Patent ID: 12247473

In the accompanying Figures, similar components or features, or both, may have a similar reference label.

DETAILED DESCRIPTION

While the scope of the apparatus and method will be described with several embodiments, it is understood that one of ordinary skill in the relevant art will appreciate that many examples, variations and alterations to the apparatus and methods described here are within the scope and spirit of the embodiments.

Accordingly, the embodiments described are set forth without any loss of generality, and without imposing limitations, on the embodiments. Those of skill in the art understand that the scope includes all possible combinations and uses of particular features described in the specification.

The systems and methods described aim to mitigate the threat of erosion by introducing a means to dissipate the energy of the stimulation treatment, while maintaining full delivery pressure, at the point of stimulation fluid introduction into the wellhead. The energy dissipating allows the stimulation fluid to maintain its velocity and pressure, while dissipating the energy that would contribute to erosion. Advantageously and unexpectedly, this is achieved by subjecting the fluid path, through a pressure contained flow block, to an induced cyclonic flow direction, thereby increasing the flow travel distance within a limited and workable dimension. In addition, the fluid flow path is not subjected to sharp changes in flow path trajectory, thus eliminating abrupt energy transfer through a sharp increase in fluid turbulence level. Advantageously, the energy dissipated throughout the increased flow travel distance in a cyclonic trajectory effectively eliminates erosion and ensures pressure retention capability throughout the well stimulation cycle. Advantageously, the energy dissipating flow block provides a means for the optimum and efficient dissipating of energy at the point of stimulation fluid introduction into a wellhead. Advantageously, the energy dissipating flow block provides a means to direct the flow trajectory of the stimulation fluid into a cyclonic flow allowing for maximum fluid travel distance and eliminates abrupt flow trajectory changes. Advantageously, the energy dissipating flow block can be used in conjunction with permanently installed wellhead components. Advantageously, the energy dissipating flow block eliminates the threat of well pressure containment loss due to erosion, while maintaining the same permanently deployed wellhead components. Advantageously, the energy dissipating flow block can increase flow rate of the stimulation fluid without increasing the primary bore size, which would necessitate replacement of component parts on the frac tree.

As used throughout, “cyclonic flow” or “cyclonic flow path trajectory” refers to circular flow that travels along the walls in a spiral from the inlet to the outlet. Cyclonic flow exerts a centripetal force.

As used throughout, “frac tree” refers to a specific type of Christmas tree for use in hydraulic fracturing that typically consists of a number of different types of valves arranged so as to manage the flow rates and pressures necessary for hydraulic fracturing.

Referring toFIG.1Aa front sectional view of energy dissipating flow block10. Energy dissipating flow block10includes body1, inlet nozzle4, cushioning sub5, and outlet nozzle6. Body1can have any internal geometry that produces cyclonic flow. The internal geometry of body1can include a conical frustum, a pyramidal frustum, a polyhedron, or combinations of the same. The maximum diameter of body1is between 20″ and 120″. In at least one embodiment, the maximum diameter of body1is 120″. The vertical height of body1is between 20″ and 120″, and alternately between 60″ and 120″. Regardless of geometric shape, the diameter of body1is wider at top2and narrower at bottom3. In at least one embodiment, the interior of body1can have a conical frustum shape that funnels the flow of the stimulation fluid down into main vertical flow path toward outlet nozzle6. The exact geometry and size of body1can be selected based on the desired flow path travel distance and cyclonic flow trajectory, and API 6A material selection and manufacturing mandates. Body1is designed to withstand the centripetal force exerted by the cyclonic flow. The desired flow path travel distance and cyclonic flow trajectory may be determined based on the flow rate and pressure of the stimulation fluid in existing applications in applications where the energy dissipating flow block is to be used in existing wellheads or in anticipated future applications.

Inlet nozzle4can be any type of connection that meets the requirements of API 6A and promotes cyclonic flow. Inlet nozzle4is positioned proximate and parallel to top2of body1of energy dissipating flow block10. Inlet nozzle4is asymmetrical or non-concentric to the centerline of body1of energy dissipating flow block10. The positioning of inlet nozzle4induces cyclonic flow of the stimulation fluid. In at least one embodiment, inlet nozzle4is an eccentric inlet. Inlet nozzle4can include monoflex hose7. Monoflex hose7connects energy dissipating flow block10to the surface frac circuit.

Cushioning sub5is positioned parallel to top2of body1of energy dissipating flow block10and across from inlet nozzle4in the shortest straight line distance. Cushioning sub5provides a damping effect to the energized stimulation fluid entering energy dissipating flow block10. Fluids with limited compressibility, but with some measure of dampening, will occupy the cushioning sub that is strategically placed in the direct primary flowpath. The fluid will occupy the volume of the cushioning sub and provide the function of dampening any subsequent fluid entry into the body of the energy dissipating flow block. Because the fluid occupying the cushioning sub is unable to travel anywhere else its lack of compressibility will in turn act as a temporary baffle to redirect any subsequent fluid entering the body to follow a direction of travel governed by the geometric shape of the body. Cushioning sub5is any type of fitting that meets the API 6A standards.

Outlet nozzle6can be any type of connection the meets the requirements of API 6A. Outlet nozzle6is sized to connect to frac tree8.

Referring toFIGS.2A-2Cwith reference toFIGS.1A-1B, energy dissipating flow block10can be installed in frac tree8. Energized stimulation fluid enters inlet nozzle4of energy dissipating flow block10and is directed into a cyclonic flow path trajectory in body1. The straight line equivalent distance the energized stimulation fluid travels depends on the size of energy dissipating flow block10and the amount of kinetic energy (pressure) that needs to be dissipated. The cyclonic flow path trajectory of the energized stimulation fluid in body1dissipates energy in the energized stimulation fluid. Dissipating the kinetic energy of the energized stimulation fluid reduces the fluid velocity of the energized stimulation fluid which reduces the Reynolds number. The reduced Reynolds number reduces the turbulence which can reduce the rate of erosion to a degree such that the well stimulation design can be delivered without risking the wellhead's pressure containment. Stimulation fluid exits energy dissipating flow block10through outlet nozzle6having reduced fluid velocity while retaining the same flow rate relative to the energized stimulation fluid. The stimulation fluid has reduced Reynolds number, reduced turbulence and will have reduced erosion rates compared to the energized stimulation fluid. The stimulation fluid enters the wellbore through frac tree8.

Energy dissipating flow block10can be used for the entire duration of the well stimulation delivery cycle. The installation of energy dissipating flow block1can increase the flow rate of the stimulation fluid entering the wellbore by at least 5 vol %, alternately by at least 10 vol %, alternately by at least 15 vol %, alternately by at least 20 vol %, alternately by at least 25 vol %, and alternately by between 5 vol % and 25 vol % compared to a system without an energy dissipating flow block10.

Increasing the flow rate of the stimulation fluid can achieve increased effective stimulation areas and greater well conductivity with the same installed equipment, which can increase operational efficiency.

The energy dissipating flow block as described is not a cyclonic separator or hydrocyclone separator. The energy dissipating flow block is in the absence of separation means.

Examples

According to a prophetic example, the inlet nozzle and cushioning sub would each be a 7 1/16″×15 M connection. The outlet nozzle would be a 5⅛″×15 M connection. Each of these connections are API 6A compliant connections. The size of these connections are selected to fit an existing frac tree. Dimensions could enable increase in flow rate from 92 barrels per minute to 120 barrels per minute without loss of pressure containment.

Although the present invention has been described in detail, it should be understood that various changes, substitutions, and alterations can be made hereupon without departing from the principle and scope of the invention. Accordingly, the scope of the present invention should be determined by the following claims and their appropriate legal equivalents.

There various elements described can be used in combination with all other elements described here unless otherwise indicated.

The singular forms “a”, “an” and “the” include plural referents, unless the context clearly dictates otherwise.

Optional or optionally means that the subsequently described event or circumstances may or may not occur. The description includes instances where the event or circumstance occurs and instances where it does not occur.

Ranges may be expressed here as from about one particular value to about another particular value and are inclusive unless otherwise indicated. When such a range is expressed, it is to be understood that another embodiment is from the one particular value to the other particular value, along with all combinations within said range.

Throughout this application, where patents or publications are referenced, the disclosures of these references in their entireties are intended to be incorporated by reference into this application, in order to more fully describe the state of the art to which the invention pertains, except when these references contradict the statements made here.

As used here and in the appended claims, the words “comprise,” “has,” and “include” and all grammatical variations thereof are each intended to have an open, non-limiting meaning that does not exclude additional elements or steps.