FIELD
The present disclosure relates to a flexible hose end fitting assembly for oil and gas fracking and production operations.
BACKGROUND
Flexible conduits have been used to transport high-pressure applications fluids in oil and gas applications. In existing technology, the end coupling to the hammer union/safety iron is integrated into the flexible hose end coupling. This end coupling is either machined as one part of two separate parts that are butt welded together.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a first example embodiment of a flexible hose end fitting assembly according to the teachings of the present disclosure;
FIG. 2 is a cross-sectional view of the first example embodiment of a flexible hose end fitting assembly according to the teachings of the present disclosure;
FIG. 3 is a cross-sectional view of a second example embodiment of a flexible hose end fitting assembly according to the teachings of the present disclosure;
FIGS. 4 and 5 are side and perspective views of the first and second example embodiments of a flexible hose end fitting assembly according to the teachings of the present disclosure;
FIGS. 6 and 7 are perspective and cross-sectional views of a third example embodiment of a flexible hose end fitting assembly according to the teachings of the present disclosure;
FIGS. 8-10 are perspective, exploded and cross-sectional views of a fourth example embodiment of a flexible hose end fitting assembly according to the teachings of the present disclosure; and
FIGS. 11-13 are perspective, exploded and cross-sectional views of a fifth example embodiment of a flexible hose end fitting assembly according to the teachings of the present disclosure.
DETAILED DESCRIPTION
Most premature failures associated with flexible hoses used in hydraulic fracturing applications occur at the end fittings. These types of failures are caused by leaks, wash/jetting, threaded connection failures, etc. When failure occurs at the end fitting, the entire flexible hose assembly must be replaced because it is constructed as a single unit. The inventive concept described herein involves separating the end coupling to the hammer union/safety iron from the flexible hose coupling, so that when the flexible hose assembly fails at the safety iron connector, the entire assembly does not require replacement. The flexible hose may be constructed of a plurality of layers that are fabricated from reinforced materials and structural components that give tensile and compressive strength to the flexible hose so that it may transport fluids at high pressures. For example, the flexible hose may include a reinforcement layer constructed of a composite tape helically wound around a pipe.
FIG. 1 is a perspective view of a first example embodiment of a flexible hose end fitting assembly 10 according to the teachings of the present disclosure. The flexible hose end fitting assembly 10 has two primary parts, a flexible hose coupling portion 12 and a safety iron/hammer union connection coupling (also referred to as a “connection coupling”) 14. The flexible hose coupling portion 12 is configured to be secured to an end of the flexible hose 16 by mechanical gripping means, bonding means, adhesive means, and/or other suitable means. Also referring to FIG. 2, the flexible hose coupling portion 12 defines a cylindrical or tubular cavity 20 that is in axial alignment with the flexible hose 16. The second part of the flexible hose end fitting, the connection coupling portion 14, includes a standard connector interface 18 that is designed to couple to another fluid conduit such as a safety iron or a hammer union. The connection coupling portion 14 also defines a cylindrical or tubular cavity 22 that is in axial alignment with the cylindrical cavity 20 of the flexible hose coupling portion 12 when the two parts 12 and 14 are assembled together. The connection coupling portion 14 includes an annular flange 24 that is designed to interface with an enlarged end 25 of the flexible hose end fitting 12 and the two portions can be secured together by a plurality of threaded fasteners 26 such as socket head cap screws (SHCS). As shown in FIG. 2, one or more annular metal gaskets or o-ring seals 28 may be disposed in a groove machined or formed in the axial faces of the flexible hose coupling and/or connection coupling portions 12 and 14 of the flexible hose end fitting assembly 10. To provide a barrier against the corrosive and abrasive frack fluid, a protective coating may be applied to all internal surfaces 21 (FIG. 2) that would be exposed to the frack fluid.
FIG. 3 is a cross-sectional view of an alternate design for a flexible hose end fitting assembly 30 according to the teachings of the present disclosure. The flexible hose end fitting assembly 30 also has two primary parts, a flexible hose coupling portion 32 and a safety iron/hammer union connection coupling (a connection coupling) 34. The flexible hose coupling portion 32 is configured to be secured to an end of the flexible hose by mechanical gripping means, bonding means, adhesive means, and/or other suitable means. The flexible hose coupling portion 32 defines a cylindrical or tubular cavity 35 that is in axial alignment with the flexible hose. The second part of the flexible hose end fitting, the connection coupling portion 34, includes a standard connector interface that is designed to couple to another fluid conduit such as a safety iron or a hammer union. The connection coupling portion 34 also defines a cylindrical or tubular cavity 36 that is in axial alignment with the cylindrical cavity 35 of the flexible hose coupling portion 32 when the two parts 32 and 34 are assembled together. The connection coupling portion 34 includes an annular flange 38 that is designed to interface with an enlarged end 39 of the flexible hose end fitting 32 and the two portions can be secured together by a plurality of threaded fasteners 40 such as socket head cap screws (SHCS). The interface contours of the two portions include a cylindrical cavity 42 on the end of flexible hose coupling portion 32 that is sized and shaped to receive the cylindrical end 43 of the connection coupling portion 34. One or more rod/piston seals 44 may be disposed in a groove machined or formed in the cylindrical faces of the connection coupling and/or flexible hose coupling portions of the flexible hose end fitting assembly.
As shown in FIGS. 2 and 3, a protective coating may be applied to all internal surfaces 21 (FIGS. 2) and 33 (FIG. 3) of the flex hose coupling that would be exposed to corrosive and abrasive frack fluids to reduce and eliminate corrosion/erosion at these areas. The protective coating may be a tungsten carbide coating applied using, e.g., HVOF spray technology. The application of the protective coating is not limited to the flex hose coupling surfaces but can be applied to the internal surfaces of the connection coupling to extend the life of this component as well.
FIGS. 4 and 5 are side and perspective views of a flexible hose end fitting assembly 10, 30 coupled to a large bore manifold 50 via a check valve 52. The connection coupling portion 14, 34 is coupled to the check valve 52 using a safety iron clamp 54. The narrow neck portion of the connection coupling 14, 34 is sized to allow a conventional tube clamp or stauff clamp 56 that would support the weight of the flexible hose end fitting assembly. For example, the narrow neck portion of the connection coupling may be approximately nine inches long from the standard connector interface 18 to the annular flange 24. The tube clamp 56 may be secured to a support or skid structure 58. The flexible hose coupling portion 12, 32 is secured to a flexible hose 16 that is coupled to a frack pump or conventional flow iron at the other end. The frack pump pumps the frack fluid to the wellbore via the large bore manifold via the flexible hose 16 and flexible hose end fitting assembly. To provide a barrier against the corrosive and abrasive frack fluid, a protective coating may be applied to all internal surfaces that would be exposed to the frack fluid.
FIGS. 6 and 7 provide perspective and cross-sectional views of another example embodiment of a flexible hose end fitting assembly 60 according to the teachings of the present disclosure. This example flexible hose end fitting assembly 60 has a flexible hose coupling 62 and a connection coupling 64, with a two-part annular clamp 66. The flexible hose coupling portion 62 is configured to be secured to an end of the flexible hose 68 by mechanical gripping means, bonding means, adhesive means, and/or other suitable means. The flexible hose coupling portion 62 defines a cylindrical or tubular cavity that is in axial alignment with the flexible hose 68. The second part of the flexible hose end fitting assembly, the connection coupling portion 64, includes a standard connector interface 70 to another fluid conduit such as a safety iron or a hammer union. The connection coupling portion 64 also defines a cylindrical or tubular cavity that is in axial alignment with the cylindrical cavity of the flexible hose coupling portion 62 when the two parts are assembled together. The flexible hose coupling and connection coupling portions of the flexible hose end fitting 60 each has flanged ends 72 and 73 that are encircled and held together by the two-part annular clamp 66 hat are secured by a plurality of threaded fasteners 74 such as socket head cap screws (SHCS). As shown in FIG. 7, one or more annular gaskets or seals 76 may be disposed in a grooved interface between the safety iron coupling and flexible hose coupling portions of the flexible hose end fitting assembly 60. The groove may be formed or machined in one or both portions. To provide a barrier against the corrosive and abrasive frack fluid, a protective coating may be applied to all internal surfaces that would be exposed to the frack fluid.
FIGS. 8-10 are various views of another example embodiment of a flexible hose end fitting assembly 80 according to the teachings of the present disclosure. This example flexible hose end fitting assembly 80 has a flexible hose coupling 82 and a connection coupling 84, with a two-part ring clamp 86. The flexible hose coupling portion 82 is configured to be secured to an end of the flexible hose 88 by mechanical gripping means, bonding means, adhesive means, and/or other suitable means. The flexible hose coupling portion 82 defines a cylindrical or tubular cavity that is in axial alignment with the flexible hose 88. The second part of the flexible hose end fitting assembly 80, the connection coupling portion 84, includes a standard connector interface 90 to another fluid conduit such as a safety iron or a hammer union. The connection coupling portion 84 also defines a cylindrical or tubular cavity that is in axial alignment with the cylindrical cavity of the flexible hose coupling portion 82 when the two parts are assembled together. The flexible hose coupling and connection coupling portions of the flexible hose end fitting each include flanged fingers 92 that are configured to interlock and be encircled and held together by the two-part ring clamp 86 that are secured by a plurality of fasteners 94. An inner conduit 96 is held within the interlocking flanged fingers 94 of both portions and ring clamp to conduct the frack fluid. To provide a barrier against the corrosive and abrasive frack fluid, a protective coating may be applied to all internal surfaces that would be exposed to the frack fluid.
FIGS. 11-13 are various views of another example embodiment of a flexible hose end fitting assembly 100 according to the teachings of the present disclosure. This example flexible hose end fitting assembly 100 has a flexible hose coupling 102 and a connection coupling 104, with collets 106 and an outer reaction collar 108. The flexible hose coupling portion 102 is configured to be secured to an end of the flexible hose by mechanical gripping means, bonding means, adhesive means, and/or other suitable means. The flexible hose coupling portion 102 defines a cylindrical or tubular cavity that is in axial alignment with the flexible hose 109. The second part of the flexible hose end fitting assembly, the connection coupling portion 104, includes a standard connector interface 110 to another fluid conduit such as a safety iron or a hammer union. The connection coupling portion 104 also defines a cylindrical or tubular cavity that is in axial alignment with the cylindrical cavity of the flexible hose coupling portion 102 when the two parts are assembled together. The flexible hose coupling and connection coupling portions of the flexible hose end fitting 100 each include flanged ends 112 and 114 that are configured to be held together by a collet 106, which is encircled by the outer reaction collar 108 and causes the collet 106 to tighten around the flanged ends 112 and 114 of the two portions. One or more annular gaskets or seals 116 may be disposed in a grooved interface between the connection coupling and flexible hose coupling portions of the flexible hose end fitting assembly. The groove may be formed or machined in one or both of the parts. To provide a barrier against the corrosive and abrasive frack fluid, a protective coating may be applied to all internal surfaces that would be exposed to the frack fluid.
Although not shown explicitly, all embodiments described herein may incorporate a narrow neck section that enables the use of a tube clamp to support the weight of the flexible hose end fitting assembly Using an end fitting assembly that has two separable portions, the entire flexible hose assembly does not need to be replaced when the integrity of the coupling to the hammer union/safety iron is compromised. When it fails, the coupling portion to the hammer union/safety iron becomes the sacrificial piece that can be easily replaced without scrapping the entire flexible hose assembly.
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 flexible hose end fitting assembly described herein thus encompasses such modifications, variations, and changes and are not limited to the specific embodiments described herein.
Patent Application
20250109811
