Pulsation Dampening System for High-Pressure Fluid Lines
20170211741 ยท 2017-07-27
Inventors
Cpc classification
F15B1/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16L55/041
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
Abstract
Disclosed is an in-flow pulsation dampening system for high-pressure (e.g., 10K psi and higher) fluid lines. At high fluid flow pressures, the dampening system is a dual stage dampening system, responsive to low (e.g., when first charging the fluid line) and to very high-pressure pulsations. An external containment shell handles the full fluid flow pressures. One or more internal shells contain and handle the internal gas dampening system. The in-flow relationship of the gas dampening component assures that pressure differences between the internal gas handling system and the high-pressure fluid flow is always relatively small. This enables the gas handling components to be constructed of less robust material than the external shell (even though the gas system's internal pressure can equal that of the fluid flow), and be less susceptible to pressure failure.
Claims
1. A pulsation dampener apparatus (10) for dampening pressure pulses in a high-pressure fluid flow line (16), the pulsation dampener apparatus (10) comprising: a dampener housing (12), the dampener housing (12) substantially being an elongated pipe having two ends (14) a first-end (14a) and a second-end (14b), and internally having a fluid flow thru-path (22) and a non-flow fluid chamber (24) both along a length (L) of the dampener housing (12), the dampener housing (12) in liquid communication with the fluid flow thru-path (22); a housing-to-flow line adapter (20) adapted to connect the ends (14) of the dampener housing (12) to said high-pressure fluid flow line (16); a series of damper canisters (50) internally disposed in the non-flow fluid chamber (24) of the dampener housing (12), the damper canisters (50) immersed in a fluid in the non-flow fluid chamber (24) and each damper canister (50) in pressure communication with the fluid flow thru-path (22) and adapted to dampen a portion of a pressure change of the fluid in the fluid flow thru-path (22); and A union interface (30) adapted to join one end (14) of the dampener housing (12) to a housing-to-flow line adapter (20), the union interface (30) having a flange member (33) connectable to another flange member (33) on the housing-to-flow line adapter (20) using flange fasteners (36), the combination when installed in the high-pressure fluid flow line (16), providing dampening of pressure pulsations of the fluid in the high-pressure fluid flow line (16).
2. A pulsation dampener apparatus (10) for dampening pressure pulses in a high-pressure fluid flow line (16) of claim 1, wherein the fluid is a fracing fluid.
3. A damper canister (50) for use in a pulsation dampener apparatus (10) for dampening fluid pressure pulses in a fluid in a high-pressure fluid flow line (16), the damper canister (50) comprising: a canister housing (52) in the form of a high-pressure gas cylinder, the canister housing (52) having a housing interior space (54) and a cross-sectional housing opening (56) at one end, and an interior wall (58) adapted to slideably receive a piston assembly (70) along a depth (D) of the interior wall (58); a damper piston assembly (70) is closely received in the cross-sectional opening (56) of the canister housing (52), the piston assembly (70) is freely slideable along the depth (D) of the interior wall (58) of the canister housing (52); a stop ring (60) is fixable to a housing rim (57) at the housing opening (56) with a stop ring fastening means (62) and adapted to retain the damper piston assembly (70) slideably within the canister housing (50); and the canister housing (52), damper piston assembly (70) and stop ring (60) in combination adapted to contain a gas in the housing interior space (54) at continuously varying pressures up to 12,000 psi to provide said damper canister (50).
4. The damper canister (50) of claim 3, wherein the piston assembly (70) comprises: a damper piston (72) having a damper piston head (74) portion and a damper piston skirt (76) portion; the piston head (74) portion having gas pressure surface (75a) and a fluid pressure surface (75b); the piston skirt (76) portion, having a piston ring channel (79) within which a wiper ring (82) is received; the wiper ring (82) being biased by the ring channel (79) to form a slideable gas/fluid pressure seal between the piston skirt (76) and the interior wall (58) of the canister housing (52); and the piston assembly (70) being slideable within the canister housing (52) in response to a sufficient positive pressure difference between a gas pressure within the canister interior space (54) and a fluid pressure of a fluid flow thru-path (22) of said pulsation dampener apparatus (10).
5. The damper canister (50) of claim 3, wherein the piston assembly (70) further comprises the damper piston head (74) portion of the damper piston (72) having a gas port fitting (90) adapted to provide a sealable through-port between the gas pressure surface (75a) and the fluid pressure surface (75b) of the piston head (74) to enable the housing interior space (54) to receive and contain a gas charge to bias the housing interior space (54) at an initial gas pressure.
6. The piston assembly (70) of claim 5 wherein gas port fitting (90) of the damper piston (72) comprises: a gas through-port (92) between the gas pressure surface (75a) and the fluid pressure surface (75b) of the piston head (74); a normally closed gas valve (94) providing a means to charge the housing interior space (54) with a gas; and a gas port cover protecting the gas valve (94) from a fluid at the fluid pressure surface (75b) of the piston head (74).
7. The piston assembly (70) of claim 5 wherein the structure provides a pressure differential energized seal system designed to maintain a constant clearance between the piston assembly (70) and the canister wall, with the deformation of the piston from the internal gas pressure causes the piston assembly (70) to flatten, thus further biasing the seal portion of the piston assembly radially and toward the canister wall, effecting an improved seal.
8. A pressure pulsation dampener apparatus for use in a HP fluid flow line, the apparatus comprising: a dampener housing (12a) substantially being a cylindrical tube having a dampener interior fluid space (28) along a dampener housing axis (15) of length (L), a first open end (14a) is in fluid communication with said HP fluid flow line (16) via a union (30), and a second closed end (14c); at least one tandem damper gas canister (50a) having a canister axis (53), the tandem damper gas canister (50a) received within the dampener housing (12a) with its canister axis (53) parallel to the housing axis (15), the damper gas canister (50a) in pressure communication with the interior fluid space (28) of the dampener housing (12a).
9. The apparatus of claim 8, wherein the tandem damper gas canister (50a) comprises: a canister housing (52a) in the form of a high-pressure gas cylinder, the canister housing (52a) having a housing interior space (54) and a cross-sectional housing opening (56) at each end, and an interior wall (58) adapted to slideably receive a piston assembly (70a) along a depth (D) of the interior wall (58); a damper piston assembly (70a) is closely received in the cross-sectional opening (56) at each end of the canister housing (52a), the damper piston assemblies (70a) are freely slideable along the depth (D) of the interior wall (56) of the canister housing (52a); a stop ring (60) is fixable to a housing rim (57) at each housing opening (56) with stop ring fastening means (62) and adapted to retain the damper piston assembly (70a) slideably within the canister housing (50); and the canister housing (52a), damper piston assembly (70a) and stop ring (60) in combination adapted to contain a gas in the housing interior space (54) at continuously varying pressures up to 12,000 psi to provide said damper canister (50a).
10. The tandem damper gas canister (50a) of claim 9, wherein the piston assembly (70a) comprises: a damper piston (72) having a damper piston head (74) portion and a damper piston skirt (76) portion; the piston head (74) portion having gas pressure surface (75a) and a fluid pressure surface (75b); the piston skirt (76) portion, having at least one piston ring channel (79) within each of which ring channels (79) a wiper ring (82) is received; the wiper ring (82) being biased by the ring channel (79) to form a slideable gas/fluid pressure seal between the piston skirt (76) and the interior wall (58) of the canister housing (52a); and the piston assembly (70a) being slideable within the canister housing (52a) in response to a sufficient pressure difference between a gas pressure within the canister interior space (54) and a fluid pressure of a fluid contained within the dampener housing interior fluid space (28) of said pulsation dampener apparatus (10a).
11. The damper canister (50a) of claim 9, wherein the piston assembly (70a) further comprises the damper piston head (74) portion of the damper piston (72) having a gas port fitting (90) adapted to provide a sealable through-port between the gas pressure surface (75a) and the fluid pressure surface (75b) of the piston head (74) to enable the canister interior space (54) to receive and contain a gas charge to bias the canister interior space (54) at an initial gas pressure.
12. The piston assembly (70a) of claim 11 wherein gas port fitting (90) of the damper piston (72) comprises: a gas through-port (92) between the gas pressure surface (75a) and the fluid pressure surface (75b) of the piston head (74); a normally closed gas valve (94) providing a means to charge the housing interior space (54) with a gas; and a gas port cover protecting the gas valve (94) from a fluid at the fluid pressure surface (75b) of the piston head (74).
13. The piston assembly (70a) of claim 11, wherein the structure of the piston (72) provides a pressure differential energized seal system designed to maintain a constant clearance between the piston assembly (70) and the canister wall, with the deformation of the piston head (74) from the pressure differential across the piston head surfaces (75a & 75b) causes the piston head (74) to flatten, thus further biasing the seal portion of the piston assembly radially and toward the canister wall, effecting an improved seal.
14. The pressure pulsation dampener apparatus of claim 8, wherein the dampener housing (12a) is adapted to receive a plurality of tandem damper gas canisters (50a) within the dampener housing (12a) with all the canister axis (53) parallel to the dampener housing axis (15), and further having a through-flow spacer ring (64) disposed between adjacent tandem damper gas canisters (50a) for communicating a fluid pressure of the dampener housing interior fluid space (28) of the dampener housing (12a) to the piston fluid pressure surface (75b) of the piston head (74) between adjacent tandem damper gas canisters (50a).
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DESCRIPTION OF THE INVENTION
[0037] Referring now to the drawings, the details of preferred embodiments of the present invention are graphically and schematically illustrated. Like elements in the drawings are represented by like numbers, and any similar elements are represented by like numbers with a different lower case letter suffix.
[0038] The present pulsation dampener apparatus 10 is disclosed for use in a Hydraulic Fracturing (frac or fracing) process. In use in a fracing process, the pulsation dampener apparatus 10 is installed inline with the flow of the fracing fluid, and acts to dampen pressure pulses in the high-pressure fluid flow in the fracing fluid line 16. However, it is to be noted that although the embodiments set forth herein use the fracing process as an example of a pumping system utilizing high-pressure, pulsatile fluid flow, the present apparatus can be practiced with substantially any such high-pressure, pulsatile fluid flow system to dampen high-pressure pulsations . . . especially in such system utilizing fluid suspensions and having abrasive properties. It is important to note that the exemplified fracing fluids process operates at flow rates and line pressures using highly abrasive liquid suspensions that can be corrosive as well. Line pressures on the order of 12,000 psi and flow rates of over 30 mph are not unusual, all of which is intended in the present invention. In major part, the pulsation dampener apparatus 10 includes: a dampener housing 12; housing-to-flow line adapters 20; a series of damper canisters 50 internally disposed inside the dampener housing 12; and union interfaces 30 for joining a dampener housing end 14 to a housing-to-flow line adapter 20 or to the dampener housing end 14 of another dampener housing 12.
[0039] In the embodiments illustrated in
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[0041] A housing-to-flow line adapter 20 is used to adaptively connect one or both ends 14 of the dampener housing 12 to a high-pressure fluid flow line 16 at the inlet port (pump side) 17a of the high-pressure fluid flow line 16 or the outlet port (down-hole side) 17b. As with the dampener housing 12, the housing-to-flow line adapter 20 is also designed to so that the flow rate of the fluid in the high-pressure fluid line 16 is not substantially impacted.
[0042] The series of damper canisters 50 internally disposed inside the dampener housing 12 are the heart of the present high-pressure pulsation dampener apparatus 10. The series of damper canisters 50 is internally disposed in the non-flow fluid chamber 24 of the dampener housing 12. Each damper canister 50 has its upper portion immersed in the fluid (and fluid pressure) of the non-flow fluid chamber 24. However, the bottom of each canister 50 is disposed so that it is exposed to the pressure and fluid flow of the thru-path 22.
[0043] Because the canister bottoms are in pressure communication with the fluid flow thru-path 22, each damper canister 50 is disposed to dampen a portion of a pressure change of the fluid in the fluid flow thru-path 22. Additionally, because the canisters are initially gas pressurized from about 2,500 to 5,000 psi, the series of canisters 50 in the housing 12 distribute the risk of a catastrophic failure of the pressure dampening system over the total number of pressure vessels (damper canister). This greatly reduces or eliminates the risk of a catastrophic failure event from the failure of a single pressure vessel.
[0044] Union interfaces 30 are designed and used to accomplish unions in the present invention in a number of situations. For example, union interfaces 30 can be used to join an end 14 of a dampener housing 12 to a housing-to-flow line adapter 20 (see
[0045] The damper canisters 50 are intended for use in the present pulsation dampener apparatus 10 as a plurality of damper canisters 50 in series. See
[0046] The canister housing 52 is in the form of a high-pressure gas cylinder, open at one end. The canister housing 52 has a housing interior space 54 and a cross-sectional housing opening 56 at the one open end. The interior wall 58 of the canister housing 52 is adapted to closely receive a piston assembly 70. The piston assembly is slideable along the interior wall 56 from the rim 57 at the housing opening 56 to a depth D of the interior wall 56. Though closely received in the cross-section of the housing opening 56 of the canister housing 52, the damper piston assembly 70 is freely slideable along the depth D of the interior wall 56 in response to a difference in pressure across the piston assembly 70.
[0047] A stop ring 60 is fixable to the housing rim 57 at the housing opening 56 of the canister housing 52. The stop ring 60 is fixed to the housing rim 57 with stop ring fastening means 62; which are threaded fasteners in the illustrated embodiment. The piston stop ring 60 is adapted to retain the damper piston assembly 70 slideably within the canister housing 52. The further adaptation of the piston stop ring 60 is not obvious and is important because of the high-pressure and fluid suspension environment in which it operates. To use fracing fluid as a fluid suspension example, fracing fluid is not only abrasive (because it contains sand suspended in the fluid), the solids that form the suspension can and do settle-out on horizontal surfaces, accumulate like plaques, and can hinder/restrict travel of the piston. Therefore, the structural cross-section of the top ring 60 and the features of its interface with the housing rim 57 and piston skirt 76 are adapted to avoid accumulating sand/suspension plaques. The canister housing 52, damper piston assembly 70 and stop ring 60 in combination are adapted to contain a gas in the housing interior space 54 at continuously varying pressures of up to 12,500 psi, to accomplish the present damper canister 50.
[0048] The piston assembly 70 comprises a damper piston 72 having a damper piston head 74 portion and a damper piston skirt 76 portion. The piston head 74 portion has a gas pressure surface 75a and a fluid pressure surface 75b. The piston skirt 76 portion has at least one piston ring channel 79, within each of which a piston ring 82 is received. A first piston ring 82 is a gas/fluid sealing ring. A sealing type piston ring 82 is biased by the ring channel 79 to form a slideable gas/fluid pressure seal between the piston skirt 76 and the interior wall 56 of the canister housing 52. Other rings may also be provided for sealing and/or particle wiping. The for example, in another embodiment (not shown) the piston skirt 76 has two ring channels 79 for mounting a gas/fluid sealing ring, and also a wiper ring between the gas/fluid sealing ring and the frac fluid. The wiper ring is adapted to prevent sand or suspension material from impacting the gas/fluid sealing ring. The piston assembly 70 is slideable within the canister housing 52 in response to a sufficient pressure difference between the gas pressure within the housing interior space 54 of the damper canister 50 and the fluid pressure of the fluid flow thru-path 22 outside of the damper canister 50.
[0049] Additionally, the damper piston head 74 portion of the damper piston 72 has a gas port fitting 90. The gas port fitting 90 is adapted to provide a sealable through-port between the gas pressure surface 75a and the fluid pressure surface 75b of the piston head 74. The gas port fitting enables the housing interior space 54 to receive and contain a gas charge to bias the housing interior space 54 at an initial gas pressure. The gas port fitting 90 component of the damper piston 72 has a gas through-port 92 between the gas pressure surface 75a and the fluid pressure surface 75b of the piston head 74. A normally closed gas check valve 94 provides a means to charge the housing interior space 54 with a gas, such as nitrogen, and prevents the gas from escaping. A gas port cover 96 protects the gas valve 94 from the fluid at the fluid pressure surface 75b of the piston head 74, and further seals the gas port fitting to prevent gas from leaking out of the canister housing 52. Although illustrated as a component of the damper piston 72 in
[0050] In an alternative embodiment for dampening pressure pulsations in a high-pressure fluid flow line/conduit, the pulsation dampener apparatus 10a of the present invention can be configured as illustrated in
[0051] As exemplified in
[0052] A damper piston assembly 70a is closely received within the cross-sectional opening 56 of each end of the canister housing 52a. In the embodiments illustrated, the damper piston assemblies 70a are freely slideable along the depth D of the interior wall 58 of the canister housing 52a. As exemplified in
[0053] As illustrated in the figures, this embodiment of the damper piston head 74 portion of the damper piston 72 has a gas port fitting 90. Although illustrated as a component of the damper piston 72 in
[0054] As shown in
[0055] As illustrated in
[0056] In another alternative embodiment exemplified in
[0057] Attached as an Appendix is an engineering & design report exemplifying materials and design considerations for various embodiments of the present invention. The report is included herein by reference.
[0058] While the above description contains many specifics, these should not be construed as limitations on the scope of the invention, but rather as exemplifications of one or another preferred embodiment thereof Many other variations are possible, which would be obvious to one skilled in the art. Accordingly, the scope of the invention should be determined by the scope of the appended claims and their equivalents, and not just by the embodiments.