PIPING SYSTEMS AND METHODS WITH AN AUGER ASSEMBLY

Description

TECHNICAL FIELD

This disclosure relates generally to pipe systems including reciprocating pumps, and in particular, to a pipe system having a low-pressure manifold including an auger assembly.

BACKGROUND

Pipe systems and reciprocating pumps are used in a variety of industrial settings. One use for such pipe systems and pumps is in the oil and gas industry. For example, pipe systems including one or more low pressure manifolds supply fluid, proppant, and the like to reciprocating pumps used in completion and stimulation operations including fracturing, cementing, acidizing, gravel packing, snubbing, and similar operations. Hydraulic well fracturing treatments are well known and have been widely described in the technical literature dealing with the present state of the art in well drilling, completion, and stimulation operations. Hydraulic fracturing is a process to obtain hydrocarbons such as natural gas and petroleum by injecting a mixture of water, chemicals, and proppant (e.g., sand, ceramic, etc.) at super high pressure into a wellbore to create cracks in deep rock formations. In a typical hydraulic fracturing operation, the subterranean well strata are subjected to tremendous pressures in order to create fluid pathways to enable an increased flow of oil or gas reserves that may then be brought up to the surface. The fracking fluids are pumped down the wellhead by high-pressure pumps located at the well surface. To reach such high-pressure pumps, fracking fluids generally first flow through one or more larger bore low-pressure manifolds which may be connected to each other via one or more conduits (e.g., hoses).

The low-pressure manifold(s) may be used to transport a mixture of fluid and proppant, for example, to the high-pressure pumps for pressurization. However, the momentum of the moving proppant creates resistance which discourages the proppant from flowing down the initial smaller transverse pipes that lead from the main low-pressure manifolds to each of the high-pressure pump inlets. Given the tendency of the proppant to continue moving down the low-pressure manifold, proppant accumulates at the end of each manifold resulting in a non-uniform distribution of proppant to the high-pressure pumps, causing increased wear to certain valve components that receive excessive volumes of proppant, and eventually resulting in rapid wear and/or premature failure of the pump components which receive excess proppant.

SUMMARY

A first aspect provided herein relates to a pipe system for oilfield operations. The pipe system includes a pipe having an inlet and an outlet. The pipe defines a cavity between the inlet and the outlet configured to receive a flow of fluid containing a proppant. A fluid outlet is fluidly coupled to the cavity and located between the inlet and the outlet of the pipe. An auger assembly installed within the cavity comprises a helical blade extending at least partially between the inlet and the outlet of the pipe. The helical blade is configured to direct a portion of the proppant through the fluid outlet. A first end support is coupled to a first end of the auger assembly and a second end support is coupled to a second end of the auger assembly. The first and second end supports engage the pipe to maintain a proper position of the helical blade within the cavity.

A second aspect provided herein relates to a frac iron system for oilfield operations. The frac iron system comprises a plurality of pipe systems. Each pipe system comprising a pipe having an inlet and an outlet, the pipe defining a cavity therebetween configured to receive a flow of fluid containing a proppant. The pipe also comprises a fluid outlet fluidly coupled to the cavity between the inlet and the outlet. The pipe system further comprises an auger assembly installed within the cavity and comprising a helical blade extending at least partially between the inlet and the outlet, the helical blade configured to direct a portion of the proppant through the fluid outlet, a support coupled to the auger assembly, the support engaging the pipe to align a longitudinal axis of the helical blade with a center of the cavity. Additionally, the frac iron system includes a low-pressure connector fluidly coupling the outlet of the pipe of a first pipe system of the plurality of pipe systems to an inlet of the pipe of a second pipe system of the plurality of pipe systems.

A third aspect provided herein relates to a method of manufacturing a pipe system for oilfield operations. The method comprises the steps of: providing a pipe having an inlet and an outlet, the pipe defining a cavity between the inlet and the outlet configured to receive a flow of fluid containing a proppant and comprising a fluid outlet fluidly coupled to the cavity; providing a helical blade; disposing the helical blade within the cavity such that the helical blade extends at least partially between the inlet and the outlet of the pipe; and coupling a first end of the helical blade to the pipe via a first end support and a second end of the helical blade to the pipe via a second end support, the first and second end supports engaging the pipe to maintain a proper position of the helical blade within the cavity.

This summary is illustrative only and is not intended to be in any way limiting. Other aspects, inventive features, and advantages of the devices or processes described herein will become apparent in the detailed description set forth herein, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a pipe system according to an example embodiment;

FIG. 2 is a perspective view of a frac iron system including a pipe system according to an example embodiment;

FIG. 3 is a perspective view of a frac iron system including a pipe system according to another example embodiment;

FIG. 4 is a perspective view from the direction of an inlet of the example pipe system of FIG. 1;

FIG. 5 is a cross-sectional side view of the example pipe system of FIG. 4, taken along the line A-A in FIG. 4;

FIG. 6 is a cross-sectional side view of the example pipe system of FIG. 4, taken along the line B-B in FIG. 4;

FIG. 7 is perspective view of an example auger assembly disposed inside an embodiment of a pipe system;

FIG. 8 is a perspective view of a first end of the example auger assembly of FIG. 7 including an example first end support;

FIG. 9 is a cross-sectional perspective view taken along plane C-C in FIG. 8 of the first end of the example auger assembly of FIG. 7 including the example first end support;

FIG. 10 is a perspective view of a second end of the example auger assembly of FIG. 7 including an example second end support;

FIG. 11 is a flowchart showing illustrative steps of an example method of manufacturing a pipe system for oilfield operations.

DETAILED DESCRIPTION

The following detailed disclosure is better understood when read in conjunction with the figures. Before turning to the figures, which illustrate certain embodiments in detail, it should be understood that the present disclosure is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that examples and terminology used herein are for the purpose of description only and should not be regarded as limiting.

A conventional pipe system for oilfield operations (e.g., fracking) may include a pipe as a component of a low-pressure manifold. As explained in more detail herein, the low-pressure manifold, via the pipe, draws fluid (e.g., fracking fluid, a mixture of water, chemicals, proppant, etc.) through a hollow tubular fluid passageway/cavity of the pipe that does not include any internal structure. A problem is that proppant, such as uniform-sized solid particles, in the fracking fluid can accumulate and become lodged and compacted in certain regions of the manifold, such as the downstream side bore furthest from the low-pressure manifold inlet. This means that some of the valves and valve seats (particularly those fluidly connected to downstream portions of the low-pressure manifold or sections of pipe) pass through/receive more of the proppant than others. The uneven proppant distribution results in irregular wear of the valves, valve seats, and other components with the downstream valves, valve seats, and other components requiring maintenance before others. The operator thus experiences shortening of the pipe system maintenance cycle and premature failure of the valves, valve seats, manifolds, pumps, and other components on the downstream side of the pipe system.

Traditional low-pressure piping designs to transport sand, proppant, and other particles (e.g., a cement mixture) to pumps for pressurization, to a high-pressure manifold, and/or to a well head face two main issues: reduced fluid velocity causing particles to settle, and resistance in smaller transverse pipes, for example, leading to uneven particle distribution and accumulation at the end of the pipe system and/or pipes thereof. To address this, an auger (e.g., a stationary auger) with a helical profile is installed within the piping, imparting a rotation to the fluid, increasing fluid velocity, and applying radial force to enhance particle distribution through fluid outlets of the low-pressure pipes of the low-pressure manifold. This solution ensures a more uniform particle/proppant flow, reducing wear on pipe system and/or frac iron components and extending their lifespan. The use of the auger assembly results in a more uniform distribution of the proppant along the length of the pipe/fluid cavity and leads to a more even wearing of valves, valve seats, etc. in the and/or downstream of the pipe system. The addition of the auger assembly also prolongs the maintenance cycle time period and meaningfully increases the operational runtime of the low-pressure manifold and other components of the pipe system and/or the frac iron system.

Turning to FIG. 1, a perspective view of an example pipe system 100 according to an example embodiment is shown. The pipe system 100 may include a skid 104. The skid 104 may act as a base on which other components of the pipe system 100 are coupled to, mounted to, or the like. As an illustration, various mounting features 108 such as fasteners, machined components with apertures configured to receive bolts, screws, etc., or other suitable mounts may secure components of the pipe system 100 to the skid 104. In this way, the skid 104 may allow for convenient transfer of pre-assembled portions of or the entirety of the pipe system 100. Additionally, the skid 104 permits multiple pipe systems 100 (e.g., a plurality of pipe systems 100) to be assembled in a modular manner, for example, to meet the needs, pumping demand, etc. of a frac iron system. In short, the assembly of the pipe system 100 via the skid 104 allows for increased ease of scaling up/down oilfield operations as required by a particular work site.

When used in conjunction with a frac iron system (e.g., the frac iron system 200 illustrated in FIG. 2), the pipe system 100 may form a portion of a low-pressure manifold 110 thereof. For example, the pipe system 100 may comprise a pipe 112 having an inlet 114 and an outlet 118. In some embodiments, the outlet 118 may be optional, sealed, or covered by an end cap or other barrier (e.g., at a downstream-most end of the low-pressure manifold 110). The pipe 112 may extend a certain length 140. The length 140 may be defined as a distance from a first end 116 of the pipe 112 to a second end 120 thereof. In some embodiments, the length 140 may be 8 feet, 10 feet, 12 feet, 20 feet, or another suitable distance. In a particular embodiment, the length 140 is 8 feet.

Further, the pipe 112 may define a cavity 122 (e.g., hollow tubular fluid passageway located within an interior wall 144 of the pipe 112) between the inlet 114 and the outlet 118. The cavity 122 may be configured to receive a flow of fluid containing proppant. The pipe 112 and/or the cavity 122 may include an inside diameter 146 corresponding to the diameter of interior wall 144 of the pipe 112. (See, e.g., FIG. 9). In some embodiments, the inside diameter 146 may be 4 inches, 6 inches, 8 inches, 12 inches, or another suitable size. In a particular embodiment, the inside diameter 146 is 8 inches. The cavity 122 and/or the pipe 112 may also include a center 123. For example, the center 123 may be defined as a line extending through the length 140 of the pipe 112 equidistant from the interior wall 144 and/or a point at a center of a cross-sectional slice of the pipe 112 taken perpendicular to the direction of flow (e.g., for a pipe 112 with a circular cross section, the center 123 of the pipe 112 and/or the cavity 122 may be defined as the center of the circular cross section extending along the length of the pipe 112 as shown for example in FIG. 4).

The pipe system 100 may also include one or more fluid outlets 126 fluidly coupled to the cavity 122. The fluid outlets 126 may be configured to divert/receive a portion of the fluid containing proppant flowing through the pipe 112. In some embodiments, the fluid outlets 126 are located between the inlet 114 and the outlet 118 of the pipe 112 as shown in FIG. 1. For example, as illustrated, each fluid outlet 126 is a side fluid outlet 126 which is disposed along a length of a side of the pipe 112. The fluid outlets 126 may direct fluid in a transverse, perpendicular, angled, or other suitable direction relative to the flow through the pipe 112. In other embodiments, the fluid outlets 126 may be oriented in a direction relative to gravity (e.g., upward, downward) such that gravity may assist or reduce the flow of proppant through the fluid outlet 126. The fluid outlet 126 may be formed of and/or defined by an outlet pipe 124 such as a transverse pipe and/or pipe segment, which may be sized equal to or smaller than the pipe 112. For example, the fluid outlet 126 as illustrated in the figures is shown having a diameter smaller than the inside diameter 146 of the pipe 112. In some embodiments, the inside diameter 146 may be 2 inches, 4 inches, 6 inches, 8 inches, 12 inches, or another suitable size. In a particular embodiment, the inside diameter 146 is 4 inches.

The fluid outlet 126 may draw fluid containing proppant from the low-pressure manifold 110 comprising the pipe 112. For example, one or more pumps 221 as shown in FIG. 2 may be configured to retrieve fluid from the pipe 112 via the fluid outlet 126 to pressurize the fluid. The pressurized fluid may then be returned to the pipe system 100 and/or to a high-pressure manifold 130. The high-pressure manifold 130 may comprise a flow iron 132 having an optional high pressure flow iron inlet 134, one or more high-pressure inlet pipes 136 configured to receive the pressurized fluid containing the proppant, and one or more high-pressure flow iron outlets 138 configured to direct the pressurized fluid containing the proppant, for example, to a well head 250.

Turning to FIG. 2, and viewing the same in conjunction with FIG. 1, a perspective view of a frac iron system 200 is shown according to an example embodiment. The frac iron system 200 may include a source 204 of fluid, proppant, chemicals, and the like. For example, the source 204 may include a blender 206 which may be configured to deliver fluid/proppant to an input manifold 208 of the frac iron system 200 via one or more conduits 210 such as hoses, pipes, etc. The input manifold 208 may be configured to direct the fluid/proppant into one or more low pressure manifolds 110 and/or one or more pipes 112. For example, as shown in FIGS. 1 and 2, each pipe system 100 may comprise two pipes 112 and/or low-pressure manifolds 110 disposed on opposite sides and below the high-pressure manifold 130. In other embodiments, the pipe system 100, frac iron system 200, or the like may comprise any number of pipes 112, low-pressure manifolds 110, high-pressure manifolds 130, etc. configured in any suitable orientation with respect to one another (e.g., parallel to each other, side by side, disposed such that the high-pressure manifold 130 and low-pressure manifold 110 are coupled/located on different skids 104 or the like).

In the embodiment shown in FIG. 2, both the high-pressure manifold 130 and the low-pressure manifold 110 comprise a plurality of pipe systems 100. For example, the input manifold 208 is coupled to a first pipe system 100a having an inlet 114 and an outlet 118 as shown in FIG. 1. In turn, the outlet 118 is fluidly coupled to the inlet 114 of a second pipe system 100b downstream of the first pipe system 100a via low-pressure connectors 212 (e.g., pipes, flow irons, etc.) and high-pressure connectors 214 (same). As illustrated in FIG. 2, the outlet of the high-pressure manifold 130 of the first pipe system 100a is coupled to the inlet of the high-pressure manifold 130 of the second pipe system 100b via the high-pressure connector 214 and the outlet of the low-pressure manifold 110 is connected to the inlet of the low-pressure manifold 110 of the second pipe system 100b via the low-pressure connector 212.

The frac iron system 200 may also include a plurality of pumps 220. One or more pumps 221 of the plurality of pumps 220 may be coupled to a respective pipe system 100. The one or more pumps 221 may comprise a pump fluid end 222 having a pump inlet 223 and a pump outlet 224 and a pump power end 225. The pumps 221 may include one or more plungers driven by a crankshaft to create alternately high and low pressures in a fluid chamber thereof. The power end 225 and the fluid end 222 are generally connected by a plurality of stay rods and tubes that make up a stay rod assembly. The power end 225 includes an internal crankshaft powered by an engine that drives the plungers. A suction manifold of the pump 221 provides a fluid passageway that delivers the fracking fluid to the pump fluid end 222. The pump fluid end 222 cylinders into which the plungers operate to draw fluid into the fluid chamber from the suction manifold (via a log manifold), and then forcibly push out the fluid at high pressure to the pump outlet 224. The pump outlet 224 then directs the pressurized fluid to the high-pressure manifold 130 (e.g., the high-pressure inlet pipe 136 of the flow iron 132 and downstream to the well head 250. In this manner, the reciprocating pump is used to forcefully deliver the fracking fluid at high pressure to the well head 250 and down the well. Specifically, fluid and proppant may flow from the cavity 122, through the fluid outlet 126 of the pipe 112, to a pump inlet 223 via a low-pressure conduit 240, then back to the high-pressure manifold 130 of a respective pipe system 100 via a high-pressure conduit 242.

Turning to FIG. 3, a perspective view of a frac iron system 300 according to another example embodiment with the low-pressure conduits 240, high-pressure conduits 242, plurality of pumps 220, and other features of the frac iron system 200 removed. In this way, FIG. 3 more clearly illustrates the modularity of the pipe system 100, the frac iron systems 200, 300, and the connection described above between the first pipe system 100a and the second pipe system 100b.

Turning to FIG. 4, a perspective view of the pipe system 100 of FIG. 1 is illustrated, viewed from a position looking into the inlet 114 of the example pipe system 100 of FIG. 1. As more clearly shown in FIG. 4, the pipe system 100 may comprise one or more pipes 112 as components of the low-pressure manifold 110.

Referring to FIGS. 5-10, a pipe system 100 is shown coupled equipped with an auger assembly 400. The auger assembly 400 is installed within the cavity 122 (e.g., a circular bore, a tubular fluid chamber, etc.) of the pipe 112 of the pipe system 100 to distribute the proppant in the fracking fluid more evenly/uniformly to the fluid outlets 126 along the length 140 of the pipe system 100.

The auger assembly 400 includes a helical blade 404 that may extend along substantially the entire length 140 of the pipe 112. Alternatively, multiple shorter helical blades 404 coupled in series may be used. Referring also to FIGS. 5-10, the helical blade 404 extends a length 408 which may be equal to or less than the length 140 of the pipe 112. In some embodiments, the length of the end supports 432, 452 may be included in the length 408 of the helical blade 404. Further, and as shown in FIGS. 8 and 10, the helical blade 404 may extend and/or be centered about a longitudinal axis 412. In some embodiments, the longitudinal axis 412 of the helical blade 404 may align/overlap with the center 123 of the pipe 112 when the auger assembly 400 is maintained/installed in a proper position within the cavity 122 of the pipe 112. The helical blade 404 may be coupled at each end to first and second end supports 432 and 452 that engage the walls (e.g., the interior wall 144 of the pipe 112). In other embodiments, other supports 424 may secure the auger assembly 400 and/or the helical blade 404 to the pipe 112 and/or the pipe system 100. For example, in some embodiments, supports 424 such as flanges, shafts, welds, or the like may couple the helical blade 404 to the pipe 112 at any point along the length 140. In some embodiments, the end supports 432, 452 and/or supports 424 may have a hub and spoke configuration with an annular rim with a chamfered profile. In some embodiments, a minimum amount of the helical blade may overlap (e.g., be positioned to affect the flow of proppant entering) the fluid outlet 126. For example, the helical blade 404 may be positioned such that at least half of the diameter of each of the fluid outlets 126 overlaps with and/or are adjacent to the helical blade 404. Further, the auger assembly 400 and/or the helical blade 404 thereof may comprise (e.g., could be split into, may have separate/spaced helical blades 404 coupled to the pipe 112, etc.) multiple separate pieces. In this way, proppant may interact with each separate blade piece as it reaches the respective isolated/spaced/separate/etc. portion of the auger assembly 400 and/or the helical blade 404. In such embodiments, the multiple pieces of the auger assembly 400 and/or the helical blade 404 may be lined up with or located just before (e.g., upstream of) the fluid outlets 126.

When disposed inside the cavity 122, an outer diameter 416 of the helical blade 404 may substantially span the inside diameter 146 of the cavity 122 and/or the pipe 112. In some embodiments, the outer diameter 416 of the helical blade 404 extends and stops short of the interior wall 144 of the pipe 112 and may form an annulus 420 (e.g., a gap, a circular open region through which fracking fluid may flow between the helical blade 404 and the pipe 112) between the outer edge of the helical blade 404 and the interior wall of the pipe 112. (See, e.g., FIGS. 5 and 9). The annulus 420 allows a portion of the fracking fluid to continue to flow directly from the inlet 114 of the pipe 112 to the outlet 118 of the pipe 112 and reduces the back pressure and resistance of the flow of the fracking fluid. Further, the helical blade 404 directs the momentum of the fracking fluid and the proppant therein towards the annulus 420 such that the proppant is more evenly distributed through the fluid outlets 126.

FIG. 5 illustrates a cross-sectional side view of the example pipe system 100 of FIG. 4, taken along the line A-A in FIG. 4. FIG. 6 illustrates a cross-sectional side view of the example pipe system 100 of FIG. 4, taken along the line B-B in FIG. 4. FIG. 7 illustrates a perspective view of the example auger assembly 400 disposed inside an embodiment of a pipe system 100. In FIGS. 7, 8, and 10, the pipe 112 is semi-transparent so that the auger assembly 400 can been viewed in its entirety and in an installed position with the pipe 112. Viewing FIGS. 5-7 together, the structural integrity of the auger assembly 400 may be further strengthened by the inclusion a support 424 such as a hollow support 428 coupled to the helical blade 404. As shown most clearly in FIG. 8, the support 424 such as the hollow support 428, a central support rod 428, or the like may extend along the longitudinal axis 412. In some embodiments, the hollow support 428 has a first end coupled to the first end support 432 and a second end coupled to the second end support 452. In other embodiments, one or more support bars may be coupled between the end supports 432 and 452. As shown in the figures, the support 424 may include a solid central support shaft instead of or in addition to the hollow support 428. The support 424 may also include support bars positioned and attached equidistantly around the annular rim of the helical blade 404 that substantially span the length 408 of the helical blade 404 or other suitable supports 424 (e.g., a sleeve fastening the helical blade 404 to the pipe 112, shafts extending radially through the pipe 112, etc.).

FIG. 8 is a perspective view of a first end of the example auger assembly 400 of FIG. 7 including an example first end support. FIG. 9 is a cross-sectional perspective view taken along plane C-C in FIG. 8 of the first end of the example auger assembly 400 of FIG. 7 including the example first end support 432. FIG. 10 is a perspective view of a second end of the example auger assembly 400 of FIG. 7 including an example second end support 452. Viewing FIGS. 8-10 together, more detailed views of embodiments of the first end support 432 and the second end support 452 are shown. The first end support 432 and the second end support 452 may engage the walls of the pipe 112 (e.g., the interior wall 144) and maintain the proper positioning of the helical blade 404 within the cavity 122 and/or the pipe system 100.

As shown most clearly in FIGS. 8 and 9, the first end support 432 may be located proximate one end of the pipe 112 and may be configured to secure the helical blade 404 of the auger assembly 400 in place such that the helical blade 404 remains centered in the pipe 112 and/or the cavity 122 thereof. For example, the first end support 432 may include a mounting block 436 such as a hard stop in the form of, for example, an annular ridge, against which other components of the first end support 432 and/or the auger assembly 400 are configured to be fastened to via fasteners 448 and/or abut. Further, one or more mounting blocks 436 may be coupled to and/or integrally formed with an interior wall 144 of the pipe 112 (e.g., a first mounting block 436 may be located opposite the pipe 112 as a second mounting block 436). In the embodiment shown, the first end support 432 may also include a brace 440 coupled to the mounting block 436. The brace 440 may include a shaft, flange, or other support structure extending across the cavity 122 of the pipe 112 (e.g., across the center 123 of the pipe 112). The helical blade 404 and/or the hollow support 428 thereof may be coupled to the first end support 432 such as via an adaptor 444 configured to be disposed inside the hollow support 428 at one end and fasted to the brace 440 at the other via a fastener 448 such that the longitudinal axis 412 of the helical blade 404 substantially aligns with the center 123 of the cavity 122.

As shown most clearly in FIG. 10, the second end support 452 may be located proximate to the second end 120 and/or the outlet 118 of the pipe 112. In some embodiments, the second end support 452 may be configured with similar components as, the same components as, or may otherwise function in the same way as the first end support 432 to secure the helical blade 404 and/or the auger assembly 400 at the center 123 of the pipe 112. In the example illustrated in FIG. 10, the second end support 452 comprises a first brace 456 configured to abut the interior wall 144 of the pipe 112 and remain in place via friction between the second end support 452 and the pipe 112. The second end support 452 may also include a housing 460 extending across the cavity 122 and/or a center 123 thereof. The housing 460 may have a first end 464 coupled to the first brace 456 and a second end 468 opposite the first end 464 coupled to the pipe 112 or another component of the second end support 452. For example, in FIG. 10, the second end 468 of the housing 460 is coupled to an extending support 478. The extending support 478 illustrated includes a second brace 482 abutting the pipe 112 and also configured to hold the auger assembly 400 in place via friction. For example, one or more bolts 479 may be adjusted to extend or retract a threaded rod 480 from the housing 460 to bias the first brace 456 and/or the second brace 482 against the pipe 112 while centering the helical blade 404 therein. Additionally, an adaptor 472 may be configured to couple the hollow support 428 to the second end support 452 (e.g., via the housing 460 and a fastener 448) such that the longitudinal axis 412 of the helical blade 404 substantially aligns with the center 123 of the cavity 122. In this way, the end supports 432 and 452 may help to maintain the centered placement and alignment of the helical blade 404 within the pipe 112 and/or the pipe system 100. In other embodiments, additional supports 424 may be located anywhere along the length of the helical blade 404 and/or the auger assembly 400 to align the helical blade 404 within the pipe 112.

The pipe system 100 and/or frac iron systems 200, 300 including an auger assembly 400 may be manufactured with a built-in auger assembly 400, or the auger assembly 400 may be retrospectively retrofitted into a pipe system 100 or the like (e.g., a pipe 112). In an alternate embodiment, the auger assembly 400 may employ multiple helical blade segments. In another embodiment, a series of spiral blades may be affixed to the wall of the pipe 112 (e.g., the interior wall 144. In yet another embodiment, an actuator may be coupled to the auger assembly 400 to rotate the helical blade 404 at a predetermined speed to further aid in the distribution of the proppant.

The features of the present invention which are believed to be novel are set forth below with particularity in the appended claims. However, modifications, variations, and changes to the exemplary embodiments described above will be apparent to those skilled in the art, and the novel pipe systems, frac iron systems, and auger assemblies described herein thus encompass such modifications, variations, and changes and are not limited to the specific embodiments described herein (e.g., features described or shown with respect to one figure or embodiment may be readily combined/interchanged with features of another embodiment and such modifications are expressly contemplated as within the scope of this disclosure).

INDUSTRIAL APPLICABILITY

The systems and methods described herein have industrial applicability in various use cases, environments, and settings that can be readily appreciated from the foregoing discussion. Specifically, in operation, the helical blade 404 of the auger assembly 400 effectively distributes the proppant in the frack fluid more evenly along the entire length 140 of the pipe system 100 and/or the pipe 112, which results in a more uniform distribution of proppant through each of the fluid outlets 126. In turn, uniformity of the proppant ensures that no component of the pipe system 100, frac iron system 200, 300, etc. receives excessive proppant, wear, and/or prematurely fails and causes unnecessary stoppages of operation/increased maintenance cycles when fracking, cementing, or the like.

Turning to FIG. 11, to achieve the benefits of the systems and apparatuses disclosed herein, a method 600 of manufacturing a pipe system 100 for oilfield operations is shown according to some aspects. In some aspects, the method 600 may include step 602 of providing a pipe 112 having an inlet 114 and an outlet 118 (which may include the fluid outlet(s) 126). As discussed above, the pipe 112 may define a cavity 122 between the inlet 114 and the outlet 118 configured to receive a flow of fluid containing a proppant and comprising one or more fluid outlet(s) 126 fluidly coupled to the cavity 122.

In some aspects, the method 600 may include step 604 of providing a helical blade 404 within the cavity 122 such that the helical blade 404 extends at least partially between the inlet 114 and the outlet 118 of the pipe 112. In this way, the helical blade 404 may alter the flow of the fracking fluid and specifically urge the proppant therein to flow towards the fluid outlets 126 (e.g., through transverse pipes) rather than maintaining momentum flowing downstream through the pipe 112.

In some aspects, the method 600 may include step 606 of coupling a first end of the helical blade 404 to the pipe 112 via a first end support 432 and a second end of the helical blade 404 to the pipe 112 via a second end support 452. For example, the first and second end supports 432, 452 may engage the pipe 112 (e.g., via fasteners 448, via friction, via being integrally formed as one unified component with the pipe 112, etc.) to maintain a proper position of the helical blade 404 and/or the auger assembly 400 within the cavity 122 of the pipe system 100. For example, and as best shown in FIGS. 7, 8 and 10, in one embodiment, one or more mounting blocks and/or stops 436 are coupled to an inside surface of the pipe 112. The auger assembly 400 and/or the helical blade 404 may be inserted into the cavity 122 of the pipe 112 through the first end 116 of the pipe 112 until the first end support 432 of the auger assembly 400 aligns and/or is adjacent to the mounting block and/or stops 436. The auger assembly 400 may then be coupled in place inside the cavity 122 by being fastened to a brace 440 that extends across the cavity 122 and couples/abuts the mounting block and/or stops 436 (e.g., via fasteners 448).

Similarly, the second end support 452 may be located adjacent to and/or at the second end 120 of the pipe 112 following insertion of the auger assembly 400 into the pipe 112 and/or coupling of the first end support 432 to the first end 116 of the pipe 112. The second end support 452 may be adjusted such that the second end support 452 becomes secured/coupled to the pipe 112 (e.g., via friction) and also centers the helical blade 404 along the length of the cavity 122. As illustrated in FIG. 10, the first brace 456 of the second end support 452 may abut the interior wall 144 of the pipe 112 and may secure the helical blade 404 via a connection between a housing 460 of the second end support 452 and the center support shaft 426 (such as the hollow support 426).

As illustrated best in FIG. 10, the method 600 may further include positioning the helical blade 404 and/or centering the helical blade 404 in the cavity 122 of the pipe 112 (e.g., by adjusting/securing the first end support 432 and/or the second end support 452 in place). For example, a second brace 482 of the second end support 452 may be adjustable via actuation of an extending support 478. The extending support 478 may comprise a threaded rod 480 and bolt 479 such that the threaded rod 480 may extend from/retract into the housing 460 in response to turning of the bolt 480. In this way, the threaded rod 480 may be extended from the housing 460 until the second brace 482 is secured and the helical blade 404 is centered in the cavity 122. In some embodiments, the second end support 452 is sized such that the adaptor 472 coupled to the helical blade 404 aligns the longitudinal axis 412 of the auger assembly 400 with the center of the pipe 112 when the second end support 452 is secured against the interior wall 144 of the pipe 112 (e.g., by sizing the second end support to fit within a particular pipe diameter). In other embodiments, the housing 460 may be spring loaded, may include a piston mechanism, or may include another suitable feature to bias the first brace 456 and the second brace 482 against the interior wall 144 of the pipe 112 such that the helical blade 404 aligns with a center of the pipe 112.

In still further embodiments, other methods of coupling the first end support 432, the second end support 452, and/or another support 424 of the auger assembly 400 to the pipe 112. For example, one or more of the end supports may be replaced with a rubber stopper or other sealing member (e.g., a plug configured to fit tightly around an outer annular region of the cavity 122). In this way, the auger assembly 400 may be inserted into the cavity 122 until the rubber stopper or other member (e.g., a stiff rubber ring having approximately a 4-inch outer diameter to abut a 4-inch interior pipe diameter) is adjacent to an end of the pipe 112 and hammered/firmly inserted inside the cavity 122 of the pipe 112. In still further embodiments, ridges and/or channels may be formed in the interior wall 144 of the pipe 112 such that flanges, protrusions, or the like extending from the auger assembly 400 may be inserted into the channels to hold the auger assembly 400 in place (e.g., centered in the cavity 122).

In some aspects, the method 600 may include step 608 of providing a hollow support 428 such as a support bar, a support rod, a tubular member of sufficient strength having a hollow internal section to save weight yet provide rigidity to the helical blade 404, or the like, coupled to the helical blade 404 and extending along the longitudinal axis 412 thereof. In other embodiments, the hollow support 428 may be another type of support 424 such as a solid support bar and/or multiple support bars extending parallel to the longitudinal axis and coupled to the outer rim of the helical blade 404.

In some aspects, the method 600 may include step 610 of providing a second pipe 112 having a second inlet 114 and a second outlet 118, the second pipe 112 defining a second cavity 122 between the second inlet 114 and the second outlet 118 configured to receive the flow of fluid containing the proppant and comprising a second fluid outlet 126 fluidly coupled to the second cavity 122. In this way, proppant not diverted through the fluid outlet(s) 126 of the first pipe 112 (e.g., of the first pipe system 100a) may flow into the second pipe 112 of the second pipe system 100b. (See, e.g., FIG. 3).

In some aspects, the method 600 may include step 612 of providing a second helical blade 404 within the second cavity 122 such that the second helical blade 404 extends at least partially between the second inlet 114 and the second outlet 118 of the second pipe 112. The second helical blade 404, similar to the first helical blade 404 in the first pipe 112, may further increase the uniformity of the proppant which flows from the first pipe system 100a into the second pipe system 100b, thereby achieving the same and/or similar benefits to component longevity and increased operation time.

In some aspects, the method 600 may include step 614 of coupling a first end of the second helical blade 404 to the second pipe 112 via a first end support 432 and a second end of the second helical blade 404 to the second pipe 112 via a second end support 452, the first and second end supports 432, 452 engaging the second pipe 112 to maintain a proper position of the second helical blade 404 within the second cavity 122 of the second pipe 112. These supports may anchor the second helical blade 404 in the second pipe 112 in the same, a similar, or a different manner than the first helical blade 404 is secured inside the first pipe 112.

In some aspects, the method 600 may include step 616 of coupling the outlet 118 of the first pipe 112 of the first pipe system 100a to the second inlet 114 of the second pipe 112 via a low-pressure connector 212 as shown in FIG. 3. In other aspects, the method 600 may include step 618 of coupling the fluid outlet 126 of the pipe 112 and the second fluid outlet 126 of the second pipe 112 to a high-pressure manifold 130 (e.g., of the frac iron system 200, 300).

As utilized herein with respect to numerical ranges, the terms “approximately,” “about,” “substantially,” and similar terms generally mean+/−10% of the disclosed values, unless specified otherwise. As utilized herein with respect to structural features (e.g., to describe shape, size, orientation, direction, relative position, etc.), the terms “approximately,” “about,” “substantially,” and similar terms are meant to cover minor variations in structure that may result from, for example, the manufacturing or assembly process and are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the disclosure as recited in the appended claims.

The term “coupled” and variations thereof, as used herein, means the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent or fixed) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members coupled directly to each other, with the two members coupled to each other using a separate intervening member and any additional intermediate members coupled with one another, or with the two members coupled to each other using an intervening member that is integrally formed as a single unitary body with one of the two members. If “coupled” or variations thereof are modified by an additional term (e.g., directly coupled), the generic definition of “coupled” provided above is modified by the plain language meaning of the additional term (e.g., “directly coupled” means the joining of two members without any separate intervening member), resulting in a narrower definition than the generic definition of “coupled” provided above. Such coupling may be mechanical, electrical, or fluidic.

References herein to the positions of elements (e.g., “top,” “bottom,” “above,” “below”) are merely used to describe the orientation of various elements in the figures. It should be noted that the orientation of various elements may differ according to other embodiments, and that such variations are intended to be encompassed by the present disclosure.

Although the figures and description may illustrate a specific order of method steps, the order of such steps may differ from what is depicted and described, unless specified differently above. Also, two or more steps may be performed concurrently or with partial concurrence, unless specified differently above. Such variation may depend, for example, on the hardware systems chosen and on designer choice. All such variations are within the scope of the disclosure.

It is important to note that the construction and arrangement of the various embodiments is illustrative only. Additionally, any element disclosed in one embodiment may be incorporated or utilized with any other embodiment disclosed herein.