FRAC HEAD APPARATUS

Abstract

A frac head apparatus has a body with an internal bore extending therethrough, a first flow bore formed through the body so as to have an inner end opening to the internal bore of the body and an outer end opening to an outer side of the body, and a second flow bore formed through the body so as to have an inner end opening to the internal bore of the body and an outer end opening at an outer side of the body. The inner end of the first and second flow bores are positioned at different levels within the body. Each of the first and second flow bores has a longitudinal axis offset from and not intersecting a longitudinal axis of the internal bore of the body such that a fluid flow through the flow bores is directed toward a wall of the internal bore offset from an opposite side of the wall of the internal bore from the inner ends of the flow bores.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

Not applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT Not applicable.

INCORPORATION-BY-REFERENCE OF MATERIALS SUBMITTED ON A COMPACT DISC

Not applicable.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to frac head apparatus. More particular, the present invention relates to frac head apparatus whereby a cyclonic flow of fluid is induced into the internal bore of the frac head. More particular, the present invention relates to frac heads having a plurality of flow bores cooperative at the internal bore of the frac head.

2. Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 37 CFR 1.98.

Well fracturing operations are well known in the oil and gas drilling industries for increasing the flow capacity of a well. During a typical well fracturing operation, large amounts of abrasive and/or acidic fluids (i.e. slurries of sand, water, and various chemicals) are pumped down the well by high-pressure pumps. The high-pressure fluids (and sometimes gels) are intended to fracture the formation, thereby improving the permeability and flow capacity of the hydrocarbons. A frac head is typically connected to the wellhead (or above the wellhead). Multiple fluid lines connect the frac head to corresponding high-pressure pumps (typically pump trucks). The frac head acts as a manifold to collect and redirect fluid from the multiple fluid lines down through the well head into the wellbore.

Because of the abrasive and corrosive nature of the fracturing fluids, the interior bore of the frac head can be subject to extreme erosion. Such erosion is costly in that it can severely limit the useful service life of the frac head. The frac head wall typically needs to be sufficiently thick to support pressures of up to about 15,000 p.s.i., fluid velocities of 200 ft/min or more, and fluid flow rates of 100 gallons per second or more. Eroded frac heads can sometimes be repaired, but are often simply scrapped. Due to the high fluid pressures, frac head erosion also potentially poses a serious safety concern. Frac head ruptures are known in the process of fracturing.

Numerous approaches have been taken in the past to address frac head erosion. For example, frac heads have been fabricated from thick-walled steel and/or with high-strength construction materials. The inner surface of the frac head has also been lined with various erosion resistant materials. Unfortunately, these approaches have met with minimal success, most likely due, in part, to the extremely high pressures and fluid flow rates.

The frac head is a common upper wellhead stationary inlet and outlet multi-bore flow manifold that is used when injecting fluids or materials within the internal bore of a traditional petrochemical oil or gas well, as well as being additionally applied toward the internal self-propelled petrochemical fluid. A traditional frac head manifold is commonly used to provide service toward all fluidous flow transfer operations or motion-induced material flow transfers within the internal bore and/or flow path of a wellhead Christmas tree assembly. The frac head is a wellhead assembly designed for typical positioning above the upper C section of a fully assembled wellhead assembly in order for the frac head to be positioned generally above all of the critical wellhead safety control devices and safety regulatory systems, such as those devices which control, monitor, adjust and regulate all open flow line bores and closed flow line bores. These items are commonly known as the lower hydraulic-actuated gate valves, the lower manually-actuated gate valves, and any pilot-operated automatic actuated gate valve assemblies. The wellhead assembly configuration can include various configurations of wellhead casing heads, casing hangers, casing spools, tubing heads, tubing hangers, tubing spools, height riser spools, adapter spools, crossover adapters, test adapters, and the integral main bore section.

The most common types of damaging effects generated by near continuous abrasive flow cavitation toward a common frac head are abrasive internal wall material washout within the entire length of the internal bore or along the affixed flow line components. These can continuously degrade during service applications so as to thereby produce a gradual product failure and deterioration. This can ultimately result in various product failure conditions. These failure conditions can include decreases in the upstream accessory flow line wall thickness, high pressure and high volume abrasive deformation of the internal wall thickness, and deformation of the internal wall surface integrity. This can develop a condition, as a result of the initial internal cavitation and internal flow washout, wherein the actual washout generated by the internal cavitation activities of the flow process begin to develop a significant compounding effect toward the wall thickness washout and material destruction.

The most common damaging effects generated by near continuous non-abrasive flow cavitation include non-abrasive internal component damage with the entire upstream sectional lengths of the internal bore of the flow line or the affixed flow line components. These can continuously degrade during service application so as to eventually produce product failure and deterioration. This can ultimately result in various degrees of product failure conditions which include damage to internal upstream flow line elastomer seals, seal kits, seal gaskets, 0-rings and other elastomer or wearable flow line components.

When traditional frac heads are utilized as a means of wellhead flow injection or flow outlet, the frac head is configured in a manner consistent with the fluid flow or material flow mass volumes which are internally directed in a standard uniform fashion in which the internal fluid flow or material flow is firstly injectably directed toward the center axis point of the internal bore in which there is an opposing or near directly center axis point of the internal bore horizontally-aligned bore section which creates a situation in which each of the independent injection flow bores are directly facing one another on an equal horizontal axis alignment plane from the center point of the internal axis of the internal bore. As such, all of the pressurized injected fluids or flow materials create a bullhead-type direct flow mass flow volume compression interference with one another at the point of injection into the internal bore of the frac head. This can generate a higher rate of injection mass flow cavitation and a lessening of the inlet mass flow pulsation dampening effects. As a result, a less consistently smooth fluid flow occurs. This is due to the fact that the traditional frac head is configured in a manner in which all of the flow bores are manufactured in a simple equal horizontal alignment around the internal diameter circumference of the frac head and at the outer diameter circumference of the frac head. This produces a flow process resulting from the colliding effect of the injected fluid flow or material flow. An aggressively forceful and highly pressurized direct alignment collision with these fluid flows occurs at the initial point of confluence at or near the vertical center axis of the internal bore section of the frac head. This collision can be deleterious to the optimum operating conditions of the frac head.

Standard frac heads are all manufactured with the individual flow bores being aligned generally in a near radially equal horizontal center axis around the outer diameter of the frac head as well as a near radially equal horizontal center axis around the inside diameter of the internal bore of the frac head. The flow bores are thus positioned in nearly equally opposing relationship in the flow bore. An example of this is when traditional frac heads are equipped with an industry-standard four side outlets or a more expensive version equipped with six side outlets. These side outlets are known as the inlet and outlet flow bores. Each flow bore will continuously generate a tremendous amount of undesirable confluence and flow turbulence. This results in a significant internal washout effect to the internal bore of the frac head as well as washout of the wellhead components which are positioned and affixed below and above the frac head. Premature product failure of the traditional frac head is generated by these various forms of destructive fluid flow. Traditional frac heads are configured to provide the means for inlet injection and outlet exhaustion of fluid flow or material flow volumes to create a near-centrally located point of confluence of all of the available flow bores. This can create damaging effects toward the entire internal bore when the traditional frac head is utilized for the purpose of inlet injection of fluid flow. Traditional frac heads are designed with the individual flow bores in an angular configuration in which the independent flow bores are all generally configured to match the same angle of flow bore alignment. These angles of flow bore alignment are typically machined within a traditional frac head at three principal degrees of angle from the vertical center point of the internal bore. These angles can be configured at 90°, 45° and 30° off the center point axis of the internal bore the frac head. These various degrees of angle do not eliminate the destructive high-pressure injection of fluid and do not eliminate the washout or damaging abrasive cavitation.

In the past, various patents have issued with respect to such frac heads in an effort to minimize the destructive effect caused by fluid injection. For example, U.S. Pat. No. 7,478,673, issued on Jan. 20, 2009 to M. D. Boyd, describes a frac head that includes a mixing chamber located in an internal bored downstream of an intercept between the side ports in the internal bore and upstream of a tapered vortex portion of the bore. The tapered vortex reduces the diameter of the bore from a first diameter to a second diameter. The length of the mixing chamber (along the longitudinal axis of the frac head) is greater than the first diameter. The ratio of the first diameter to the second diameter is greater than 1.5.

U.S. Pat. No. 7,828,153, issued on Nov. 9, 2010 to McGuire et al., describes a multipart frac head with replaceable components which permit the frac head to be refurbished in the field. A bottom leg of the multipart frac head is replaceable. The inlet ports of the frac head are also replaceable.

U.S. Pat. No. 8,016,031, issued on Sep. 13, 2011 to B. McGuire, shows an erosion resistant frac head having a conversion chamber. The frac head also includes an expansion chamber and a mixing chamber so as to provide improved resistance to erosion caused by abrasive frac fluids pumped through the frac head. A bottom leg of the erosion resistant frac head maybe replaced in the field.

U.S. Patent Application Publication No. 2013/0075079, published a Mar. 28, 2013 to D. L. Artherholt, describes a frac head having a sacrificial wash ring. The sacrificial wash ring is located above a mixing chamber so as to protect the frac head body from erosion caused by abrasive frac fluids pumped through the head.

It is an object of the present invention to provide a frac head apparatus that improves overall cycle durability.

It is another object of the present invention to provide a frac head apparatus that allows for improved long-lasting performance of the upstream components.

It is another object of the present invention to provide a frac head apparatus that provides a less restrictive flow process.

It is another object of the present invention to provide a frac head apparatus that has a smoother inlet injection flow.

It is a further object of the present invention to provide a frac head apparatus that reduces damaging effects caused by abrasive and non-abrasive flow processes, cavitation, and back pressure to upstream components.

It is another object of the present invention to provide a frac head apparatus that generates an injection-based cyclonic flow effect.

It is another object of the present invention to provide a frac head apparatus that reduces vibratory cavitation washout.

It is another object of the present invention to provide a frac head apparatus that reduces premature product failure.

It is another object of the present invention to provide a frac head apparatus that is more cost effective.

It is still a further object of the present invention to provide a frac head apparatus that allows for the option of alternating or eliminating the use of more expensive quinteplex-type injection pumps.

It is still a further object of the present invention to provide a frac head apparatus that makes available the use of cheaper triplex injection pumps.

It is still a further object the present invention to provide a frac head apparatus that serves to maintain bore wall thickness and reduce material washout.

These and other objects and advantages of the present invention will become apparent from a reading of the attached specification and appended claims.

BRIEF SUMMARY OF THE INVENTION

The present invention is a frac head apparatus that includes a body having an internal bore extending therethrough with an inlet at an upper end thereof and an outlet at a lower end thereof. A first flow bore is formed through the body so as to have an inner end opening to the internal bore of the body and an outer end opening at an outer side of the body. The first flow bore angles through the body such that the inner end is at a level lower than the outer end. A second flow bore is formed through the body so as to have an inner end and an outer end. The inner end of the second flow bore is positioned opposite the inner end of the first flow bore. The second flow bore angles through the body such that the inner end of the second flow bore is at a level lower than the outer end of the second flow bore. In one embodiment, the inner end of the first flow bore is at a level different than the inner end of the second flow bore.

The first flow bore has a longitudinal axis offset from and not intersecting a longitudinal axis of the internal bore of the body such that a fluid flow through the first flow bore is directed toward a wall of the internal bore offset from an opposite side of the wall of the internal bore from the inner end of the first flow bore. The second flow bore extends angularly through the body at an angle relative to the longitudinal axis of the internal bore. The angle of the second flow bore is similar to the angle at which the first flow bore extends relative to the longitudinal axis of the internal bore. The second flow bore has a longitudinal axis offset from and not intersecting the longitudinal axis of the internal bore of the body such that a fluid flow through the second flow bore is directed to the wall of the internal bore offset from an opposite side of the wall of the internal bore from the inner end of the second flow bore. The longitudinal axis of the first flow bore is in parallel planar relationship to a longitudinal axis of the second flow bore. The inner end of the second flow bore is positioned at a level above the inner end of the first flow bore.

A third flow bore is formed through the body so as to have an inner end and an outer end. The inner end of the third flow bore opens to the internal bore of the body of location circumferentially between the inner ends of the first and second flow bores. The third flow bore angles through the body such that the inner end of the third flow bore is at a level lower than a level of the outer end of the third flow bore. A fourth flow bore is formed to the body so as to have an inner end and an outer end. The inner end of the fourth flow bore opens to the internal bore of the body in a location circumferentially between the inner ends of the first and second flow bores and located generally opposite to the location of the inner end of the third flow bore. The fourth flow bore extends through the body such that the inner end of the third flow bore is at a level lower than a level of the outer end of the third flow bore. The third flow bore angles through the body at an angle relative to the longitudinal axis of the internal bore of the body. The fourth flow bore also angles through the body at an angle relative to the longitudinal axis of the internal bore of the body. The angle of the third flow bore is similar to the angle of the fourth flow bore. The inner end of the third flow bore is diametrically opposite the inner end of the fourth flow bore.

In the present invention, the inner ends of the first, second, third and fourth flow bores are at different levels relative to the longitudinal axis of the internal bore of the body. The third flow bore has a longitudinal axis offset from and not intersecting the longitudinal axis of the internal bore of the body such that a fluid flow through the third flow bore is directed toward the wall of the internal bore offset from an opposite side of the wall of the internal bore from the inner end of the third flow bore. Similarly, the fourth flow bore has longitudinal axis offset and not intersecting the longitudinal axis of the internal bore of the body such that a fluid flow through the fourth flow bore is directed toward the wall of the internal bore offset from an opposite side of the wall of the internal bore from the inner end of the fourth flow bore. In an embodiment of the present invention, the longitudinal axis of the third flow bore is in parallel planar relationship to the longitudinal axis of the fourth flow bore.

This foregoing Section is intended to describe, with particularity, the preferred embodiments of the present invention. It is understood that modifications to these preferred embodiments can be made within the scope of the present claims without departing from the true spirit of the present invention. As such, the Section should not be construed as limiting, in any way, the broad scope of the present invention. The present invention should only be limited by the following claims and their legal equivalents.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is side elevational view showing the frac head apparatus of the present invention.

FIG. 2 is a cross-sectional view showing the frac head apparatus in accordance with the teachings of the present invention.

FIG. 3 is a cross-sectional view in a horizontal plane of the frac head apparatus of the present invention.

FIG. 4 is a perspective view of an alternative version of the frac head apparatus of FIG. 1 showing six fluid connections.

FIG. 5 is a perspective view of an alternative embodiment of the frac head apparatus of the present invention.

FIG. 6 is a cross-sectional view of the alternative embodiment of the frac head apparatus of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1, there is shown the frac head apparatus 10 in accordance with the present invention. The frac head apparatus 10 includes a body 12 having a flange 14 located at an upper end thereof and a flange 16 located at a bottom end thereof. Flow bores 18 and 20 are illustrated as formed within the body 12. Each of the flow bores 18 and 20 includes respective fluid connections 22 and 24. Fluid connections 22 and 24 are suitable for connection to a fluid inlet or outlet pipe. Another accessory component 26 is formed on the body 12 and includes an accessory line 28 applied in bolted connection at the connector 30 thereof. The body 12 includes an inlet 32 located at the upper end thereof and an outlet 34 located at the bottom end thereof. Each of the inlet 32 and the outlet 34 will communicate with an internal bore (not shown) extending through the body 12.

The flange connections 14 and 16 are basic API-6A-type flanged end connections that are suitable for connection to a variety of wellhead assembly components. These components are generally located at a very top of the wellhead Christmas tree assembly, such as a general flanged end connection toward the top of the wellhead's tubing head unit. These flange connections 14 and 16 can also be connected to any type of adapter or crossover-type adapter for application toward the top side of an upper outlet bore section of a variety of optional API-6A-type connections for use when the wellbore is serviceably connected for specialized operations, such as wireline injection services, snubbing-type wellbore operations and general fracture injection practices toward the wellbore. The top side upper inlet bore section is generally where the blind tree cap or bottom hole test adapter tree cap will be connectably affixed toward the frac head flow enhancement flow system in order to provide a blind plug-type or test plug-type service toward the upper main inlet bore section. The body 12 can be generally equipped with any number of six flow bore chambers that can be connectably engaged toward secondary attachable API-6A-type connections in order to perform the inlet injection and outlet exhaustion practices of wellbore-related fluids and chemicals. These integrally positioned side-mounted inlet and outlet flow bore chambers are generally comprised of API-6A-type flanged end side studded outlets for jointable connection toward all companion type API-6A unions and adapter.

FIG. 2 is a cross-sectional view of the frac head apparatus 10 of the present invention as taken across a vertical plane. In FIG. 2, it can be seen that the body 12 has an internal bore 36 having an inlet 32 at the upper end thereof and an outlet 34 at a lower end thereof. The first flow bore 18 is formed through the body 12 so as to have an inner end 38 opening to the internal bore 36 of the body 12 and an outer end 40 opening at an outer side of the body 12. The first flow bore 18 angles through the body 12 such that the inner end 38 is at a level lower than a level of the outer end 40. A second flow bore 42 (illustrated in FIG. 1 as connected to the accessory component 26) has an inner end 44 and an outer end 46. The second flow bore 42 extends through the body 12 such that the inner end 44 opens to the internal bore 36 of the body 12. The inner end 44 is at a level lower than the outer end 46 of the second flow bore 42. The accessory component 26 is illustrated as bolted to the flange 27 associated with the second flow bore 42.

FIG. 3 also illustrates that there is a third flow bore 48 and a fourth flow bore 50 that will be positioned so as to open to the internal bore 36 of the body 12. The third flow bore 48 and the fourth flow bore 50 will be positioned between the first flow bore 18 and the second flow bore 42. The inner ends 38 and 44 are at generally positioned diametrically opposite to one another within the internal bore 36. Similarly, the third flow bore 48 and the fourth flow bore 50 are positioned generally diametrically opposite to each other within the internal bore 36 of the body 12.

FIG. 2 illustrates that there is a tubing string 52 that is positioned so as to extend through the internal bore 36. The tubing string can have a specialty tool 54 mounted thereto. The tubing string 52 is illustrated so as to extend so as to have a lower end extending outwardly of the lower end of the body 12.

In FIG. 2, the first flow bore 18 extends angularly through the body 12 such that the inner end 38 is at a level lower than the outer end 40. Similarly, the second flow bore 42 extends through the body 12 such that the inner end 44 is at a level lower than the outer end 46. As such, fluids can be directed downwardly from the outer side of the body 12. The angle of the first flow bore 18 is similar to the angle of the second flow bore 42.

In FIG. 2, it can be seen that in broken lines that there is a zone of confluence 55 located within the internal bore 36. As fluid is directed through the flow bores 18, 42, 48 and 50, the flows will converge in a cyclonic manner within this zone of confluence 55. As such, the unique effects created by the present invention are achieved within this zone of confluence 55.

FIG. 3 illustrates the configuration of the flow bores 18, 42, 48 and 50. The flow bores 18, 42, 48 and 50 are illustrated across a horizontal plane and illustrated in the manner in which these flow bores will angle toward the internal bore 36 of the body 12.

In particular, the first flow bore 18 has a longitudinal axis offset from and not intersecting the longitudinal axis 56 of the internal bore 36. As such, a fluid flowing through the first flow bore 18 is directed toward a wall 58 of the internal bore 36 that is offset from the opposite side of the wall 58 from the internal bore 36. Similarly, the second flow bore 42 has a longitudinal axis offset and not intersecting the longitudinal axis 56 of the internal bore 36 of the body 12 such that fluid passing through the second fluid flow bore 42 is directed to the wall 58 of the internal bore 36 offset from the opposite side of the wall 58 from the inner end 44 of the flow bore 42. The third flow bore 48 and fourth flow bore 50 will have similar configurations. As can be seen in FIG. 3, the longitudinal axis of the first flow bore 18 will be in parallel planar relationship to the longitudinal axis of the second flow bore 42. The longitudinal axis of the third flow bore 48 will be in parallel planar relationship to the longitudinal axis of the fourth flow bore 50.

FIG. 4 shows a modification 60 of the frac head apparatus 10 of FIG. 1. In FIG. 4, it can be seen that there are a total of six (6) flow bores connected to the body 62 and extending therethrough. Each of these flow bores 64, 66, 68, 70 and 72 will have a configuration similar to the flow bores illustrated in FIGS. 2 and 3. As such, fluid passing through these flow bores will be directed in a cyclonic manner into the internal cavity 74 extending through the body 62.

FIG. 5 shows an alternative embodiment of the frac head apparatus 80 of the present invention. In FIG. 5, it can be seen that there is a first flow bore 82, a second flow bore 84, a third flow bore 86 and a fourth flow bore 88. Each of the flow bores 82, 84, 86 and 88 are arranged at different levels along the side 90 of the body 92. The body 92 will generally have the same configuration as the body 12 (as shown in FIG. 1).

FIG. 6 illustrates that the first flow bore 82 extends at an angle through the body 92 of the frac head apparatus 80. Similarly, the second flow bore 84 extends at an angle through the body 92 of the frac head apparatus 80. The inner end 94 of the first flow bore 82 is located at a level lower than the inner end 96 of the second flow bore 84. Similarly, the inner end 98 of the third flow bore 86 is located at a lower level than the level of the inner end 100 of the fourth flow bore 88. In FIG. 6, it can be seen that these inner ends 94, 96, 98 and 100 are each located at different levels within the internal bore 102 of the body 92. This arrangement of flow bores will achieve a unique cyclonic flow path (illustrated by broken line 104) within the internal bore 102. The various fluid flows will encounter each other within a zone of confluence (illustrated by broken line area 106). As such, this is a different technique for achieving a similar cyclonic form of flow delivery of fluids through the frac head apparatus 80.

The frac head apparatus of the present invention provides an advanced flow process within the frac head assembly. This generates an advanced method of high-pressure flow dynamics in order to produce an optimal fluid flow or material flow through the use of the injected fluid flow. The arrangement of the present invention is capable of providing a true method of automatic vortical flow inlet injection through a variety and any number of flow bores. As a result, a generally cyclonic flow is achieved with vortical flow characteristics developed at or near the center point axis of the internal bore of the frac head apparatus.

The present invention provides a substantial service improvement in overall lifecycle durability in the long-lasting performance of all the components connected to the upstream flow side of the frac head. This is the result of the fact that the apparatus of the present invention provides for a less restrictive flow process throughout the full flow inlet injection pathway within the internal bore. This allows a smoother inlet injection flow to develop which significantly reduces known damaging effects such as abrasive and non-abrasive cavitation as well as flow line back pressure toward the upstream accessory equipment that can be affixed to or connected to the frac head apparatus. These upstream components can include high-pressure triplex or quinteplex fluid injection pumps, segmental high-pressure flow line components, flexible hose flowlines, flow diverters, and directional flow control manifold systems.

The cyclonic injection effect is achieved by manipulating the standard flow bores of a traditional frac head so as to provide a slightly offset angular degree of inlet injection so as to generate a downwardly spiraling fluid flow at the plenum of the internal bore. This cyclonic effect generated by the flow system of the present invention reduces vibratory cavitation washout and premature product failure situations toward all internal upstream flow components or controls connected thereto. These components can include the upstream pump's internal valve seats, drive plungers, drive pistons, body housings, crankshafts, flow manifold end sections, high-pressure flow line connections, connectable conduit unions and flow line hoses.

The reduction in flow process cavitation and subsequent pulsation dampening creates a working environment in which the injection of high-pressure material flow can be accomplished by a high-pressure inlet injection pump and related inlet injection pump systems jointably connected toward a high-pressure inlet injection pump, electronic drive systems, diesel-power drive systems, natural gas-power drive systems, solar-powered drive systems, secondary-power drive systems and operation control modules. One example of such a type is a standard quinteplex-type injection pump which operates by means of five individual direct drive pistons or drive plungers. The operation of the present invention allows the user to utilize, instead of such a quinteplex pump, a more cost-effective triplex injection pump. The triplex injection pump operates by means of only three direct drive pistons or drive plungers in order to provide the necessary inlet pressure required to artificially inject high-pressure oil and gas wells. The frac head apparatus of the present invention offers the service operator an option of alternating and/or eliminating the use of the higher cost quinteplex-type injection pump in favor of a downsized triplex-type injection pump. This significantly lowers the pressure pumping operating costs and all associated downtime maintenance and related operating costs associated with the more expensive piece of equipment.

The present invention significantly reduces those common destructive elements of flow processes that can prematurely destroy the frac head's service application. The present invention develops and promotes a less restrictive fluid flow and/or material flow cavitation effect. As such, the present invention minimizes any abrasive wash-out effects so as to provide for a longer-lasting product service. This additional flow process configuration is developed by means of altering the angular degree of inlet injection reception of each individual flow bore by means of offsetting the angular bore configuration of the flow bores which is generally angularly offset from a near perpendicular alignment of the radial internal diameter circumference of the internal bore toward a modified development of the flow bores to any degree of offset of the flow bores at a near equal angular proximity toward the next sequential flow bore degree of angle which is not equally perpendicularly aligned with the internal diameter of the internal bore of the frac head system. This achieves a desired decrease in visibly evidenced erosive and/or abrasive effects. The present invention also eliminates those problems associated with non-abrasive washout. The initial flow injection flow bores are configured at an offset of any degree of angular offset from the radial axis internal diameter of the internal bore in order to first provide a means of automatically generating a cyclonic turbine effect toward any fluids or materials injected within the flow bores and to secondarily pre-align inlet injected fluid flow and/or material flow elements in a manner which is of a lessening effect with respect to cavitation and abrasive and/or non-abrasive washout. The present invention provides a fluid flow which enhances smooth flow dynamics within the flow bores and within the internal bore of the system.

The frac head apparatus of present invention reduces the forceful impacts of fluid flow and/or material flow elements by creating a simple directional uniform angular offset of the injection flow bores in order to develop a downward forced injection cyclonic fluid flow toward the fluid elements that are applied through the frac head. The angular inlet injection offset of the flow path of the flow bores reduces destructive internal flow cavitation, increases pulsation dampening and reduces destructive abrasive and non-abrasive washout. When the flow bores are configured in a spiral wound configuration, the angular offset of the flow bores is more defined since they are each at a further distance from one another within the spiral wound configuration.

The frac head apparatus of the present invention can be applied toward a service application for which material flow is injected, such as a downhole liquefied cement injection head. Such a cement injection head is commonly utilized to provide artificially pressurized inlet injection and artificially pressurized inlet injection back-filling of liquefied cement, liquefied cement fluidous formulas or compounds, and fluidous cement gravel pack materials into the vacant cavity developed between the installed downhole casing string and the maximum internal diameter of the originally-drilled wellbore in order to establish the final installation and permanent setting of the downhole casing string assembly.

The present invention reduces common wear, abrasive wear, non-abrasive wear and specialized downhole tooling damage. Such downhole tooling can include instrumentation, electronics, sensors, data transfer devices, recorders, and hardware and software components that are permanently installed or temporarally positioned within the internal wellbore casing string or tubing string. The present invention avoids such damage due to an increase in downhole fluid flow and/or material flow pulsation dampening so as to significantly reduce the effects of the fluid flow, the cavitation, and the non-abrasive and abrasive washout. This reduction of the generally damaging effects applies toward all connectably engaged and jointably engaged wellhead components that are surface-based and are made up either above the frac head apparatus or mounted below the frac head apparatus. The present invention is applicable to subsea-type wellhead assemblies and wellbore completion operations.

The frac head apparatus of the present invention provides a service application by way of an angular offset of the flow bores in relation to a directionally uniform angular offset of the inlet injection bores in order to develop a downward forced injection spiraling cyclonic fluid flow. This downward forced spiraling cyclonic inlet injection is enhanced by providing the near same angular inlet injection offset of each individual internal bore of the flow bore path angle in which each individual internal bore of the flow bore is integrally machined within the main body housing in order to actively effect all accessory component flowlines or secondary conduit units. As such, these components can establish a common straight line extension toward the flow bore in an orientation at the same linear angle of the flow path direction. This creates a uniform flow path relation to the internal bores so as to develop a straight extended length of injection flow or outlet exhaustion flow.

All secondary straight sections that are externally affixed to the frac head apparatus provide an internal straight flow path which is nearly equally aligned in the same linear flow path as the internal bores of the flow bores to provide a greater internal flow path length section. This helps to develop an optimal performance toward the spiral wound cyclonic flow path.

The foregoing disclosure and description of the invention is illustrative and explanatory thereof. Various changes in the details of the illustrated construction can be made within the scope of the appended claims without departing from the true spirit of the invention. The present invention should only be limited by the following claims and their legal equivalents.

Claims

1. A frac head apparatus comprising:

a body having an internal bore extending therethrough, said internal bore having an inlet at an upper end thereof and an outlet at a lower end thereof;

a first flow bore formed through said body so as to have an inner end opening to said internal bore of said body and an outer end opening at an outer side of said body, said first flow bore angling through said body such that said inner end is at a level lower than said outer end; and

a second flow bore formed through said body so as to have an inner end and an outer end, said inner end of said second flow bore being positioned opposite said inner end of said first flow bore, said second flow bore angling through said body such that said inner end of said second flow bore is at a level lower than said outer end of said second flow bore, said inner end of said first flow bore being at a level different than a level of said inner end of said second flow bore.

2. The frac head apparatus of claim 1, said first flow bore having a longitudinal axis offset and not intersecting a longitudinal axis of said internal bore of said body such that a flow through said first flow bore is directed toward a wall of said inner bore offset from an opposite side of said wall of said internal bore.

3. The frac head apparatus of claim 1, said second flow bore angling through said body at an angle relative to the longitudinal axis of said internal bore, said angle of said second flow bore being similar to an angle at which said first flow bore extends relative to the longitudinal axis of said internal bore.

4. The frac head apparatus of claim 2, said second flow bore having a longitudinal axis offset from and not intersecting the longitudinal axis of said internal bore of said body such that a fluid flow through said second flow bore is directed toward said wall of said internal bore offset from an opposite side of said wall of said internal bore.

5. The frac head apparatus of claim 4, said longitudinal axis of said first flow bore being in parallel planar relationship to a longitudinal axis of said second flow bore.

6. The frac head apparatus of claim 1, said inner end of said second flow bore positioned at a level above said inner end of said first flow bore.

7. The frac head apparatus of claim 1, further comprising:

a third flow bore formed through said body so as to have an inner end and an outer end, said inner end of said third flow bore opening to said internal bore of said body in a location circumferentially between said inner ends of said first and second flow bores, said third flow bore angling through said body such that said inner end of said third flow bore is at a level lower than a level of said outer end of said third flow bore.

8. The frac head apparatus of claim 7, further comprising:

a fourth flow bore formed through said body so as to have an inner end and an outer end, said inner end of said fourth flow bore opening to said internal bore of said body in a location circumferentially between inner ends of said first and second flow bores and generally opposite to said inner end of said third flow bore, said fourth flow bore angling through said body such that said inner end of said fourth flow bore is at a level lower than a level of said outer end of said fourth flow bore.

9. The frac head apparatus of claim 8, said third flow bore angling through said body at an angle relative to the longitudinal axis of said internal bore of said body, said fourth flow bore angling through said body at an angle relative to the longitudinal axis of said internal bore of said body, said angle of said third flow bore being similar to said angle of said fourth flow bore.

10. The frac head apparatus of claim 8, said inner end of said third flow bore being diametrically opposite said inner end of said fourth flow bore.

11. The frac head at apparatus of claim 8, said inner ends of said first flow bore, said second flow bore, said third flow bore and said fourth flow bore being at different levels relative to the longitudinal axis of said internal bore of said body.

12. The frac head apparatus of claim 9, said third flow bore having a longitudinal axis offset and not intersecting the longitudinal axis of said internal bore of said body such that a fluid flow through said third flow bore is directed toward the wall of said internal bore offset from an opposite side of said wall of said internal bore from said inner end of said third flow bore.

13. The frac head apparatus of claim 12, said fourth flow bore having a longitudinal axis offset from and not intersecting the longitudinal axis of said internal bore of said body such that a fluid flow through said fourth flow bore is directed to said wall of said internal bore offset from an opposite side of said wall of said internal bore from said inner end of said fourth flow bore.

14. The frac head apparatus of claim 13, said longitudinal axis of said third flow bore being in parallel planar relationship to the longitudinal axis of said fourth flow bore.

15. A frac head apparatus comprising:

a body having an internal bore extending therethrough, said internal bore having an inlet at an upper end thereof and an outlet at a lower end thereof;

a first flow bore formed through said body so as to have an inner end opening to said internal bore of said body and an outer end opening at an outer side of said body, said first flow bore angling through said body such that said inner end is at a level lower than said outer end, said first flow bore having a longitudinal axis offset and not intersecting a longitudinal axis of said internal bore of said body such that a fluid flow through said first flow bore is directed toward a wall of said internal bore offset from an opposite side of said internal bore from said inner end of said first flow bore; and

a second flow bore formed through said body so as to have an inner end and an outer end, said inner end of said second flow bore being positioned opposite said inner end of said first flow bore, said second flow bore angling through said body such that said inner end of said second flow bore is at a level lower than said outer end of said second flow bore, said second flow bore having a longitudinal axis offset from and not intersecting the longitudinal axis of said internal bore of said body such that a fluid flow through said second flow bore is directed toward said wall of said internal bore offset from an opposite side of said wall of said internal bore from said inner end of said second flow bore.

16. The frac head apparatus of claim 15, said second flow bore angling through said body at an angle relative to the longitudinal axis of said internal bore, said angle of said second flow bore being similar to an angle at which said first flow bore extends relative to the longitudinal axis of said internal bore.

17. The frac head apparatus of claim 16, further comprising:

a third flow bore formed through said body so as to have an inner end and outer end, said inner end of said third flow bore opening to said internal bore of said body in a location circumferentially between said inner ends of said first and second flow bores, said third flow bore angling through said body such that said inner end of said third flow bore is at a level lower than a level of said outer end of said third flow bore; and

a fourth flow bore formed through said body so as to have an inner end and an outer end, said inner end of said fourth flow bore opening to said internal bore of said body in a location circumferentially between said inner ends of said first and second flow bores and generally opposite to said inner end of said third flow bore, said fourth flow bore angling through said body such that said inner end of said fourth flow bore is at a level lower than a level of said outer end of said fourth flow bore.

18. The frac head apparatus of claim 15, said inner end of said second flow bore positioned at a level above said inner end of said first flow bore.

19. A frac head apparatus comprising:

a body having an internal bore extending therethrough, said internal bore having an inlet at an upper end thereof and an outlet at a lower end thereof;

a first flow bore formed through said body so as to have an inner end opening to said internal bore of said body and an outer end opening at an outer side of said body, said first flow bore angling through said body such that said inner end is at a level lower than said outer end;

a second flow bore formed to said body so as to have an inner end and an outer end, said inner end of said second flow bore being positioned opposite said inner end of said first flow bore, said second flow bore angling through said body such that said inner end of said second flow bore is at a level below said outer end of said second flow bore;

a third flow bore formed through said body so as to have an inner end and an outer end, said inner end of said third flow bore opening to said internal bore of said body in a location circumferentially between said inner ends of said first and second flow bores, said third flow bore angling through said body such that said inner end of said third flow bore is at a level lower the level of said outer end of said third flow bore; and

a fourth flow bore formed through said body so as to have an inner end and an outer end, said inner end of said fourth flow bore opening to said internal bore of said body in a location circumferentially between said inner ends of said first and second flow bores and generally opposite said inner end of said third flow bore, said fourth flow bore angling through said body such that said inner end of said fourth flow bore is at a level lower than a level of said outer end of said fourth flow bore.

20. The frac head apparatus of claim 19, said inner ends of said first flow bore and second flow bore and said third flow bore and said fourth flow bore being positioned at different levels within said body.