Inline fracturing valve systems and methods
11697981 · 2023-07-11
Assignee
Inventors
- Michael Krejci (Houston, TX, US)
- Pheng Aun Soh (Singapore, SG)
- Stuart Robinson (Katy, TX, US)
- Edward L. Ganzinotti, III (Houston, TX, US)
Cpc classification
E21B43/2607
FIXED CONSTRUCTIONS
International classification
E21B43/12
FIXED CONSTRUCTIONS
Abstract
Fracturing systems with frac valves for controlling flow of fracturing fluid are provided. In one embodiment, a fracturing apparatus includes a frac valve having a housing with a bore to convey fracturing fluid, a seal disposed within the bore, and an actuator coupled to control movement of the seal. The actuator can be disposed within the bore so as to move the seal between a closed position in which the seal blocks fracturing fluid flow through the bore and an open position that allows fracturing fluid flow through the bore. Additional systems, devices, and methods for fracturing are also disclosed.
Claims
1. A fracturing apparatus comprising: a frac valve to control flow of fracturing fluid through the frac valve, the frac valve comprising: a housing having a bore to convey the fracturing fluid, wherein the bore has a central axis extending from an inlet of the housing to an outlet of the housing; a seal disposed within the bore; and an actuator coupled to control movement of the seal, wherein the actuator is disposed within the bore so as to move the seal between a closed position in which the seal blocks fracturing fluid flow through the bore and an open position that allows fracturing fluid flow through the bore, the actuator includes flow-by conduits that permit fracturing fluid flow past the actuator when the seal is in the open position, and the actuator is positioned inline with the inlet of the housing and the outlet of the housing such that the central axis extending from the inlet of the housing to the outlet of the housing intersects the actuator.
2. The fracturing apparatus of claim 1, wherein the actuator is disposed within the bore so as to move axially along the central axis when moving the seal between the closed position and the open position.
3. The fracturing apparatus of claim 1, wherein the seal includes an elastomer seal.
4. The fracturing apparatus of claim 1, wherein the frac valve does not have an external actuator.
5. The fracturing apparatus of claim 1, wherein the actuator includes a piston disposed within the bore.
6. The fracturing apparatus of claim 1, wherein the frac valve includes a tapered sealing surface along the bore and the seal is closed against the tapered sealing surface to block fracturing fluid flow through the bore when the seal is in the closed position.
7. The fracturing apparatus of claim 6, wherein the seal includes a tapered outer surface oriented to seal against the tapered sealing surface of the frac valve when the seal is in the closed position.
8. The fracturing apparatus of claim 1, wherein the flow-by conduits include flow-by holes extending through the actuator.
9. The fracturing apparatus of claim 1, comprising a seal carrier that carries the seal, wherein the actuator is coupled to the seal carrier to control movement of the seal via the seal carrier.
10. The fracturing apparatus of claim 1, wherein the seal is carried by the actuator.
11. The fracturing apparatus of claim 10, wherein the seal is positioned on a side of the actuator that is transverse to the bore of the housing.
12. The fracturing apparatus of claim 11, wherein the frac valve includes an additional seal positioned on an additional side of the actuator, and the additional side is also transverse to the bore of the housing.
13. The fracturing apparatus of claim 1, comprising a fracturing tree having the frac valve.
14. The fracturing apparatus of claim 1, comprising a wellhead, wherein the housing of the frac valve is installed within a bore of the wellhead.
15. The fracturing apparatus of claim 14, wherein the housing of the frac valve is landed on a shoulder of the wellhead.
16. A method of controlling flow of fracturing fluid in a fracturing apparatus, the method comprising: routing the fracturing fluid into a frac valve of the fracturing apparatus, the frac valve including: a housing having a bore to convey the fracturing fluid, wherein the bore has a central axis extending from an inlet of the housing to an outlet of the housing; a seal disposed within the bore; and an actuator coupled to control movement of the seal, wherein the actuator is disposed within the bore so as to move the seal between a closed position in which the seal blocks fracturing fluid flow through the bore and an open position that allows fracturing fluid flow through the bore, the actuator includes flow-by conduits that permit fracturing fluid flow past the actuator when the seal is in the open position, and the actuator is positioned inline with the inlet of the housing and the outlet of the housing such that the central axis extending from the inlet of the housing to the outlet of the housing intersects the actuator; and closing the frac valve to block fracturing fluid flow through the frac valve, wherein the seal includes an elastomer seal and closing the frac valve includes operating the actuator to compress the elastomer seal against an opposing surface to block fracturing fluid flow through the frac valve.
17. The method of claim 16, comprising opening the frac valve to permit fracturing fluid flow through the frac valve, wherein opening the frac valve includes moving the elastomer seal away from the opposing surface to permit fracturing fluid flow through the frac valve via an opening between the elastomer seal and the opposing surface.
18. The method of claim 16, wherein the actuator is a hydraulic actuator or an electric actuator.
19. The method of claim 16, wherein operating the actuator to compress the elastomer seal against the opposing surface includes operating a piston disposed within the bore to compress the elastomer seal against the opposing surface.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) These and other features, aspects, and advantages of certain embodiments will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
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DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS
(21) Specific embodiments of the present disclosure are described below. In an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.
(22) When introducing elements of various embodiments, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Moreover, any use of “top,” “bottom,” “above,” “below,” other directional terms, and variations of these terms is made for convenience, but does not require any particular orientation of the components.
(23) Turning now to the present figures, an example of a fracturing system 10 is provided in
(24) The fracturing system 10 includes various components to control flow of a fracturing fluid into the well 12. For instance, the fracturing system 10 depicted in
(25) The fracturing fluid supply system 22 may also (or instead) include one or more frac valves 18 for controlling flow of fracturing fluid to the well 12. The frac valves 18 of the fracturing fluid supply system 22 may be provided in the form of a frac valve described below or in any other suitable form. In some embodiments, the fracturing fluid supply system 22 includes trucks that pump the fracturing fluid to the wellhead assembly 16, but any suitable sources of fracturing fluid and manners for transmitting such fluid to the wellhead assembly 16 may be used. In some instances, the fracturing fluid supply system 22 includes a fracturing manifold for distributing fracturing fluid to multiple wells 12 via respective wellhead assemblies 16. The fracturing manifold may include frac valves 18 to control flow of fracturing fluid to the individual wells 12.
(26) In some embodiments, a frac valve 18 of the fracturing system 10 is embodied by one of the valves 30 described below. Various examples of valves 30 are described below as frac valves 30 for controlling flow of fracturing fluids. But it will be appreciated that the various valves 30 described herein could also or instead be used in other applications to convey other fluids. As described in greater detail below, the valves 30 can include inline actuators and seals positioned within flow paths of the valves to selectively control flow through the valves.
(27) In
(28) In operation, the actuator 32 moves the seal 34 between open and closed positions to control flow of fracturing fluid between ends 44 and 46 of the bore 36. While fracturing fluid could flow in either direction through the valve 30, in at least some instances the end 44 of the bore 36 is used as an inlet of the valve 30 and the end 46 of the bore 36 is used as an outlet of the valve 30. In some embodiments, including that shown in
(29) Flow-by holes 50 extend through the actuator 32 and the seal carrier 52 to facilitate flow of fracturing fluid through the bore 36 of the valve 30 when the seal 34 is in an open position. Although one example of a valve 30 having twelve circumferentially spaced flow-by holes 50 is depicted in
(30) In some embodiments, the flow-by holes 50 collectively provide a flow area similar to that of the inlet flow bore. That is, in the case of flow through the valve 30 from end 44 to end 46, the sum of the cross-sectional area of each flow-by hole 50 (measured perpendicular to the flow axis of that hole 50) may be within ten, five, three, two, or one percent of the cross-sectional area of the bore 36 at the end 44 (measured perpendicular to the flow axis of the bore 36 at the end 44), for instance. Further, in one embodiment the sum of the cross-sectional area of each flow-by hole 50 is equal to the cross-sectional area of the bore 36 at the end 44.
(31) As noted above, the position of the seal 34 is controlled via the actuator 32. In the example of
(32) The actuator 32, the seal 34, and the seal carrier 52 are shown positioned within the flow path of the valve 30, inline with the ends 44 and 46 along a central axis of the bore 36. The actuator 32, the seal 34, and the seal carrier 52 may be moved axially along the central axis between open and closed positions. With the seal 34 in an open position that allows flow, fracturing fluid may enter the housing 38 through the end 44 of the bore 36, flow past the seal 34 through an opening between the seal 34 and an opposing sealing surface 76 (e.g., a tapered sealing surface along the bore 36), flow through the seal carrier 52 and the actuator 32 via the flow-by holes 50, and exit the housing 38 through the end 46 of the bore 36. In some embodiments, including that of
(33) In at least some embodiments, the seal 34 is an elastomer (e.g., rubber) seal that is energized when compressed against the sealing surface 76 by the actuator 32. But the seal 34 may be made of any other suitable material, such as another polymer or metal, in other embodiments. The housing 38, the actuator 32, and the seal carrier 52 may be formed of metal (e.g., carbon or stainless steel) or any other suitable material. Although the seal carrier 52 could be permanently joined to the actuator 32 (e.g., via welding) or formed integrally with the actuator 32 (e.g., as a single forged or cast body), in at least some embodiments, the seal carrier 52 is removable from the actuator 32 to facilitate maintenance. For example, the seal 34 can be molded onto or otherwise affixed to the seal carrier 52 and, when the seal 34 is worn or otherwise damaged, the seal carrier 52 can be removed from the actuator 32 and replaced by a new seal carrier 52 and seal 34. In other instances, the seal 34 may be independently removable (from the seal carrier 52), allowing a replacement seal 34 to be used with the seal carrier 52 and the actuator 32.
(34) Another embodiment of a valve 30 is depicted in
(35) In the presently depicted embodiment, the actuator 32 is positioned within the bore 36 inline with the seal 34, the seal carrier 52, and the flow path through the valve 30 such that fracturing fluid flows through a flow-by area 94 around the exterior of the actuator 32 when the seal 34 is in an open position (e.g., as shown in
(36) In some embodiments, the actuator 32 itself carries the seal 34 without a separate seal carrier 52. Some examples of such embodiments are depicted in
(37) The two seals 34 in
(38) As discussed above, the number, size, shape, and orientation of the flow-by holes 50 in the actuator 32 may vary between embodiments. The flow-by holes 50 (e.g., twelve or sixteen holes) can be spaced circumferentially about the actuator 32 radially outward of the seals 34. In some instances, the valve 30 can be constructed such that the flow-by holes 50 collectively provide a flow-by area that is within ten, five, three, two, or one percent, or is equal to, the cross-sectional area of the bore 36 at the end 44 or 46 of the bore 36 upstream of the actuator 32.
(39) As shown in
(40) The seal 34 can be made of any suitable material. In some embodiments, the seal 34 is an elastomer, thermoplastic, or other non-metal seal. In some other embodiments, the seal 34 may be a metal seal. Further, a combination of metal and non-metal seals 34 may be used in some instances. The seal 34 may also have any suitable shape. In
(41) An additional embodiment of a valve 30 is depicted in
(42) The plug assembly 112 may be installed within the wellhead 14 in any suitable manner. As one example, in
(43) In operation, the seal 34 (e.g., an elastomer seal or other polymeric seal, or a metal seal) moves between open and closed positions to control flow between a central bore 142 and a port 144 in the plug body 124. While a single port 144 is presently shown, the plug body 124 may include additional ports 144 in some instances. As generally depicted in
(44) Like the flow-by holes 50 discussed above, the number, size, shape, and orientation of the flow-by slots 148 in the seal carrier 52 may vary. The flow-by slots 148 may be spaced circumferentially about the exterior of the seal carrier 52. In some instances, these flow-by slots 148 may collectively provide a flow-by area that is within ten, five, three, two, or one percent, or is equal to, the cross-sectional area of the bore 142 at another location, such as at a cylindrical portion of the bore 142 below the tapered sealing surface 76 in
(45) While the actuatable plug assembly 112 is shown installed within a wellhead 14 in
(46) The actuator 32 of the various embodiments described above can take any suitable form, such as a hydraulic actuator, a manual actuator, an electric actuator, or a pneumatic actuator, or combinations thereof. In at least some embodiments, the actuator 32 of a valve 30 is an internal actuator positioned within the flow path through the valve 30, actuation is within the valve body, and the valve 30 does not have an external actuator for controlling flow through the valve.
(47) While the aspects of the present disclosure may be susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and have been described in detail herein. But it should be understood that the invention is not intended to be limited to the particular forms disclosed. Rather, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the following appended claims.