Patent ID: 12252949

DETAILED DESCRIPTION

Reference is now made toFIGS.1A through25Din describing embodiments of the disclosed fluid connections. For the purposes of the following disclosure,FIGS.1A and1Bdepict prior art devices.FIGS.2through25Ddepict embodiments of new fluid connection designs.FIGS.2through17depict embodiments without an adapter release feature, andFIGS.18through25Ddepict embodiments with an adapter release feature.FIGS.2through17should be viewed together, andFIGS.18through25Dshould be viewed together with further reference toFIGS.2through17. Any part, item, or feature that is identified by part number on one ofFIGS.1A through25Dwill have the same part number when illustrated on another ofFIGS.1A through25D. It will be understood that the embodiments as illustrated and described with respect toFIGS.2through25Dare exemplary, and the scope of this disclosure is not limited to such illustrated and described embodiments.

FIGS.1A and1Billustrate examples of existing fluid connections, and are based upon FIG. 2 in U.S. Pat. Nos. 9,644,443 and 9,670,745.FIGS.1A and1Bshould be viewed together. InFIGS.1A and1B, pressure control equipment (“PCE”) is labeled generally as P, and wellhead is labeled generally as W. Pressure control assembly10is secured to wellhead W via a conventional bolted flange, although not limited in such regard. The wellhead end of pressure control assembly10advantageously provides a customized fitting F to connect to wellhead W. Adapter12is secured to PCE P via conventional threading, although not limited to a threaded connection between PCE P and adapter12. In operation, adapter12enters pressure control assembly10via tulip14. Adapter12and pressure control assembly10thereupon combine to form a fluid connection and seal according to the disclosure of U.S. Pat. Nos. 9,644,443 and 9,670,745.

FIGS.2,5and6should now be viewed together.FIGS.2,5and6illustrate one embodiment of the remotely-operated fluid connection and seal technology described in this disclosure. Referring first toFIG.6, fluid connection assembly100comprises fluid connection adapter200and fluid connection housing assembly300. Fluid connection adapter200has first and second adapter ends, in which the first adapter end is blank (or closed off) and the second adapter end is configured to be inserted into fluid connection housing assembly300. Fluid connection housing assembly300has first and second housing ends, in which the first housing end is configured to receive the second adapter end. Fluid connection housing assembly300may provide a wellhead adapter312with a flanged connection313at the second housing end to enable ultimate connection to a pressurized source of fluids (such as, for example, a wellhead). Stated generally with reference toFIG.6, fluid connection housing assembly300provides: (i) a retractable locking ring318; (ii) a plurality of locking elements317, and (iii) at least a first seal bore341.

As noted, the embodiments illustrated onFIGS.2,5and6include fluid connection adapter200having a blank (or closed off) first adapter end. As such, fluid connection adapter200is suitable for use as a nightcap, or when operators wish to close off a wellhead temporarily. Fluid connection adapter is not limited in its deployments.

FIGS.3and4illustrate alternative embodiments to fluid connection adapter200onFIGS.2,5and6. For example, flanged fluid connection adapter200A onFIG.3provides a flange at its first adapter end thereof for further connection to other equipment (such as pressure control equipment in wellhead pressure control applications. By way of further example, goat head fluid connection adapter200B onFIG.4provides a “goat head”-style manifold at its first adapter end thereof for connection to multiple fracturing fluid lines during hydraulic fracturing service. The scope of this disclosure is not limited to the examples ofFIGS.2,3and4.

It will nonetheless be noted fromFIGS.2,3and4that each of the illustrated alternative adapter embodiments200,200A,200B each share a common configuration at their second adapter ends, to be described in more detail immediately below with reference toFIG.2. In this way, and with reference now toFIG.6, such common configuration allows alternative adapter embodiments200,200A,200B to be interchangeable when inserted into fluid connection housing assembly300.

With reference now toFIG.2, fluid connection adapter200generally provides in order towards the second adapter end: (a) a tapered lock engagement surface209, (b) a locking element actuating section206, and (c) at least a first seal section207. In more detail, fluid connection adapter200provides an enlarged outer diameter (OD) section205. Enlarged OD section205includes tapered lock engagement surface209and rib210. As will be described, enlarged OD section205acts as a positive stop to enable fluid connection adapter200to enter fluid connection housing assembly300to only a predetermined longitudinal position.

Fluid connection adapter200also provides locking element actuating section206. Fluid connection adapter200further provides first and second seal sections207,208. Locking element actuating section206and first and second seal sections207,208are described in more detail below with reference to interaction with cooperating parts within fluid connection housing assembly300. However, it will be seen onFIG.2that first and second seal sections207,208also preferably each provide one or more grooves in which sealing rings may be located, in order to further facilitate seals between cooperating machined surfaces. Sealing rings (such as o-rings, for example) have been omitted for clarity in this disclosure.

FIGS.5and6should now be viewed together.FIG.5is an exploded view andFIG.6is a section view of the illustrated embodiments of fluid connection assembly100.FIG.6shows fluid connection assembly100in an “open” position. Fluid connection adapter200is described in detail above with reference toFIG.2.

Fluid connection housing assembly300includes wellhead adapter312at a second housing end thereof, per earlier disclosure. Fluid connection housing314is connected to wellhead adapter312by a flange/bolted connection. In other embodiments (not illustrated), fluid connection housing314and wellhead adapter312may be integrally formed, or connected by a threaded connection, and the scope of the disclosure is not limited in this regard.

Wellhead adapter312provides first and second seal bores341,342formed therein. First and second seal bores341,342are shaped to receive and form seals with first and second seal sections207,208respectively on fluid connection adapter200. Note first and second seal bores341,342and first and second seal sections207,208may preferably further include sealing rings to enhance sealing. Such sealing rings (such as o-rings, for example) are omitted for clarity onFIGS.5and6.

Fluid connection housing314provides housing notches327. When fluid connection adapter200is received into fluid connection housing assembly300, rib210on fluid connection adapter200eventually abuts housing notches327, thereby limiting the travel of fluid connection adapter200into fluid connection housing assembly300.

A plurality of locking elements317rotate within fluid connection housing314. In the embodiments illustrated onFIGS.5and6, four (4) locking elements317are provided. The scope of this disclosure is not limited to any specific number of locking elements317that may be provided in other embodiments. Stated generally, each locking element317is disposed to constrict radially via rotation about a corresponding pivot pin316provided in the fluid connection housing assembly300. In more detail, locking elements317rotate about pivot pins316received into pin bores332on locking elements317and housing bores334on fluid connection housing314. Pivot pins316preferably provide pin grooves331for sealing cooperation with pin rotation gaskets333deployed within pin bores332in locking elements317. In the embodiments illustrated onFIGS.5and6, rotation stops322on locking elements317limit rotation of locking elements317about pivot pins316to a user-selected angular displacement. In other embodiments (not illustrated), rotation stops322may not be provided. Locking elements317also have straps319rigidly affixed (e.g. via bolting) to the exterior thereof in illustrated embodiments. Referring now toFIG.9, tension springs321connect locking elements317to fluid connection housing314via straps319. Generally stated, a spring bias ordains a default rotational position for locking elements317about their corresponding pivot pins316. In more detail, tension springs321create the spring bias to ordain and hold a default rotational position for locking elements317against rotation stops322in an “open” position. This disclosure is not limited to the manner in which such a spring bias is created. Other non-illustrated embodiments may, for example, use torsion springs to create the spring bias. Alternatively, other non-illustrated embodiments may, for example, use hydraulic or pneumatic arrangements to create bias to hold locking elements317in a default position. Other non-illustrated embodiments may forego holding locking elements317in a default position via a spring bias.

FIGS.5and6illustrate locking elements317having locking element inner and outer surfaces323,324. Locking elements317also have locking element rocking surfaces325. Locking element rocking surfaces325, and locking element inner and outer surfaces323,324are all described in more detail below with reference to interaction with cooperating parts within fluid connection housing assembly300.

Generally stated, at least one actuator assembly380energizes retraction of locking ring318. In some embodiments, actuator assemblies380may be remotely operable. In more detail, at least one actuator assembly380is rigidly affixed (e.g. via bolting) to fluid connection housing314. In the embodiments illustrated onFIGS.5and6, three (3) circumferentially spaced-apart actuator assemblies380are provided. The scope of this disclosure is not limited to any specific number of actuator assemblies380that may be provided in other embodiments. Actuator assemblies380are also rigidly affixed (e.g. via bolting) to locking ring318. In illustrated embodiments, actuator assemblies380are hydraulically-actuated piston assembles in which pistons382extend and retract locking ring318away from and towards locking elements317. The scope of this disclosure is not limited, however, to any particular design of actuator assemblies380. Actuator assemblies380further preferably provide guide rods381running parallel to the travel of pistons382to keep such piston travel rigid and straight under operational loads.

Locking ring318has locking ring inner surface326. Locking ring inner surface326is described in more detail below with reference to interaction with cooperating parts within fluid connection housing assembly300. Locking ring318is rigidly affixed (e.g. via bolting) to guide funnel311. Guide funnel311assists directing fluid connection adapter200into fluid connection housing assembly300.

FIG.6shows wellhead adapter312providing quick test fitting401received into quick test port402, preferably by threaded engagement. It will be appreciated that althoughFIG.6illustrates an embodiment in which one quick test fitting and port401,402are provided, the scope of this disclosure is not limited in this regard, and any number quick test ports402may be provided (or none at all). However, in most deployments only one will be in operation at any time. Quick test ports402that are not in operation may be sealed with threaded plugs for future use. One purpose of providing redundant quick test ports402is in case one or more become damaged during service, and have to be permanently sealed. In presently preferred embodiments, quick test ports402are preferably 3/16″ in diameter, although the scope of this disclosure is not limited in this regard.

Generally stated, fluid connection housing assembly300further provides quick test port402. Quick test port402comprises a fluid passageway from the exterior of fluid connection housing assembly300through to first seal bore341, for example. In more detail, quick test fitting401and quick test port402provide a fluid passageway through wellhead adapter312into the space between first and second seal sections207,208and first and second seal bores341and342when fluid connection adapter200is fully received into fluid connection housing assembly300. Fluid may be introduced through quick test fitting401into the space between first and second seal sections207,208and first and second seal bores341and342(via, for example, hand pumping). Pressure in the space between first and second seal sections207,208and first and second seal bores341and342may thus be equalized (and in particular, pressure between sealing rings in such space may be equalized) after the introduction of operational high pressure fluid (e.g. from a well) into wellhead adapter312.

Conversely, it will be appreciated that upon removal of operational pressure within wellhead adapter312, the seals created between first and second seal sections207,208and first and second seal bores341and342(and in particular, between sealing rings in such seals) may not immediately release by themselves. Quick test fitting401enables fluid trapped at pressure in the space between first and second seal sections207,208and first and second seal bores341and342to be relieved. In other applications, fluid delivered through quick test fitting401enables the integrity of the seals created between first and second seal sections207,208and first and second seal bores341and342(and in particular, between sealing rings in such seals) to be checked prior to introducing high pressure fluid into a connection between fluid connection adapter200and fluid connection housing assembly300.

FIGS.5and6also illustrate transducer ports602. It will be appreciated that althoughFIG.6illustrates an embodiment in which two transducer ports602are provided, the scope of this disclosure is not limited in this regard, and any number of transducer ports602may be provided (or none at all). It will be understood that various suitable equipment may be deployed into transducer ports602, including (without limitation) pressure sensors/transducers to monitor internal pressure IP such as shown and described below with reference toFIG.7D, for example. In illustrated embodiments (such as inFIG.6, for example), needle valve601is deployed in one of transducer ports602. In such embodiments, needle valve601may be used to drain/equalize pressure within wellhead adapter312during service operations when, for example, fluid connection adapter200is being removed and fluid connection housing assembly300is being exposed to atmospheric pressure. The scope of this disclosure is not limited to particular uses for transducer ports602or equipment deployed therein.

FIGS.6,7A through7D,8A through8C, and9should now be viewed together for an understanding of the operation of embodiments of the disclosed remotely-operated fluid connection and seal technology.FIGS.7A through7Dare sequential “freeze frame” views illustrating engagement of fluid connection assembly100to form a fluid connection and seal.FIGS.8A,8B and8Care additional, enlarged “freeze frame” views further illustrating engagement of fluid connection assembly100to form a fluid connection and seal.FIG.9is a partial section through fluid connection assembly100in a “closed and locked” position.FIG.7Ais a simplified rendering ofFIG.6depicting fluid connection assembly in an “open” position.FIG.7Dis a simplified rendering ofFIG.9depicting fluid connection assembly100in a “closed and locked” position.

Referring first toFIG.7A, the second adapter end of fluid connection adapter200enters the first housing end of the fluid connection housing assembly300through guide funnel311and past locking ring318. Stated generally with reference toFIGS.6,7A and7B, during entry of the second adapter end into the first housing end: (A) locking element actuating section206contacts locking element rocking surfaces325, thereby causing locking elements317to rotate such that locking element inner surfaces323contact the tapered lock engagement surface209; and (B) first seal section207sealingly contacts first seal bore341. Transitioning fromFIG.7AtoFIG.7Bin more detail, locking element actuating section206on fluid connection adapter makes contact with locking element rocking surfaces325, causing locking elements317to “close” via rotation as shown onFIG.7B, whereupon locking element inner surfaces323begin to engage enlarged OD section205on fluid connection adapter200.FIG.8Aillustrates such “closing” of locking elements317in enlarged format. The rotation of locking elements317as shown onFIG.7Balso restrains fluid connection adapter200from unintended reverse longitudinal movement (i.e. from accidentally “exiting” fluid connection housing assembly300).

Stated generally with reference toFIGS.6,7B and7C, when locking ring318is retracted, progressive engagement of locking ring inner surface326on locking element outer surfaces324urges locking element inner surfaces323to tighten against tapered lock engagement surface209. Transitioning now fromFIG.7BtoFIG.7Cin more detail, fluid connection adapter200ends its travel into fluid connection housing assembly300as rib210abuts housing notches327. Locking element inner surfaces323make full contact with tapered lock engagement surface209on fluid connection adapter200. Actuator assemblies380retract to bring locking ring318onto locking elements317. Retraction of actuator assemblies380causes locking ring inner surface326to make contact with locking element outer surfaces324. Locking element outer surfaces324have a taper. Progressive engagement of locking ring inner surface326on locking element outer surfaces324causes locking elements317to constrict radially. As locking ring inner surface326tightens its contact with locking element outer surfaces324, locking ring318urges locking element inner surfaces323tighter onto tapered lock engagement surface209. Preferably, tapered lock engagement surface209has a taper selected to cooperate with locking element inner surfaces323such that a full tightening action and force translation is enabled as locking elements317constrict radially, while still allowing relatively easy disengagement in reverse when releasing fluid connection adapter200from fluid connection housing assembly300. This disclosure is not limited to any specific cooperating tapers selected, and may include curved tapers as well as straight tapers.FIG.8Billustrates in enlarged format the above-described movement of locking ring318onto locking elements317to place locking elements317into a “closed” position.

Additionally, as illustrated onFIG.7C, when fluid connection adapter200ends its travel into fluid connection housing assembly300: (1) first seal section207on fluid connection adapter200sealingly engages first seal bore341inside wellhead adapter312, and (2) second seal section208on fluid connection adapter200sealingly engages second seal bore342also inside wellhead adapter312.

Stated generally with reference toFIGS.6,7C and7D, the locking element inner surfaces323are disposed to further tighten against the tapered lock engagement surface209responsive to displacement of the second adapter end towards the first housing end during engagement of the locking ring inner surface326on the locking element outer surfaces324. Transitioning now fromFIG.7CtoFIG.7Din more detail, operational internal pressure IP is introduced inside fluid connection housing assembly300. Well pressure may be the source of internal pressure IP, for example. Internal pressure IP displaces fluid connection adapter200into tighter restraint by locking elements317. Specifically, responsive to internal pressure IP, rib210displaces from abutment with housing notches327, urging tapered lock engagement surface209even tighter onto locking element inner surfaces323, and urging locking element outer surfaces324even tighter onto locking ring inner surface326.

FIG.7Dalso depicts first seal section207still sealingly engaged with first seal bore341, and second seal section208still sealingly engaged with second seal bore342. It will be understood that when internal pressure IP displaces fluid connection adapter200, first and second seal sections207,208also slidingly displace within first and second seal bores341,342but nonetheless maintain sealing contact and engagement. Further, with additional reference toFIG.9, it will be understood that, generally stated, first seal section207is disposed to expand radially and further tighten sealing contact against first seal bore341responsive to introduction of internal pressure IP within the second adapter end. In more detail, the presence of internal pressure IP urges first and second seal sections207,208to expand radially to make tighter contact with first and second seal bores341,342, thereby enhancing the seals formed therebetween.FIG.8Cillustrates in enlarged format the displacement of fluid connection adapter200into tighter restraint by locking elements317wherein locking elements317are now in a “closed and locked” position.

Disengagement of fluid connection adapter200from fluid connection housing assembly300is essentially the reverse operation of the one described immediately above with reference toFIGS.7A through7D. Internal pressure IP is removed. Actuator assemblies380extend, causing locking ring318to release locking elements317from radial constriction. Fluid connection adapter200may be removed. As enlarged OD section205on fluid connection adapter200withdraws, tapered lock engagement surface209and rib210cause locking elements317to rotate about pivot pins316back into an “open” position.

FIG.9is similar toFIGS.7D and8C, in thatFIG.9also illustrates locking elements317in a “closed and locked” position. InFIG.9, however, the illustrated embodiment depicts additional features, some of which may be considered optional in other embodiments. As described above with reference toFIGS.5and6,FIG.9shows rotation stops322on locking elements317to limit rotation of locking elements317about pivot pins316to a user-selected angular displacement. As also described above with reference toFIGS.5and6,FIG.9shows straps319and tension springs321. Tension springs321create a spring bias to ordain and hold a default rotational position for locking elements317against rotation stops322in an “open” position.

FIG.9further illustrates locking ring ridge328on locking ring318matched with locking element groove329on locking elements317. Locking ring ridge318is preferably a geometrically inverted ridge shaped to fit within locking element groove329. Locking ring ridge328cooperates with locking element groove329to provide an additional locking feature, strengthening the contact between locking ring inner surface326and locking element outer surfaces324against sliding displacement. Further, the additional locking feature provided by locking ring ridge328and locking element groove329may prevent inadvertent movement of locking ring318during operational service. Such inadvertent movement might arise by erroneous actuation of an actuator assembly380during operational service while the disclosed fluid connection is in the “closed and locked” position. The additional locking feature, although optional, may thereby enhance operational safety of the disclosed fluid connection when operational pressure is introduced.

FIG.10is a general perspective view of fluid connection housing300, with actuator assemblies380and locking ring318removed to reveal locking elements317.FIG.10also illustrates other features described above with reference to other Figures in this disclosure.

FIGS.11through13show various views of fluid connection assembly100.FIG.11is a general elevation view of fluid connection assembly100.FIG.12is a general plan (or “top”) view of fluid connection assembly100.FIG.13is a general perspective view of fluid connection assembly100.FIGS.11through13illustrate features and aspects of fluid connection assembly100also described above with reference to other Figures in this disclosure.FIGS.11through13are intended to aid further understanding of such features and aspects by providing additional views.

FIG.14illustrates one embodiment of an actuator assembly380in a fully retracted position, andFIG.15is a section as shown onFIG.14. As noted in the description above with reference toFIGS.5and6, actuator assemblies380may be hydraulically-actuated piston assembles in which pistons382extend and retract. Pistons382are hidden onFIGS.14and15in order to better view guide rods381. As shown onFIGS.14and15, guide rods381preferably run parallel to the travel of pistons382to keep such piston travel rigid and straight under operational loads. In illustrated embodiments, two (2) guide rods381are provided for each actuator assembly380, although the scope of this disclosure is not limited in this regard.

FIG.16is a section view through high strength fluid connection assembly150.FIG.17is an enlargement as shown onFIG.16. High strength fluid connection assembly150presents additional embodiments. In contrast to previously-described embodiments,FIGS.16and17depict high strength fluid connection assembly150providing strengthening sleeve501.

It will be noted that the illustrated embodiments ofFIG.16also include depiction of flanged fluid connection adapter200A fromFIG.3. It will nonetheless be understood that the following description of strengthening sleeve501is independent of the style of fluid connection adapter deployed. Strengthening sleeve501may be provided on any style of fluid connection adapter (including as depicted onFIGS.2,3and4) and the scope of this disclosure is not limited in this regard.

Generally stated, and as shown onFIGS.16and17, the second adapter end further includes strengthening sleeve501, wherein strengthening sleeve501provides wall thickness strengthening to a selected portion of the second adapter end. In more detail, strengthening sleeve501strengthens the material on flanged fluid connection adapter200A in the region of second seal section208, and further provides a strengthening sleeve extended portion503on the second adapter end that sealingly engages with strengthening sleeve bore343provided in wellhead adapter312. Advantageously, strengthening sleeve501is made from a strengthening metal such as titanium, although the scope of this disclosure is not limited to any particular material selection for strengthening sleeve501.FIG.17shows that the presence of strengthening sleeve501is operative to reduce the effective internal diameter at which a seal is formed to coincide with strengthening sleeve bore343, either via direct contact between strengthening sleeve501and strengthening sleeve bore343, or via contact between strengthening sleeve501and second seal section208.

It will be understood that in some embodiments, flanged fluid connection adapter200A has a wall thickness that is thinnest at the second adapter end, in the region of second seal section208. This thinning of wall thickness is inevitable given a geometry that requires (1) keeping external diameter towards the second adapter end small (to pass through locking elements317in the “open” position), and (2) keeping internal diameter large throughout so as not to affect internal flow or pressure. Especially at higher working pressures, it will be appreciated that when internal pressure IP onFIG.16urges second seal section208to expand radially onto second seal bore342, the thinner wall thickness of flanged fluid connection adapter200A in the regions of second seal section208may be susceptible to deformation or cracking, possibly leading to failure.

In other embodiments, such as illustrated onFIGS.16and17, strengthening sleeve501may be operative to act as a substitute “effective internal wall” of the second adapter end at the location where a pressure seal is formed. In this way, the internal diameter at which the seal is formed may be reduced (the seal now being formed on the exterior of the sleeve). The overall circumferential wall cross-sectional area at such reduced internal diameter is now also reduced (by virtue of a reduced diameter), thereby reducing the force exerted by internal pressure IP on the internal wall. Since the wall material itself in the sleeve is preferably strengthening material, such as titanium, the wall thickness of strengthening sleeve501may be thin to retain the force exerted by internal pressure IP.

Thus, as shown onFIGS.16and17, strengthening sleeve501is provided as an insert on the second adapter end of flanged fluid connection adapter200A. In the illustrated embodiments, strengthening sleeve501strengthens second seal section208by providing strengthening sleeve insert portion502received into second seal section208. In illustrated embodiments (to which the scope of this disclosure is not limited), strengthening sleeve501further provides strengthening sleeve extended portion503protruding from the second adapter end. As shown onFIG.17, strengthening sleeve extended portion503sealingly engages directly with strengthening sleeve bore343provided within wellhead adapter312.

It will be appreciated that the foregoing description of illustrated embodiments of strengthening sleeve501are exemplary only. The scope of this disclosure contemplates embodiments in which a strengthening insert or sleeve may be deployed as required to provide wall thickness strengthening to a selected portion of the second adapter end.

Further, in addition to providing strengthening, some embodiments of strengthening sleeve501may also provide wear protection to the inside of second adapter end via wear coatings such as, for example, tungsten carbide coatings.

Adapter release embodiments will now be described. While the fluid connection assembly100described above with reference toFIGS.1through15is highly serviceable, some applications have suggested room for additional innovation to assist with actively releasing fluid connection adapter200from fluid connection housing assembly300, especially after depressurization of internal pressure IP. Theoretically, fluid connection adapter200may be lifted clear of fluid connection housing assembly300once internal pressure IP is removed and fluid connection assembly100is moved to an “unlocked” state. However, in some applications, fluid connection adapter200and fluid connection housing assembly300can still remain “stuck together” until the seal between first and second seal sections207,208and first and second seal bores341,342is broken. In such situations, additional operations may be required to assist breaking the seal, such as pressurizing through quick test fitting401, applying an external lift force on fluid connection adapter200, “wiggling” adapter200while lifting, etc.

FIGS.18through23illustrate fluid connection assembly embodiments with an adapter release. Adapter release embodiments are designed to assist with breaking a seal between first and second seal sections207,208and first and second seal bores341,342in situations where fluid connection adapter200and fluid connection housing assembly300remain “stuck together” even though in an unlocked state with internal pressure IP removed. In adapter release embodiments according toFIGS.18through23, guide funnel311X is configured to contact a release collar211provided on fluid connection adapter200X when the locking ring318X is actuated to move away from the fluid connection housing314. Contact by guide funnel311X on release collar211, followed by further displacement of locking ring318X away from fluid connection housing314, causes fluid connection adapter200X to separate from fluid connection housing assembly300X, thereby breaking a pressure seal between adapter seal sections207,208and housing seal bores341,342. In some embodiments, further displacement of locking ring318X also proffers fluid connection adapter200X to a crane, for example, which can then withdraw adapter200X from fluid connection housing assembly300X.

FIGS.24A through25Dillustrate an embodiment of actuator assembly380X including position sensors. It will be appreciated fromFIG.19, for example, that actuator assembly380X causes guide funnel311X and locking ring318X to displace relative to fluid connection housing314. First and second sensors384A,384B onFIGS.24A through25Ddetect positional states of actuator assembly380X. The detected positional states correspond to selected positions of fluid connection adapter200X relative to fluid connection housing assembly300X during entry, lock, seal, release and exit of fluid connection adapter200X into and out from fluid connection housing assembly300X. In embodiments illustrated onFIGS.24A through25D, first and second sensors384A,384B detect proximity to first and second sensed portions387A,387B of guide rods311X. First and second sensed portions387A,387B are located on guide rods311X such that detected proximity to either, neither or both of first and second sensors384A,384B corresponds to a positional state of fluid connection adapter200X during travel into and out from fluid connection housing assembly300X. The positional states of fluid connection adapter200X detected by sensors384A,384B relative to fluid connection housing assembly300X may be monitored remotely.

In more detail,FIGS.18and19are similar toFIGS.3and6, except thatFIGS.18and19depict fluid connection adapter200X and fluid connection housing assembly300X configured in an exemplary adapter release embodiment.FIG.18is an elevation view of fluid connection adapter200X. Fluid connection adapter200X includes enlarged OD section205, locking element actuating section206, first seal section207, second seal section208, tapered lock engagement surface209and rib210as previously described with reference toFIG.3. Fluid connection adapter200X onFIG.18also includes release collar211. As will be described, release collar211is for contact engagement with guide funnel311X onFIG.19. Release collar211is thus positioned, shaped and sized on fluid connection adapter200X for such contact engagement with guide funnel311X. In preferred embodiments, release collar211is provided in annular parts (such as two semicircular parts) that may be fixed around fluid connection adapter200X at a desired location via screw clamping. In other embodiments, release collar211may be attached to fluid connection adapter200X via set screws, heat shrinking or welding. In other embodiments, release collar211and fluid connection adapter200X may be a unitary workpiece.

FIG.19is a section view of fluid connection housing assembly300X configured to receive fluid connection adapter200X. Fluid connection adapter200X is not in section onFIG.19. Similar toFIG.18,FIG.19shows fluid connection adapter200X including enlarged OD section205, locking element actuating section206, first seal section207, second seal section208, tapered lock engagement surface209, rib210and release collar211. Similar toFIG.6,FIG.19shows fluid connection housing assembly300X including wellhead adapter312, flanged connection313, fluid connection housing314, pivot pins316, locking elements317, locking element inner surface323, locking element outer surface324, locking element rocking surface325, housing notch327, first seal bore341, second seal bore342, quick test fitting401, quick test port402, needle valve601and transducer ports602, all as shown and described above with reference toFIG.6. Fluid connection housing assembly300X onFIG.19also includes guide funnel311X, locking ring318X and locking ring inner surface326X. Actuator assemblies380X as shown onFIG.19each include actuator link382X (for example, a piston), actuator housing383X, actuator base385X, and actuator cylinder386X. As will be described in further detail below, guide funnel311X, locking ring318X and actuator assemblies380X onFIG.19interoperate with release collar211on fluid connection adapter200X to enable adapter release embodiments illustrated and described herein. In some adapter release embodiments, actuator assemblies380X illustrated onFIG.19may provide a longer actuation stroke than, for example, counterpart actuator assemblies380as shown and described with reference toFIG.6. The longer actuation stroke further facilitates adapter release functionality.

FIG.20is an exploded view similar toFIG.5, except thatFIG.20depicts fluid connection adapter200X and fluid connection housing assembly300X configured in an exemplary adapter release embodiment. Many of the same parts commonly depicted onFIG.19andFIG.6are also depicted onFIG.20. Additionally, fluid connection housing assembly300X onFIG.20shows straps319, biasing elements321(such as tension springs, for example), rotation stops322, locking element inner surfaces323, locking element outer surfaces324, locking element rocking surfaces325, pin bores332and housing bores334, all as shown and described above with reference toFIG.5. Fluid connection housing assembly300X onFIG.20also includes guide funnel311X, locking ring318X and locking ring inner surface326X, as also shown onFIG.19. Actuator assemblies380X as shown onFIG.20each include guide rods381X, actuator housing383X, first sensor384A, second sensor384B, and actuator base385X. As will be described in further detail below, first and second sensors384A,384B operate to allow a positional state of fluid connection adapter200X to be determined and monitored during travel of fluid connection adapter200X into and out from fluid connection housing assembly300X.

FIGS.21A through21Hare sequential “freeze frame” views illustrating various positional states during entry, engagement, release and exit of fluid connection adapter200X into and out from fluid connection housing assembly300X in an exemplary adapter release embodiment.FIGS.21A through21Dcorrespond toFIGS.7A through7Das illustrated and described above for fluid connection embodiments without an adapter release. Fluid connection adapter200X enters fluid connection housing assembly300X, and then locks into fluid connection housing assembly300X onFIGS.21A through21Cessentially the same way fluid connection adapter200enters fluid connection housing assembly300, and then locks into fluid connection housing assembly300onFIGS.7A through7C. Refer to description above associated withFIGS.7A through7Cfor details. Likewise, internal pressure IP displaces fluid connection adapter200X into tighter restraint against fluid connection housing assembly300X onFIG.21Dessentially the same way internal pressure IP fluid displaces fluid connection adapter200into tighter restraint against fluid connection housing assembly300onFIG.7D. Also, the presence of internal pressure IP urges first and second seal sections207,208on fluid connection adapter200X to expand radially to make tighter contact with first and second seal bores341,342on fluid connection housing assembly300X, thereby enhancing the seals formed therebetween. Again, refer to description above associated withFIG.7Dfor additional details.

FIGS.21E through21Hare sequential “freeze frame” views illustrating various positional states during release and exit of fluid connection adapter200X from fluid connection housing assembly300X in an exemplary adapter release embodiment. Prior description associated withFIGS.7A through7Dnoted that fluid connection adapter200's disengagement from fluid connection housing assembly300was essentially the reverse operation of engagement.FIGS.21E through21Hillustrate that disengagement of fluid connection adapter200X from fluid connection housing assembly300X in adapter release embodiments is not essentially a reverse operation of engagement.FIGS.21E through21Hillustrate additional disengagement aspects and features once internal pressure IP is removed.

The sequential “freeze frame views ofFIGS.21A through21Hwill now be described in more detail. Fluid connection adapter200X onFIGS.21A through21Hincludes release collar211. Release collar211is configured on fluid connection adapter200X to stand sufficiently proud so as to be capable of being contacted by guide funnel311X on fluid connection housing assembly300X.FIG.21Aillustrates embodiments in which, in an operational mode, fluid connection adapter200X is free and may be inserted into guide funnel311X when guide funnel311X is in an extended state (via guide funnel connection to locking ring318X in an extended state). Guide funnel311X, in an extended state, is thus disposed to support fluid connection adapter200X by the release collar211. In these embodiments, engagement of release collar211on guide funnel311X may help to center fluid connection adapter200X in fluid connection housing assembly300X in preparation for locking and seal engagement. Further, in these embodiments, retraction of guide funnel311X (via retraction of locking ring318X) may bring fluid connection adapter200X smoothly and predictably into fluid connection housing assembly300X for locking, and for seal engagement between first and second seal sections207,208and first and second seal bores341,342.

In other embodiments, in an operational mode, guide funnel311X and locking ring318X may be sufficiently retracted so that guide funnel311X does not support fluid connection adapter200X by release collar211. In such other embodiments, fluid connection adapter200X may be inserted into fluid connection housing assembly300X via gravity or an external downward pushing force.

FIG.21Billustrates an adapter release embodiment in a “sealed” positional state, in which fluid connection adapter200X has been inserted into fluid connection housing assembly300X and a seal has been established between first seal section207and first seal bore341, and second seal section208and second seal bore342.

FIG.21Cillustrates an adapter release embodiment in a “locked” positional state per prior disclosure with reference toFIGS.7A through7C. It will be understood generally with reference toFIGS.21A through21Dthat adapter release embodiments lock and seal in essentially the same way as described above with reference toFIGS.7A through7D. Refer to counterpart prior description associated withFIGS.7A through7D. Note also that release collar211on fluid connection adapter200X onFIGS.21A through21Dis not in play in locking and seal engagement.

FIG.21Dillustrates an adapter release embodiment in a “pressurized” positional state per prior disclosure with reference toFIG.7D. Refer to counterpart prior description associated withFIG.7D.

FIG.21Eillustrates depressurization of an adapter release embodiment, in which internal pressure IP as shown onFIG.21Dhas been removed. Locking elements317may displace as shown onFIG.21Eresponsive to depressurization.

FIG.21Fillustrates an adapter release embodiment moving to an “unlocked” positional state. Locking ring318X is extended until locking ring318X no longer restrains locking element outer surfaces324. Locking element inner surfaces323are free to rotate and completely disengage from tapered lock engagement surfaces209on fluid connection adapter200X, such that fluid connection adapter200X is free to be withdrawn from fluid connection housing assembly300X. Note that a prior-established seal between first seal section207and first seal bore341, and/or between second seal section208and second seal bore342is not broken in the “unlocked” positional state illustrated onFIG.21F. The “unlocked” positional state onFIG.21Fdisposes the seal as “available to be broken” without breaking the seal.FIG.21Fdepicts the limit of the “unlocked” positional state where locking ring318X is extended until guide funnel311X contacts (but does not displace) release collar211on fluid connection adapter200X.

FIG.21Gillustrates an adapter release embodiment moving to a “released” (or “unsealed”) positional state. Locking ring318X is extended so that guide funnel311X displaces release collar211on fluid connection adapter200X (and thereby separates fluid connection adapter200X from fluid connection housing assembly300X). Separation of fluid connection adapter200X from fluid connection housing assembly300X breaks any prior-established seal between first seal section207and first seal bore341, and/or between second seal section208and second seal bore342. Fluid connection adapter200X is now free and available to be lifted clear of fluid connection housing assembly300X in this “released” (or “unsealed”) positional state according toFIG.21G.

FIG.21Hillustrates an adapter release embodiment moving to an optional, additional “proffered” positional state to assist further subsequent retrieval of fluid connection adapter200X from fluid connection housing assembly300X. Locking ring318X is extended further so that guide funnel311X separates fluid connection adapter200X further from housing assembly300X (via further displacement of release collar211on adapter200X). This action, as shown onFIG.21H, proffers fluid connection adapter200X clear of fluid connection housing assembly300X and holds adapter200X steady to be lifted clear if desired.

As noted above, in some adapter release embodiments, actuator assemblies380X illustrated onFIGS.21A through21Hmay provide a longer actuation stroke than, for example, counterpart actuator assemblies380as shown and described with reference toFIGS.7A through7D. The longer actuation stroke in such adapter release embodiments provides sufficient extension and retraction of locking ring318X (and guide funnel311X) onFIGS.21A through21Hto enable, for example, a “free” positional state such as illustrated onFIG.21A, or a “released” positional state such as illustrated onFIG.21G, or a “proffered” positional state such as illustrated onFIG.21H.

FIGS.22A through22Hare partial, enlarged views corresponding toFIGS.21A through21H, allowing the “freeze frame” views ofFIGS.21A through21Hto be understood in more detail. Refer to description above associated withFIGS.21A through21H.

FIG.23is an enlarged view corresponding toFIG.21DandFIG.22D, depicting fluid connection adapter200X and fluid connection housing assembly300X in a locked and pressurized state. Refer to description above associated withFIGS.21C and21D.

FIGS.24A and24Bdepict details of an embodiment of actuator assembly380X which may be deployed in adapter release embodiments. Actuator assembly380X onFIGS.24A and24Bis configured to determine and monitor selected positional states during entry, engagement, release and exit of fluid connection adapter200X into and out from fluid connection housing assembly300X.FIGS.24A and24Bshould be viewed together.FIGS.24A and24Billustrate actuator assembly380X including guide rods381X, actuator link382X (for example, a piston), actuator housing383X, first sensor384A, second sensor384B, actuator base385X, actuator cylinder386X, first sensed portion387A and second sensed portion387B.

The mechanical and hydraulic operation of actuator assembly380X onFIGS.24A and24Bis essentially the same for actuator assembly380as described above with reference toFIGS.14and15. Actuator assemblies380X may be hydraulically-actuated piston assembles in which actuator links382X extend and retract out from and back into actuator cylinder386X. Guide rods381X run essentially parallel to the travel of actuator links382X to keep such travel rigid and straight under operational loads. In illustrated embodiments, two (2) guide rods381X are provided for each actuator assembly380X, although the scope of this disclosure is not limited in this regard.

Referring momentarily toFIG.19, for example, actuator housings383X are rigidly connected to locking ring318X and actuator bases385X are rigidly connected to fluid connection housing314. In other, non-illustrated embodiments, actuator housings383X may be rigidly connected to guide funnel311X. Returning toFIGS.24A and24B, hydraulic extension and retraction of actuator links382X within actuator cylinders386X correspondingly displaces locking ring318X and guide funnel311X with respect to fluid connection housing314. Note also description above with reference toFIG.19, in which, in some adapter release embodiments, actuator assemblies380X may provide a longer actuation stroke than, for example, counterpart actuator assemblies380as shown and described with reference toFIGS.14and15.

FIG.24Billustrates actuator assembly380X onFIG.24Acut away to reveal first and second sensors384A,384B disposed to interact with first and second sensed portions387A,387B on at least one guide rod381X.FIG.24Billustrates an example of the positional determination and monitoring by first and second sensors384A,384B that will be described more comprehensively below with reference toFIGS.25A through25D. Actuator assemblies380X onFIGS.24A and24Billustrate actuator link382X in an extended position corresponding to locking ring318X onFIG.19being in the fully “extended” position.FIG.24Bshows that first sensor384A is positioned on guide rod381X so that first sensor384A detects the presence of second sensed portion387B when actuator link382X is in a fully extended position such that locking ring318X is also in a fully extended position.

FIGS.25A through25Dare sequential “freeze frame” views illustrating exemplary positional states of actuator assembly380X during entry, seal and lock of fluid connection adapter200X with respect to fluid connection housing assembly300X. Refer also toFIGS.21A through21CandFIGS.22A through22Cand associated description for discussion of the entry, seal and lock of fluid connection adapter200X with respect to fluid connection housing assembly300X.

FIG.25Ais essentially the same view as shown inFIGS.24A and24B. Actuator assembly380X onFIG.25Ashows actuator link382X in an extended position corresponding to locking ring318X onFIG.19being in the fully extended position. Referring momentarily toFIGS.21A and21H, a fully extended locking ring318X corresponds to “free” and “proffered” positional states.FIG.25Ashows that first sensor384A is positioned on guide rod381X so that first sensor384A detects the presence of second sensed portion387B when actuator link382X is in a fully extended position. First sensor384A thus detects either a “free” or “proffered” positional state.

FIG.25Bshows that first sensor384A is positioned on guide rod381X so that first sensor384A detects the presence of first sensed portion387A and second sensor384B detects the presence of second sensor387B when actuator link382X is in a first partially-retracted (or first partially-extended) position.FIG.25Bcorresponds toFIGS.21B and21Fin a sealed but unlocked positional state, such that fluid connection adapter200X may either be inserted into or withdrawn from fluid connection housing assembly300X. With additional reference to FIG.21B,FIG.25Balso corresponds to fluid connection adapter200X inserted into fluid connection housing assembly300X and ready for locking.

FIG.25Dshows that first sensor384A is positioned on guide rod381X so that second sensor384B detects the presence of first sensed portion387A when actuator link382X is in a fully retracted position.FIG.25Dcorresponds toFIG.21Cin a locked positional state with locking ring318X fully retracted.

FIG.25Cshows that neither of first and second sensors384A,384B detect the presence of a sensed portion387A or387B. Actuator link382X onFIG.25Cis in a second partially-retracted (or second partially-extended) position, corresponding to being in transition between positional states, such as betweenFIGS.25B and25D(between unlocked and locked), for example.

It will thus be appreciated fromFIGS.24A through25Dthat selected positional states onFIGS.21A through21Hmay be determined and monitored depending on the condition of first and second sensors384A,384B with respect to first and second sensed portions387A,387B. The specific positional states detected and monitored with reference toFIGS.25A through25Dare exemplary only, and the scope of this disclosure is not limited to the specific positional states that may be available to be detected and monitored by embodiments of actuator assembly380X with multiple sensors and sensed portions. In currently preferred embodiments, first and second sensors384A,384B are magnetic sensors. In such magnetic sensor embodiments, guide rods381X on which first and second sensed portions387A,387B are deployed are preferably made from a non-ferrous material such as stainless steel, and first and second sensed portions387A,387B are ferrous portions in the stainless steel guide rod381X (such as a ferrous steel grub screw or rivet). The scope of this disclosure is not limited, however, to the type of sensor deployed for first and second sensors384A,384B, or the manner in which the sensors are activated.

FIGS.24A and24Beach depict currently preferred embodiments of actuator assembly380X providing two (2) guide rods381X, with only one guide rod381X addressed by first and second sensors384A,384B. In other (non-illustrated) embodiments, actuator assembly380X may provide two (2) guide rods381X configured to be addressed by first and second sensors384A,384B in order to provide redundancy in case of sensor failure. The scope of this disclosure, however, is not limited to any embodiments including specific guide rod and sensor redundancy.

Earlier description made clear that the scope of this disclosure in no way limits the described fluid connection design embodiments and associated seal embodiments to specific sizes or models. Currently envisaged embodiments make the disclosed technology available in several sizes, shapes, and pressure ratings to adapt to desired applications. Proprietary connections may require specialized adapters. It will be nonetheless understood that the scope of this disclosure is not limited to any particular sizes, shapes, and pressure ratings for various embodiments thereof, and that the embodiments described in this disclosure and in U.S. provisional patent application Ser. No. 62/649,008 (incorporated herein by reference) are exemplary only.

Currently envisaged embodiments of the fluid connection designs (and associated seals) provide pressure ratings up to and including at least 15,000 psi MAWP. Currently envisaged sizes include internal diameters up to and including at least 8″ ID. The foregoing sizes and performance metrics are exemplary only, and the scope of this disclosure is not limited in such regards.

Although fluid connection embodiments and associated seal embodiments have been described in this disclosure with reference to an exemplary application in hydraulic fracturing, pressure control at a wellhead, alternative applications could include, for example, areas such as subsea connections, deep core drilling, offshore drilling, methane drilling, open hole applications, well pressure control, wireline operations, coil tubing operations, mining operations, and various operations where connections are needed under a suspended or inaccessible load (i.e., underwater, hazardous area). The scope of this disclosure is not limited to any particular application in which the described fluid connections may be deployed.

Exemplary materials used in the construction of the disclosed embodiments include high strength alloy steels, high strength polymers, and various grades of elastomers.

Although the material in this disclosure has been described in detail along with some of its technical advantages, it will be understood that various changes, substitutions and alternations may be made to the detailed embodiments without departing from the broader spirit and scope of such material as set forth in the following claims.