understood that modifications to these preferred embodiments
can be made within the scope of the present claims without
departing from the true spirit of the present invention. As such,
the Section should not be construed as limiting, in any way, the
broad scope of the present invention. The present invention should
only be limited by the following claims and their legal
equivalents.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0039] FIG. 1 is side elevational view showing the frac head
apparatus of the present invention.
[0040] FIG. 2 is a cross-sectional view showing the frac head
apparatus in accordance with the teachings of the present
invention.
[0041] FIG. 3 is a cross-sectional view in a horizontal plane of
the frac head apparatus of the present invention.
[0042] FIG. 4 is a perspective view of an alternative version of
the frac head apparatus of FIG. 1 showing six fluid
connections.
[0043] FIG. 5 is a perspective view of an alternative embodiment of
the frac head apparatus of the present invention.
[0044] FIG. 6 is a cross-sectional view of the alternative
embodiment of the frac head apparatus of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0045] Referring to FIG. 1, there is shown the frac head apparatus
10 in accordance with the present invention. The frac head
apparatus 10 includes a body 12 having a flange 14 located at an
upper end thereof and a flange 16 located at a bottom end thereof.
Flow bores 18 and 20 are illustrated as formed within the body 12.
Each of the flow bores 18 and 20 includes respective fluid
connections 22 and 24. Fluid connections 22 and 24 are suitable for
connection to a fluid inlet or outlet pipe. Another accessory
component 26 is formed on the body 12 and includes an accessory
line 28 applied in bolted connection at the connector 30 thereof.
The body 12 includes an inlet 32 located at the upper end thereof
and an outlet 34 located at the bottom end thereof. Each of the
inlet 32 and the outlet 34 will communicate with an internal bore
(not shown) extending through the body 12.
[0046] The flange connections 14 and 16 are basic API-6A-type
flanged end connections that are suitable for connection to a
variety of wellhead assembly components. These components are
generally located at a very top of the wellhead Christmas tree
assembly, such as a general flanged end connection toward the top
of the wellhead's tubing head unit. These flange connections 14 and
16 can also be connected to any type of adapter or crossover-type
adapter for application toward the top side of an upper outlet bore
section of a variety of optional API-6A-type connections for use
when the wellbore is serviceably connected for specialized
operations, such as wireline injection services, snubbing-type
wellbore operations and general fracture injection practices toward
the wellbore. The top side upper inlet bore section is generally
where the blind tree cap or bottom hole test adapter tree cap will
be connectably affixed toward the frac head flow enhancement flow
system in order to provide a blind plug-type or test plug-type
service toward the upper main inlet bore section. The body 12 can
be generally equipped with any number of six flow bore chambers
that can be connectably engaged toward secondary attachable
API-6A-type connections in order to perform the inlet injection and
outlet exhaustion practices of wellbore-related fluids and
chemicals. These integrally positioned side-mounted inlet and
outlet flow bore chambers are generally comprised of API-6A-type
flanged end side studded outlets for jointable connection toward
all companion type API-6A unions and adapter.
[0047] FIG. 2 is a cross-sectional view of the frac head apparatus
10 of the present invention as taken across a vertical plane. In
FIG. 2, it can be seen that the body 12 has an internal bore 36
having an inlet 32 at the upper end thereof and an outlet 34 at a
lower end thereof. The first flow bore 18 is formed through the
body 12 so as to have an inner end 38 opening to the internal bore
36 of the body 12 and an outer end 40 opening at an outer side of
the body 12. The first flow bore 18 angles through the body 12 such
that the inner end 38 is at a level lower than a level of the outer
end 40. A second flow bore 42 (illustrated in FIG. 1 as connected
to the accessory component 26) has an inner end 44 and an outer end
46. The second flow bore 42 extends through the body 12 such that
the inner end 44 opens to the internal bore 36 of the body 12. The
inner end 44 is at a level lower than the outer end 46 of the
second flow bore 42. The accessory component 26 is illustrated as
bolted to the flange 27 associated with the second flow bore
42.
[0048] FIG. 3 also illustrates that there is a third flow bore 48
and a fourth flow bore 50 that will be positioned so as to open to
the internal bore 36 of the body 12. The third flow bore 48 and the
fourth flow bore 50 will be positioned between the first flow bore
18 and the second flow bore 42. The inner ends 38 and 44 are at
generally positioned diametrically opposite to one another within
the internal bore 36. Similarly, the third flow bore 48 and the
fourth flow bore 50 are positioned generally diametrically opposite
to each other within the internal bore 36 of the body 12.
[0049] FIG. 2 illustrates that there is a tubing string 52 that is
positioned so as to extend through the internal bore 36. The tubing
string can have a specialty tool 54 mounted thereto. The tubing
string 52 is illustrated so as to extend so as to have a lower end
extending outwardly of the lower end of the body 12.
[0050] In FIG. 2, the first flow bore 18 extends angularly through
the body 12 such that the inner end 38 is at a level lower than the
outer end 40. Similarly, the second flow bore 42 extends through
the body 12 such that the inner end 44 is at a level lower than the
outer end 46. As such, fluids can be directed downwardly from the
outer side of the body 12. The angle of the first flow bore 18 is
similar to the angle of the second flow bore 42.
[0051] In FIG. 2, it can be seen that in broken lines that there is
a zone of confluence 55 located within the internal bore 36. As
fluid is directed through the flow bores 18, 42, 48 and 50, the
flows will converge in a cyclonic manner within this zone of
confluence 55. As such, the unique effects created by the present
invention are achieved within this zone of confluence 55.
[0052] FIG. 3 illustrates the configuration of the flow bores 18,
42, 48 and 50. The flow bores 18, 42, 48 and 50 are illustrated
across a horizontal plane and illustrated in the manner in which
these flow bores will angle toward the internal bore 36 of the body
12.
[0053] In particular, the first flow bore 18 has a longitudinal
axis offset from and not intersecting the longitudinal axis 56 of
the internal bore 36. As such, a fluid flowing through the first
flow bore 18 is directed toward a wall 58 of the internal bore 36
that is offset from the opposite side of the wall 58 from the
internal bore 36. Similarly, the second flow bore 42 has a
longitudinal axis offset and not intersecting the longitudinal axis
56 of the internal bore 36 of the body 12 such that fluid passing
through the second fluid flow bore 42 is directed to the wall 58 of
the internal bore 36 offset from the opposite side of the wall 58
from the inner end 44 of the flow bore 42. The third flow bore 48
and fourth flow bore 50 will have similar configurations. As can be
seen in FIG. 3, the longitudinal axis of the first flow bore 18
will be in parallel planar relationship to the longitudinal axis of
the second flow bore 42. The longitudinal axis of the third flow
bore 48 will be in parallel planar relationship to the longitudinal
axis of the fourth flow bore 50.
[0054] FIG. 4 shows a modification 60 of the frac head apparatus 10
of FIG. 1. In FIG. 4, it can be seen that there are a total of six
(6) flow bores connected to the body 62 and extending therethrough.
Each of these flow bores 64, 66, 68, 70 and 72 will have a
configuration similar to the flow bores illustrated in FIGS. 2 and
3. As such, fluid passing through these flow bores will be directed
in a cyclonic manner into the internal cavity 74 extending through
the body 62.
[0055] FIG. 5 shows an alternative embodiment of the frac head
apparatus 80 of the present invention. In FIG. 5, it can be seen
that there is a first flow bore 82, a second flow bore 84, a third
flow bore 86 and a fourth flow bore 88. Each of the flow bores 82,
84, 86 and 88 are arranged at different levels along the side 90 of
the body 92. The body 92 will generally have the same configuration
as the body 12 (as shown in FIG. 1).
[0056] FIG. 6 illustrates that the first flow bore 82 extends at an
angle through the body 92 of the frac head apparatus 80. Similarly,
the second flow bore 84 extends at an angle through the body 92 of
the frac head apparatus 80. The inner end 94 of the first flow bore
82 is located at a level lower than the inner end 96 of the second
flow bore 84. Similarly, the inner end 98 of the third flow bore 86
is located at a lower level than the level of the inner end 100 of
the fourth flow bore 88. In FIG. 6, it can be seen that these inner
ends 94, 96, 98 and 100 are each located at different levels within
the internal bore 102 of the body 92. This arrangement of flow
bores will achieve a unique cyclonic flow path (illustrated by
broken line 104) within the internal bore 102. The various fluid
flows will encounter each other within a zone of confluence
(illustrated by broken line area 106). As such, this is a different
technique for achieving a similar cyclonic form of flow delivery of
fluids through the frac head apparatus 80.
[0057] The frac head apparatus of the present invention provides an
advanced flow process within the frac head assembly. This generates
an advanced method of high-pressure flow dynamics in order to
produce an optimal fluid flow or material flow through the use of
the injected fluid flow. The arrangement of the present invention
is capable of providing a true method of automatic vortical flow
inlet injection through a variety and any number of flow bores. As
a result, a generally cyclonic flow is achieved with vortical flow
characteristics developed at or near the center point axis of the
internal bore of the frac head apparatus.
[0058] The present invention provides a substantial service
improvement in overall lifecycle durability in the long-lasting
performance of all the components connected to the upstream flow
side of the frac head. This is the result of the fact that the
apparatus of the present invention provides for a less restrictive
flow process throughout the full flow inlet injection pathway
within the internal bore. This allows a smoother inlet injection
flow to develop which significantly reduces known damaging effects
such as abrasive and non-abrasive cavitation as well as flow line
back pressure toward the upstream accessory equipment that can be
affixed to or connected to the frac head apparatus. These upstream
components can include high-pressure triplex or quinteplex fluid
injection pumps, segmental high-pressure flow line components,
flexible hose flowlines, flow diverters, and directional flow
control manifold systems.
[0059] The cyclonic injection effect is achieved by manipulating
the standard flow bores of a traditional frac head so as to provide
a slightly offset angular degree of inlet injection so as to
generate a downwardly spiraling fluid flow at the plenum of the
internal bore. This cyclonic effect generated by the flow system of
the present invention reduces vibratory cavitation washout and
premature product failure situations toward all internal upstream
flow components or controls connected thereto. These components can
include the upstream pump's internal valve seats, drive plungers,
drive pistons, body housings, crankshafts, flow manifold end
sections, high-pressure flow line connections, connectable conduit
unions and flow line hoses.
[0060] The reduction in flow process cavitation and subsequent
pulsation dampening creates a working environment in which the
injection of high-pressure material flow can be accomplished by a
high-pressure inlet injection pump and related inlet injection pump
systems jointably connected toward a high-pressure inlet injection
pump, electronic drive systems, diesel-power drive systems, natural
gas-power drive systems, solar-powered drive systems,
secondary-power drive systems and operation control modules. One
example of such a type is a standard quinteplex-type injection pump
which operates by means of five individual direct drive pistons or
drive plungers. The operation of the present invention allows the
user to utilize, instead of such a quinteplex pump, a more
cost-effective triplex injection pump. The triplex injection pump
operates by means of only three direct drive pistons or drive
plungers in order to provide the necessary inlet pressure required
to artificially inject high-pressure oil and gas wells. The frac
head apparatus of the present invention offers the service operator
an option of alternating and/or eliminating the use of the higher
cost quinteplex-type injection pump in favor of a downsized
triplex-type injection pump. This significantly lowers the pressure
pumping operating costs and all associated downtime maintenance and
related operating costs associated with the more expensive piece of
equipment.
[0061] The present invention significantly reduces those common
destructive elements of flow processes that can prematurely destroy
the frac head's service application. The present invention develops
and promotes a less restrictive fluid flow and/or material flow
cavitation effect. As such, the present invention minimizes any
abrasive wash-out effects so as to provide for a longer-lasting
product service. This additional flow process configuration is
developed by means of altering the angular degree of inlet
injection reception of each individual flow bore by means of
offsetting the angular bore configuration of the flow bores which
is generally angularly offset from a near perpendicular alignment
of the radial internal diameter circumference of the internal bore
toward a modified development of the flow bores to any degree of
offset of the flow bores at a near equal angular proximity toward
the next sequential flow bore degree of angle which is not equally
perpendicularly aligned with the internal diameter of the internal
bore of the frac head system. This achieves a desired decrease in
visibly evidenced erosive and/or abrasive effects. The present
invention also eliminates those problems associated with
non-abrasive washout. The initial flow injection flow bores are
configured at an offset of any degree of angular offset from the
radial axis internal diameter of the internal bore in order to
first provide a means of automatically generating a cyclonic
turbine effect toward any fluids or materials injected within the
flow bores and to secondarily pre-align inlet injected fluid flow
and/or material flow elements in a manner which is of a lessening
effect with respect to cavitation and abrasive and/or non-abrasive
washout. The present invention provides a fluid flow which enhances
smooth flow dynamics within the flow bores and within the internal
bore of the system.
[0062] The frac head apparatus of present invention reduces the
forceful impacts of fluid flow and/or material flow elements by
creating a simple directional uniform angular offset of the
injection flow bores in order to develop a downward forced
injection cyclonic fluid flow toward the fluid elements that are
applied through the frac head. The angular inlet injection offset
of the flow path of the flow bores reduces destructive internal
flow cavitation, increases pulsation dampening and reduces
destructive abrasive and non-abrasive washout. When the flow bores
are configured in a spiral wound configuration, the angular offset
of the flow bores is more defined since they are each at a further
distance from one another within the spiral wound
configuration.
[0063] The frac head apparatus of the present invention can be
applied toward a service application for which material flow is
injected, such as a downhole liquefied cement injection head. Such
a cement injection head is commonly utilized to provide
artificially pressurized inlet injection and artificially
pressurized inlet injection back-filling of liquefied cement,
liquefied cement fluidous formulas or compounds, and fluidous
cement gravel pack materials into the vacant cavity developed
between the installed downhole casing string and the maximum
internal diameter of the originally-drilled wellbore in order to
establish the final installation and permanent setting of the
downhole casing string assembly.
[0064] The present invention reduces common wear, abrasive wear,
non-abrasive wear and specialized downhole tooling damage. Such
downhole tooling can include instrumentation, electronics, sensors,
data transfer devices, recorders, and hardware and software
components that are permanently installed or temporarally
positioned within the internal wellbore casing string or tubing
string. The present invention avoids such damage due to an increase
in downhole fluid flow and/or material flow pulsation dampening so
as to significantly reduce the effects of the fluid flow, the
cavitation, and the non-abrasive and abrasive washout. This
reduction of the generally damaging effects applies toward all
connectably engaged and jointably engaged wellhead components that
are surface-based and are made up either above the frac head
apparatus or mounted below the frac head apparatus. The present
invention is applicable to subsea-type wellhead assemblies and
wellbore completion operations.
[0065] The frac head apparatus of the present invention provides a
service application by way of an angular offset of the flow bores
in relation to a directionally uniform angular offset of the inlet
injection bores in order to develop a downward forced injection
spiraling cyclonic fluid flow. This downward forced spiraling
cyclonic inlet injection is enhanced by providing the near same
angular inlet injection offset of each individual internal bore of
the flow bore path angle in which each individual internal bore of
the flow bore is integrally machined within the main body housing
in order to actively effect all accessory component flowlines or
secondary conduit units. As such, these components can establish a
common straight line extension toward the flow bore in an
orientation at the same linear angle of the flow path direction.
This creates a uniform flow path relation to the internal bores so
as to develop a straight extended length of injection flow or
outlet exhaustion flow.
[0066] All secondary straight sections that are externally affixed
to the frac head apparatus provide an internal straight flow path
which is nearly equally aligned in the same linear flow path as the
internal bores of the flow bores to provide a greater internal flow
path length section. This helps to develop an optimal performance
toward the spiral wound cyclonic flow path.
[0067] The foregoing disclosure and description of the invention is
illustrative and explanatory thereof. Various changes in the
details of the illustrated construction can be made within the
scope of the appended claims without departing from the true spirit
of the invention. The present invention should only be limited by
the following claims and their legal equivalents.
* * * * *