Early erosion tracking layer for high pressure fracturing hose

Abstract

A rubber hose comprising a differentially colored internal wear indicator integrated into a bushing of the rubber hose, wherein the distance b of the internal wear indicator from the inner surface of the bushing is less than 40% of the thickness v of the bushing, and the height h of the wear indicator measured perpendicular to the longitudinal axis of the hose falls between 1% and 90% of the bushing thickness v or even 10% to 40% of the bushing thickness v. The concentric cross-sectional area of ​​the internal wear indicator may even gradually decrease in the radial direction with increasing distance from the longitudinal axis. The rubber hose may be in an oilfield pump system, connected at one end to a plunger pump and at the other end to a common manifold, or for any hose application in an oilfield fluid pump system.

Description

Technical Field

[0001] The field of the present disclosure relates generally to rubber hoses having high abrasion resistance and erosion detection capabilities. Background Art

[0002] This section provides background information to facilitate a better understanding of various aspects of the present disclosure. It should be understood that the statements in this section of this document are to be read in this light and not as admissions of prior art.

[0003] In oilfield applications, pump assemblies are used to pump fluids from the surface of a well site to a wellbore at extremely high pressures. Such applications include hydraulic hydraulic fracturing, cementing, and other applications such as pumping through coiled tubing. In instances of hydraulic fracturing operations, multiple pump assemblies are often used to direct abrasive-containing fluids or fracturing fluids through the wellbore and into target areas of the wellbore to form side "cracks" in the wellbore. In order to form such cracks, the fracturing fluid is pumped at extremely high pressures, sometimes in the range of 10,000 to 15,000 psi or more. In addition, the fracturing fluid contains abrasive proppants, which are both beneficial to the initial formation of the cracks and used to keep the cracks "propped" open after the cracks are formed. These cracks provide additional paths for underground oil and gas accumulations to flow from the underground formations to the surface of the well. These additional paths are used to increase the production of the well.

[0004] Piston pumps are typically used in high pressure oilfield pumping applications such as hydraulic fracturing operations. These pumps can be interconnected by a common manifold that mechanically collects and distributes the combined output of the individual pumps. These pumps are typically individually connected to the common manifold via steel pipe conduits and swivel elbows (chiksan).

[0005] Due to the abrasive nature of the fluid delivered from the pump to the common manifold at high pressure, the interior of the steel pipe may corrode over time during use. Such corrosion may result in an unsafe condition in which the steel pipe may rupture, thereby leaking and releasing the pressurized abrasive fluid.

[0006]

[0006] It would therefore be desirable to provide a catheter having adequate wear resistance and improved erosion detection, a need which is at least partially met by embodiments according to the present disclosure. Summary of the invention

[0007] This section provides a general summary of the disclosure, and is not necessarily a comprehensive disclosure of its full scope or all of its features.

[0008] In a first aspect of the present disclosure, a rubber hose includes a differentially colored internal wear indicator integrated into its bushing, wherein the distance b of the internal wear indicator from the inner surface of the bushing is less than 40% of the thickness v of the bushing, and the height h of the wear indicator measured perpendicular to the longitudinal axis of the hose falls between 1% and 90% of the bushing thickness v. In some aspects, the distance b of the internal wear indicator from the inner surface of the bushing is equal to or less than 20% of the bushing thickness v, and the height h of the wear indicator measured perpendicular to the longitudinal axis of the hose is 10% to 40% of the bushing thickness v. The rubber hose may further include one or more embossed rubber grooves in the bushing that act as washouts when the bushing is exposed to high velocity fluids.

[0009] In some cases, the concentric cross-sectional area of ​​the inner wear indicator varies with respect to radial distance from the longitudinal axis, and the concentric cross-sectional area of ​​the inner wear indicator may even gradually decrease in the radial direction with increasing distance from the longitudinal axis.

[0010] According to some aspects of the present disclosure, the internal wear indicator has a profile applied in a spiral shape and having a triangular cross section, or the internal wear indicator profile is applied in a spiral shape and has a multi-triangular cross section. Furthermore, the internal wear indicator in the rubber hose can have a triangular cross section, laid in a ring shape perpendicular to the longitudinal axis. The internal wear indicator can even have a multi-triangular cross section, placed perpendicular to the longitudinal axis, laid in a ring shape. In some other cases, the rubber hose has a rectangular cross section, laid in a ring shape perpendicular to the longitudinal axis, and in some other cases, the internal wear indicator in the rubber hose consists of basic conical elements placed in a spot-like pattern.

[0011] According to some other aspects of the present disclosure, the rubber hose further includes an additional external wear indicator, which is radially relative to the longitudinal axis and is placed more outward than the internal wear indicator. The cross-sectional area of ​​the external wear indicator can gradually increase with increasing distance from the longitudinal axis in the radial direction relative to the longitudinal axis.

[0012] According to other aspects of the present disclosure, the rubber hose is connected to a plunger pump at one end and to a common manifold at the other end in an oilfield pump system, or the rubber hose can be used for any hose application in an oilfield fluid pump system. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figures 1 to 7 A possible implementation according to the present disclosure on a longitudinal cross section of a rubber hose is shown;

[0014] Figure 8 An oilfield fluid pump system is shown. DETAILED DESCRIPTION

[0015] The following description of variants is essentially only illustrative, and is by no means intended to limit the scope of the present disclosure, the application of the present disclosure or the use. Presenting descriptions and examples herein is only for the purpose of illustrating the different embodiments of the present disclosure, and should not be interpreted as limiting the scope and applicability of the present disclosure. In the present disclosure of the invention and this specific embodiment, each numerical value should be read once as modified by the term "about" (unless it has been explicitly modified in this way), and then read again as if it has not been modified in this way, unless otherwise specified in the context. In addition, in the present disclosure of the invention and this specific embodiment, it should be understood that the amount or value range listed or described as useful, suitable, etc. is intended to be considered as having been stated in the whole amount or value (including endpoints) within the range. For example, "a range of 1 to 10" will be read as indicating every possible number along the continuum between about 1 and about 10. Therefore, even at a specific data point within the range, or even without the data point within the range being explicitly specified or only referring to a few specific points, it should be understood that the inventors appreciate and understand that any and all data points within the range are considered to have been specified, and the inventors have the entire range and all points within the range.

[0016] Unless expressly stated to the contrary, "or" refers to an inclusive or and not an exclusive or. For example, condition A or B can be satisfied by any of the following situations: A is true (or exists) and B is false (or does not exist), A is false (or does not exist) and B is true (or exists), and both A and B are true (or exist).

[0017] In addition, "a / an" is used to describe the elements and components of the embodiments herein. This is done only for convenience and to give a general meaning of the concepts according to the present disclosure. This description should be interpreted as including one / a or at least one / a, and the singular also includes the plural, unless otherwise specified.

[0018] The terms and phrases used herein are for descriptive purposes and should not be construed as limiting in scope. Language such as "including," "comprising," "having," "containing," or "involving," and variations thereof, are intended to be broad and include the subject matter listed thereafter, equivalents, and additional subject matter that is not listed.

[0019] Furthermore, as used herein, any reference to "one embodiment" or "an embodiment" means that a particular element, feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. The phrase "in one embodiment" appearing in different places in the specification does not necessarily refer to the same embodiment.

[0020] Embodiments according to the present disclosure allow operators to visually determine the degree of erosion on the hose rubber bushing at an early stage in the service life, calculate the remaining life of the hose, and thereby provide maintenance and replacement planning, thereby saving operating expenses. These embodiments provide safety for operations because based on the early stage erosion tracking layer, the expected service life of the hose can be inferred for its specific operating conditions. Having an early life erosion tracking layer ultimately leads to safer operations because it clearly indicates the condition of the hose even to the untrained eye.

[0021] Embodiments of the present disclosure provide advantages over prior art solutions which are not proven to work at high pressures (15,000 psi or greater) and high fluid velocities (over 16 m / s) with abrasive fluids. A disadvantage of prior art solutions is that they do not provide continuous information about the wear status and they alert the user only after a preset level of wear is reached. This means that in most cases they alert the user only when the hose needs to be replaced as soon as possible. Unplanned hose replacement may interrupt the shipping process and incur significant additional costs. Embodiments of the present disclosure overcome these problems and these embodiments inform the user of any hose bushing wear at its early stages. This enables the user to calculate the wear rate while the wear is still in its early stages, thus allowing the user to plan hose replacement in advance and perform the replacement at their convenience.

[0022] According to the present disclosure, one or more wear indicator elements are placed inside the bushing (innermost layer) of a rubber hose and are colored differently from the bushing itself. As an example, the wear indicator element can be a rubber profile laid in a spiral. In the case of multiple elements, they can be placed in an annular pattern perpendicular to the hose axis, or a spot-like pattern is also possible. In some aspects, the wear indicator element or elements are placed on the inner surface of the hose bushing, but can also be placed completely inside the bushing. In some cases, the wear indicator element or elements cover up to about 50% of the inner surface of the bushing, or even not more than about 20%. The wear indicator element or elements have been dimensioned in the radial direction, and in some aspects, the radial dimensions of the wear indicator element or elements constitute about 1% to about 90% of the thickness of the bushing. In some embodiments, the axial dimension of the wear indicator element or elements and / or the dimension perpendicular to the hose axis (tangential direction) gradually decrease radially, so that the visible size of the wear indicator (on the inside of the hose) gradually decreases with increasing wear. Knowing the geometry of the wear indicator and its dimensional change (visible on the inside of the hose), the wear rate can be calculated.

[0023] One or more colored wear indicator elements of the bushing allow for easier and more reliable inspection using low-cost optical devices such as a borescope, a small portable camera (eg, a GoPro), or even a mobile phone.

[0024] exist Figures 1 to 7 In the following reference numerals apply:

[0025] 1 Hose bushing

[0026] 2 Strengthening layer

[0027] 3 Covering

[0028] 4 Differentially colored wear indicators

[0029] 5 Differentially colored external wear indicators

[0030] 6 Reinforcement spiral

[0031] a Hose differently colored wear indicators when new 4 profile widths

[0032] a1 hose Differentially colored wear indicators when new 4 spots width

[0033] h hose Differentially colored wear indicators when new 4 profile heights

[0034] l Differentiated colored wear indicators 4 profile thread pitch

[0035] l1 Differentially colored wear indicators 4 Repeat distance of the profile in the axial direction of the hose

[0036] Wear time

[0037] a t Remaining width of the wear indicator 4 profile after time t

[0038] t c Total time remaining before the hose is completely worn out

[0039] a x Remaining width of the external wear indicator 5 profile at time x

[0040] b Radial distance between the inner surface of the hose and the wear indicator

[0041] ID The inner diameter of the hose

[0042] OD hose outer diameter

[0043] vThickness of bushing

[0044] Reference now Figure 1 , in one embodiment, a hose is depicted, wherein, in a longitudinal section of the rubber hose, the hose has a lining 1, a reinforcement layer 2 and a rubber covering 3. An integrated internal wear indicator 4 profile with a width a, height h and a triangular cross section, with a distinguishing color, is placed on the inside of the lining in a spiral form and with a pitch l.

[0045] Figure 2 Another possible implementation according to the present disclosure is shown in a longitudinal section of a rubber hose, which also has a bushing 1, a reinforcement layer 2 and a rubber covering 3. An integrated internal wear indicator 4 profile with a width a, a height h and a triangular cross section with a distinguishing color is placed on the inside of the bushing in a tangential direction perpendicular to the hose axis and at a repeat distance l1.

[0046] Figure 3 Another possible implementation according to the present disclosure is shown in a longitudinal section of a rubber hose, which also has a bushing 1, a reinforcement layer 2, a rubber covering 3 and an internal wear indicator 4. The wear indicator 4 on the inside is integrated in the form of a conical wear indicator spot with diameter a1, height h and a distinguishing color.

[0047] Figure 4A possible implementation according to the present disclosure is shown on a longitudinal section of a rubber hose having a bushing 1, a reinforcement layer 2 and a rubber covering 3. An integrated internal wear indicator 4 profile with width a, height h and triangular cross section is laid on the inside of the bushing in a spiral form and with a pitch l. An integrated external wear indicator 5 profile with width a, height h and triangular cross section is similarly laid on the outside of the bushing in a spiral form and with a pitch l. For practical purposes, the tip of the profile on the outside of the bushing points to the hose axis and the external wear indicator 4 profile and the internal wear indicator 4 profile have different colors.

[0048] Figure 5 A possible implementation according to the disclosure is shown on a longitudinal section of a rubber hose with a bushing 1, a reinforcing layer 2, a reinforcing spiral 6 and a rubber covering 3. The inside of the bushing is continuous; the internal wear indicator 4 profile with a multi-triangular cross section is placed radially at a distance b from the inner surface of the bushing and consists of three triangular cross-section parts with width a and height h. Its color is different from that of the bushing. It is integrated in a spiral with a pitch of l. In the hose according to the disclosure, if the wear indicator is placed on the inner surface of the bushing, the variation of the profile width (or the diameter of the conical wear indicator) enables an easy calculation of the wear rate.

[0049] If after t operation time, Figures 1 to 5 The width of the wear indicator 4 profile shown decreases from a to a t , then the wear rate k is calculated as follows:

[0050] k=h(aa t ) / (at).

[0051] This equation can also be used in a similar way for the cone wear indicator 4. Figure 4 According to one implementation method of the present disclosure, the total life of the hose can be calculated, that is, the remaining potential life before the liner is completely worn away. If the visible width of the outer indicator 5 profile at time x is a x , the remaining potential life before complete wear-out can be determined using the following equation: c :

[0052] t c =h (a - a x ) / (ak)

[0053] This naturally presupposes that the wear rate k is determined in advance.

[0054] Figure 6A preferred implementation according to the present disclosure is shown in longitudinal section of a rubber hose with a bushing 1, a reinforcement layer 2 and a rubber covering 3. An integrated internal wear indicator 4 profile with width a, height h and rectangular cross section is placed on the inside of the bushing in a spiral form and with a pitch l.

[0055] Figure 7 Another possible implementation according to the present disclosure is shown in a longitudinal section of a rubber hose, which also has a bushing 1, a reinforcement layer 2 and a rubber covering 3. An integrated internal wear indicator 4 profile with width a, height h and a rectangular cross section with a distinguishing color is placed on the inside of the bushing in a tangential direction perpendicular to the hose axis and at a repeat distance l1.

[0056] The hose is checked regularly after each operation. If after an operating time t, the full thickness h of the wear indicator 4 profile has washed away and the underlying bushing 1 begins to show, the wear rate k is calculated as follows:

[0057] k = h / t.

[0058] Use as Figure 6 and Figure 7 The demonstrated implementation method according to the present disclosure can calculate the total life of the hose, that is, the remaining potential life before the bushing is completely worn away. After t operating time, the remaining thickness of the bushing 1 is vh.

[0059] Therefore, the remaining potential life of the hose can be calculated as follows:

[0060] t c =(vh) / k.

[0061] The rubber hose according to some aspects of the present disclosure has a distinctively colored internal wear indicator 4 integrated into the bushing 1, characterized as follows: the distance b of the internal wear indicator 4 from the inner surface of the bushing 1 is less than about 40% of the bushing thickness v, and the height h of the wear indicator measured perpendicular to the hose axis falls between about 1% and about 90% of the bushing thickness v. In some aspects, the distance b of the internal wear indicator 4 from the inner surface of the bushing 1 is equal to or less than about 20% of the bushing thickness v, and the height h of the wear indicator 4 measured perpendicular to the hose axis is about 10% to about 40% of the bushing thickness v.

[0062] According to one implementation of the present disclosure, the cross-sectional area of ​​the internal wear indicator 4 changes with its radial distance from the hose axis. According to another implementation of the present disclosure, the cross-sectional area of ​​the internal wear indicator 4 located concentrically with the bushing inside the rubber hose gradually decreases with its increasing radial distance from the hose axis.

[0063] According to another implementation of the present disclosure, the profile of the internal wear indicator 4 in the rubber hose has a triangular cross section and the indicator is laid in a spiral. According to yet another implementation of the present disclosure, the profile of the internal wear indicator 4 in the rubber hose has a multi-triangular cross section and the indicator is laid in a spiral.

[0064] According to another implementation of the present disclosure, the profile of the internal wear indicator 4 in the rubber hose has a triangular cross section, which is laid in a ring shape perpendicular to the hose axis. According to yet another implementation of the present disclosure, the profile of the internal wear indicator 4 in the rubber hose has a multi-triangular cross section, which is laid in a ring shape perpendicular to the hose axis.

[0065] According to another implementation of the present disclosure, the internal wear indicator 4 in the rubber hose consists of substantially conical elements placed in a spot-like pattern.

[0066] According to another implementation of the present disclosure, the rubber hose with the wear indicator 4 features an additional external wear indicator 5 which is placed radially further outwards than the wear indicator 4 with respect to the hose axis.

[0067] According to another implementation of the present disclosure, the surface of the external wear indicator 5 in the rubber hose with the internal wear indicator 4 gradually increases as its distance from the hose axis increases in the radial direction relative to the hose axis.

[0068] According to another preferred implementation of the present disclosure, the profile of the internal wear indicator 4 in the rubber hose has a rectangular cross section and the indicator is laid in a spiral. According to another preferred implementation of the present disclosure, the profile of the internal wear indicator 4 in the rubber hose has a rectangular cross section and is laid in a ring perpendicular to the hose axis.

[0069] In yet another aspect of the disclosure, embossed rubber grooves are added to the bushing material during manufacturing that will wash away when the product is exposed to high velocity fluids. The grooves can be machined into the mandrel on which the hose is built, mirroring the grooves to the rubber bushing.

[0070] The material of the bushing as well as the inner wear indicator 4 and the outer wear indicator 5 may be any vulcanized or cured rubber compound, such as rubber compounds based on styrene-butadiene copolymers, polybutadiene, natural rubber, synthetic polyisoprene, but also oil-resistant polychloroprene, nitrile rubber, hydrogenated nitrile rubber, chlorinated or sulfon-chlorinated polyethylene, acrylate rubber, fluorinated elastomers, etc. The material of the bushing may be a blend of different rubbers.

[0071] According to the present disclosure, the reinforcement layer 2 can be steel wire, cable, steel cord or textile cord and other structures made of woven polyester, polyamide, aramid or other artificial or natural fibers embedded in rubber.

[0072] According to the present disclosure, the hose may include additional elements such as a rubberized load distributing fabric layer, a reinforcing spiral, a steel ring or composite ring, a stainless steel outer wrap, a plastic spiral guard, a rubber cover 3, etc.

[0073] Reference now Figure 8 , the figure shows an oilfield fluid pump system 200 for pumping fluid from the surface 118 of a well site 120 to a wellbore 122 during an oilfield operation. In this specific example, the operation is a hydraulic fracturing operation, so the fluid pumped is a fracturing fluid. As shown, the oilfield fluid pump system 200 includes a plurality of water tanks 221 that feed water to a gelling machine 223. The gelling machine 223 combines the water from the water tanks 221 with a gelling agent to form a gel. The gel is then sent to a blender 225, where it is mixed with a proppant from a proppant feeder 227 to form a fracturing fluid. The gelling agent increases the viscosity of the fracturing fluid and allows the proppant to be suspended in the fracturing fluid. It can also be used as a friction reducer to allow higher pumping speeds at lower friction pressures.

[0074] The fracturing fluid is then pumped from the blender 225 to the plurality of plunger pumps 201 at a low pressure (e.g., about 60 to 120 psi), as indicated by the solid line 212. Figure 8 As shown, each plunger pump 201 receives the fracturing fluid at low pressure and discharges it at high pressure through a hose according to the present disclosure to a common manifold 210 (sometimes referred to as a missile trailer or missile), as shown by dashed line 214. The missile 210 then directs the fracturing fluid from the plunger pump 201 to the wellbore 122, as shown by solid line 215.

[0075] According to another aspect of the present disclosure, some hose embodiments can be used for combined flow from a so-called zipper manifold to a wellhead. A zipper manifold is a system of fracturing equipment valves that directs fracturing treatment fluid from a projectile to multiple wellbores. A zipper manifold facilitates rapid redirection of fracturing fluid from one well to another, allowing pump trucks to operate almost continuously to minimize downtime. Hose embodiments according to the present disclosure can also be used from a projectile 210 to pipework to reduce vibrations in the pipework. In other embodiments, a hose according to the present disclosure can be used to connect a fluid flow from a projectile to one or more wellheads, thereby replacing all of the pipework and zipper manifolds.

[0076] For the purpose of illustration and description, the foregoing description of the embodiment has been provided. Exemplary embodiments are provided so that this disclosure will be fully thorough and the scope is conveyed to those skilled in the art. Many specific details, such as examples of specific parts, devices and methods, are set forth to provide a thorough understanding of the embodiments of this disclosure, but are not intended to be exhaustive or limit this disclosure. It should be understood that within the scope of this disclosure that the individual elements or features of a specific embodiment are generally not limited to the specific embodiment, but are interchangeable and can be used in the selected embodiment (even if not explicitly shown or described) where applicable. This disclosure can also change in many ways. Such changes are not considered to depart from this disclosure, and all such modifications are intended to be included within the scope of this disclosure.

[0077] Although several embodiments of the present disclosure have been described in detail above, it will be readily appreciated by those skilled in the art that many modifications are possible without departing substantially from the teachings of the present disclosure. Therefore, such modifications are intended to be included within the scope of the present disclosure as defined in the claims.

Claims

1. A rubber hose comprising a differentially colored internal wear indicator integrated into a bushing of the rubber hose, wherein: The internal wear indicator is disposed at a distance (b) from the inner surface of the liner, wherein (b) is less than 40% of the thickness (v) of the liner, and wherein a height (h) of the wear indicator measured perpendicular to the longitudinal axis of the hose falls between 1% and 90% of the liner thickness (v), and Wherein, the internal wear indicator has the following profile: o Applied in a spiral shape and with a triangular cross section, o Applied in a spiral shape and with a multi-triangular cross section, o triangular cross-section, laid in a ring-like shape perpendicular to the longitudinal axis, o having a multi-triangular cross-section, placed perpendicular to the longitudinal axis, laid in a ring-like shape, or oBasic cone-shaped elements placed in a spot-like pattern.

2. The rubber hose according to claim 1, wherein The concentric cross-sectional area of ​​the internal wear indicator varies with radial distance from the longitudinal axis.

3. The rubber hose according to claim 2, wherein: The concentric cross-sectional area of ​​the inner wear indicator gradually decreases with increasing distance from the longitudinal axis in the radial direction.

4. The rubber hose according to claim 1, wherein An additional outer wear indicator is positioned radially relative to the longitudinal axis and further outward than the inner wear indicator.

5. The rubber hose according to claim 4, wherein: The cross-sectional area of ​​the external wear indicator gradually increases with increasing distance from the longitudinal axis in a radial direction relative to the longitudinal axis.

6. The rubber hose of claim 1 further comprising one or more embossed rubber grooves in the bushing that act to wash away when the bushing is exposed to high velocity fluid.

7. The rubber hose according to claim 1, wherein The distance (b) of the internal wear indicator from the inner surface of the liner is equal to or less than 20% of the liner thickness (v), and the height (h) of the wear indicator measured perpendicular to the longitudinal axis of the hose is 10% to 40% of the liner thickness (v).

8. The rubber hose according to claim 1, wherein In an oilfield pump system, the rubber hose is connected to a plunger pump at one end and wherein the rubber hose is connected to a common manifold at the other end.

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