U.S. patent application number 17/735584 was filed with the patent office on 2022-08-18 for flow diverter.
This patent application is currently assigned to OIL STATES ENERGY SERVICES, L.L.C.. The applicant listed for this patent is OIL STATES ENERGY SERVICES, L.L.C.. Invention is credited to Mickey Claxton, Darin Grassmann, Bob McGuire, Richard Brian Sizemore.
Application Number | 20220259963 17/735584 |
Document ID | / |
Family ID | |
Filed Date | 2022-08-18 |
United States Patent
Application |
20220259963 |
Kind Code |
A1 |
Sizemore; Richard Brian ; et
al. |
August 18, 2022 |
FLOW DIVERTER
Abstract
A flow diverter comprises a surface to divert fluid flow within
oil and gas wellbore equipment exposed to flows of abrasive,
corrosive, or otherwise deleterious fluids, such as those used in
hydraulic fracturing. The diverter may comprise a concave surface
used to limit damage to surfaces within components used to connect
a frac manifold to a frac tree or to prevent the flow of fracturing
fluid from a frac manifold to a frac tree.
Inventors: |
Sizemore; Richard Brian;
(White Oak, TX) ; McGuire; Bob; (Meridian, OK)
; Grassmann; Darin; (Piedmont, OK) ; Claxton;
Mickey; (Tuttle, OK) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
OIL STATES ENERGY SERVICES, L.L.C. |
Houston |
TX |
US |
|
|
Assignee: |
OIL STATES ENERGY SERVICES,
L.L.C.
Houston
TX
|
Appl. No.: |
17/735584 |
Filed: |
May 3, 2022 |
Related U.S. Patent Documents
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Application
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Filing Date |
Patent Number |
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17376252 |
Jul 15, 2021 |
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17735584 |
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16702301 |
Dec 3, 2019 |
11091993 |
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17376252 |
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16443689 |
Jun 17, 2019 |
11118927 |
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16702301 |
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17086916 |
Nov 2, 2020 |
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16443689 |
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16850414 |
Apr 16, 2020 |
10895139 |
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17086916 |
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62838026 |
Apr 24, 2019 |
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International
Class: |
E21B 43/26 20060101
E21B043/26; F17D 5/00 20060101 F17D005/00; E21B 43/267 20060101
E21B043/267; G05D 7/06 20060101 G05D007/06 |
Claims
1. A flow component comprising: a conduit comprising a central
longitudinal axis; a first surface substantially orthogonal to the
central longitudinal axis; a flow diverter comprising a second
surface configured to divert fluid flowing through the conduit to
flow in a first direction which is not along the central
longitudinal axis.
2. The flow component of claim 1, wherein the second surface is
concave.
3. The flow component of claim 2, wherein the second surface is
substantially conical.
4. The flow component of claim 1, wherein the second surface is
convex.
5. The flow component of claim 1, wherein the first surface
comprises the inner surface of a blind flange upon which the flow
diverter is mounted.
6. The flow component of claim 1, wherein the first surface
comprises the lower end of a mandrel.
7. The flow component of claim 1, wherein the flow diverter further
comprises a third surface configured to divert fluid flowing
through the conduit to flow in a second direction which is
different from the first direction and not along the central
longitudinal axis.
8. The flow component of claim 7, wherein the second surface and
the third surface are both concave.
Description
TECHNICAL FIELD
[0001] The present disclosure relates generally to oil or gas
wellbore equipment, and, more particularly, to a flow diverter
which may be used in conjunction with components exposed to flows
of abrasive, corrosive, or otherwise deleterious fluids, such as
those used in hydraulic fracturing.
BACKGROUND
[0002] Within the field of oil and gas exploration and production,
there are many applications in which abrasive or corrosive fluids
must be moved from one point to another. These substances are often
transported through components manufactured using carbon steel or
other materials that may be particularly susceptible to being
damaged by certain types of fluids. The risk of damage is generally
increased if there are particular surfaces within a flow conduit
which are orthogonal to the direction of flow within another
portion of the conduit.
[0003] Further, abrasive or corrosive fluids may be transported
under high-pressure and/or high-velocity conditions, which can
increase the risks of damage to the components through which the
fluids are flowing. The risk of damage may be further increased if
the components through which the fluids are flowing are configured
such that turbulent flow is created within the flow conduits. In
addition, certain components disposed within fluid conduits, such
as elastomeric seals may be particularly susceptible to being
damaged by abrasive or corrosive fluids.
[0004] For all these reasons, when transporting fluids that are
abrasive, corrosive, or otherwise deleterious, it may be
advantageous to divert the flow of such fluids in order to decrease
velocity, reduce turbulence, limit the instances of surfaces being
impacted by orthogonal fluid flow, and/or prevent or reduce contact
between the fluids and particularly fragile or sensitive
components.
[0005] One particular application involving the transport of
abrasive, corrosive, or otherwise deleterious fluids is hydraulic
fracturing performed as part of the process of producing oil and
gas from an underground formation. For example, frac manifolds,
also referred to herein as zipper manifolds, are designed to allow
hydraulic fracturing operations on multiple wells using a single
frac pump output source. Frac manifolds are positioned between the
frac pump output and frac trees of individual wells. A frac
manifold system receives fracturing fluid from the pump output and
directs it to one of many frac trees. Fracturing fluid flow is
traditionally controlled by operating valves to isolate output to a
single tree for fracking operations.
[0006] Frac zipper manifolds may be rigged up to frac trees before
frac equipment arrives at the well site. Once onsite, the frac
equipment need only be connected to the input of the frac manifold.
Because individual frac trees do not need to be rigged up and down
for each fracking stage and because the same frac equipment can be
used for fracking operations on multiple wells, zipper manifolds
reduce downtime for fracking operations while also increasing
safety and productivity. Another benefit includes reducing
equipment clutter at a well site.
[0007] Despite their benefits, further efficiencies and cost
savings for zipper manifolds may be gained through improved
designs. In particular, typically treatment fluid in the zipper
manifold passes to frac trees via goat heads or frac heads and frac
iron, but there are several drawbacks to using such setups to span
the distance between the zipper manifold and each frac tree. Goat
heads, or frac heads, traditionally employ multiple downlines and
restraints that clutter the area between the zipper manifold and
the frac tree, which can make for a more difficult and less safe
work environment to operate and maintain the frac equipment.
[0008] Some designs have been developed to avoid using frac iron.
One design uses a single line made from studded elbow blocks and
flow spools with swiveling flanges. Such a design is disclosed in,
for example, U.S. Pat. Nos. 9,932,800, 9,518,430, and 9,068,450. A
similar design is currently offered for sale by Cameron
International of Houston, Tex., under the brand name Monoline. One
drawback of this design is that the weight of the equipment
combined with the potentially awkward orientation of the lines can
make installation difficult and can place uneven or increased
stress on the connections to the frac manifold and/or the frac
tree. Another drawback is that using a single line to connect the
frac manifold to the frac tree can lead to increased velocity and
turbulence of the flow, when compared to using multiple lines. Such
conditions may lead to a greater risk of erosion in the frac tree.
Replacing a damaged frac tree can be very expensive and
time-consuming.
[0009] Due to the velocity and turbulence of flow within the
components used to connect a frac manifold to a frac tree, this is
an application in which the use of a flow diverter may be
particularly advantageous. Such use of a flow diverter is explained
below in greater detail, and also in U.S. Pat. No. 11,091,993 to
Sizemore, et al. The Sizemore '993 patent is hereby incorporated by
reference, particularly with respect to its discussion of flow
diverter 300 as shown in FIGS. 6A, 6B and 8, and flow diverter 310
as shown in FIGS. 7A-8.
[0010] Similarly, a flow diverter may be used in a device intended
to prevent the flow of fracturing fluid from a frac manifold to a
frac tree. Such use of a flow diverter is explained below in
greater detail, and also in US Patent Publication No. 2021/0047907
to Sizemore, et al. The Sizemore '907 application is hereby
incorporated by reference, particularly with respect to its
discussion of compression member 1700 as shown in FIGS. 13-15.
SUMMARY OF THE INVENTION
[0011] Within the interior of flow components, particularly those
used in hydraulic fracturing operations, a diverter is used to
redirect the flow of fluids that may be abrasive, corrosive, or
otherwise deleterious. The diverter comprises a surface that is
oblique in relation to the central longitudinal axis of the
adjacent flow component. The surface of the diverter may be
generally concave. The use of the flow diverter may decrease
velocity, reduce turbulence, and limit the instances of interior
surfaces of the flow component being impacted by orthogonal fluid
flow
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Various embodiments of the present disclosure will be
understood more fully from the detailed description given below and
from the accompanying drawings of various embodiments of the
disclosure. In the drawings, like reference numbers may indicate
identical or functionally similar elements.
[0013] FIG. 1 illustrates one embodiment of a dual spool connection
from a zipper manifold to a frac tree.
[0014] FIG. 2 illustrates a dual spool connection including three
flow diverters mounted on blind flanges.
[0015] FIGS. 3A-3B illustrate the bi-directional flow diverter
shown in FIG. 2.
[0016] FIGS. 4A-4B illustrate the uni-directional flow diverter
shown in FIG. 2.
[0017] FIG. 5 illustrates a frac manifold isolation tool including
a bottom surface comprising a flow diverter.
[0018] FIG. 6 illustrates the omni-directional flow diverter shown
in FIG. 5.
[0019] FIG. 7 illustrates the frac manifold isolation tool of FIG.
5 after the cup tool and flow diverter have been moved into the
operative position.
DETAILED DESCRIPTION
[0020] FIG. 1 illustrates an exemplary embodiment of a well
configuration unit 210 with a bridge connector header 230. The
bridge connector header 230, which connects to a frac tree, forms a
"T" junction 215 with a short spool 238a extending upward from
valve 102a and 102b, and two additional short spools 238b extending
from either side of bridge connector header 230.
[0021] The T-junction 215 of the bridge connector header 230
connects to two studded blocks 250. Each studded block 250 joins to
a bridge spool 255 that connects similarly to studded blocks 250
and a frac tree header 270 on the frac tree 290.
[0022] Fluid flowing through short spool 238a is traveling along
the y-axis, as shown in FIG. 1. The T-junction 215 formed by bridge
connector header 230 splits the fluid flow into two streams, each
of which travel along the z-axis to one the two studded blocks 250.
Because the y-axis is orthogonal to the z-axis, the flow has a
tendency to become turbulent as it shifts from the y-axis to the
z-axis. This turbulence, as well as other dynamic flow
characteristics of this configuration, can lead to increased
erosion and premature failure of bridge connector header 230 and
short spools 238b. In addition, if fluid flows straight through
bridge connector header 230 such that it orthogonally impacts the
inner surface of blind flange 236, that surface will be
particularly susceptible to erosion.
[0023] Referring to FIG. 3A, flow diverter 300 may be mounted on
blind flange 236. As shown in FIG. 2, flow diverter 300 extends
downward from blind flange 236, such that it is disposed within the
flow of fracturing fluid from short spool 238a. Flow diverter 300
may be generally cylindrical with diverting surfaces 302 and 304.
In this configuration, the central axis of flow diverter 300 may be
substantially aligned with the central axis of short spool 238a,
which is coincident with the y-axis. Diverting surfaces 302 and 304
may be curvilinear and are preferably concave, as shown in FIG. 3B.
Alternatively, diverting surfaces 302 and/or 304 may be convex,
planar, or any other configuration, provided that the surfaces
divert the fluid flowing through short spool 238a to travel in a
direction other than along the y-axis. This redirection may
decrease the turbulence of the flow as it shifts from the y-axis to
the z-axis, and thus decrease the erosion of bridge connection
header 230 and short spools 238b.
[0024] Studded blocks 250 are elbow-shaped to redirect the flow
streams from the z-axis to the x-axis, which is coaxial with bridge
spools 255. The frac fluid travels through the bridge spools 255 to
the studded blocks 250 on the frac tree side, and the two flows are
rejoined at the frac tree header 270 of the frac tree 200. Although
splitting the flow into two streams results in lower velocities and
reduced turbulence within frac tree 200, the interior surfaces of
studded blocks 250 are still subject to significant risks of
erosion.
[0025] Referring now to FIG. 4A-4B, either or both blind flange 240
may include flow diverter 310, with diverting surface 312. Flow
diverter 310 may be generally cylindrical with a central axis along
the z-axis, as shown in FIG. 4A. Diverting surface 312 may be
curvilinear and is preferably concave. Alternatively, diverting
surface 312 may be convex, planar, or any other configuration,
provided that the surface diverts the fluid flowing through short
spools 238b to travel in a direction other than along the z-axis.
This redirection may decrease the turbulence of the flow as it
shifts from the z-axis to the x-axis, and thus decrease the erosion
of studded blocks 250.
[0026] Although flow diverters 300 and 310 may also experience
erosion, replacement of blind flanges 236 and 240 is much easier
and less expensive than replacing bridge connector header 230,
short spools 238b, and/or studded blocks 250.
[0027] It will be understood by one of ordinary skill in the art
that the placement and configuration of diverters 300 and 310 is
exemplary and illustrative only. Flow diverters could also be
placed within frac tree 290 or at any other location within the
dual spool connection disclosed herein or other similar components
which may be used for the flow of abrasive, corrosive, or otherwise
deleterious fluids.
[0028] As one additional exemplary embodiment, as explained in
greater detail in the Sizemore '907 application, valves 102a and
102b shown in FIG. 1 of the present application may be replaced
with a frac manifold isolation tool. One exemplary embodiment of
such a tool is well configuration unit 1210, as shown in FIG. 5-7.
Well configuration unit 1210 may comprise two concentric mandrels,
an inner 1255 and an outer 1250. Inner mandrel 1255 comprises a
lower end which is connected to compression member 1700.
[0029] As described in further detail below, the two mandrels 1255
and 1250 are moved together by the setting cylinders 1220 and 1225
to position the cup tool 1260 at the pack off location below bridge
connector header 1230, as shown in FIG. 7.
[0030] The inner mandrel 1255 can be moved independently of the
outer mandrel 1250 by a second hydraulic setting tool 1625. Second
hydraulic setting tool 1625 comprises hydraulic cylinders 1630 and
1635, which are connected to upper plate 1640. Hydraulic cylinders
1630 and 1635 comprise outer housings 1628 and 1629 respectively,
which are connected to upper plate 1640. Hydraulic cylinders 1630
and 1635 also comprise rods 1626 and 1627 respectively. Rods 1626
and 1627 each comprise a lower end, each of which is connected to
lower plate 1245.
[0031] In operation, improved well configuration unit 1210 begins
in the position shown in FIG. 5, with cup tool 1260 located above
bridge connector header 1230. In this position, fluid is free to
flow through bridge connector header 1230. The position of the cup
tool is shown in more detail in FIG. 6.
[0032] When the operator desires to seal bridge connector header
1230, hydraulic fluid is injected into the upper portion of
hydraulic setting cylinders 1220 and 1225, thereby forcing rods
1222 and 1227 downward. Due to the connection between rods 1222 and
1227 and lower plate 1245, as well as the connection between lower
plate 1245 and mandrel head 1251, the downward movement of rods
1222 and 1227 causes outer mandrel 1250 to move downward through
bridge connector 1230 and into lower spool 1240 to the point that
cup tool 1260 is located below the "T" junction of bridge connector
header 1230 as shown in FIG. 7. In addition, due to the connection
between rods 1626 and 1627 and upper plate 1640, inner mandrel 1255
and compression member 1700 also move downward towards lower spool
1240.
[0033] Once the cup tool 1260 has been positioned at the pack-off
location, and the operator desires to engage seals 1265, hydraulic
cylinders 1630 and 1635 are pressurized such that rods 1626 and
1627 move upwards, or away from the cup tool 1260, which causes the
inner mandrel 1255 to move upward relative to the outer mandrel
1250. When this happens, upper surface 1703 of compression member
1700 contacts the lower surface of gage ring 1261 of cup tool 1260.
Because the upper surface of gage ring 1261 contacts seals 1265,
continued upward movement of inner mandrel 1255 and compression
member 1700 causes gage ring 1261 to compress seals 1265, with the
result that seals 1265 are extruded outward and form a seal within
lower spool 1240 and/or the inner surface of bridge connector
1230.
[0034] Compression member 1700 comprises concave lower surfaces
1701 and 1702, which may serve to divert high-pressure flow and
protect the integrity of seals 1265. Lower surfaces 1701 and 1702
may also be convex, planar, or any other configuration, provided
that the surface(s) divert the fluid flowing through lower spool
1240 and/or bridge connector 1230 to travel in a direction other
than along their common central axis A. The lower surface of
compression member 1700 may also comprise more or less than two
diverting surfaces. For example, lower surfaces 1701 and 1702 may
comprise portions of a flow diverter that is generally conical,
such that it comprises one continuous diverting surface. In such a
configuration, the generally conical diverting surface may also be
concave, convex, planar, or any other configuration.
[0035] It is understood that variations may be made in the
foregoing without departing from the scope of the present
disclosure. In several exemplary embodiments, the elements and
teachings of the various illustrative exemplary embodiments may be
combined in whole or in part in some or all of the illustrative
exemplary embodiments. In addition, one or more of the elements and
teachings of the various illustrative exemplary embodiments may be
omitted, at least in part, and/or combined, at least in part, with
one or more of the other elements and teachings of the various
illustrative embodiments.
[0036] Any spatial references, such as, for example, "upper,"
"lower," "above," "below," "between," "bottom," "vertical,"
"horizontal," "angular," "upwards," "downwards," "side-to-side,"
"left-to-right," "right-to-left," "top-to-bottom," "bottom-to-top,"
"top," "bottom," "bottom-up," "top-down," etc., are for the purpose
of illustration only and do not limit the specific orientation or
location of the structure described above.
[0037] In several exemplary embodiments, while different steps,
processes, and procedures are described as appearing as distinct
acts, one or more of the steps, one or more of the processes,
and/or one or more of the procedures may also be performed in
different orders, simultaneously and/or sequentially. In several
exemplary embodiments, the steps, processes, and/or procedures may
be merged into one or more steps, processes and/or procedures.
[0038] In several exemplary embodiments, one or more of the
operational steps in each embodiment may be omitted. Moreover, in
some instances, some features of the present disclosure may be
employed without a corresponding use of the other features.
Moreover, one or more of the above-described embodiments and/or
variations may be combined in whole or in part with any one or more
of the other above-described embodiments and/or variations.
[0039] Although several exemplary embodiments have been described
in detail above, the embodiments described are exemplary only and
are not limiting, and those skilled in the art will readily
appreciate that many other modifications, changes and/or
substitutions are possible in the exemplary embodiments without
materially departing from the novel teachings and advantages of the
present disclosure. Accordingly, all such modifications, changes,
and/or substitutions are intended to be included within the scope
of this disclosure as defined in the following claims. In the
claims, any means-plus-function clauses are intended to cover the
structures described herein as performing the recited function and
not only structural equivalents, but also equivalent structures.
Moreover, it is the express intention of the applicant not to
invoke 35 U.S.C. .sctn. 112, paragraph 6 for any limitations of any
of the claims herein, except for those in which the claim expressly
uses the word "means" together with an associated function.
* * * * *