Radial flow block modular wellhead

Abstract

A modular wellhead modular system with a radial flow block. The system including a modular radial flow block and can include a plunger lift lubricator system. A pin connection mechanism can be incorporated into the modular radial flow block. This system enables easy attachment and detachment of various wellhead accessories, including a versatile “night cap” conversion cap, allowing seamless transitions between connection standards. The system facilitates tubing size changes without the need for significant modifications, achieved through an innovative spacer sleeve and / or crossover spacer configuration. The system can include replaceable radial flow sleeves, optimized flow paths, and real-time operational adjustments.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and the benefit of the filing of U.S. Provisional Patent Application No. 63 / 762,692, entitled “Radial Flow Block Modular Wellhead”, filed on Feb. 25, 2025, and the specification and claims thereof are incorporated herein by reference.BACKGROUND OF THE INVENTION

[0002] Embodiments of the present invention relate to oil and gas well equipment. More particularly, to a modular wellhead block and plunger lift lubricator system configured to streamline the transition of wellheads to accommodate various production phases and accessories without necessitating extensive modifications.

[0003] The conventional operation of oil and gas wells often involves complex modifications to the wellhead assembly as the well evolves through various production stages. These modifications are typically labor-intensive, time-consuming, and costly due to the necessity of altering or replacing the existing wellhead setup. Therefore, there is a critical need for a versatile and easily adaptable wellhead system that can reduce the frequency of such changes, thereby minimizing downtime and associated expenses.BRIEF SUMMARY OF EMBODIMENTS OF THE PRESENT INVENTION

[0004] Embodiments of the present invention relate to a modular wellhead system. In one embodiment, the modular wellhead system can include: a radial flow block having a flow block opening passing from a top to a bottom thereof; a spacer sleeve including a spacer sleeve opening passing from a top to a bottom thereof; a radial flow sleeve, the radial flow sleeve including at least one opening disposed in a sidewall thereof, the flow block opening including a diameter throughout said radial flow block that is at least as large as an outer diameter of the radial flow sleeve; a radial sleeve retainer opening formed in at least an upper portion of the spacer sleeve opening; and the radial sleeve retainer opening including a diameter that is at least equal to an outer diameter of a bottom end portion of the radial flow sleeve, such that a bottom end portion of the radial flow sleeve can be seated and retained within the radial sleeve retainer opening. The radial flow block can include a tangential pin connection. The tangential pin connection can include a pair of pin openings that pass through a side of the flow block and a pair of pins, each of the pair of pins having a diameter that allows them to be inserted into a respective one of the pair of pin openings. The radial flow block can include a flange connection in communication with the radial flow block. The radial flow block can include a thread connection. The system can further include a welded connection in communication with the radial flow block.

[0005] Embodiments of the present invention also relate to a modular wellhead system. In one embodiment, the modular wellhead system can include: a radial flow block having a flow block opening passing from a top to a bottom thereof; a crossover spacer comprising outer dimensions that allow it to rest within a portion of the opening; a radial flow sleeve, the radial flow sleeve including at least one opening disposed in a sidewall thereof, the flow block opening including a diameter throughout the radial flow block that is at least as large as an outer diameter of the radial flow sleeve; a radial sleeve retainer opening formed in the crossover spacer; and the radial sleeve retainer opening including a diameter that is at least equal to an outer diameter of a bottom end portion of the radial flow sleeve, such that a bottom end portion of the radial flow sleeve can be seated and retained within the radial sleeve retainer opening. The crossover spacer and flow block opening can include dimensions such that the crossover spacer can be inserted and seated into the flow block by passing the crossover spacer down into the flow block through the top thereof. The crossover spacer can include a 2-piece configuration. The crossover spacer and flow block opening can include dimensions which allow the crossover spacer to be seated within a lower one-third of the flow block. The system can further include an upper crossover spacer, the upper crossover spacer including an internal opening that seats onto an upper end portion of the radial flow sleeve. The system can further include a tangential pin connection. The tangential pin connection can include a pair of pin openings that pass through a side of the flow block and a pair of pins, each of the pair of pins having a diameter that allows them to be inserted into a respective one of the pair of pin openings.

[0006] Embodiments of the present invention also relate to a method for providing a modular wellhead. In one embodiment, the method can include flowing fluid up through a radial flow sleeve having a bottom portion seated on a spacer sleeve that is disposed below a radial flow block and wherein a top portion of the radial flow sleeve is seated in a night cap or in a plunger lift tube. The method can further include flowing fluid through one or more openings. The method can further include adjusting the fluid flow with the radial flow sleeve. The method can further include swapping components of the modular wellhead system through a modular universal connector component.

[0007] Embodiments of the present invention also relate to a method for changing a tubing size on a well while maintaining compatibility with existing surface flow infrastructure. In one embodiment, the method includes removing surface wellhead equipment from a well to permit workover operations; pulling a first string of tubing from the well using conventional workover or rig procedures, the first string of tubing having a first diameter; installing a second string of tubing into the well using conventional workover or rig procedures, the second string of tubing having a diameter different from the first diameter; reconfiguring or replacing wellhead components as required to accommodate the second string of tubing; reinstalling a modular flow block onto the wellhead following completion of the tubing change; and reconnecting surface production flow equipment to the modular flow block, wherein the modular flow block is configured to interface with the reconfigured wellhead while maintaining compatibility with existing surface flowline or highline connections. In this manner, the modular flow block may be removed and reinstalled during tubing change operations while allowing continued use of existing surface flow infrastructure, thereby reducing or eliminating the need for extensive flowline modification, relocation, or replacement.

[0008] Embodiments of the present invention relate to a radial completion wellhead block and plunger lift lubricator system (the “system”) that introduces a novel method and apparatus for a highly adaptable wellhead configuration. The system is based on a modular configuration that includes a wellhead block with a pin connection, facilitating easy attachment and detachment of a wide variety of wellhead accessories, which can include, in one embodiment, a “night cap” conversion cap, which adapts to different connection standards including flange, weld, or all-thread types.

[0009] The system provides a notable advancement by enabling changes in tubing size without the need for extensive modifications to the existing piping or wellhead setup. This is made possible through an innovative spacer sleeve that seamlessly integrates with the current flow block and the new wellhead configuration. The spacer sleeve incorporates a landing area designed to support an inner ported radial sleeve, upon which an upper radial plunger lift tube is placed. This configuration effectively alters the original wellhead flow path to accommodate smaller tubing sizes, including options like 2-⅜″ and / or 2-⅞″ plunger lift lubricators, while preserving the integrity and functionality of the wellhead.

[0010] This capability extends beyond plunger lift applications, encompassing any scenario where the wellhead transitions from a larger size to a smaller size. The modular flow block plays a pivotal role in facilitating these size adjustments, with plunger lift often being one of the most desired objectives in many instances.

[0011] Objects, advantages and novel features, and further scope of applicability of the present invention will be set forth in part in the detailed description to follow, taken in conjunction with the accompanying drawings, and in part will become apparent to those skilled in the art upon examination of the following, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0012] The accompanying drawings, which are incorporated into and form a part of the specification, illustrate one or more embodiments of the present invention and, together with the description, serve to explain the principles of the invention. The drawings are only for the purpose of illustrating one or more embodiments of the invention and are not to be construed as limiting the invention. In the drawings:

[0013] FIG. 1A and FIG. 1B are drawings which respectively illustrate a cut-away view and a perspective view of a wellhead with a modular flow block, tubing spacer spool, sleeve insert, and smaller wellhead and plunger lift lubricator insert, according to an embodiment of the present invention;

[0014] FIG. 2A is a drawing which illustrates a section view of a modular flow block with a threaded night cap, according to an embodiment of the present invention;

[0015] FIG. 2B is a drawing which illustrates a perspective view of the modular flow block of FIG. 2A, according to an embodiment of the present invention;

[0016] FIG. 2C is a drawing which illustrates a cut-away view of a modular flow block with a flanged night cap, according to an embodiment of the present invention;

[0017] FIG. 2D is a drawing which illustrates a perspective view of the modular flow block with flanged night cap of FIG. 2C, according to an embodiment of the present invention;

[0018] FIG. 2E is a drawing which illustrates a perspective view of the modular flow block with a short sleeve, according to an embodiment of the present invention;

[0019] FIG. 2F is a drawing which illustrates a section view of the modular flow block with a short sleeve, according to an embodiment of the present invention;

[0020] FIG. 2G is a drawing which illustrates a perspective view of the modular flow block with a short sleeve and flanged night cap, according to an embodiment of the present invention;

[0021] FIG. 2H is a drawing which illustrates a section view of the modular flow block with a short sleeve and flanged night cap, according to an embodiment of the present invention;

[0022] FIG. 3A is a drawing which illustrates a section of a large bore wellhead with modular block and flanged night cap before a small tubing conversion has been applied, according to an embodiment of the present invention;

[0023] FIG. 3B is a drawing which illustrates a perspective view of the large bore wellhead of FIG. 3A, according to an embodiment of the present invention;

[0024] FIG. 4A is a drawing which illustrates a front view of a modular flow block with a tangential pin, according to an embodiment of the present invention;

[0025] FIG. 4B is a drawing which illustrates a section view of the modular flow block of FIG. 4A, taken along line A-A, looking in the direction of the arrows, according to an embodiment of the present invention;

[0026] FIG. 4C is a drawing which illustrates a front view of a modular flow block with a crossover spacer not inserted, according to an embodiment of the present invention;

[0027] FIG. 4D is a drawing which illustrates a front view of a modular flow block with a crossover spacer inserted, according to an embodiment of the present invention;

[0028] FIG. 5A is a drawing which illustrates a front view of a spacer spool with a sleeve seat, according to an embodiment of the present invention;

[0029] FIG. 5B is a drawing which illustrates a sectional view of the spacer spool with a sleeve seat of FIG. 5A, taken along line 5B-5B, looking in the direction of the arrows, according to an embodiment of the present invention;

[0030] FIG. 5C is a drawing which illustrates a front view of a shortened spacer spool, according to an embodiment of the present invention;

[0031] FIG. 5D is a drawing which illustrates a sectional view of the shortened spacer spool of FIG. 5C, taken long line C-C, looking in the direction of the arrows, according to an embodiment of the present invention;

[0032] FIG. 6A and FIG. 6B are drawings which respectively illustrate a modular flow block held together with a pair of tangential pins with a threaded night cap sleeve and a spacer spool attached thereto as illustrated from different perspectives, according to an embodiment of the present invention;

[0033] FIG. 7A is a drawing which illustrates a modular flow block held together with a pair of tangential pins with a flanged night cap sleeve and a spacer spool attached thereto according to an embodiment of the present invention;

[0034] FIG. 7B is a section view the modular flow block of FIG. 7A, taken along line 7B-7B, looking in the direction of the arrows, according to an embodiment of the present invention;

[0035] FIG. 8A is a drawing which illustrates a front view of a modular flow block held together with a pair of tangential pins and with a plunger lift lubricator and a spacer spool attached thereto, according to an embodiment of the present invention

[0036] FIG. 8B is a section view the modular flow block of FIG. 8A taken along line 8B-8B, looking in the direction of the arrows, according to an embodiment of the present invention;

[0037] FIG. 8C is a drawing which illustrates a front view of a modular flow block held together with a pair of tangential pins and with a plunger lift lubricator, crossover spacer, short sleeve and a short spacer spool attached thereto, according to an embodiment of the present invention;

[0038] FIG. 8D is a section view drawing of the modular flow block of FIG. 8C, according to an embodiment of the present invention;

[0039] FIG. 9 is a drawing which illustrates a section view of a conventional spacer sleeve, and which illustrates an erosion causing eddy current location that is created when high velocity fluid flows around a corner;

[0040] FIG. 10 is a drawing which illustrates a section view of a spacer sleeve according to embodiment of the present invention, and which causes eddy currents to form away from the sidewall of the pipe, thus reducing erosion;

[0041] FIG. 11 is a drawing which illustrates a section view of modular flow block assembly with an inner sleeve configured to operate a plunger lift system on smaller bore pipe using the upper lubricator tube, according to an embodiment of the present invention;

[0042] FIG. 12 is a drawing which illustrates a cut-away view of a modular flow block assembly without a plunger lift and with a night cap, according to an embodiment of the present invention;

[0043] FIG. 13 is a drawing which illustrates a section view of a modular flow block in a large bore configuration for free flow conditions without a plunger lift, according to an embodiment of the present invention;

[0044] FIG. 14 is a drawing which illustrates a cut-away view of a spacer spool for smaller bore tubing, according to an embodiment of the present invention;

[0045] FIG. 15 is a drawing which illustrates a perspective view of a plunger lift tube, according to an embodiment of the present invention;

[0046] FIG. 16 is a drawing which illustrates a perspective view of a radial flow sleeve with openings in an arranged pattern, according to an embodiment of the present invention;

[0047] FIGS. 17 and 18 are drawings which respectively illustrate upper and lower perspective views of a modular flow block with openings for tangential pins and fluid passageways, according to an embodiment of the present invention;

[0048] FIG. 19 is a drawing which illustrates some of the various optional sizes that a crossover sleeve can be provided, according to an embodiment of the present invention;

[0049] FIG. 20A is a drawing which illustrates a perspective view of a radial flow tube with enlarged ends that can be used in lieu of a radial flow tube and a crossover sleeve, according to an embodiment of the present invention;

[0050] FIG. 20B is a drawing which illustrates a section view of the radial flow tube with enlarged ends of FIG. 20A, taken along line C-C, looking in the direction of the arrows;

[0051] FIG. 21A is a drawing which illustrates a perspective view of a modular wellhead with a plunger lift tube having a large diameter radial flow tube that can be used in lieu of a smaller diameter radial flow tube with a crossover sleeve, according to an embodiment of the present invention;

[0052] FIG. 21B is a drawing which illustrates a section view of the modular wellhead of FIG. 21A taken along line B-B, looking in the direction of the arrows;

[0053] FIG. 22A is a drawing which illustrates a perspective view of a modular wellhead with a night cap having a large diameter radial flow tube that can be used in lieu of a smaller diameter radial flow tube with a crossover sleeve, according to an embodiment of the present invention; and

[0054] FIG. 22B is a drawing which illustrates a section view of the modular wellhead of FIG. 22A taken along line C-C, looking in the direction of the arrows.DETAILED DESCRIPTION OF THE INVENTION1. Modular Wellhead Block

[0055] Embodiments of the present invention relate to a modular wellhead block that can be configured to accommodate existing wellheads (including but not limited to those that are that are 4.5 inches in width) with a larger diameter, for example four inches internal diameter or larger. The wellhead block is preferably secured using a dual tangential pin connection, which facilitates the swift and effortless attachment of various accessories. One such accessory is a night cap conversion cap, which allows for seamless transitions between different types of connections based on operational needs. By incorporating tangential pins in the flow block, the overall modularity of the flow block can be enhanced. Other connections—for example flanges, bolts, compression, welded or threaded can be used, enabling easy customization and adaptability for different applications.2. Spacer Sleeve and Radial Sleeve

[0056] Embodiments of the present invention also relate to a unique spacer sleeve wherein the spacer sleeve includes a designated land area to anchor an inner ported radial sleeve. This functionality plays a role in effortlessly transitioning to smaller tubing sizes without extensive modifications to the wellhead. This spacer sleeve and ported radial flow sleeve adds distinct operational advantages and adaptability, particularly by providing the ability to adapt to varying flow and tubing requirements. Different wellhead configurations and different well operation conditions are possible—for example transitioning from a free flowing well to a plunger lifted well.3. Plunger Lift Lubricator Conversion

[0057] A final stage of the conversion process can include placing an upper radial plunger lift tube above the assembled configuration. This effectively converts the current wellhead arrangement into a plunger lift lubricator assembly that can support smaller tubing sizes, including, for example, but not limited to 2-⅜″ and / or 2-⅞″ variants. This innovative aspect enables a smooth shift in wellhead functionality to align with the changing production requirements of the well.

[0058] The inner sleeve configuration within the wellhead assembly tackles crucial challenges related to managing fluid dynamics at the wellhead, especially in scenarios where high-velocity fluid containing particulates need to be handled. Conventional single-point flow outlets often result in localized flow eddies and fast streams—potentially causing significant erosional damage to wellhead components over time.

[0059] Referring now to the figures generally, modular wellhead 10 preferably includes radial flow block 12, which includes radial flow sleeve 14 seated within spacer sleeve 16. Spacer sleeve 16 preferably includes radial sleeve retainer opening 18 to receive radial flow sleeve 14. Radial flow sleeve 14 preferably includes one or more—and most preferably a plurality of openings 20 disposed in a side portion thereof. One or more, or all of openings, can optionally have any shape and need not necessarily be round. For example, in one embodiment, one or more of openings 20 can optionally be in the form of elongated slots. Tangential pins 23 are preferably used to secure multiple types of attachments, including for example a plunger lift lubricator 24 and / or a night cap 26.

[0060] In one embodiment, as illustrated in FIG. 4C and FIG. 4D, crossover spacer 19 can be used to change an internal flow diameter and to accommodate the seating of radial flow sleeve 14. Crossover spacer 19 can drop into radial flow block 12 and seat therein. Crossover spacer 19 reduces the effective bottom entry port internal diameter (i.e., open area) and provides an interface and / or seat sleeve 17, within which radial flow sleeve 14 (see FIG. 2H) can be seated and thus retained. In one embodiment, to install it, crossover spacer 19 can be lowered down into the top opening of radial flow block 12 and dropped into place to reduce the open area and define a smaller through-bore. This allows use and operation of a much smaller inner sleeve and corresponding smaller plunger within the same large-bore block. Because radial flow block 12 need not be removed to insert and remove crossover spacer 19, radial flow block 12 can remain in place when the size of the tubing of the well is changed. In one embodiment, a radial flow sleeve having an outer diameter equal to that of the crossover spacer 19 can be used without crossover spacer 19—this provides a larger diameter bore. However, if a smaller diameter bore is desired, the radial flow sleeve 14 can be replaced with one having a smaller diameter. In this embodiment, a crossover is preferably dropped into place and the smaller diameter radial flow sleeve is seated therein. Optionally, however, instead of using crossover spacer 19 and radial flow sleeve 14, modified radial flow spacer 52 (see FIGS. 20A and B), having enlarged first and / or second end 54 can optionally be used. Modified radial flow spacer 52 thus functions as a crossover spacer formed onto one or both ends of the radial flow sleeve.

[0061] As best illustrated in FIG. 7B, in one embodiment, radial flow sleeve 14 extends up through an inner / internal diameter of radial flow block 12, ensuring consistency throughout the entirety of the wellhead setup. This configuration ensures a uniform inner / internal diameter, promoting operational efficiency and maintaining integrity across the entire wellhead system. Thus, in one embodiment, crossover spacer 19 can be used as a conversion component when transitioning from large-bore wellhead hardware to a smaller-bore configuration. In some embodiments, crossover spacer 19 can be configured as a drop-in insert seated within radial flow block 12 to (i) reduce an effective internal diameter and define a smaller through-bore and (ii) provide a radial sleeve retainer opening / seat (18 / 17) for receiving and retaining radial flow sleeve 14. In this manner, crossover spacer 19 provides a transition interface between the large-bore radial flow block 12 and the smaller-bore sleeve / tubing / lubricator configuration. The radial flow sleeves can be added during the initial conversion or at a later time, including during a lubricator conversion. See, for example, FIGS. 4C-4D (crossover spacer 19) and associated sleeve seat / retainer features.

[0062] In the extended neck / flange crossover embodiment, a longer crossover spacer can be used in the conversion stack-up to bridge the assembly, as described above, when converting from large-bore wellhead hardware to a smaller-bore configuration. Crossover spacer 19 functions by bridging the large-bore wellhead block to the smaller-bore configuration. The extended neck / flange crossover embodiment provides sleeve seat 17 for radial flow sleeves that may be added now or later (including for a lubricator conversion).

[0063] FIG. 4C and FIG. 4D. The operational advantage of crossover spacer 19 is that a single large-bore lubricator block (for example a 4.5″ diameter) can be converted to smaller internal diameters (for example 2-⅜″ and / or 2-⅞″) by installing crossover spacers 19 and an inner sleeve, while leaving the flow block and most external hardware in place. Using crossover spacers 19 minimizes on-location fabrication and flowline changes when wells are converted to smaller tubing / flow conduit sizes over the well's producing life. Using crossover spacers 19 provides a modular, transformable platform with multiple de-liquification configurations as wellbore conditions evolve. Crossover spacers 19 provide flexibility through lower cross over flange / spacer with the extended neck, where one can insert the smaller sleeve.

[0064] As described herein, the use of a crossover spacer with an extended neck or landing surface for a sleeve can be inserted in different ways. For example, for example it can be in the form of a collar which can be dropped in from the top and which sits on the lower sleeve land as a reducer collar (for example, 4″ outer diameter with a 2-⅜″ internal diameter). In one embodiment, the lower crossover spacer 19 can include, but is not limited to, a one piece or a two piece design (for example, it can be split vertically to facilitate insertion and removal.

[0065] FIG. 19 is a drawing which illustrates a variety of possible sizes that crossover spacers 19 can be provided in, in order to accommodate common tubing sizes. The dimensions provided in FIG. 19 are merely examples of some of the most preferred sizes. To be clear, crossover spacers 19 can be manufactured to any desired inner and / or outer dimensions for any given application. In the figure, the crossover spacers on the upper row illustrate some examples of 4-½″ diameter radial sleeve crossovers while those on the bottom row illustrate some examples of 5-½″ radial sleeve crossovers.

[0066] In one embodiment, an upper crossover can be positioned at a top end of radial flow sleeve 14, such that a single plunger lift tube 36, and / or night cap 26 can be provided and used to accommodate radial flow sleeves 14 of different diameters. In these embodiments, the second (upper) crossover spacer 19, which can be same size as the lower crossover spacer or can be a different size, can be positioned such that the upper end of radial flow sleeve 14 is retained therein and such that the second crossover spacer 19 is retained in the lower portion of plunger lift tube 36 and / or night cap 26.

[0067] As described in embodiments herein, the lower flow block may be removed as part of conventional workover operations (for example, to permit rig access for pulling and running tubing) and then reinstalled after the tubing and / or wellhead configuration is changed. Importantly, the lower flow block does not need to be replaced with a different-sized flow block to convert between tubing and / or wellhead sizes. Instead, the same lower flow block is configured to interface with the updated wellhead and to adapt to smaller or larger tubing sizes using inserted modular components (e.g., crossover sleeves, radial flow sleeves, and / or modified radial flow sleeves) and, where applicable, spacers placed beneath the block to account for elevation changes between configurations. Optionally, rings, collars, sleeves or spacers can be installed into and / or removed from the flow block to adjust a diameter of a flow path. This modular reconfiguration reduces changeover time and cost and can avoid extensive high line or flow line modifications when transitioning between wellhead / tubing configurations, since existing surface connections can be maintained or reconnected with minimal modification.

[0068] Optionally, instead of radial flow sleeve 14 being retained in radial flow block 12, or a crossover spacer 19 installed therein, in one embodiment, spacer sleeve 16 with a sleeve seat 17, as shown in FIG. 5A, can be attached to a bottom of radial flow block 12 (see FIG. 2A). As with the foregoing embodiments, in this embodiment, spacer sleeve 16 and radial flow block 12 can also remain in place and radial flow sleeve 14 can be inserted, removed, or swapped out with a different one with the same or a different diameter as desired, by passing it into and / or out through the top of radial flow block 12. Thus, the diameter of tubing and / or addition or removal of a lubricator or cap can be accomplished without removal of the existing flow block. FIG. 1A. illustrates the embodiment of FIG. 2A but wherein the cap has been replaced with a lubricator.

[0069] In one embodiment, after the well has been converted from a cased hole flowing well as illustrated in FIGS. 3A and 3B, spacer sleeve 16 of FIGS. 5A and 5B can be inserted to bridge the elevation change and establish a support structure for the insertion of radial flow sleeve 14. This configuration ensures the stability of radial flow sleeve 14 at its bottom, thus enabling a secure and efficient setup for the wellhead system.

[0070] In one embodiment, a representative sequence for reconfiguration of the wellhead, where not all steps are required, is to begin with the configuration shown in FIG. 3A / 3B (i.e., large bore with night cap), Then, convert that configuration into the configuration illustrated in FIG. 2A / 2B (for example with a night-cap configuration with reduced internal diameter) or FIG. 2C / 2D (for example a night-cap configuration with conversion hardware in place), then convert it into the configuration shown in FIG. 1A / 1B (i.e., plunger lift upper section installed). Any of the foregoing steps can optionally be skipped as may be desired for a particular application or well.

[0071] In one embodiment, after the large-bore ‘night cap’ configuration, an intermediate configuration can include installing a 4.5-inch (large-bore) plunger-lift lubricator upper section as a top-barrel replacement mounted on top of the radial flow block. This intermediate stage does not require insertion of the inner sleeve or the crossover spacer / extended landing components (i.e., crossover spacer 19 and sleave seat 17) and allows operation of 4.5-inch (large-bore) plungers. Thereafter, if and when flow rates decline below the velocities required to effectively lift and remove liquids, the system can be converted to the smaller-bore configuration by reducing tubing size and adding the applicable crossover spacer / extension components to accommodate a smaller internal sleeve size. In that final stage, the night cap can be removed and the upper plunger-lift lubricator section can be installed for plunger-lift operation in the reduced-bore configuration. Any of the foregoing steps can optionally be skipped as may be desired for a particular application or well. FIGS. 21A and 21B illustrate a plunger lift configuration of radial flow sleeve 14 with a widened outer diameter that matches the internal diameter of sleave seat 17, eliminating the need for crossover spacer 19. FIGS. 22A and 22B illustrate a night cap configuration of radial flow sleeve 14 with a widened outer diameter that matches the internal diameter of sleave seat 17, eliminating the need for crossover spacer 19.

[0072] FIGS. 5A and 5B illustrate spacer sleeve 16, having radial sleeve retainer opening 18 configured to facilitate the seamless insertion of a radial flow sleeve. Radial sleeve retainer opening 18 not only enables but also ensures the precise and secure placement of the radial flow sleeve within the modular wellhead.

[0073] FIGS. 6A, 6B, 7A and 7B can all provide the same function, however FIGS. 6A and 6B illustrate an example of an Acme thread “night cap” connection, while FIGS. 7A and 7B illustrate an example of a typical flange “night cap” connection. All other functions between the two configurations can optionally be the same with respect to the internal radial flow sleeve placement.

[0074] As best illustrated in FIG. 9, the absence of a radial sleeve can lead to the generation of flow eddies 30, resulting in elevated friction and added back pressure within the well, thus affecting the overall flowing pressure. Introducing radial flow sleeve 14 into the system helps mitigate these issues by promoting smoother fluid flow and reducing the impact of flow eddies 30, thereby improving operational efficiency, and minimizing pressure variations within the well.

[0075] Multiple flow paths out of openings 20, disperse and change the flow pattern out of radial flow block 12, thus reducing the formation of the flow eddies 30 (compare the flow eddy size of FIG. 9, which is created with a conventional system to the size and location of flow eddies created by an embodiment of the present invention in FIG. 10). FIG. 10 also illustrates a connection between spacer sleeve 16 and radial flow sleeve 14.

[0076] In some embodiments, the presence of an inner sleeve (e.g., spacer sleeve and / or radial flow sleeve) within radial flow block 12 defines an annular chamber between the outer surface of the inner sleeve and an inner wall of the radial flow block. Fluid flowing upward through the inner sleeve is redirected radially into the annular chamber and discharged through a plurality of circumferentially spaced outlet openings 20. The distribution of flow through multiple radial outlets disperses the exiting stream and reduces localized recirculation and eddy formation compared to a single large outlet path.

[0077] In some embodiments, the inner sleeve remains disposed within radial flow block 12 even when a night cap is installed. In such configurations, the annular chamber and multiple radial discharge paths are maintained, thereby preserving improved flow characteristics. The redirection and dispersion of flow within the annular chamber can reduce pressure losses and back pressure at elevated liquid and gas flow rates relative to conventional single-path discharge systems.

[0078] FIG. 11 illustrates radial flow block 12 and radial flow sleeve 14 configured to operate plunger lift lubricator 24 on a smaller bore pipe. Spacer sleeve 16 preferably has a seat area that allows radial flow sleeve 14 to be set into and held securely; this allows the smaller tube to be in line with the smaller bore at the bottom of the sleeve while the upper portion of the sleeve is preferably contained in a seat area within the upper section of plunger lift tube 36. Openings 20 can be placed on radial flow sleeve 14 in any desired patterns.

[0079] FIG. 12 illustrates radial flow block 12 configured for free flow. In this configuration, radial flow block 12 preferably operates without plunger lift lubricator 24 and instead preferably uses night cap 26.

[0080] FIG. 13 illustrates radial flow block 12 configured to operate without a plunger lift lubricator on a large bore pipe with free flow conditions. In this figure, there is no sleeve in place, allowing for full diameter access. As can be seen by contrasting this FIG. 13 with FIG. 12, it can be observed that spacer sleeve 16 is not present in FIG. 13. This is because spacer sleeve 16 is preferably used for the smaller bore and sleeve insert. Instead, in FIG. 13, radial flow block 12 is preferably attached directly to a master valve on the wellhead without any sleeve inside, thus facilitating unobstructed flow and functionality. In FIG. 13, night cap 26 covers radial flow block 12 instead of plunger lift lubricator 24.

[0081] In one embodiment, FIG. 14 illustrates spacer sleeve 16, having radial sleeve retainer opening 18 configured to facilitate the seamless insertion of a smaller bore tubing. Spacer sleeve 16 in this configuration accommodates elevation changes between the larger wellhead and the smaller bore wellhead. Spacer sleeve 16 in this configuration also preferably features tapered opening 34 at the top to enable the installation of radial flow sleeve 14 of radial flow block 12, maintaining a consistent inner flow path with the smaller wellbore tubing. Radial sleeve retainer opening 18 in the top of spacer sleeve 16 allows radial flow sleeve 14 to be securely set and held in place after the wellhead conversion to small bore.

[0082] FIG. 15 illustrates plunger lift tube 36. Plunger lift tube 36 is preferably used as the upper assembly in a small bore pipe plunger installation. In one embodiment, this is preferably not used in a large bore application because it features a smaller internal diameter that is preferably configured for the small bore pipe and plunger installation. Plunger lift tube 36 preferably includes threads 38 which help it attach to plunger lift lubricator 24. Plunger lift tube 36 preferably includes one or more tangential pin engagement grooves 21. When plunger lift tube 36 is disposed within opening 44 of radial flow block 12, it is preferably rotated such that tangential pin engagement grooves 21 are axially aligned with pin openings 22 in radial flow block 12 and then tangential pins 23 (see FIG. 11) are inserted into pin openings 22, thus locking plunger lift tube 36 onto radial flow block 12. Optionally, pin openings 22 can comprise threads cut near their opening so that cap screws 25 (see FIG. 8A) can be screwed in, thus trapping tangential pins 23 therein. In one embodiment, when the assembly is configured for a small bore plunger, the upper tube and inner sleeve are preferably provided as illustrated in FIGS. 8A and 8B. The block, illustrated in FIGS. 4A and 4B, can be universal across all the configurations (large diameter and smaller diameter). The upper tube is preferably added when the wellhead is changed to accommodate smaller tubing, and a spacer, as illustrated in FIG. 14, is preferably placed under the block to account for the elevation change between the large wellhead and the smaller wellhead. This configuration ensures proper alignment and functionality in varying wellhead sizes.

[0083] FIG. 16 illustrates radial flow sleeve 14 with openings 20 in an arranged pattern. In one embodiment, radial flow sleeve 14 is preferably installed after the conversion of a well from large bore pipe to a smaller bore pipe.

[0084] FIG. 17 and FIG. 18 illustrate another embodiment of radial flow block 12. As illustrated, radial flow block 12 can include passageways 40 and 46 (which are preferably communicable with opening 44), attachment locations 42, and tangential pin openings 22 into which tangential pins 23, (see FIG. 11) can be inserted. Most preferably, tangential pins 23 are positioned such that they intersect, most preferably near or along their centerline, a portion of night cap 26 and / or plunger lift tube 36 such that the centerline of the pins are arranged at least substantially tangential to an outer surface of night cap 26 and / or plunger lift tube 36 (or at least where that outer surface would be if not for the fact that the pin openings 22 were bored through it).

[0085] By introducing a system that evenly distributes and dissipates fluid flow across a wider area within the flow block embodiments of the present invention can provide a longer-lasting flow block. In one embodiment, the flow area of openings 20 of radial flow sleeve 14 is preferably greater than the flow area of the inlet or outlet openings within the block, as illustrated in FIG. 14. Because the flow is preferably dispersed across multiple openings 20, these multiple openings divides the flow evenly over several openings (in FIG. 14 three levels of slots are provided, thus, in this configuration the flow is evenly split over three levels of slots: about 33%, about 33%, and about 33% for the top, middle, and bottom sections). However, in one embodiment, in the plunger lift configuration, when radial flow sleeve 14 is installed for a plunger application, the sleeve ports are preferably arranged as about 33%, about 45%, and about 22% from top to bottom. Radial flow sleeve 14 can also optionally be flipped or otherwise replaced with another sleeve to move the lower 22% to the midpoint and the midpoint 45% to the lower point. While this flexibility is not essential to the operation of the invention, it presents advantages because it allows for easy changes or adjustments to the sleeve configuration in response to changing well conditions. This can be achieved by splitting the assembly into two pieces or accessing radial flow sleeve 14 to replace or flip it over, thereby changing the flow area exit points into the annulus of the lubricator body. Embodiments of the present invention effectively lower fluid velocity and disrupt the formation of harmful flow patterns. This configuration not only prolongs the operational lifespan of wellhead components but also enhances the overall efficiency of fluid transfer through the wellhead assembly. Different implementations of this invention enhance the durability and operational reliability of the wellhead under varying operational conditions and material compositions, providing a significant advantage.

[0086] The utilization of the sleeve configuration notably reduces flowing friction within the wellhead, while the radial sleeve configuration effectively decreases pressure drop and restrictions across the flow block. This innovative configuration not only helps in mitigating erosion and failures but also demonstrates enhanced performance in maintaining wellhead integrity and minimizing frictional losses, particularly in challenging conditions.

[0087] Embodiments of the present invention preferably introduce a highly adaptable radial completion wellhead block and plunger lift lubricator system set to revolutionize operations in the oil and gas industry. Featuring a modular design that can leverage a tangential pin connection, this system allows for quick modifications in wellhead setups and smooth integration of plunger lift mechanisms. Embodiments of the present invention can include adjustable spacer sleeves, optimized flow paths. The ability to quickly access radial flow sleeve 14 allows for multiple configurations and adjustment options—from changing out the sleeve to different flow port sizes and adjusting the total flow percentage throughout the inner sleeve or simply flipping over an existing sleeve to reposition a smaller outlet to either the upper or lower exit point. Because the sleeve is securely captured between the two sections of the assembly, it cannot move or become dislodged, enabling simple adjustments not available in typical lubricators that might incorporate orifices or chokes at the outlet points. Additionally, the sleeve slot configuration benefits the plunger's function within the lubricator. As the plunger covers or uncovers the outlet slots, the flow can self-adjust to support the plunger within the lubricator and gas / liquid flow. As the flow reduces, the plunger tends to drop lower in the lubricator, closing more slots and acting like a slide valve, which restricts the outlet flow area and increases inner pressure to hold and lift the plunger, thus keeping it stable while minimizing restriction to only what is necessary.

[0088] Embodiments of the present invention also provide real-time operational adjustments and safety features. The use of a two-piece assembly allows for modular components that can be easily removed and replaced in different configurations as the wellhead configuration changes. This capability enables quick separation and access to the sleeve or removal of the upper section of the block, ensuring that most reconfiguration changes can typically be completed within one hour on location. In contrast, known systems often require the removal and replacement of the entire assembly, and in many cases, significant modifications to the pipeline are necessary to accommodate changes in wellhead or tubing size. This process can lead to several hours of manufacturing pipe changes and welding pipe fittings to align with the adjusted wellhead. By reducing the time and expense associated with these changes, especially for high-rate wells that need to maintain effective flow and production, this assembly method provides a more efficient solution to adapt to evolving well conditions. This comprehensive solution is configured to reduce operational downtime, boost production efficiency, and ensure safety across various production stages, thereby establishing a new standard in well operation management.

[0089] The incorporation of a tangential pin and radial flow lubricator into the modular configuration provides a significant competitive advantage. The connection methods can include flange, threaded bolts, compression, and welding to encompass all potential configurations of this concept, preferably with tangential pins.

[0090] A modular wellhead block system can include a spacer sleeve with a land that allows the use of an inner flow sleeve within the flow block, ensuring consistency of the wellhead inner diameter with tubing or master valves. A night cap can be provided which allows access to the inner tubing through a connection, which can include for example a flange, hammer union, acme threaded or any type of “quick connection” typically used on well servicing equipment. An inner sleeve configured to disperse fluid flow radially over single or multiple elevations within the bore of a flow block.

[0091] This system aims to significantly reduce flow velocity by expanding the cross-sectional flow area and modifying the flow pattern from the block. By doing so, it helps in preventing the formation of flow eddies and decreasing erosional forces on the flow block and wing valves. The inner sleeve accomplishes this by directing fluid flow radially across multiple points within the bore, thereby decreasing the potential for erosive damage caused by high-velocity particulates.

[0092] This method of flow dissipation is diverse and adaptable, as it can be implemented in various sizes, pressure ratings, and designs with single or multiple outlets. This versatility ensures that the system can be tailored to meet different operational requirements without being constrained by the physical attributes of the inner sleeve or the flow block itself.

[0093] In one embodiment of the modular wellhead system, the radial flow block and spacer sleeve can define an annular chamber between an outer surface of the radial flow sleeve and an inner wall of the radial flow block (also referred to herein as the “flow block”), the annular chamber being in fluid communication with a plurality of radial outlet openings. The plurality of radial outlet openings can be circumferentially spaced around the radial flow block to disperse fluid exiting the annular chamber. A night cap can be provided and can be removably coupled to the radial flow block, the spacer sleeve and radial flow sleeve can remain disposed within the radial flow block while the night cap is installed. The annular chamber can have a radial width greater than a radial width of a wall of the radial flow sleeve, and each of the plurality of radial outlet openings can be in direct fluid communication with the annular chamber along a circumferential distribution extending around the radial flow block. The radial flow block and crossover spacer can define an annular chamber between an outer surface of the radial flow sleeve and an inner wall of the radial flow block, the annular chamber being in fluid communication with a plurality of radial outlet openings. The plurality of radial outlet openings can be circumferentially spaced around the radial flow block. Optionally a night cap can be removably coupled to the radial flow block; the crossover spacer and radial flow sleeve can remain disposed within the radial flow block while the night cap is installed. The annular chamber can have a radial width greater than a radial width of a wall of the radial flow sleeve. The method can also include directing fluid upward through a radial flow sleeve disposed within a radial flow block, redirecting the fluid radially outward into an annular chamber defined between the radial flow sleeve and an inner wall of the radial flow block, and discharging the fluid through a plurality of circumferentially spaced radial outlet openings. The radial flow sleeve can remain installed within the radial flow block while a night cap is installed on the radial flow block.

[0094] The preceding examples can be repeated with similar success by substituting the generically or specifically described components and / or operating conditions of embodiments of the present invention for those used in the preceding examples.

[0095] The terms, “a”, “an”, “the”, and “said” mean “one or more” unless context explicitly dictates otherwise.

[0096] Note that in the specification and claims, “about”, “approximately”, and / or “substantially” means within twenty percent (20%) of the amount, value, or condition given. All computer software disclosed herein may be embodied on any non-transitory computer-readable medium (including combinations of mediums).

[0097] Embodiments of the present invention can include every combination of features that are disclosed herein independently from each other. Although the invention has been described in detail with particular reference to the disclosed embodiments, other embodiments can achieve the same results. Variations and modifications of the present invention will be obvious to those skilled in the art and this application is intended to cover, in the appended claims, all such modifications and equivalents. The entire disclosures of all references, applications, patents, and publications cited above are hereby incorporated by reference. Unless specifically stated as being “essential” above, none of the various components or the interrelationship thereof are essential to the operation of the invention. Rather, desirable results can be achieved by substituting various components and / or reconfiguring their relationships with one another.

Claims

1. A modular wellhead system comprising:a radial flow block having a flow block opening passing from a top to a bottom thereof;a spacer sleeve comprising a spacer sleeve opening passing from a top to a bottom thereof;a radial flow sleeve, said radial flow sleeve comprising at least one opening disposed in a sidewall thereof, said flow block opening comprising a diameter throughout said radial flow block that is at least as large as an outer diameter of said radial flow sleeve;a radial sleeve retainer opening formed in at least an upper portion of said spacer sleeve opening; andsaid radial sleeve retainer opening comprising a diameter that is at least equal to an outer diameter of a bottom end portion of said radial flow sleeve, such that a bottom end portion of said radial flow sleeve can be seated and retained within said radial sleeve retainer opening.

2. The system of claim 1 wherein said radial flow block comprises a tangential pin connection.

3. The system of claim 2 wherein said tangential pin connection comprises a pair of pin openings that pass through a side of said flow block and a pair of pins, each of the pair of pins having a diameter that allows them to be inserted into a respective one of the pair of pin openings.

4. The system of claim 1 wherein said radial flow block comprises a flange connection in communication with said radial flow block.

5. The system of claim 1 wherein said radial flow block comprises a thread connection.

6. The system of claim 1 further comprising a welded connection in communication with said radial flow block.

7. A modular wellhead system comprising:a radial flow block having a flow block opening extending from a top to a bottom thereof;a crossover spacer comprising outer dimensions that allow it to be seated within a portion of said flow block opening;a radial flow sleeve, said radial flow sleeve comprising at least one opening disposed in a sidewall thereof, said flow block opening comprising a diameter at least equal to an outer diameter of said radial flow sleeve;a radial sleeve retainer opening formed in said crossover spacer; andsaid radial sleeve retainer opening comprising a diameter that is at least equal to an outer diameter of a bottom end portion of said radial flow sleeve, such that bottom end portion of said radial flow sleeve can be seated and retained within said radial sleeve retainer opening.

8. The modular wellhead system of claim 7 wherein said crossover spacer and said flow block opening comprise dimensions such that said crossover spacer can be inserted and seated into said flow block by passing said crossover spacer down into said flow block through said top thereof.

9. The modular wellhead system of claim 7 wherein said crossover spacer comprises a 2-piece configuration.

10. The modular wellhead system of claim 7 wherein said crossover spacer and said flow block opening comprise dimensions which allow said crossover spacer to be seated within a lower one-third of said flow block.

11. The modular wellhead system of claim 7 further comprising an upper crossover spacer, said upper crossover spacer comprising an internal opening that seats onto an upper end portion of said radial flow sleeve.

12. The modular wellhead system of claim 7 further comprising a tangential pin connection.

13. The modular wellhead system of claim 12 wherein said tangential pin connection comprises a pair of pin openings that pass through a side of said flow block and a pair of pins, each of the pair of pins having a diameter that allows them to be inserted into a respective one of the pair of pin openings.

14. A method for providing a modular wellhead, the method comprising:flowing fluid up through a radial flow sleeve having a bottom portion seated on a spacer sleeve that is disposed below a radial flow block and wherein a top portion of the radial flow sleeve is seated in a night cap or in a plunger lift tube.

15. The method of claim 14 further comprising flowing fluid through one or more openings.

16. The method of claim 14 further comprising adjusting the fluid flow with the radial flow sleeve.

17. The method of claim 14 further comprising swapping components of the modular wellhead system through a modular universal connector component.

18. A method for changing a tubing size on a well, the method comprising:removing surface wellhead equipment to permit workover operations;pulling a first string of tubing from the well, the first string of tubing having a first diameter;installing a second string of tubing into the well, the second string of tubing having a diameter different from the first diameter;reconfiguring or replacing wellhead components to accommodate the second string of tubing;reinstalling a flow block onto the wellhead following completion of the tubing change; andproducing fluid up through the flow block.

19. The method of claim 18 further comprising installing or removing a crossover sleeve within the flow block to change an internal diameter through which fluid flows within the flow block.

20. The method of claim 18 further comprising adjusting an internal diameter within the flow block by selectively installing or removing one or more elements selected from the list consisting of one or more sleeves, one or more collars, one or more rings, one or more spacers, and a combination thereof.

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