Patent ID: 12196235

DETAILED DESCRIPTION

Embodiments of the present disclosure are described below in detail with reference to the accompanying figures. In the following detailed description, numerous specific details are set forth in order to provide a more thorough understanding of the claimed subject matter. However, it will be apparent to one having ordinary skill in the art that the embodiments described may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the description. As used herein, the term “coupled” or “coupled to” or “connected” or “connected to” may indicate establishing either a direct or indirect connection, and is not limited to either unless expressly referenced as such. Wherever possible, like or identical reference numerals are used in the figures to identify common or the same elements. The figures are not necessarily to scale and certain features and certain views of the figures may be shown exaggerated in scale for purposes of clarification.

In one aspect, embodiments disclosed herein relate to inserts within a flow bore of a valve block. An insert may also be interchangeably referred to as a guide vane insert in the present disclosure. Additionally, a valve block may also be interchangeably referred to as a flow manifold or flow control module assembly or a Christmas tree in the present disclosure, and may or may not include valves disposed therein. Further, embodiments disclosed herein may include a block with at least one flow bore that may control and regulate the flow of fluids for purposes of either injecting fluid (e.g., frac fluid) into an injection well or recovering fluid (e.g., hydrocarbons or other reservoir fluid) from a production well. Additionally, a cross-drill intersection bore may be formed within a valve block by a first flow bore intersecting a second flow bore. In addition, any terms designating valve block or flow manifold (e.g., any wellheads or frac valves) at a rig type (e.g., any land rig or offshore rig) should not be deemed to limit the scope of the disclosure. It is to be further understood that the various embodiments described herein may be used in various stages of a well, such as rig site preparation, drilling, completion, abandonment etc., and in other environments, such as work-over rigs, fracking installation, well-testing installation, oil and gas production installation, without departing from the scope of the present disclosure. It is recognized by the different embodiments described herein that a flow manifold or valve block plays a valuable and useful role in the life of a well. Further, it is recognized that the fluid flow configuration and arrangement of components for a valve block according to one or more embodiments described herein may provide a cost effective alternative to conventional valve blocks. The embodiments are described merely as examples of useful applications, which are not limited to any specific details of the embodiments herein.

Guide vane inserts, according to embodiments herein, are apparatuses that include vanes extending from a body of the inserts and into a passageway of the inserts. The guide vane inserts may be removably attached or fixed within components having a flow path for fluids, such as a flow bore or valve, that are arranged in a certain layout and contained within a valve block or flow manifold. The flow bores included in valve blocks may be used to direct fluid produced from or injected into a well. As used herein, fluids may refer to slurries, liquids, gases, and/or mixtures thereof. In some embodiments, solids may be present in the fluids. When fluids flow through the passageway of the inserts, the vanes of the inserts may turn the flow of the fluids to be more uniform and steady. By creating a more uniform and steady flow, the guide vane inserts may significantly reduce erosion rates within the valve block and increase equipment functionality for longer periods of time, and may also allow for significant reduction in the complexity, design, and weight of the valve block. It is further envisioned that the guide vane inserts may also be used to deflect erosion agents from sensitive areas and/or act as sacrificial elements which will sustain high erosion rates in place of other more critical areas of the valve block or components such as valves or sensors.

In addition, one or more valves may be disposed or integrated with one or more of the flow bores to direct the fluids within the valve block. Further, one or more flow meters may be integrated with one or more of the flow bores of a flow control module. Furthermore, one or more chokes may be coupled to one of the flow bores of the valve blocks. As known in the art, a choke may be an apparatus used to control pressure of fluid flowing through the choke and also may control a back pressure in the upstream fluid. Other instruments and devices, including without limitation, sensors and various valves may be incorporated within a valve block according to embodiments of the present disclosure.

Conventional valve blocks in the oil and gas industry are typically very large and heavy. Conventional valve blocks may include an extensive layout and arrangement of pipes that weigh several tons each. In some instances, a pipe used to direct fluid into another pipe may be ten inches in diameter and may include complicated bends or changes in orientation. Such valve blocks may be both heavier in weight and may also be more expensive to manufacture because of the higher number of parts and components. For example, flow bores in conventional valve blocks may be machined or manufactured to have a longer length and/or CRA layers in order to mitigate erosion rates of the flow bores. This additional length and/or CRA layers needed to account for erosion effects due to fluid flow adds to the weight, size, manufacture costs and time, repair time, and overall cost of valve blocks.

Accordingly, one or more embodiments in the present disclosure may be used to overcome such challenges as well as provide additional advantages over conventional valve blocks. In one or more embodiments, valve blocks with one or more inserts may be lighter in weight and lower in cost as compared with conventional valve blocks due, in part, to including an insert of the present disclosure within one or more flow bores of the valve block to reduce erosion rates rather than increasing the size and complexity of the flow manifold. As discussed herein, fixing or removably attaching an insert within one or more of the flow bores may create a more uniform and steady flow within the flow bores to reduce erosion rates as well as deflect particles and/or act as a sacrificial element. Additionally, the guide vane insert may comprise components that are forged and/or machined, and thus may be easily installed within the flow bores, relaxing control tolerances and improving manufacture (e.g., reduced cost and reduced time to manufacture). It is further envisioned that the guide vane insert may be manufactured by additive manufacturing such as 3-D printing, powder metallurgy, casting or injection molding. Furthermore, by having the guide vane insert within one or more flow bores, the valve block may be manufactured to minimize or eliminate the need for long length flow bores and/or applying additional CRA layers to a surface of the flow bores for erosion allowance. Overall the guide vane insert may minimize product engineering, risk associated with erosion in flow bores, reduction of assembly time, hardware cost reduction, and weight and envelope reduction.

Further, according to embodiments of the present disclosure, a guide vane insert may be integrated with a pig bar insert disposed in the flow bore of the valve block instead of requiring additional manufacturing, thus reducing cost and weight of such a valve block. In a non-limiting example, a structure and installation of the pig bar insert in accordance with the present disclosure may utilize the pig bar insert systems and methods, according to the systems and methods as described in World Intellectual Property Organization (“WIPO”) Patent Application No. PCT/BR2016/050153, of which the entire teachings are incorporated herein by reference.

Turning toFIG.1,FIG.1shows a cross-sectional view of a valve block100in accordance with one or more embodiments of the present disclosure. In one or more embodiments, the valve block100may be coupled to well equipment, such as a well head (not shown). As known in the art, a well head may be a structure useful for producing fluid or injecting fluid into a well, and is often a complex configuration of actuated valves and other components having various functions relevant to the well. In some embodiments, the valve block100may be coupled to frac equipment. In addition, the valve block100may be arranged in series to distribute and manage fluid flow over a wider area in some instances and to connect to multiple pieces of equipment. In one or more embodiments, the valve block100may be used to direct fluid flowing from in or out of the well to another structure or distribution point for storage and/or processing.

In one or more embodiments, the valve block100may have a fluid conduit, such as one or more flow bores101. In a non-limiting example, a first flow bore102may intersect a second flow bore103to form a first cross-drill intersection bore104. Additionally, a third flow bore105may also intersect the second flow bore103to a form a second cross-drill intersection bore106. It is noted that three flow bores (102,103,105) and two cross-drill intersection bores (104,106) in the valve block100are shown for example purposes only, and the valve block100may have any number of flow bores and cross-drill intersection bores without departing from the scope of the disclosure. Additionally, the valve block100may include more than one inlet or outlet107, such as two, three, or more inlets or outlets107. In addition, the valve block100may have one or more valves108to direct the flow traveling through the one or more flow bores101. In a non-limiting example, a fluid may enter the valve block100through the inlet107. From the inlet107, the fluid may flow through the first cross-drill intersection bore104, the first flow bore102, the second flow bore103, the third flow bore105and/or the second cross-drill intersection bore106in a direction indicated by arrows109. It is further envisioned that the direction of arrows109may be reversed or the flow of fluids may be redirected by opening or closing the one or more valves108. As will be described herein, a guide vane insert may be provided in any of the one or more flow bores101of the valve block100. Furthermore, one skilled in the art will appreciate how the flow bores (101,102,103,105) and the cross-drill intersection bores (104,106) of valve block100may be cladded with a corrosion resistant alloy.

As seen byFIG.2, in one or more embodiments, a guide vane insert200may extend a length L from a first end surface201to a second end surface202. One skilled in the art will appreciate how the length L of the guide vane insert200may be any length to fit in the flow bores (e.g.,101,102,103,105inFIG.1) of a valve block (e.g.,100). Additionally, the guide vane insert200may have a wall203with a thickness T measured from an inner surface204of the wall203to an outer surface205of the wall203. In a non-limiting example, the thickness T of the guide vane insert200may have a value that is less than or equal to five percent of an inner diameter of a fluid conduit that the guide vane insert200is inserted within (or less than or equal to five percent of the diameter measured between the outer surface205of the wall203). In some embodiments, the thickness T of the guide vane insert may have a value ranging from a lower limit selected from 0.5%, 1%, 2% and 3% of the insert diameter measured between its outer surface to an upper limit selected from 5%, 6%, 8% and 10% of the insert diameter measured between its outer surface, where any combination of lower limit and upper limit may be selected.

Further, the inner surface204may define a passageway206within the wall203and the passageway206may have openings at the first end surface201and the second end surface202opposite each other. The passageway206may allow for fluids to pass through the guide vane insert200.

In some embodiments, the guide vane insert200may have a plurality of vanes207extending in the same direction from the inner surface204of the wall203into the passageway206. The vanes207shown inFIG.2form a grating within the insert200, where the vanes207are a plurality of regularly spaced, parallel, elongated elements. In a non-limiting example, the guide vane insert200may be provided with three vanes207spaced equal distances from each other in a radial direction of the guide vane insert200. While it is noted that three vanes207are shown, the guide vane insert200may include any number of vanes spaced equally or unequally spaced apart without departing from the scope of the disclosure. Additionally, the plurality of vanes207may each have a length extending axially within the guide vane insert200. In a non-limiting example, the length of the plurality of vanes207may be shorter than the length L of the guide vane insert200. It is further envisioned that the plurality of vanes207may extend in a direction perpendicular to a radial cross section of the insert wall203. The plurality of vanes207may be parallel with each other and each may have a height extending between opposite sides of the inner surface204of the wall203. For example, in the embodiment shown inFIG.2, a central vane may have a height extending the inner diameter of the insert, and the remaining vanes may have a height extending a chord of the insert inner diameter, where each of the vanes form parallel planes with each other.

Further, in some embodiments, the plurality of vanes207may be angled from a longitudinal axis A of the guide vane insert200such that the plurality of vanes207may be slanted within the passageway206. Additionally, the plurality of vanes207may have different angles between each other and the axis A. Furthermore, each of the plurality of vanes207may have equal thicknesses.

Still referring toFIG.2, in one or more embodiments, at least one pig bar208may be provided within the guide vane insert200in a first portion209of the passageway206. The first portion209may be an area of the insert200extending a length from the first end surface201, e.g., a length from the first end surface201to an end of the plurality of vanes207. In a non-limiting example, the pig bar208may extend longitudinally in a direction perpendicular to the plurality of vanes207between the inner surface204of the wall203. In some embodiments, the pig bar208may extend a depth equal to a full length of the first portion209, from the first end surface201to the end of the plurality of vanes207. In some embodiments, the pig bar208may extend a depth less than the full length of the first portion209. The pig bar208depth may extend in a direction parallel with the direction of the central longitudinal axis of the insert, or in some embodiments, may extend in a direction at an angle from the direction of the central longitudinal axis of the insert. Additionally, the pig bar208may be positioned at any height within the passageway206, e.g., below the longitudinal axis of the insert (as shown inFIG.2), at the same height as the longitudinal axis, or above the longitudinal axis.

In accordance with one or more embodiments, the guide vane insert200may be forged, machined, formed by additive manufacturing from a material selected from metal materials, plastic materials, carbon fiber materials, composite materials, ceramics, or structural insulating materials (e.g., using a 3D printing process). In a non-limiting example, the guide vane insert200may be the same material as the valve block. Additionally, the guide vane insert200may be coated in an anti-corrosion material. It is further envisioned that the guide vane insert200may be made out of any material and then coated with an erosion resistant layer of materials such as tungsten carbide. In some embodiments, the guide vane insert200may be machined, forged, or formed by additive manufacturing as one integrated piece or may have the plurality of vanes207and/or the pig bar208removably attached thereto.

Now referring toFIG.3,FIG.3illustrates a perspective cross-section view of the guide vane insert200within the valve block100in accordance with one or more embodiments of the present disclosure. In a non-limiting example, the guide vane insert200may be within a first flow bore102of the valve block100. While it is noted thatFIG.3shows the guide vane insert200in the first flow bore102, the guide vane insert200may be in any flow bore of the valve block100without departing from the scope of the disclosure. The outer surface205of the wall203may contact an inner surface110of the first flow bore102. It is further envisioned the outer surface205may be machined to match the shape of the inner surface110of the first flow bore102. For example, the insert200may have a wall outer surface205that corresponds in size and shape with a portion of the inner surface110of the first flow bore102, such that the insert200fits within the portion of the first flow bore102in a secured manner (including manufacturing tolerances).

In some embodiments, the inner surface110of the first flow bore102may have a groove111for the guide vane insert200to fit into. It is further envisioned that one or more seals may be disposed between the guide vane insert200and the first flow bore102to ensure there is a complete seal between the bodies (between the outer surface of the insert wall203and inner surface110of the first flow bore102) and preventing flow between said bodies. One skilled in the art will appreciate how the guide vane insert200may be fixed or removably attached to the first flow bore102using various methods as known in the art, including without limitation welding, mechanical fasteners, integrally forming, adhesives, and other known methods or combination thereof. Additionally, the central longitudinal axis (see A inFIG.2) of the guide vane insert200may be positioned to be concentric with a central axis CA of the first flow bore102. It is further envisioned that in the process of manufacturing the valve block100, the cladding of the flow bores (101,102,103,105) and the cross-drill intersection bores (104,106) of valve block100may be done after or during the welding of the guide vane insert200. One skilled in the art will appreciate how the guide vane insert200may be removable to allow for repairs and/or replacement of the guide vane insert200. According to some embodiments, with the guide vane insert200inserted in the first flow bore102, the thickness (see T inFIG.2) of the wall203may reduce an inner diameter ID of the first flow bore102, for example, by up to five percent, up to ten percent, or up to fifteen percent.

In a non-limiting example, each of the vanes207may have a planar wall207apositioned along parallel planes with each other. Additionally, the planar wall207amay extend a direction parallel with the central axis CA of the first flow bore102and from opposite radial ends of the inner surface204of the wall203. Further, the pig bar208may be extend from a first end211of the plurality of vanes207to the first end surface201of the guide vane insert200such that the pig bar208is proximate the end of guide vane insert200and aligned with the first cross-drill intersection bore104. In some embodiments, the pig bar208may be proximate an end of the guide vane insert200opposite of the first cross-drill intersection bore104. In addition, the pig bar208may have a length extending in a direction perpendicular to the planar walls207aof the plurality of vanes207and between opposite sides of the inner surface204.

According to embodiments of the present disclosure, walls of an insert may have different profile shapes. For example, in the embodiment shown inFIG.3, the vanes207of the insert have planar walls207a. In other embodiments, vanes of an insert may have non-planar walls. For example, an insert may have one or more vanes having an airfoil shape. In another example, an insert may have one or more vanes having a twisted or spiral-like shape.

In one or more embodiments, the first end surface201of the guide vane insert200may align with a surface112of the first cross-drill intersection bore104such that the plurality of vanes207and/or the pig bar208of the guide vane insert200may not be within the first cross-drill intersection bore104. In a non-limiting example, the first end surface201may be curved to match surface112of the first cross-drill intersection bore104such that the first portion209of the guide vane insert200may be enlarged and flare outward. As further shown byFIG.3, one skilled in the art will appreciate how the first portion209may include an over-thickness portion210to further seal the wall203against the inner surface110of the first flow bore102.

In some embodiments, the guide vane insert200may be integrated within the first flow bore102. As seen inFIG.4, a front view an integrated guide vane insert within the first flow bore102of valve block100is illustrated in accordance with one or more embodiments of the present disclosure. In such an embodiment, the wall (203) of guide vane insert (200) may in fact be the inner surface110of the first flow bore102such that the plurality of vanes207and the pig bar208may directly contact the inner surface110of the first flow bore102. The vanes207may extend a height H in a direction perpendicular to the direction of the central axis of the first flow bore102and may extend a length (not shown from the front view) in a direction parallel with the direction of the central axis of the first flow bore102. The pig bar208may extend a length1in a direction perpendicular to both the height H of the vanes and the direction of the central axis.

Now referring toFIGS.5A and5B, a valve seat114may be formed in a first fluid conduit113of the valve block100in accordance with one or more embodiments of the present disclosure. In a non-limiting example, a second portion212of the guide vane insert200may extend into the valve seat114from the first portion209to the second end surface202. The wall203of guide vane insert200may have a constant inner and/or outer diameter throughout the second portion212. It is further envisioned that the second portion212of the guide vane insert200may be fully within the first fluid conduit113and the first portion209of the guide vane insert200may exit the first fluid conduit113to directly contact the valve block100. Additionally, the wall203of the insert defining the first portion209may be angled outwardly from the second portion212to the surface112of the first cross-drill intersection bore104such that the first portion209is flared. By angling the wall203in the first portion209, the inner and outer diameter of the wall203in the first portion209may progressively increase from the constant inner/outer diameter throughout the second portion212to a maximum inner/outer diameter of the wall203at the first end surface201aligned with the first cross-drill intersection bore104.

In one or more embodiments, the first portion209may include a slanted inner surface213that is sloped to align with a curvature of the surface112of the first cross-drill intersection bore104. Additionally, the over-thickness portion210of the wall203may extend from the slanted inner surface213such that the first end surface201may be curved to align with the curvature of the surface112of the first cross-drill intersection bore104.

As further shown inFIGS.5A and5B, the plurality of vanes207may extend from the second end surface202a full length of the second portion212and into the first portion209. In some embodiments, the plurality of vanes207may intersect with the pig bar208within the first portion209such that each of the vanes207are interlocked with the pig bar208. In other words, the length of the vanes207may overlap with the depth of the pig bar208. It is further envisioned that ends of each of the vanes207in the passageway206may be a straight edge such that one end of the plurality of vanes207aligns with the second end surface202and an opposite end of the plurality of vanes207is within the first portion209of the wall to have the plurality of vanes207fully enclosed within the wall203. One skilled in the art will appreciate that the guide vane insert200installed in the valve block may steady a flow of fluids through the valve block. In a non-limiting example, the fluids flow (e.g., in a direction of arrows labeled Flow) from the first cross-drill intersection bore104and turning into the valve seat114or vice versa. As the fluids flow in the valve seat114, the fluids travel through the passageway206of the guide vane insert200. The plurality of vanes207within the passageway206may disrupt the flow of the fluids such that a velocity of the fluid may increase and create turbulent flow through the insert, and thereby may deflect particles away from sensitive areas and may also act as sacrificial elements.

According to embodiments of the present disclosure, inserts may be positioned at least partially in different components of a flow module, such as valve seats or flow bores. For example, as shown inFIGS.5A and5B, an insert may extend partially into a valve seat. Further, in some embodiments, an insert may be a separate component positioned at least partially in another component of a flow module. In some embodiments, an insert of the present disclosure may be integrally formed with a component of the flow module (e.g., valve seat).

Referring now toFIGS.6A and6B, another embodiment of a guide vane insert according to embodiments herein is illustrated, where like numerals represent like parts. The embodiment ofFIGS.6A and6Bis similar to that of the embodiment ofFIGS.5A and5B, where a plurality of vanes207extend a length through the insert in a longitudinal direction parallel with the longitudinal axis of the insert200. However, the guide vane insert200may only have the plurality of vanes207without a pig bar.

Referring now toFIGS.7A and7B, another embodiment of a guide vane insert700according to embodiments herein is illustrated. The embodiment ofFIGS.7A and7Bis similar to that of the embodiment ofFIGS.2-6B, in that a plurality of vanes extend longitudinally through a length of an insert. InFIGS.7A and7B, the portion of the insert wall surrounding the vanes is presented transparently in order to see the configuration of the vanes therein.

As seen byFIGS.7A and7B, in one or more embodiments, the guide vane insert700may extend a first length Lf from a first end701to a second end702. One skilled in the art will appreciate how the length Lf of the guide vane insert700may be any length to fit in the flow bores (e.g.,101,102,103,105inFIG.1) of a valve block (e.g.,100). Additionally, the guide vane insert700may have a wall703with a first thickness Tf measured from an inner surface704of the wall703to an outer surface705of the wall703. In a non-limiting example, the first thickness Tf of the guide vane insert700may have a value that is less than or equal to five percent of an inner diameter of a fluid conduit that the guide vane insert700is inserted within (or less than or equal to five percent of the diameter measured between the outer surface705of the wall703). In some embodiments, the thickness Tf of the guide vane insert may have a value ranging from a lower limit selected from 0.5%, 1%, 2% and 3% of the insert diameter measured between its outer surface to an upper limit selected from 5%, 6%, 8% and 10% of the insert diameter measured between its outer surface, where any combination of lower limit and upper limit may be selected.

Further, the inner surface704may define a passageway706within the wall703and the passageway706may have openings at the first end701and the second end702opposite each other. The passageway706may allow for fluids to pass through the guide vane insert700.

In some embodiments, the guide vane insert700may have a plurality of vanes707extending in the same direction from the inner surface704of the wall703into the passageway706. In a non-limiting, the plurality of vanes707may extend in any direction in an X-axis, Y-axis and Z-axis within the passageway706. In addition, the guide vane insert700may be provided with two vanes707spaced equal distances from each other in a radial direction of the guide vane insert700. While it is noted that two vanes707are shown, the guide vane insert700may include any number of vanes spaced equally or unequally spaced apart without departing from the scope of the disclosure. Additionally, the plurality of vanes707may each have a length extending axially within the guide vane insert700. In a non-limiting example, the length of the plurality of vanes707may be shorter than the first length Lf of the guide vane insert700.

In one or more embodiments, the plurality of vanes707may include a change in direction (e.g., twist) along its length. For example, the plurality of vanes707may have a first end at the first end surface701extending in a direction parallel to a radial cross section750of the insert, and a second end at the second end surface702may extend in a non-parallel direction (e.g., perpendicular) to the radial cross section750of the insert wall703. With the change in direction, the plurality of vanes707may have a twisted or helix shape within the passageway706. In embodiments having one or more twisted vanes extending through a length of the insert, the vane(s) may intersect with the inner surface704of the insert wall along a helix or spiral pattern.

In some embodiments, vanes707having a change in direction along its length may be parallel with each other, where each vane707has corresponding changes in direction along its length to follow in parallel directions with each other. Further, vanes707having a change in direction along its length may each have a height extending between opposite sides of the inner surface704of the wall703. For example, in the embodiment shown inFIGS.7A and7B, the two vanes707may have a height extending a chord of the insert inner diameter, where each of the vanes are parallel with each other. Furthermore, each of the plurality of vanes707may have equal thicknesses.

Still referring toFIGS.7A and7B, in one or more embodiments, the guide vane insert700may have a pig bar assembly708at the first end701. The pig bar assembly708may be removably attached or integrated to the first end701such that the guide vane insert700has a second length Ls which is greater than the first length Lf. The pig bar assembly708may have an outer diameter equal to the outer diameter of the insert wall703surrounding the vanes707. The pig bar assembly708may include a first pig bar708aand a second pig bar708bextending a depth from the first end701to an opposite end. In addition, the first pig bar708aand the second pig bar708bmay be spaced equal distances from each other in a radial direction of the guide vane insert700. While it is noted that two pig bars (708a,708b) are shown, the pig bar assembly708may include any number of pig bars spaced equally or unequally spaced apart without departing from the scope of the disclosure.

In some embodiments, the first pig bar708aand the second pig bar708bmay form a plurality of openings (720,721,722) in the pig bar assembly708. In a non-limiting example, the pig bar assembly708may have an upper opening720, a middle opening721, and a lower opening722. The upper opening720and the lower opening722may be equal in size and shape. Further, the middle opening721may be larger than the upper opening720and the lower opening722. Additionally, the first pig bar708aand the second pig bar708bmay be positioned in the pig bar assembly708such that an end of the plurality of vanes707are colinear with the first pig bar708aand the second pig bar708b. The pig bars708a,708bmay be attached to the ends of the vanes707or integrally formed with the vanes707, e.g., using a 3D printing process to form the insert.

In accordance with one or more embodiments, the guide vane insert700may be forged, machined, formed by additive manufacturing from a material selected from metal materials, plastic materials, carbon fiber materials, composite materials, ceramics, or structural insulating materials. In a non-limiting example, the guide vane insert700may be the same material as the valve block. Additionally, the guide vane insert700may be coated in an anti-corrosion material. It is further envisioned that the guide vane insert700may be made out of any material and then coated with an erosion resistant layer of materials such as tungsten carbide. In some embodiments, the guide vane insert700may be machined, forged, or formed by additive manufacturing as one integrated piece or may have the plurality of vanes707and/or the pig bar assembly708removably attached thereto.

Furthermore, methods of the present disclosure may include manufacturing the guide vane insert (e.g.,200,700), valve block, and other structures, such as inFIGS.1-7Bfor creating a steadier and uniform flow. Because the following method may apply to any of the embodiments disclosed herein, reference numbers are not referenced to avoid confusion of the numbering between the different embodiments.

In one or more embodiments, a valve block may be machined or forged from one solid piece of material. Those skilled in the art would appreciate how the material can be any material suitable for well site conditions, for example, metals, ceramics, and/or composites. Additionally, coatings may be added to the valve block for thermal insulation and to prevent corrosion. The valve block may be forged and/or machined into the size and shape needed based on a required application. Further, the valve block may be forged and/or machined to integrate at least two intersecting flow bores in a body of the valve block, where manufacturing processes well known in the art may be used to ensure proper dimensions and cleanliness of the bores are achieved. In a non-limiting example, the body of the valve block may be forged and/or machined without any flow bores, and then the body may be drilled to have a first flow bore intersecting a second flow bore to form a cross-drill intersection bore at the intersection. Further, the cross-drill intersection bore may be further machined to have curved profile. In some embodiments, a groove may be cut into a portion of the first flow bore or the second flow bore.

Additionally, a guide vane insert may be manufactured from a process of machining, forging, additive manufacturing or other methods from one solid piece of material or multiple components. In a non-limiting example, the guide vane insert may be forged, machined, made from additive manufacturing, and/or other methods to have an outer wall and a passageway defined through the outer wall such that an inner surface is defined is opposite the outer wall. Additionally, the passageway may have openings at opposite ends of the guide vane insert. Further, a plurality of vanes may be forged, machined, made from additive manufacturing, and/or other methods to extend from an inner surface of the outer wall. In some embodiments, the plurality of vanes may extend a full height of the passageway and may be equally spaced in a radial direction. Furthermore, a pig bar may be positioned perpendicular to the plurality of vanes at an end of the guide vane insert, or in some embodiments, a pig bar may be positioned non-perpendicularly to the plurality of vanes, such as colinear with an end of the plurality of vanes. The vanes and/or pig bar may be integrally formed with the insert wall, or in some embodiments, the vanes and/or pig bar may be attached within a pre-formed insert wall.

With the flow bores and the cross-drill intersection bore formed, the guide vane insert may be positioned within one of the flow bores and be held in the groove, such as by welding the insert to the groove. The guide vane insert may be welded or integrally formed such that the guide vane insert is fixed in the first flow bore or the second flow bore. It is further envisioned that the guide vane insert may also be removably attached to a flow bore via, without limitation, mechanical fasteners, adhesives, and other known methods or combination thereof. In particular, the outer wall of the guide vane insert may be connected to an inner surface of a flow bore. Additionally, the guide vane insert may be positioned in a flow bore such that an end of the guide vane insert is aligned with a surface of the cross-drill intersection bore. Additionally, said end of the guide vane insert may be machined to have a curve align with a curvature of the surface of the cross-drill intersection bore. It is further envisioned that an edge of the pig bar of the guide vane insert may also be aligned with the surface of the cross-drill intersection bore. In some embodiments, a pig bar and/or vanes in an insert may be inset from an end surface of the insert, and the end surface of the insert may be aligned with the surface of the cross-drill intersection bore, such that a length of the insert wall measured from the end surface of the insert does not have a pig bar and/or vanes extending therefrom.

Further, one skilled in the art will appreciate how the flow bores, the cross-drill intersection bore, and the guide vane insert may be cladded with a corrosion resistant alloy during or after the installation of the guide vane insert in the valve block. Corrosion resistant alloys may be formed of, for example, martensitic and martensitic/ferritic stainless steel, duplex stainless steel, austenitic-nickel-base alloys, and others, depending on, for example, the environment in which the CRA is to be used.

According to embodiments of the present disclosure, a block of metal or alloy used to form a manifold may be heat treated. After heat treatment, the block may be pre-machined to form one or more flow bores through the block. Portions of the pre-machined block (e.g., the inner surfaces of the flow bores) may then optionally be cladded, for example, with a material for added erosion resistance. An insert according to embodiments of the present disclosure may be welded within one or more of the flow bores either before or during the cladding. Thus, according to embodiments of the present disclosure, an insert may be pre-made prior to attaching within a flow bore. A second machining step may be performed after cladding to assure critical dimensions are maintained.

In addition to the benefits described above, with the guide vane insert reducing the effects of erosion from fluids by deflecting particles away from sensitive areas (and may also act as sacrificial elements), the valve block may have more sensitive components installed thereof and may include components near regions within the valve block subjected to high velocity flow. Further, the guide vane insert may beneficially enable a compact and lighter weight valve block that may reduce overall cost and complexity of the design. A lighter more compact valve block may increase the range of valve block types being capable of installing to corresponding well equipment, thereby reducing the reliance on a limited number of multi service valve blocks. It is noted that the guide vane insert may be used for onshore and offshore oil and gas operations.

While the present disclosure has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments may be devised which do not depart from the scope of the disclosure as described herein. Accordingly, the scope of the disclosure should be limited only by the attached claims.