U.S. patent application number 17/839901 was filed with the patent office on 2022-09-29 for frac manifold isolation tool.
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 Danny Artherholt, Mickey Claxton, Darin Grassmann, Jimmy Livingston, Bob McGuire, Haifang Zhao.
Application Number | 20220307362 17/839901 |
Document ID | / |
Family ID | 1000006394983 |
Filed Date | 2022-09-29 |
United States Patent
Application |
20220307362 |
Kind Code |
A1 |
Livingston; Jimmy ; et
al. |
September 29, 2022 |
FRAC MANIFOLD ISOLATION TOOL
Abstract
A frac manifold isolation tool configured to connect to a zipper
spool, and comprising a mandrel that is axially movable and a
hydraulic setting tool configured to move the mandrel from an open
position, in which fracturing fluid is allowed to flow from a
zipper spool to a connected frac tree, to a closed position, in
which the mandrel and its associated cup tool direct flow.
Inventors: |
Livingston; Jimmy; (Manvel,
TX) ; Zhao; Haifang; (Katy, TX) ; McGuire;
Bob; (Meridian, OK) ; Claxton; Mickey;
(Tuttle, OK) ; Artherholt; Danny; (Asher, OK)
; Grassmann; Darin; (Piedmont, 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
|
Family ID: |
1000006394983 |
Appl. No.: |
17/839901 |
Filed: |
June 14, 2022 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16984453 |
Aug 4, 2020 |
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17839901 |
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16850414 |
Apr 16, 2020 |
10895139 |
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16984453 |
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62838026 |
Apr 24, 2019 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E21B 43/2607
20200501 |
International
Class: |
E21B 43/26 20060101
E21B043/26 |
Claims
1. A zipper manifold comprising two or more well configuration
units, wherein one or more well configuration units comprises: a
bridge connector header comprising a throughbore and a bore in
fluid communication with the throughbore; a first mandrel
comprising a first end, a second end, and a generally tubular
member with an outer surface and a throughbore; a cup tool
proximate to the second end of the first mandrel and adapted to
sealingly engage, at a pack-off location, an inner portion of the
well configuration unit located below the bore of the bridge
connector header; one or more first hydraulic setting cylinders
configured to axially move the first mandrel through the
throughbore to position the first mandrel and cup tool at the
pack-off location.
2. The zipper manifold of claim 1, wherein the cup tool comprises a
first seal assembly configured to seal within the inner portion of
the well configuration unit.
3. The zipper manifold of claim 2, wherein the cup tool comprises a
first piston configured to energize the first seal assembly.
4. The zipper manifold of claim 3, wherein the cup tool comprises a
first actuator configured to direct a fluid flow to the first
piston.
5. The zipper manifold of claim 1, wherein the cup tool comprises a
first seal assembly and a second seal assembly, the seal assemblies
configured to seal within the inner portion of the well
configuration unit.
6. The zipper manifold of claim 5, wherein the cup tool comprises a
first piston configured to energize the first seal assembly and a
second piston configured to energize the second seal assembly.
7. The zipper manifold of claim 6, wherein the cup tool comprises a
first actuator configured to direct a fluid flow to the first
piston and a second actuator configured to direct the fluid flow to
the second piston.
8. The zipper manifold of claim 3, wherein the first piston is an
internal beveled piston.
9. The zipper manifold of claim 3, wherein the first piston is an
external beveled piston.
Description
TECHNICAL FIELD
[0001] The present disclosure relates generally to oil or gas
wellbore equipment, and, more particularly, to a frac manifold.
BACKGROUND
[0002] 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 controlled by operating valves to isolate
output to a single tree for fracking operations.
[0003] 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.
[0004] Despite their benefits, further efficiencies and cost
savings for zipper manifolds may be gained through improved
designs. In particular, the valves that have traditionally been
used to control the flow of fracturing fluid to individual trees
are expensive and greatly increase the cost of using a zipper
manifold. With multiple valves required for each frac tree, when a
zipper manifold is arranged to connect to several adjacent wells,
the cost of the valves can easily be several hundred thousand
dollars. Accordingly, what is needed is an apparatus, system, or
method that addresses one or more of the foregoing issues related
to frac zipper manifolds, among one or more other issues.
SUMMARY OF THE INVENTION
[0005] The frac manifold isolation tool uses one or more mandrels
that may be hydraulically positioned to control frac fluid flow to
one or more outputs of the manifold. When the mandrel is in the
open position, frac fluid is able to flow to a bridge that is
connected to a frac tree or wellhead, and the connected well can be
fracked. When in the closed position, the mandrel stops flow to the
bridge. With this design, the mandrel can serve to replace or
reduce the number of valves that would otherwise control fluid in
the manifold, thus making the use of a frac manifold much less
expensive and more efficient.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] 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.
[0007] FIG. 1 illustrates a zipper manifold as known in the prior
art.
[0008] FIG. 2 illustrates an improved zipper manifold with a
mandrel in the open position.
[0009] FIG. 3 illustrates an improved zipper manifold with a
mandrel in the closed position.
[0010] FIG. 4 illustrates an improved zipper manifold with a
hydraulic setting cylinder.
[0011] FIG. 5 is an enlarged view of a mandrel cup tool.
[0012] FIG. 6 illustrates an embodiment of a hydraulic setting
cylinder with two mandrels and stay rods.
[0013] FIG. 7 illustrates an embodiment of a hydraulic setting
cylinder with two mandrels and stay rods.
[0014] FIG. 8 illustrates an embodiment of a hydraulic setting
cylinder with two mandrels.
[0015] FIG. 9 illustrates an embodiment of a lock mechanism in the
unlocked position.
[0016] FIG. 10 illustrates a lock mechanism in the locked
position.
[0017] FIG. 11 illustrates a lock mechanism with a linear
actuator.
[0018] FIG. 12 illustrates an alternative embodiment of an improved
zipper manifold.
[0019] FIG. 13 illustrates the embodiment of FIG. 12 with the
mandrel in the open position.
[0020] FIG. 14 is an enlarged view of the bottom portion of the
mandrel shown in FIG. 13.
[0021] FIG. 15 illustrates the embodiment of FIG. 12 with the
mandrel in the closed position, after the seal is set.
[0022] FIG. 16 illustrates a top view of the lock mechanism shown
in FIG. 10.
[0023] FIG. 17 illustrates the position of an upper locking ring
when the mandrel is in the closed position, but prior to the seal
being set.
[0024] FIG. 18 illustrates the position of an upper locking ring
when the mandrel is in the closed position and the seal has been
set.
[0025] FIG. 19 illustrates an improved zipper manifold with a
mandrel in an open position
[0026] FIG. 20 illustrates an improved zipper manifold with a
mandrel in a closed position.
[0027] FIG. 21A is an enlarged view of the improved cup tool shown
in FIG. 19.
[0028] FIG. 21 B is the cup tool shown in FIG. 19 with energized
seal assemblies.
[0029] FIG. 22A illustrates a improved cup tool with a single seal
assembly.
[0030] FIG. 22 B illustrates the improved cup tool in FIG. 22A with
the energized seal assembly.
[0031] FIG. 23A illustrates a improved cup tool with dual actuation
and a dual seal assembly.
[0032] FIG. 23 B illustrates the improved cup tool in FIG. 23A with
the energized seal assemblies.
[0033] FIG. 24A illustrates a improved cup tool with dual actuation
and a dual seal assembly with an external beveled piston.
[0034] FIG. 24 B illustrates the improved cup tool in FIG. 24A with
the energized seal assemblies.
DETAILED DESCRIPTION
[0035] FIG. 1 illustrates an example of a prior art zipper manifold
100. The manifold may be positioned vertically, as shown in FIG. 1,
or it may be positioned horizontally. The frac manifold 100 can
include two or more well configuration units 101. Each well
configuration unit 101 includes one or more valves 102 and a bridge
connector header 103, and the well configuration units 101 may be
collectively or individually (as shown) positioned on skids 106.
Each bridge connector header 103 connects to a frac tree. As shown
in FIG. 1, each well configuration unit 101 typically includes a
hydraulically actuated valve 102a and a manually actuated valve
102b. The well configuration units 101 of the zipper manifold 100
are connected together by zipper spools 104, and the final zipper
spool 104 may be capped off or connected to other well
configurations 101 as needed. The zipper manifold 100 connects to
the output of the frac pump at the frac supply header 105.
[0036] The bridge connector head 103 connects to the frac head of a
frac tree. In operation, the valves 102 of one well configuration
unit 101 are opened to allow fluid flow to the corresponding frac
tree through its bridge connector 103 while the valves 102 of other
well configuration units 101 in the zipper manifold 100 are closed.
The valves 102 may be closed and opened to control the flow to
different well configuration units 101 of the zipper manifold
100.
[0037] FIG. 2 illustrates an exemplary embodiment of an improved
well configuration unit 210. Improved well configuration unit 210
includes a hydraulic setting cylinder 220 (as shown in FIG. 4)
connected to a mandrel 250. The bridge connector header 230, which
connects to a frac tree, comprises a horizontal throughbore 225, as
well as an axial throughbore 235 which forms a "T" junction by
connecting to a lower bore, such as that shown within lower spool
240. It is not necessary that bridge connector header 230 include
two throughbores. For example, bridge connector header 230 may
comprise only a portion 225a of bore 225, and not portion 225b, or
vice versa. All that is required is a throughbore 235 to provide an
inlet allowing fluid to flow into bridge connector header 230 and a
second bore, such as 225a or 225b, to provide an outlet for fluid
to flow out of bridge connector header 230.
[0038] The hydraulic setting cylinder 220 actuates a mandrel 250
that moves within throughbore 235 and axially in line with the
lower bore, e.g., lower spool 240. In the embodiment shown in FIG.
2, as described in more detail below, the hydraulic setting
cylinder 220 and mandrel 250 are used in place of valves in the
well configuration unit 210. In another embodiment, valves (whether
manually or hydraulically actuated) may be used in conjunction with
the hydraulic setting cylinder 220 and mandrel 250 in a well
configuration unit 210 to control fluid flow.
[0039] Two or more well configuration units 210 are used in a
zipper manifold to provide connectivity and fluid control to
multiple frac trees and wells. Improved well configuration units
210 are fluidly connected through zipper spools 104 along the
zipper manifold. A frac supply header 105 (similar to that shown in
FIG. 1) provides fluid connectivity from the frac pump to the
zipper manifold and zipper spools 104.
[0040] The hydraulic setting cylinder 220 moves the mandrel 250
into two primary positions. When the well configuration unit 210 is
in the open position, which is shown in FIG. 2, the cup 260 of the
mandrel 250 sits above bridge connector header 230, which allows
fluid to flow from the zipper spool 104, through the lower spool
240, and through the "T" junction of the bridge connector header
230 to the connected bridge and frac tree. The mandrel 250 is solid
at the cup 260 such that fluid does not flow through the mandrel
250. The cup 260 includes one or more seals 265, such as o-rings,
that are able to form a seal against an inner spool above the "T"
junction of the bridge connector header 230 and prevent pressure
leaks and fluid flow around the cup 260 and to the hydraulic
setting cylinder 220.
[0041] In the closed position, which is shown in FIG. 3, the
hydraulic setting cylinder 220 may move the mandrel 250 through the
"T" junction of the bridge connector header 230, such that the cup
260 of the mandrel 250 will seat at a location below the "T"
junction. As shown in FIG. 3, the cup 260 may optionally seal
within lower spool 240, where seals 265 form a seal against the
lower spool's 240 inner surface, which is preferably corrosion
resistant. Alternatively, some or all of cup 260 may form a seal
with the inner surface of bridge connector header 230, as long as
the seal is formed below the "T" junction. When the mandrel 250 is
in the closed position and a seal has been formed at a location
below the junction of bridge connector header 230, fluid cannot
flow past the cup 260 to the bridge connection header 230.
[0042] In an embodiment, which is shown in FIGS. 2 and 3, the inner
diameter of the lower spool 240 and lower portion of bridge
connector 230 is consistent, and the mandrel 250 is stroked to a
location far enough down below the "T" junction of bridge connector
header 230 to allow mandrel cup 260 to seal. The mandrel cup seals
265 may form a seal with the inner surface of the lower spool 240
and/or the inner surface of bridge connector 230 when the mandrel
cup 260 is axially compressed and the seals 265 extrude radially
outward. The mandrel cup 260 will axially compress when the
pressure below the mandrel cup 260 sufficiently exceeds the
pressure above it, or in other words, when the pressure
differential exceeds a particular threshold. The mandrel 250 is
preferably moved from one position to another only when a seal has
not been formed to avoid damaging the sealing elements. Thus,
before the mandrel 260 is moved, the pressure above and below the
mandrel cup 260 may be equalized, which will decompress the mandrel
cup 260 and disengage the seals 265 from the inner surface of the
spool.
[0043] In an embodiment, the mandrel cup 260 may be actuated to
seat at or near an inner shoulder on the inner surface of the lower
spool 240. In an embodiment, the inner shoulder serves as a
physical stop for the actuation of the hydraulic setting cylinder
220, and the inner shoulder itself may be used as a stop against
which to compress the mandrel cup 260, such that it forms a seal
with the inner surface of the lower spool 240.
[0044] In an embodiment, the mandrel 250 may include one or more
locking mechanisms. FIG. 4 illustrates an example of a hydraulic
setting cylinder 220 that is connected on top of the bridge
connection header 230. The hydraulic setting cylinder 220 includes
a mandrel lock 270. The mandrel lock 270 accommodates a lock pin
280 that may be actuated by a second hydraulic cylinder (not
shown). After the mandrel 250 has been stroked down to allow
mandrel cup 260 to seal in the lower spool 240 and/or the inner
surface of bridge connector header 230, the lock pin can be
actuated into mandrel lock 270 to mechanically fix the mandrel 250
into position. Other types of locking mechanisms may also be used,
such as cams, dogs, or wing nuts.
[0045] The hydraulic setting cylinder 220 may be electronically
controlled to actuate the mandrel 250. Similarly, the back-up
mechanism, such as lock pin and mandrel lock 270 system, may also
be actuated electronically or pneumatically. In this way, the flow
paths within the zipper manifold 220 may be opened and closed
remotely, thus enhancing worker safety. As described above, in an
embodiment, manually actuated valves may also be used as an
alternative or a backup to the hydraulically actuated cylinder
220.
[0046] FIG. 5 illustrates a close up view of an exemplary sealing
configuration for a mandrel cup tool 260. Cup tool 260 has o-rings
265 and plates 266, which act as pack off seals with the inner
surface of the spools when the mandrel 250 is either above or below
the bridge header connection 230.
[0047] FIGS. 6-8 show embodiments in which the mandrel system
actuated by the hydraulic setting cylinder 620 may be a dual
mandrel system. In the dual mandrel system, two concentric
mandrels, an inner 645 and an outer 640, are used. The two mandrels
640 and 645 are moved together by the hydraulic setting cylinder
620 to position the mandrel cup tool 260 at the pack off location
in either the open or closed position. The inner mandrel 645 can be
moved independently of the outer mandrel 640 by a second hydraulic
setting tool 625. Once the mandrel cup tool 260 has been positioned
at the pack off location, the second hydraulic cylinder 625 is
pressurized to move upwards, or away from the mandrel cup tool 260,
which causes the inner mandrel 645 to move upward relative to the
outer mandrel 640. The inner mandrel 645 is connected to one end of
the mandrel cup tool 260 while the outer mandrel 640 is connected
to the other. The upward movement of the inner mandrel 645 relative
to the outer mandrel 640 causes the mandrel cup tool 260 to be
compressed and the seals 265 to be extruded and form a seal at the
pack off location.
[0048] FIG. 6 shows an embodiment in which the lock mechanism 670
is relatively close to the pack off location where the mandrel cup
260 will be positioned. The stay rods 690 provide access to the
lock mechanism 670 and the packing boxes 622 and 624, but also
increase the well configuration unit's overall height. The packing
box 622 seals between the outer mandrel 640 and the flange 623 to
prevent pressurized fluid from leaking out of the well
configuration unit. Similarly, the packing box 624 provides a seal
between the outer mandrel 640 and the hydraulic cylinder 620 to
contain the pressurized fluid within the hydraulic cylinder 620.
The stay rods 695 maintain the position of the inner mandrel 645
relative to the outer mandrel 640 and provide access to the packing
boxes 626 and 628.
[0049] FIG. 7 shows an embodiment in which the lock mechanism 670
is positioned above the first hydraulic cylinder 620. The stay rods
690 and 695 are able to be shortened relative to those shown in
FIG. 6, but still allow access to the packing boxes 622 and
624.
[0050] FIG. 8 illustrates an embodiment which does not use stay
rods. Once a seal has been formed at the mandrel cup tool 260, the
relative position of the inner mandrel 645 to the outer mandrel 625
may be fixed by a second lock mechanism 625 so that the seal is
maintained. When the mandrel system needs to be moved again, from
one position to another, the second lock mechanism is unlocked so
that the inner and outer mandrels are able to move relative to each
other. The inner and outer mandrels are moved relative to each
other such that the sealing element does not form a seal against
the spool, and then the mandrels may be moved together to the open
or closed position.
[0051] FIGS. 9-11 illustrate an exemplary lock mechanism 900. The
lock mechanism 900 may comprise a plate 905 which comprises slots
910. The slots 910 are positioned near the outer circumference of
plate 905 and radially extend inward/outward, such that the radial
distance from one end of the slot to the center of the plate 905 is
different than the radial distance from the other end of the slot
to the center of the plate 905. Pins 915 are engaged in the slots
910. Each pin 915 is connected to a lock segment 920, such that
when the pins 915 travel along the slots 910, the change in radial
distance for the pins 915 causes the lock segments 920 to
correspondingly constrict or enlarge in inner circumference. The
lock segments 920 circumscribe a mandrel, which is not shown in
FIGS. 9-11. When the lock segments 920 are constricted, they engage
the mandrel and lock it in place. The plate 905 can be rotated to
cause the lock segments 920 to lock or unlock.
[0052] FIG. 9 illustrates the lock mechanism 900 in an unlocked
position, FIG. 10 illustrates the lock mechanism 900 in a locked
position. FIG. 11 illustrates that a linear actuator may be used to
rotate the plate 905 to lock and unlock the lock mechanism. FIG. 11
further illustrates a second lock mechanism 940, which may be
similarly locked or unlocked using a linear actuator. FIG. 16
illustrates a top view of lock mechanism 900 in a locked
position.
[0053] FIG. 12 illustrates an alternative embodiment of an improved
well configuration unit 1210. Improved well configuration unit 1210
includes two hydraulic setting cylinders 1220 and 1225. Setting
cylinders 1220 and 1225 comprise outer housings 1221 and 1226
respectively, which are connected to flange 1235. Flange 1235 is
connected to bridge connector header 1230 via bolts 1232. Bridge
connector header 1230 forms a "T" junction with a lower bore, such
as lower spool 1240, similar to the above discussion concerning the
embodiment shown in FIGS. 2-11. As with that above discussion, it
is not necessary for bridge connector header to include two
throughbores, as long as it has one throughbore to serve as a fluid
inlet and a second bore to serve as a fluid outlet.
[0054] Setting cylinders 1220 and 1225 also comprise rods 1222 and
1227 respectively. Rods 1222 and 1227 each comprise an upper end,
each of which is connected to lower plate 1245. As shown in FIG.
13, lower plate 1245 is also connected to mandrel head 1251, which
is in turn connected to outer mandrel 1250. Cup tool 1260,
comprising gage ring 1261 and seals 1265, is located at the lower
end of outer mandrel 1250.
[0055] Similar to the embodiment shown in FIGS. 6-8, improved well
configuration unit 1210 comprises a dual mandrel system. In the
dual mandrel system, two concentric mandrels, an inner 1255 and an
outer 1250, are used. Inner mandrel 1255 comprises a lower end
which is connected to compression member 1700. Compression member
1700 comprises a generally planar surface 1703 and may also
comprise concave lower surfaces 1701 and 1702, which may serve to
divert high-pressure flow and protect the integrity of seals
1265.
[0056] 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. 15.
[0057] 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.
[0058] In operation, improved well configuration unit 1210 begins
in the position shown in FIG. 13, 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. 14.
[0059] 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. 15. 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.
[0060] 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.
[0061] Improved well configuration unit 1210 may also comprise
upper lock mechanism 1800 and lower lock mechanism 1900. Upper lock
mechanism 1800 and lower lock mechanism 1900 are generally
structured consistent with the design discussed above in connection
with lock mechanism 900, and shown in FIGS. 9-11 and 16. The linear
actuator for upper lock mechanism 1800 and lower lock mechanism
1900 may comprise hydraulic cylinder 925. As will be understood by
those of ordinary skill in the art, the linear actuator may also
comprise an electronic actuator.
[0062] As illustrated in FIG. 15, lower lock mechanism 1900 is
locked when cup tool 1260 has been moved into position below bridge
connector header 1230. The lock segments of lower lock mechanism
1900 engage with a groove 1100 on the outer surface of the mandrel
head 1251. This engagement prevents outer mandrel 1250 from being
forced upward by high-pressure fluid within lower spool 1240, and
thus maintains the integrity of the seal formed by seals 1265.
[0063] As shown in FIGS. 17 and 18, upper lock mechanism 1800 may
be engaged in two distinct positions. FIG. 17 illustrates improved
well configuration unit 1210 when cup tool 1260 has been moved into
the pack-off location below bridge connector header 1230, but
before seals 1265 have been engaged. Inner mandrel 1255 comprises
inner mandrel head 1355, which also comprises lower portion 1365.
Lower portion 1365 comprises a beveled lower face 1366 and a planar
upper face 1367. As shown in FIG. 17, before seals 1265 have been
engaged, upper lock mechanism 1800 is locked such that its segments
920 engage with planar upper face 1367 of lower portion 1365 of
inner mandrel head 1355. In this position, seals 1265 cannot be
engaged until upper lock mechanism 1800 is disengaged.
[0064] FIG. 18 illustrates improved well configuration unit 1210
when cup tool 1260 has been moved into the pack-off location below
bridge connector header and after seals 1265 have been engaged by
the upward movement of inner mandrel 1255 and compression member
1700. As shown in FIG. 17, upper lock mechanism 1800 is locked such
that its segments 920 engage with beveled lower face 1366 of lower
portion 1365 of inner mandrel head 1355. In this position, inner
mandrel 1255 and compression member 1700 may not be moved downward,
thereby disengaging seals 1265, until upper lock mechanism 1800 is
disengaged.
[0065] The improved well configuration unit 2000 may include an
improved cup tool 2005. A cup tool 2005 allows for a way to divert
flow in order to energize a seal assembly. The cup tool 2005
replaces the current method of using a valve for dual closure on
the zipper manifold. The cup tool 2005 reduces the total number of
valves needed for a multi-well pad which results in less
maintenance, repair, and transportation costs. The cup tool 2005
also increases efficiency and provides added safety benefits.
[0066] In the embodiment shown in FIG. 19, as described in more
detail below, a cup tool 2005 is used in place of the mandrel cup
tool discussed in FIGS. 2-5. As shown in FIG. 19, a hydraulic
setting cylinder 2015 actuates a mandrel 2010 to stroke down to
allow a cup tool 2005 to engage with a lower spool 2075. The
hydraulic setting cylinder 2015 includes a mandrel lock 2025. The
mandrel lock 2025 may be engaged to lock the cup tool 2005 in
position.
[0067] FIG. 19 illustrates the mandrel 2010 in the open position.
While the mandrel 2010 is in the stroked out or open position, the
cup tool 2005 sits above the "T" junction of bridge connector
header 2070, which allows fluid to flow through the "T" junction to
the connected bridge and frac tree. The mandrel 2010 is solid at
the cup tool 2005 such that fluid does not flow through the mandrel
2010.
[0068] In the closed position, which is shown in FIG. 20, the
hydraulic setting cylinder 2015 may move the mandrel 2010 through
the "T" junction of the bridge connector header 2070, such that the
cup tool 2005 of the mandrel 2010 will seal at a location below the
"T" junction. As shown in FIG. 20, the cup tool 2005 may optionally
seal within lower spool 2075, where the seal assemblies of the cup
tool form a seal against the lower spool 2075's inner surface. When
the mandrel 2010 is in the closed position and a seal has been
formed at a location below the junction of bridge connector header
2070, fluid cannot flow past the cup tool 2005 to the bridge
connector header 2070.
[0069] The improved well configuration unit 2000 is actuated from
the open position to the closed position when fluid flows through a
hydraulic port 2060 into the cavity 2055 of the hydraulic setting
cylinder 2015. The fluid drives the mandrel head 2050 from the open
position to the closed position. The mandrel head 2050 is connected
to the mandrel 2010. By driving the mandrel head 2050 into the
closed position, the mandrel 2010 moves from the open position to
the closed position.
[0070] FIGS. 21-24 show various embodiments of the cup tool 2005.
FIG. 21A depicts the preferred embodiment of the cup tool 2005. In
the preferred embodiment, a cup tool 2005 comprises a single
actuator 2030 with a dual seal assemblies 2040 and 2045. The cup
tool 2005 also comprises seals 2065 on the outer surface of a
piston 2080. The seals 2065 prevent the hydraulic fluid flow from
leaking past the pistons 2080 into the spool 2075 or interfering
with the operation of the seal assemblies 2040 and 2045. The seal
assemblies 2040 and 2045 are energized by the pistons. As shown in
FIG. 21B, hydraulic fluid flows through the actuator 2030. The
fluid then pushes the pistons 2080. The pistons 2080 then energize
the seal assemblies 2040 and 2045 so that the seal assemblies
extrude outward from the cup tool 2005 and seal with the inner
surface of the lower spool 2075.
[0071] FIG. 22A depicts an alternative embodiment of the cup tool
3005. In the illustrated embodiment, the cup tool 3005 comprises a
single actuator 3030 with a single seal assembly 3040. The cup tool
3005 also comprises seals 3065 on the outer surface of a piston
3080. In the illustrated embodiment, the cup tool 3005 also
comprises seals 3065 on the inner surface of the cup tool 3005
above the piston 3080. Similarly to FIG. 21B, FIG. 22B depicts the
energized seal assemblies 3040. The seal assembly 3040 is energized
in the same was as in FIG. 21 B, with hydraulic fluid flow
actuating a piston 3080 to energize the seal assembly 3040.
[0072] FIG. 23A depicts an alternative embodiment of the cup tool
4005. In the illustrated embodiment, the cup tool 4005 comprises
dual actuators 4030 and 4035 with a dual seal assemblies 4040 and
4045. The cup tool 4005 also comprises seals 4065 on the outer
surface of the piston 4050. In the illustrated embodiment, the cup
tool 4005 also comprises seals 4065 on the inner surface of the cup
tool 4005 above the piston 4080. In the illustrated embodiment, the
pistons 4050 and 4080 are internal beveled pistons. Similarly to
the embodiments discussed above, FIG. 23B depicts the energized
seal assemblies 4040 and 4045. As shown in FIG. 23B, hydraulic
fluid flows through actuator 4035 to piston 4080. Piston 4080 then
energizes seal assembly 4045 so that seal assembly 4045 extrudes
from the cup tool 4005 and seals against the inner surface of lower
spool 4075. Actuator 4030 directs hydraulic fluid flow to piston
4050. Piston 4050 energizes seal assembly 4040 in the same way as
piston 4080 energizes seal assembly 4045.
[0073] FIG. 24A depicts an alternative embodiment of the cup tool
5005. In the illustrated embodiment, the cup tool 5005 comprises
dual actuators 5030 and 5035 with dual seal assemblies 5040 and
5045. The cup tool 5005 also comprises seals 5065 on the outer
surface of the piston 5050. In the illustrated embodiment, the cup
tool 5005 also comprises seals 5065 on the inner surface of the cup
tool 5005 above the piston 5080. In the illustrated embodiment, the
pistons 5050 and 5080 are external beveled pistons. Similar to the
FIG. 23 B discussed above, FIG. 24 B depicts the energized seal
assemblies 5040 and 5045. The seal assemblies 5040 and 5045 are
energized in the same ways as in FIG. 23 B, with hydraulic fluid
flow traveling through actuators 5035 and 5030 to actuate pistons
5080 and 5050 respectively so that piston 5080 can energize seal
assembly 5045 and piston 5050 can energize seal assembly 5040.
[0074] 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.
[0075] Any spatial references, such as, for example, "upper,"
"lower," "above," "below," "between," "bottom," "vertical,"
"horizontal," "angular," "upwards," "downwards," "si de-to-si de,"
"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. Similarly, references to
the general shape of certain components, such as for example,
"planar" or "cylindrical," are for the purpose of illustration only
and do not limit the specific configuration of the structure
described above.
[0076] 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.
[0077] 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.
[0078] 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.
* * * * *