Flow conditioning device for hydraulic fracturing systems and related methods

Abstract

A hydraulic fracturing system includes at least one manifold along which a pressurized fracturing fluid is supplied to an injection system for injection of the pressurized fracturing fluid into a wellbore at a well site. The hydraulic fracturing system can include one or more flow conditioning devices positioned along a fluid flow path of the pressurized fracturing fluid through the manifold and injection system. The flow conditioning devices can include an internal structure configured to reduce turbulence in the flow of pressurized fluid and create a substantially laminar flow within a substantially reduced distance.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and the benefit of U.S. Provisional Application No. 63 / 779,382, filed Mar. 28, 2025, titled “FLOW CONDITIONING DEVICE FOR HYDRAULIC FRACTURING SYSTEMS AND RELATED METHODS,” the disclosure of which is incorporated herein by reference in its entirety.BACKGROUND

[0002] During a hydraulic fracturing operation, a series of pumps supply volumes of a pressurized fracturing fluid to a wellbore or multiple wellbores for injection into a subterranean formation. The fracturing fluid is injected into the subterranean formation at a higher pressure than the fracture pressure of the subterranean formation such that the pressurized fracturing fluid creates fractures therein. The fractures increase a permeability of the subterranean formation so that fluids such as oil, gas, water, etc. may more easily escape the subterranean formation and flow to the surface via the wellbore(s). Proppants (such as sand or other solids) generally may be mixed with the pressurized fracturing fluid prior to injecting the fracturing fluid into the wellbore(s), and will flow into the fractures to hold the fractures open. The pressurized fracturing fluid is delivered to a fracturing tree or other injection equipment at the wellbore(s) through a manifold that typically has a large diameter to accommodate the volume of the pressurized fluid. As the length of the manifold is shortened, such as to provide more compact installations of the hydraulic fracturing system or at locations with limited space, the flow of the pressurized fluid becomes more turbulent. This turbulent pressurized fracturing fluid, with the proppant materials entrained therein, tends to abrade and cause erosion of the conduits, manifolds, valves and other components of the fracturing system, which can damage such components and substantially shorten the operating life thereof. This can result in premature failures or the components and require more frequent maintenance and replacement thereof, causing considerable down time of the hydraulic fracturing system as well as increased costs of maintaining and conducting the overall fracturing operation.

[0003] Accordingly, it can be seen that a need exists for hydraulic fracturing systems, including assemblies, systems and devices for controlling the flow of pressurized fracturing fluids supplied to a wellbore or wellbores, and methods of assembly and use thereof, which are directed to addressing the foregoing and other related and unrelated problems in the art.SUMMARY

[0004] Briefly described, the present disclosure is directed to aspects and embodiments of hydraulic fracturing systems and methods of installation and operation thereof. In embodiments, the hydraulic fracturing system will include a plurality of components configured for delivery of a pressurized fracturing fluid to the injection equipment at one or more wellbores for injection of the pressurized fracturing fluid into a subterranean formation. In addition, in embodiments, the hydraulic fracturing system further can include a flow conditioning device or assembly arranged between one or more components of the hydraulic fracturing system and configured for converting a turbulent flow of the pressurized fracturing fluid passing through the hydraulic fracturing system to a substantially laminar flow upstream of the wellbore(s) to protect one or more selected components of the hydraulic fracturing system from erosional wear due to the turbulent flows of the pressurized fracturing fluid, and do so within a substantially reduced or shortened distance, which can thus enable a reduction of the overall length of a fluid conduit and overall fluid flow path of the pressurized fracturing fluid from a manifold to the wellbore, which in turn can potentially enable a reduction of the overall area or footprint of the hydraulic fracturing system.

[0005] In embodiments, the flow conditioning device may be configured to convert the turbulent flow of the fracturing fluid to a substantially laminar flow within a shortened space / distance (e.g., within about ½ to ⅕th of the amount of space generally required for converting a turbulent flow passing along a manifold of the hydraulic fracturing system) before it passes through the junctions, valve(s), or other costly equipment of an injection system at a wellbore, to substantially reduce the potential effects of erosion due to erosive materials contained within the turbulent fracturing fluid flow. In addition, in embodiments, the flow conditioning device can comprise an internal structure designed to separate and / or change the flow of the pressurized fluid to substantially reduce the turbulence thereof, and in some further embodiments can include one or more replaceable and / or sacrificial wear components.

[0006] In various embodiments, the hydraulic fracturing systems can include one or more manifold assemblies that, in embodiments, can include one or more manifolds (e.g., inlet and outlet manifolds), and one or more pumping systems connected to the one or more manifold for supplying a pressurized fracturing fluid thereto. The one or more manifolds can be connected to one or more injection systems at one or more wellbores, including fracturing equipment such as zipper modules, fracturing trees (“frac tree”), or other components, that will receive the pressurized fracturing fluid and inject it into the subterranean formation. In addition, in embodiments, one or more flow conditioning devices can be arranged along one or more flow paths for the pressurized fracturing fluid extending between the various components, such as, in embodiments, at areas of transition between a fluid conduit of manifold and a conduit, junction or valve of a zipper module or frac tree at a wellbore. The flow conditioning devices will be configured for converting a turbulent flow of the pressurized fracturing fluid received from the manifold to a substantially laminar flow prior to the pressurized fracturing fluid passing into the downstream component (e.g., a valve or other component) so as to enable a significant reduction in the length of the manifold, and, in embodiments, further enabling a reduction in the overall footprint or area of the hydraulic fracturing system.

[0007] According to some aspects, a hydraulic fracturing system is provided comprising fracturing equipment or components, including at least one inlet fluid conduit along which a pressurized fracturing fluid is received and directed to an injection system for injecting the pressurized fracturing fluid into a subterranean formation through one or more wellbores. The pressurized fracturing fluid generally will be received at the injection system from the at least one inlet fluid conduit as a turbulent flow, which will subject the components of the injection system to erosional wear, which can cause faster wearing and premature failure of more sensitive, expensive components such as valves, junctions, etc. In embodiments, the hydraulic fracturing system can include one or more flow conditioning devices configured to convert a turbulent flow of a pressurized fracturing fluid to a substantially laminar flow upstream of a protected component of a fracturing tree within a substantially shortened space or distance.

[0008] In embodiments, the fracturing equipment of components of the hydraulic fracturing system can include a manifold assembly comprising inlet and outlet manifolds, with at least one outlet manifold defining the at least one fluid conduit along which a pressurized fracturing fluid is received and directed to the one or more wellbores. In embodiments, one or more pumping systems can be coupled to the at least one manifold for supplying the pressurized fracturing fluid thereto.

[0009] In embodiments, the flow conditioning device(s) configured for converting a turbulent flow of the pressurized fracturing fluid to a substantially laminar flow can be arranged along one or more fluid conduits, which define an overall fluid flow path along which the pressurized fracturing fluid is directed for injection at the wellbore. The flow conditioning device each generally will be configured with an internal structure designed to substantially reduce the turbulence of the pressurized fracturing fluid so as to convert this turbulent flow to a substantially laminar flow within a substantially shortened space.

[0010] The flow conditioning device is designed to convert the turbulent flow of the fracturing fluid to a substantially laminar flow within a shortened space / distance. For example, generally the length of the fluid conduit should be about 10 times its diameter to enable a transition from a turbulent to a laminar flow. The flow conditioning device will be configured to enable a substantial reduction in the length of the fluid conduit (e.g., by about ½ to about ⅕th the length of the fluid conduit, and, in embodiments, possibly less) along which the pressurized fracturing fluid is transported before it passes through the valve(s), junctions, or other equipment of the injection system that is more susceptible to erosion and wear and which is more costly to replace. As a result, the potential effects of erosion due to erosive materials contained within the turbulent fracturing fluid flow can be substantially reduced, extending a working life of components and reducing the need for maintenance and servicing thereof.

[0011] By way of example, in embodiments, one or more flow conditioning devices can be positioned at various locations, such as at a location or point of transition between the at least one fluid conduit of the at least one manifold and a conduit or an inlet of a junction, valve, or other component of the injection system where the pressurized fracturing fluid is transferred from the at least one fluid conduit of the manifold to the injection system. In addition, in some embodiments, one or more flow conditioning devices can be positioned between the conduits, valves, junctions, gates, etc. of a zipper module or frac tree, and in some further embodiments, multiple flow conditioning devices can be used together, for example, two or more flow conditioning devices can be arranged in series along a flow path, and can be positioned between upstream and downstream portions of various components, or can be arranged in other configurations.

[0012] In some embodiments, each flow conditioning device can comprise a body having a first or upstream end portion, a second or downstream end portion and a central portion located between the first and second end portions. For example, in embodiments, the flow conditioning device can be configured as a conduit, such as a spool, while in other embodiments, can comprise an insert configured to be received within an existing conduit of the injection system, for example within a spool, trunk line or other conduit extending between and defining a fluid flow path between adjacent components such as the fluid conduit of the manifold, valves, junctions, and / or conduits of the injection system.

[0013] In embodiments, the first and / or second end portions can include connectors adapted to couple the flow conditioning device to an adjacent component such as to another spool, a junction, conduit, valve, etc. In embodiments, the central portion can be configured to receive and convert a turbulent flow of the pressurized fracturing fluid (which can include proppant materials entrained therein) to a substantially laminar flow upstream of the wellbore.

[0014] In embodiments, the central portion of the flow conditioning device can be formed with an internal structure configured to divert and / or disrupt the turbulent flow of the pressurized fracturing fluid by creating multiple flow paths for the pressurized fracturing fluid through the flow conditioning device. In embodiments, the internal structure can be formed with or integrated within the central portion, while in some embodiments, the central portion can include a chamber in which the internal structure can be received.

[0015] For example, in embodiments, the internal structure of the central portion can include a plurality of internal bores. The bores can include different diameters and can be arranged in different patterns within the central portion and each can define a flow path having a reduced size or area along which the pressurized fracturing fluid flows.

[0016] In embodiments, the number and size of the bores can be selected to enable the pressurized fracturing fluid to flow therethrough without a significant reduction in a flow volume of the pressurized fracturing fluid. Various numbers, arrangements, and diameters of bores can be calculated to account for particle size, maximum flow area, length of chamber, etc.

[0017] In addition, in embodiments, a number of the bores, an arrangement of the bores about the chamber, a diameter of each bore, or combinations thereof, selected to convert a turbulent flow of the fracturing fluid to a substantially laminar flow of the fracturing fluid based on a diameter of the body, a length of the body, a projected particle size of particulates entrained within the fracturing fluid, a maximum flow area, or combinations thereof.

[0018] Further, in some embodiments, the flow conditioning device can comprise or can include one or more sacrificial wear components that can be formed from rubber, steel, or other erosion resistant material. For example, in embodiments, the flow conditioning device can be formed from an erosion resistant material and can be designed to be easily removed and replaced as a unit. In other embodiments, the internal structure thereof can be formed as a replaceable insert comprising a sacrificial wear component.

[0019] According to some aspects of the present disclosure, a hydraulic fracturing system can be constructed or assembled having at least one flow conditioning device configured to convert a turbulent flow of a pressurized fracturing fluid to a substantially laminar flow upstream of a protected component of a fracturing tree within a substantially shortened space or distance so as to accommodate substantial reductions in the length of the fluid flow path of the pressurized fracturing fluid required for converting the turbulent flow thereof to a substantially laminar flow. The flow conditioning device can be installed as part of the hydraulic fracturing system using a variety of installation methods and / or techniques.

[0020] For example, in embodiments, a flow conditioning device, or multiple flow conditioning devices, can be installed as part of a fluid conduit (e.g., being mounted between or within one or more components of a fluid conduit).

[0021] In embodiments, the flow conditioning can be located within a conduit section such as a spool or, in embodiments, a junction, of the fluid conduit, while in some embodiments, can include a body configured to define the fluid conduit, and will generally be located upstream of a component to be protected. For example, in embodiments, the flow conditioning device can be located along the fluid conduit extending between a first, upstream component and a second, downstream component (e.g., a protected component), and can be coupled to the first and second components attaching connectors (e.g., flanges) at the first and second ends thereof to corresponding connectors (e.g., flanges) of the adjacent components.

[0022] In some embodiments, the flow conditioning device can include a body configured to be received within a chamber or passage of a component. In some configurations, the body can be seated against a shoulder within the chamber or passage of the component.

[0023] In other embodiments, the flow conditioning device can have a body including a first or upstream end portion that can be engaged between a first component and an adjacent second component and a second or downstream end portion configured to be received within a fluid conduit upstream of the second component (e.g., a protected component). The body can be secured within the fluid conduit by attachment of connectors at the upstream and downstream ends of the fluid conduit to corresponding connectors of the first and second components.

[0024] Alternatively, in embodiments, the flow conditioning device can be located along a fluid conduit upstream from a component to be protected. For example, the flow conditioning device can comprise at least a portion of a fluid conduit extending between components of the fracturing tree, such as a junction and a valve (e.g., a protected component). In such embodiments, the body of the flow conditioning device can comprise a conduit section such as a spool or tube with an internal structure including a plurality of bores received therein, or can be configured with a tubular, T-shaped, or other construction and can be at least partially received within a conduit section such as a spool or tube of a fluid conduit..

[0025] In still other embodiments, the flow conditioning device can be engaged clamped between adjacent components, retained with pins, tie-down devices, threaded retainers, or other detachable connectors.

[0026] According to an aspect of the present disclosure, a flow conditioning device comprises a body comprising: a first end portion; a second end portion; and a central portion extending between the first end portion and the second end portion, the central portion having a plurality of longitudinally extending bores, each of the bores configured to define a flow path through the body; wherein the body is configured to: (a) be positioned between an upstream component and a downstream component with the central portion aligned with a flow passage of the upstream component such that a portion of a fracturing fluid moving along the flow passage of the upstream component is received though one or more of the bores; and (b) have a number of the bores, an arrangement of the bores about the central portion, a diameter of each bore, or combinations thereof, selected to convert a turbulent flow of the fracturing fluid to a substantially laminar flow of the fracturing fluid based on a diameter of the body, a length of the body, a projected particle size of particulates entrained within the fracturing fluid, a maximum flow area, or combinations thereof.

[0027] In embodiments, at least one of the first and second end portions of the body comprises a connector configured for coupling to a corresponding connector of the upstream component, the downstream component or a combination thereof.

[0028] In embodiments, each of the first and second end portions comprises a flange having a diameter greater than an overall diameter of the central portion and configured for coupling the body to the upstream component and to the downstream component.

[0029] In embodiments, the central portion further comprises an insert received within a chamber of the central portion and along which the bores extend; and wherein the insert comprises an erosion resistant material.

[0030] In embodiments, the insert is configured as a replaceable sacrificial wear component.

[0031] In embodiments, the erosion resistant material of the insert comprises rubber, metal, metal alloys, ceramic materials, or combinations thereof.

[0032] In embodiments, the plurality of bores comprises at least one bore extending approximately through a center of the central portion, and a series of bores arranged about a periphery of the central portion.

[0033] In embodiments, at least some of the bores have a first bore diameter, and at least some of the bores have a second bore diameter that is different from the first bore diameter.

[0034] In embodiments, the body comprises a substantially T-shaped configuration, a tapered configuration, a substantially straight configuration, an offset configuration, or a substantially I-shaped configuration.

[0035] In embodiments, the body is configured to be received within a chamber of a conduit positioned between the upstream and downstream components.

[0036] In embodiments, the body further comprises one or more screens, one or more flow diverters, tapering bores, different size bores, different arrangements of bores, different configurations of bores, or combinations thereof.

[0037] In embodiments, one or more of the bores comprise a substantially straight configuration, an inwardly tapering configuration, an expanding configuration, or combinations thereof.

[0038] According to another aspect, a hydraulic fracturing system comprises: a first component; a second component; a conduit positioned between the first and second components and configured to transport a fracturing fluid from the first component to the second component; wherein a fluid flow path along which a fracturing fluid is supplied to a wellbore is defined between the first component, the second component, and the conduit; and at least one flow conditioning device positioned along the fluid flow path, the flow conditioning device comprising: a body having a first end portion, a second end portion, and a plurality of bores extending longitudinally though the body; wherein each of the bores defines a separate flow path through the body; wherein each of the plurality of bores is configured to receive a portion of the fracturing fluid flowing through the conduit so as to substantially reduce a turbulence of the fracturing fluid; and wherein a diameter of each of the plurality of bores, a number of the plurality of bores, an arrangement of the plurality of bores, or combination thereof, are selected to create a substantially laminar flow of the fracturing fluid within a substantially reduced length of an overall flow path of the fracturing fluid between the first and second components, prior to introduction of the fracturing fluid into the second component.

[0039] In embodiments, the first component comprises a fluid conduit of a manifold and the second component comprises a valve.

[0040] In embodiments, the body includes an internal structure received within a chamber defined along the body and through which the plurality of bores is formed.

[0041] In embodiments, the internal structure is configured as a sacrificial wear component.

[0042] In embodiments, the plurality of bores comprises at least one central bore extending along a longitudinally extending center axis of the body, and a series of bores arranged about the central bore.

[0043] In embodiments, at least some of the bores have a first bore diameter, and at least some of the bores have a second bore diameter that is different from the first bore diameter.

[0044] In embodiments, at least one of the first and second end portions of the body includes a connector configured to couple to a corresponding connector of the first component or the component with pins, threaded fasteners, locking features, or combinations thereof.

[0045] In embodiments, the body of the flow conditioning device is configured to be at least partially received within the conduit.

[0046] In embodiments, the second end portion of the body has a first diameter and is configured to be received along a chamber extending through the conduit, and the first end portion of the body has a second diameter that is greater than the first diameter and is configured to seat against an upstream end of the conduit so as to be engaged between an inlet of the conduit and an outlet of the first component.

[0047] In embodiments, the body of the flow conditioning device is configured to be received within the conduit and is releasably retained within the conduit by pins, fasteners, threaded retainers, or combinations thereof.

[0048] In embodiments, at least one flow conditioning device comprises a plurality of flow conditioning devices positioned at selected locations along the fluid flow path between the first and second components.

[0049] In embodiments, the plurality of flow conditioning devices comprises at least one flow conditioning device having a first length and at least one flow conditioning device having a second length that is different from the first length.

[0050] In embodiments, the flow conditioning devices of the plurality of flow conditioning devices comprise different arrangements of bores, different sizes of bores, different configurations of bores, different numbers of bores, screens, flow diverters, or combinations thereof.

[0051] According to still another aspect, a system comprises: at least one manifold configured to receive and direct a fracturing fluid along a fluid flow passage; at least one fracturing tree located downstream from the at least one manifold, the at least one fracturing tree having an inlet connected to the manifold at an outlet connected to a wellbore; wherein the at least one fracturing tree is configured to receive the fracturing fluid from the at least one manifold and direct the fracturing fluid to the wellbore for injection into a wellbore; and at least one flow conditioning device positioned between adjacent components of the at least one fracturing tree, the at least one flow conditioning device comprising: a body including a plurality of bores, each of the bores defining a flow path extending through the body; and wherein the bores are configured to create a substantially laminar flow of the fracturing fluid within a substantially reduced length of an overall fluid flow path of the fracturing fluid passing through the at least one manifold and the at least one fracturing tree, prior to introduction of the fracturing fluid into the wellbore.

[0052] In embodiments of the system, the body of the at least one flow conditioning device is configured as an insert configured to be received within a component of the at least one fracturing tree.

[0053] In embodiments of the system, the body comprises a corrosion resistant material replaceable wear resistant material, or a combination thereof.

[0054] In some embodiments of the system, the body includes a replaceable internal structure through which the plurality of bores are formed.

[0055] In embodiments of the system, the at least one flow conditioning device comprises two or more flow conditioning devices arranged in series between the at least one manifold and the at least one fracturing tree.

[0056] In embodiments of the system, at least one of the two or more flow conditioning devices has a first length and another one of the two or more flow conditioning devices has a second length; and wherein the second length is greater than the first length.

[0057] In embodiments of the system, a number of the bores extending through the body, an arrangement of the bores within the body, a diameter of each bore, a taper of each bore, or combinations thereof, are selected to convert a turbulent flow of the fracturing fluid to the substantially laminar flow of the fracturing fluid based on a diameter of the body, a length of the body, a projected particle size of particulates entrained within the fracturing fluid, a maximum flow area, or combinations thereof.

[0058] In embodiments of the system, one or more of the bores include one or more screens, one or more fins, one or more geometric objects, or combinations thereof, positioned along a length of the one or more bores.

[0059] In embodiments of the system, one or more bores comprise a substantially straight configuration, an inwardly tapering configuration, an expanding configuration, or combinations thereof.

[0060] In embodiments of the system, the body is configured to be received within an internal passage of a conduit; and wherein the body comprises an erosion resistant material including rubber, metal, metal alloys, ceramic materials, or combinations thereof.

[0061] In embodiments of the system, the plurality of bores comprises two or more bores having a different diameter; and wherein the bores are arranged with at least one bore extending approximately through a center of the body, and a series of bores arranged about the at least one bore.

[0062] In embodiments of the system, the body comprises a spool including a first flange at a first end and a second flange at a second end; and wherein each of the first and second flanges is configured to couple the body to an adjacent spacer, cross flow junction, manifold, valve, or combinations thereof.

[0063] In embodiments, the system further comprises one or more pumping units connected to the at least one manifold for supplying fracturing fluid under pressure to the at least one manifold.

[0064] According to a further aspect, a method comprises: assembling a manifold at a hydraulic fracturing site; wherein the manifold is configured to receive and deliver a fracturing fluid to a fracturing tree during a hydraulic fracturing operation; and connecting an outlet of the manifold to an inlet of at least one fracturing tree coupled to a wellbore at the hydraulic fracturing site; and locating at least one flow conditioning device along a fluid flow path of the fracturing fluid extending from the manifold through the at least one fracturing tree; wherein the at least one flow conditioning device comprises: a body having a plurality of bores, each of the bores defining a flow path extending through the body parallel to the fluid flow path of the fracturing fluid; and wherein the bores are configured to create a substantially laminar flow of the fracturing fluid within a substantially reduced length of the fluid flow path along which the fracturing fluid is transported prior to introduction of the fracturing fluid into at least one fracturing tree.

[0065] In embodiments of the method, locating the at least one flow conditioning device comprises inserting the body into a chamber of a conduit positioned between adjacent components of the fracturing tree such that the fracturing fluid is converted to a substantially laminar flow upstream of the wellbore.

[0066] In some embodiments of the method, the at least one flow conditioning device is positioned between a junction and a valve of the fracturing tree.

[0067] In some embodiments of the method, the body of the at least one flow conditioning device comprises a first section and a second section, the first section having a diameter that is larger than a diameter of the second section so as to define a shoulder portion configured to seat against a corresponding shoulder portion of the chamber of the conduit.

[0068] In embodiments, the method further comprises inserting one or more retainers, tie-down pins, fasteners, or combinations thereof into the body of the at least one flow conditioning device to substantially secure the body of the at least one flow conditioning device within the conduit.

[0069] In embodiments of the method, the chamber of the conduit comprises a tapered bore and the body of the at least one flow conditioning device comprises a corresponding tapering configuration adapted to seat within the tapered bore of the chamber.

[0070] In embodiments of the method, the body of the at least one flow conditioning device can comprise a first end portion and a second end portion, and a central portion extending between the first and second end portions; and further coupling connectors of the first and second end portions to corresponding connectors of adjacent upstream and downstream components of the fracturing tree.

[0071] In embodiments of the method, the body further comprises a replaceable internal structure received within the central portion and through which the plurality of bores extends; and further comprising removing the internal structure from the body and inserting a new internal structure.

[0072] According to another aspect, a flow conditioning device comprises: a body comprising a plurality of longitudinally extending bores, each of the bores configured to define a flow path through the body; wherein the body is configured to: (a) be positioned between an upstream component and a downstream component and aligned with a fluid flow path extending between the upstream component and the downstream component such that a portion of a fracturing fluid moving along the fluid flow path is received though one or more of the bores; and (b) have a number of the bores, an arrangement of the bores about the, a diameter of each bore, or combinations thereof, selected to convert a turbulent flow of the fracturing fluid to a substantially laminar flow of the fracturing fluid based on a diameter of the body, a length of the fluid flow path, a projected particle size of particulates entrained within the fracturing fluid, a maximum flow area, or combinations thereof.

[0073] In embodiments of the flow conditioning device, the body further comprises a connector located at a first end thereof, the connector configured for coupling to a corresponding connector of the upstream component.

[0074] In embodiments of the flow conditioning device, the body further comprises an internal structure configured as an insert received within a chamber of the body and along which the bores extend; and wherein the internal structure comprises an erosion resistant material.

[0075] In embodiments of the flow conditioning device, the internal structure is configured as a replaceable sacrificial wear component.

[0076] In embodiments of the flow conditioning device, the erosion resistant material of the internal structure comprises rubber, metal, metal alloys, ceramic materials, or combinations thereof.

[0077] In embodiments of the flow conditioning device, the plurality of bores comprises at least one bore extending approximately through a center of the central portion, and a series of bores arranged about the at least one bore.

[0078] In embodiments of the flow conditioning device, at least some of the bores have a first bore diameter, and at least some of the bores have a second bore diameter that is different from the first bore diameter.

[0079] In embodiments of the flow conditioning device, the body comprises a substantially T-shaped configuration, a tapered configuration, a substantially straight configuration, an offset configuration, or a substantially I-shaped configuration.

[0080] In embodiments of the flow conditioning device, the body is configured to be received within a chamber of a conduit positioned between the upstream and downstream components.

[0081] In embodiments of the flow conditioning device, the body includes a second end portion having a first diameter and configured to be received along the chamber extending through the conduit, and a first end portion having a second diameter that is greater than the first diameter and configured to seat against an upstream end of the conduit so as to be engaged between an inlet of the conduit and an outlet of the upstream component.

[0082] In embodiments of the flow conditioning device, the body further comprises one or more screens, one or more flow diverters, tapering bores, different size bores, different arrangements of bores, different configurations of bores, or combinations thereof.

[0083] In some embodiments of the flow conditioning device, the body is configured as a spool having a first end portion, a second end portion and a central portion through which the plurality of bores extend.

[0084] In various embodiments of the flow conditioning device, one or more of the bores comprise a substantially straight configuration, an inwardly tapering configuration, an expanding configuration, or combinations thereof.

[0085] In embodiments of the flow conditioning device, at least one of the first and second end portions of the body includes a connector configured to couple to a corresponding connector of the upstream component or the downstream component with pins, threaded fasteners, locking features, or combinations thereof.

[0086] Various other aspects, features, and advantages of a hydraulic fracturing system, including one or more flow conditioning devices configured for converting a turbulent flow of a pressurized fracturing fluid to a substantially laminar flow of the pressurized fluid along a substantially reduced space or distance so as to substantially shorten the length of the fluid flow path along which the pressurized fracturing fluid is delivered to a wellbore, and methods of use thereof according to exemplary embodiments thereof are discussed herein. The embodiments described herein comprise a combination of features and characteristics intended to address various shortcomings associated with certain prior devices, systems, and methods.

[0087] Moreover, it is to be understood that both the foregoing information and the following detailed description provide merely illustrative examples of various aspects and embodiments and are intended to provide an overview or framework for understanding the nature and character of the claimed aspects and embodiments. It further should be appreciated that this disclosure may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes as the disclosed embodiments, and that such equivalent constructions do not depart from the spirit and scope of the principles disclosed herein. Accordingly, these and other aspects, along with advantages and features of the present disclosure, will become apparent through reference to the following description and the accompanying drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0088] The accompanying drawings, which are included to provide a further understanding of the embodiments of the present disclosure, are incorporated in and constitute a part of this specification, illustrate embodiments of the present disclosure, and together with the detailed description, serve to explain principles of the embodiments discussed herein. No attempt is made to show structural details of this disclosure in more detail than may be necessary for a fundamental understanding of the embodiments discussed herein and the various ways in which they may be practiced. According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate embodiments of the disclosure. For a detailed description of various embodiments, reference will now be made to the accompanying drawings in which:

[0089] FIG. 1 is a schematic diagram of a hydraulic fracturing system including a manifold.

[0090] FIG. 2A is a perspective view of an example embodiment of a fracturing tree of the hydraulic fracturing system of FIG. 1, including one or more flow conditioning devices configured to facilitate the conversion of a turbulent flow of a pressurized fluid to a substantially laminar flow in accordance with the principles of the present disclosure.

[0091] FIG. 2B is an exploded perspective view of the fracturing tree of FIG. 2A, illustrating a series of flow conditioning devices configured to facilitate the conversion of a turbulent flow of a pressurized fluid to a substantially laminar flow located between various components of the fracturing tree in accordance with the principles of the present disclosure.

[0092] FIG. 3A is a perspective view of an example embodiment of a flow conditioning device configured to facilitate the conversion of a turbulent flow of a pressurized fluid to a substantially laminar flow in accordance with the principles of the present disclosure.

[0093] FIG. 3B is a side elevational view taken in partial cross-section of an embodiment of a flow conditioning device configured to facilitate the conversion of a turbulent flow of a pressurized fluid to a substantially laminar flow such as shown in FIG. 3A in accordance with the principles of the present disclosure.

[0094] FIGS. 4A-4C illustrate additional embodiments of flow conditioning devices configured to facilitate the conversion of a turbulent flow of a pressurized fluid to a substantially laminar flow, including different arrangements, numbers and diameters of bores thereof in accordance with the principles of the present disclosure.

[0095] FIG. 5A is a side elevational view schematically illustrating an example embodiment of a fracturing tree, including embodiments of flow conditioning devices configured to facilitate the conversion of a turbulent flow of a pressurized fluid to a substantially laminar flow and having different internal structures in accordance with the principles of the present disclosure.

[0096] FIG. 5B is a side elevational view schematically illustrating another example embodiment of a fracturing tree, including embodiments of flow conditioning devices configured to facilitate the conversion of a turbulent flow of a pressurized fluid to a substantially laminar flow and having different internal structures in accordance with the principles of the present disclosure.

[0097] FIGS. 6A-6B are cross-sectional side elevational views schematically illustrating an example embodiments of flow conditioning devices configured to facilitate the conversion of a turbulent flow of a pressurized fluid to a substantially laminar flow and having tapering internal structures in accordance with the principles of the present disclosure.

[0098] FIGS. 7A-7B illustrate an embodiment of a flow conditioning device including a flow obstruction including a screen at least one end thereof for further facilitating the conversion of a turbulent flow of a pressurized fluid to a substantially laminar flow in accordance with the principles of the present disclosure.

[0099] FIGS. 8A-8C illustrate example embodiments of arrangements of flow conditioning devices arranged as part of or within a fluid conduit assembly and configured to facilitate the conversion of a turbulent flow of a pressurized fluid to a substantially laminar flow in accordance with the principles of the present disclosure.

[0100] FIGS. 9A-9D schematically illustrate various example embodiments of mounting arrangements of flow conditioning devices configured to facilitate the conversion of a turbulent flow of a pressurized fluid to a substantially laminar flow as part of or along a fluid conduit, in accordance with the principles of the present disclosureDETAILED DESCRIPTION

[0101] Embodiments of the present disclosure are directed to hydraulic fracturing systems, and various components and methods of installation and use thereof. In embodiments, the hydraulic fracturing systems can include a manifold assembly having one or more manifolds (e.g., inlet and outlet manifolds) configured to receive and transport a pressurized fracturing fluid along a flow path to an injection system or assembly, which can include one or more zipper modules and / or fracturing trees, for injection of the pressurized fracturing fluid to one or more wellbores. In various embodiments, one or more flow conditioning devices can be arranged as part of or along one or more fluid conduits or connections between the one or more manifolds and the zipper module(s), the fracturing tree(s), and / or components thereof.

[0102] In embodiments, the flow conditioning devices can be located along a trunk line, bridge or conduit upstream of a fracturing tree and / or components thereof, and will be configured to facilitate the conversion of a turbulent flow of a pressurized fracturing fluid to a substantially laminar flow within a substantially reduced length or distance so as to enable a substantial reduction in an overall area or space required for the various components of the hydraulic fracturing system and thus potentially a reduction in the overall area or size required for the hydraulic fracturing system, while protecting components of the fracturing tree(s), such as valves, junctions, and other more expensive components, from wear and erosion, to help prolong the operational life thereof.

[0103] As will be understood, the terms “pressurized fracturing fluid,”“fracturing fluid,”“pressurized fluid,” and “fluid” may be used interchangeably throughout the present disclosure to refer to a fluid injected into a wellbore during operation of embodiments of the hydraulic fracturing systems of the present disclosure.

[0104] As used herein, the terms “comprises,”“comprising,”“includes,”“including,”“has,”“having,” or any other variation thereof, and are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but may include other features not expressly listed or inherent to such process, method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive-or and not to an exclusive-or.

[0105] Dimensional information in the following description should be understood as nominal dimensions that are intended to encompass variations in dimensions that normally occur in the pumping systems and components thereof such as described herein. Terms such as “approximately,”“about,” and “substantially” may be used to qualify dimensional information in the following description but such qualifications are intended merely to reinforce that the dimensions are nominal dimensions and not to differentiate qualified dimensions from unqualified dimensions.

[0106] Also, the terms “couple,”“linked,” and “connect” and any variations thereof will be understood to cover both indirect and direct connections between one or more parts or elements.

[0107] The terminology used herein is for the purpose of description only and is not intended to be limiting of the present disclosure. Spatially relative terms, such as “beneath,”“below,”“lower,”“above,”“upper,” and the like may be used herein for ease of description to describe one element's or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the exemplary term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (e.g., rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0108] In addition, the terms “axial” and “axially” generally mean along or substantially parallel to a given axis (e.g., central axis of a body or a port), while the terms “radial” and “radially” generally mean substantially perpendicular to or extending at a tangent to a given axis.

[0109] As used herein, the singular forms “a,”“an,” and “the” are intended to include the plural forms as well, unless the context indicates otherwise. It will be further understood that the terms “comprises” and / or “comprising” specify the presence of stated features, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof.

[0110] FIG. 1 shows a schematic diagram of a hydraulic fracturing system 10 including various fluid conveyance devices along which flows of a relatively high-pressure fracturing fluid are supplied to one or more injection systems 100 connected to a wellbore 103 extending into a subterranean formation 102. It should be appreciated that the hydraulic fracturing system 10 shown in FIG. 1 schematically depicts some components and assemblies that may be used during a hydraulic fracturing operation, and that in some embodiments additional or fewer components may be used within the hydraulic fracturing system 10. Thus, the particular combination and / or arrangement of components of the system 10 depicted in FIG. 1 is not limiting to other potential embodiments of hydraulic fracturing system 10.

[0111] For instance, in embodiments, the hydraulic fracturing assembly 10 can include a manifold assembly 20, which can include one or more manifolds 22 (e.g., one or more inlet manifolds and one or more outlet manifolds) that each define or include a frac. conduit 23 configured to deliver the pressurized fracturing fluid received from one or more pumping units 40 to an injection system 100. Such manifolds sometimes can be referred to as “missiles,” and in embodiments, can comprise monobore type manifolds with a single fluid conduit, while in other embodiments, can have other configurations including more than one fluid conduit.

[0112] In embodiments, each manifold of the manifold assembly 20 also may include one or more junctions 24 through which the pressurized fracturing fluid is received into the manifold. In an example embodiment, such as shown in FIGS. 2A-2B, a manifold 22 (e.g., an outlet manifold of the manifold assembly 20) will be connected to one or more injection systems 100 located at a wellhead for supplying the pressurized fracturing fluid thereto. In embodiments, the injection system 100 can comprise one or more zipper modules 95 and / or one or more fracturing trees 101 (which also can be referred to as a “frac tree” or a “Christmas tree”), configured for injection of the pressurized fracturing fluid into the subterranean formation 102 via the wellbore as indicated at 103 in FIG. 1.

[0113] In addition, in embodiments, the hydraulic fracturing system 10 generally can include a plurality of storage vessels 12 that are each configured to hold a volume of fracturing fluid therein. The fracturing fluid stored in the storage vessels 12 may include any liquid or semi-liquid (such as a gel) that is suitable for injection into and fracturing of the subterranean formation 103 as previously described. In some embodiments, the fracturing fluid includes an aqueous solution including substantially pure water or water mixed with one or more additives (such as gels or gelling agents, chemicals, etc.). The storage vessels 12 may include any suitable container for holding a volume of fluids (such as liquids) therein. For instance, in some embodiments, storage vessels may include rigid tanks, flexible tanks (such as bladders), open pits, mobile tanks (that may be pulled by a tractor trailer or other vehicle), or a combination thereof.

[0114] A blender 14 can be positioned downstream of the storage vessels 12 that is configured to mix a proppant into the fracturing fluid. The proppant may include sand or other suitable solids. As previously described, the proppant is configured to flow into the fractures within the subterranean formation 102 so as to hold the fractures open after the hydraulic fracturing operation has ended. In some embodiments, additives (such as chemical additives) may be mixed into the fracturing fluid within the blender 14 either in addition or alternatively to the proppant. The blender 14 emits the fracturing fluid, now with proppant mixed therein, to a manifold assembly 20 that communicates the fracturing fluid to and from a plurality of pumping units 40.

[0115] In various embodiments, the manifolds 22 of the manifold assembly 20 include at least one inlet manifold and at least one outlet manifold. However, in other embodiments, different numbers, arrangements, and combinations of inlet manifolds and outlet manifolds may be utilized, such as, for instance, a single outlet manifold, a plurality of outlet manifolds, a single inlet manifold, or a plurality of inlet manifolds. For example, in embodiments, a plurality of inlet conduits 30 can connect at least one inlet manifold at least one to of the pumping units 40. In addition, a plurality of outlet conduits 28 can connect the plurality of pumping units 40 to at least one outlet manifold.

[0116] Each pumping unit 40 can include at least one pump 44 driven by a driver 42 (which may be referred to herein as a “prime mover”). Pump 44 may include any suitable fluid pumping device or assembly for pressurizing the fracturing fluid (with or without proppant and / or other additives entrained therein) to the pressures associated with a hydraulic fracturing operation. For instance, in some embodiments, the pump 44 may be configured to pressurize the fracturing fluid (again, with or without proppant and / or other additives entrained therein) to a pressure of about 9000 pounds per square inch (psi) or higher, and may be referred to herein as a “hydraulic fracturing pump”44.

[0117] In some embodiments, pump 44 may include a positive displacement pump, centrifugal pump, or other suitable pump types. Each driver 42 may include any suitable motor or engine that is configured to drive or actuate the corresponding pump 44 during operations. For instance, in some embodiments, each driver 42 may include a diesel engine, a turbine (such as a gas turbine, steam turbine, etc.), an electric motor, or some combination thereof. During operations, within each pumping unit 40, the driver 42 may drive its associated pump 44 to draw fracturing fluid F into the pump 44 via the corresponding inlet conduit 30 and to pressurize and output the fracturing fluid from the pump 44 via the corresponding outlet conduit 28.

[0118] During a hydraulic fracturing operation, a pressurized fracturing fluid is pumped from the pumping units 40 to the manifold assembly 20, generally being received by an outlet manifold 22 via the outlet conduits 28. The outlet manifold 22 directs the pressurized fracturing fluid toward an injection system 101 at a wellhead for injection into the subterranean formation 102 as previously described. The fracturing fluid further may be emitted from the wellbore 103 via the wellhead and recycled back to the storage vessels 12 through one or more recycle conduits 16. In some embodiments, the fracturing fluid output from the wellhead 103 may be routed through one or more filtering or separation assemblies or devices (not shown) to remove additives, proppant, and / or other fluids or solids (such as, rock chips, formation fluids, etc.) that may be entrained within the fracturing fluid, prior to recycling the fracturing fluid to the storage vessels 12.

[0119] In embodiments of the hydraulic fracturing system 10 as shown in FIGS. 2A-2B, the outlet manifold 22 can include an elongate frac. conduit 23 connecting the outlet manifold 22 to the injection system 100. In embodiments, the manifold 22 can have an upstream end, a plurality of tubular sections 22a with a plurality of junctions 24 interleaved therebetween and defining one or more fluid inlets, and a downstream end coupled to the frac. conduit 23, which is in fluid communication with the injection system 100. The frac. conduit 23 can have a flow passage 50 defined therethrough, extending along a longitudinal central axis 55 and along which a pressurized fracturing fluid is received and is directed for supplying the pressurized fracturing fluid to the injection system 100. As used herein, the terms “upstream” and “downstream” denote a general flow direction of fracturing fluid during hydraulic fracturing operations, according to some embodiments.

[0120] In an example embodiment of the hydraulic fracturing system 10 as shown in FIGS. 2A-2B, the injection system 100 can include a fracturing tree 101 having various components and configured to inject the pressurized fracturing fluid through the wellbore 103 and into the subterranean formation. In addition, in some example embodiments such as illustrated in FIGS. 2A-2B, the injection system further can include at least one zipper module 95 between the frac. conduit 23 and the fracturing tree 101.

[0121] In a typical hydraulic fracturing operation, large volumes of fluids, which further contain proppant materials such as sand and other particulates, are pumped through the manifold and supplied to one or more fluid conduits and into the well bore(s) 103 at high pressures and rates. The fluid conduits generally have diameters of, for example, 5″ 7″ or possibly greater, to accommodate the high flow rates needed for a fracturing operation. The high pressures and high volume of the pressurized fracturing fluids passing though the conduits creates a turbulent flow that is responsible for substantially most of the erosional wear and tear on fracturing equipment, which can lead to premature failure of such equipment of components, shortening their operational life and increasing maintenance and service costs. It therefore is important to reduce the turbulence of the pressurized fluid flows as much as possible and create a substantially laminar flow to reduce such erosional wear.

[0122] It has been recognized that the length of the conduits supplying the pressurized fracturing fluid to the injection systems should be at least about ten times the diameter of the conduit to provide a sufficient length of a flow path to achieve to achieve laminar flow at which point erosional wear is believed to be sufficiently reduced. For a 7″ diameter conduit, the length of the conduit should be at least 70″-84″ (e.g., generally at least about 6-7 feet in length). However oftentimes the space available is much less, for example, limiting the length of the conduits to only about 16″ in length, leaving insufficient space to reduce the turbulent flows of the pressurized fracturing fluid to create the desired laminar flow and therefore exposing the fracturing equipment of components to substantial erosional wear.

[0123] For some fracturing equipment or components, the increased erosion and wear created by the turbulent flows due to the smaller space constraints has been viewed as acceptable collateral damage for lower cost and easier serviceable components such as spools and other fluid conduits and cross junctions. However, for more expensive components such as frac valves, such increased erosional wear can lead to significant costs increases and more downtime for servicing and premature replacement of such components. In addition, the frac valves themselves have been reduced substantially in length (e.g., from 39″ or more to 17″), further shortening the length of the fluid flow path of the pressurized fracturing fluid through the fracturing tree, and increasing the exposure to erosional wear.

[0124] As illustrated in FIGS. 2A-2B, in embodiments, the injection system 100 can include a zipper module 95 or multiple zipper modules, while in other embodiments, a zipper module may not be used. In an example embodiment, the zipper module 95 such as shown in FIGS. 2A-2B, can be positioned between the frac. conduit 23 and the fracturing tree 101 and can receive the pressurized fracturing fluid form the conduit and transfer the pressurized fracturing fluid along a fluid flow path indicated at 105, to the fracturing tree. In embodiments, the zipper module can include a first cross or junction 96, a fluid conduit 97 (which can be formed as a spool) connecting the first cross or junction to a second cross or junction 98, and a spacer spool or conduit 99 that is configured to couple to an upstream or inlet fluid conduit 110 of the fracturing tree 101. Other configurations of a zipper module 95 also can be provided.

[0125] As further illustrated in FIGS. 2A-2B, in embodiments, fracturing tree 101 of the injection system 100 can include a junction 111 connected to the upstream fluid conduit 110. For example, in embodiments, the fluid conduit 110 can include one or more spools 112 coupled together in series so as to define an elongated fluid conduit 110 extending between the cross or junction 98 of the zipper module 95 and the junction 111 of the fracturing tree 101. The junction 111 further can be connected to a cross junction 113 by a downstream fluid conduit 114. In embodiments, one or more valves, such as more or hydraulic gate valves 116 (or other actuator driven valves) and one or more manual valves 117 can be coupled to opposite lateral sides 118 of the cross junction 113, as illustrated in FIG. 2B.

[0126] As further illustrated in FIG. 2A, an outlet fluid conduit 119 can be coupled to a downward side of the cross junction 113 into a bore tube or pipe 121 of the wellbore 103 for delivery of the pressurized fracturing fluid into the wellbore. In embodiments, a flow control valve 122 (e.g., a gate valve or other valve) can be positioned between the cross junction 113 and the pipe 121 of the wellbore 103 along the fluid flow path 105 extending through the fracturing tree 101 to the wellbore 103. In embodiments, the valve 122 can be connected to the cross junction 113 by one or more spools 123 defining a fluid conduit 124, and to the pipe 121 of the wellbore 103 by one or more spools 126 defining a fluid conduit 128. Other configurations of fracturing trees also can be provided.

[0127] As illustrated in FIG. 2B, in embodiments, at least one flow conditioning device 130 can be positioned between various frac. equipment or components of the hydraulic fracturing system 10, such as being mounted within or located along a trunk line, bridge or conduit extending between a first component 125A and a second component 125B of the hydraulic fracturing system 10, as indicated in FIGS. 9A-9D. For example, in some embodiments, such components 125A / 125B can include the frac. conduit 23 (FIGS. 2A-2B) of the manifold assembly of the hydraulic fracturing system and the injection system 100 or the zipper module, or along a conduit 110 extending between the zipper module 95 and the fracturing tree 101 such that the at least one flow conditioning device is positioned ahead of the fracturing tree 101 (e.g., as indicated in FIGS. 5A and 5B).

[0128] In some embodiments, the first and second components can include one or more adjacent components of the fracturing tree 101 (FIGS. 2A-2B, and 5A-5B), such as a junction and one or more of the valves (e.g., at least one flow conditioning device can be located along the fluid flow path between a first, lower cost component 125A (FIGS. 9A-9B), such as a spool or other conduit section, and a second, greater cost component 125A such as the flow control valve 122 or other more component for which greater protection from erosion is needed or required). In such embodiments, at least one flow control device 130 can be positioned along a fluid flow path F of the pressurized fracturing fluid through the injection system, for example, being positioned within or in-line with any of the fluid conduits 110, 114, 124, and / or 128 (FIGS. 2A-2B) of the fracturing tree (each of which fluid conduits can also be referred to as a frac. conduit) located along the fluid flow path extending from the inlet of the fracturing tree to its outlet at the wellbore 103.

[0129] In embodiments, the flow conditioning device(s) 130 will be configured to provide a reduction in turbulence of the incoming pressurized fluid flow so as to convert the turbulent flow of the pressurized fracturing fluid to a substantially laminar flow upstream of the fracturing tree and / or the valves and other more expensive components or equipment of the fracturing tree (e.g., the junctions or valves), while also enabling a substantial reduction of a length of the conduits supplying the pressurized fracturing fluid and an overall fluid flow path of the pressurized fracturing fluid. Thus, the flow conditioning device 130 can help prolong an operational life and reduce required maintenance and servicing of such more expensive components, which can further reduce costs of operation and downtime of the hydraulic fracturing system.

[0130] For example, in embodiments, one or more flow conditioning devices 130 can be positioned along and / or mounted within the inlet fluid conduit 110 extending between the cross or junction 98 of the zipper module 99 and the junction 111 of the fracturing tree, between the junction 111 and the cross junction 113 of the fracturing tree, between the cross junction and the valve 122 of the fracturing tree, or any combinations thereof. In some embodiments, such as shown in FIGS. 2B, 5B and 8A-8C, multiple flow conditioning devices 130 can be located along one or more of the fluid conduits, including having multiple flow conditioning devices arranged in series or spaced on one or both sides of a spool or other conduit section.

[0131] In embodiments, such as shown in FIGS. 3A-3B, 5A-7A, and 8A-9D, the flow conditioning device 130 generally can include a body 131 having a first or upstream end portion 132 and a second or downstream end portion 133, with a central portion 135 extending therebetween. In some embodiments, such as generally illustrated in FIGS. 6A-6B and 8A-8B, the body 131 of each flow conditioning device 133 can be formed as a spool or conduit having a central portion 135 that can be of a smaller diameter than the first and second end portions 132 / 133, and which can be mounted between first and second or upstream and downstream components of the injection system, such as, for example, between the junction 98 of a zipper module 95 and junction 111 of the fracturing tree or between the cross junction 113 and valve 122 of the fracturing tree.

[0132] As shown in FIGS. 2B-3B, and 5A-7A, in embodiments, one or both of the first and second end portions 132 / 133 of the body 131 of the flow conditioning device can be configured with a connector such as a flange 134. The flange 134 can be configured to be coupled to a corresponding connector (e.g., a corresponding flange) of the adjacent first or upstream component 125A (FIG. 9A) and / or the second or downstream component 125B, for example, in some embodiments, including a plurality of fastener openings 139A for receiving threaded retainer pins, bolts, or other fasteners 139B, such as indicated in FIG. 3B.

[0133] In embodiments, the flow conditioning device can include an internal structure 140 that can be received within a chamber 141 of the body 131, such as shown in FIGS. 3A-3B, 6A-6B and 8A-8B. In some embodiments, the body 131 can comprise an internal structure that can be formed as an insert configured to be received within a chamber 136 of a conduit such as a spool 137, while in other embodiments, the body can include or comprise an internal structure 140 of a conduit section such as a spool 137 of a fluid conduit (e.g., one or more of fluid conduits 110, 114, 124). In such embodiments, as shown in FIGS. 3A and 9A-9D, the body can be configured as a sleeve or tubular component adapted to be received within a chamber 136 of a conduit section such as a spool 137 and can extend therethrough. For example, as shown in FIGS. 9A-9D, in embodiments, the flow conditioning device can comprise a tubular body 131 configured to fit into a traditional bore of a fluid conduit (e.g., a fluid conduit such as shown at 110, 114, or 124,) supplying the flow of pressurized fracturing fluid into and / or through the fracturing tree to the wellbore.

[0134] In addition, in various embodiments, an outer sleeve can be formed from an erosion resistant material, and each can comprise a replaceable wear component. For example, in embodiments such as indicated in FIG. 3A, the body 131 can comprise an outer sleeve formed from a first erosion resistant material such as a metal or metal alloy, while the internal structure 141 can be formed as a sleeve or tube that can be received within the outer tubular body 131, and can comprise a second erosion resistant material that can be different form the first erosion resistant material. In embodiments, the body and internal structure could be formed as separate removable and replaceable inserts, while in other embodiments, the body and internal structure can comprise a unitary insert that can be removed and replaced from a spool of other conduit as a unit.

[0135] Still further, in some embodiments, the body and the internal structure will include a fluid flow path inlet 138 defined at the upstream end portion thereof, and which is aligned with an outlet opening of an adjacent upstream component of the injection system. For example, the flow conditioning device 130 (FIGS. 2A and 2B) can be positioned upstream from the fluid control valve 122, such as being located between the cross junction 113 and an inlet of the flow control valve 122, and with its fluid flow path inlet 138 generally aligned with the outlet of the cross junction 113. In some embodiments, the fluid flow path inlet 138 of the body of the flow conditioning device further generally will have a diameter D that substantially matches the overall diameter D of the fluid conduit and the outlet of the upstream component through which the pressurized fluid is received when the flow conditioning device or a spool in which it is received are mated with the outlet of an upstream component such as an upstream fluid conduit or a junction as indicated in FIG. 2B. In other embodiments, the fluid flow path inlet 138 can have a diameter d1 (e.g., as shown in FIG. 6A) that is different from the diameter D of the outlet of the upstream component.

[0136] In embodiments, the internal structure of the body can include one or more bores 142 (FIGS. 3A-5B). The bores 142 generally can be formed as tubes or passages 143 extending from a first or upstream end 144A through the length of the body 131 to a second or downstream end 144B and each having a substantially reduced diameter D′ (FIGS. 4A-4C) as compared to an overall diameter D of the fluid or frac. conduit(s) supplying the pressurized fracturing fluid into the fracturing tree.

[0137] As shown in FIGS. 4A-4B, in various embodiments, the bores 142 can include a center bore 146 that can be generally aligned with a central axis 147 of the body of the flow conditioning device, and a series of additional bores 148 arranged thereabout. As shown in FIGS. 4A-4B, the additional bores 148 can be arranged about a periphery of the body. In addition, in embodiments, the bores 142 can have substantially a same diameter “D”, while in other embodiments, such as indicated in FIG. 3A, the bores 142 can have at least two different diameters.

[0138] In addition, in some embodiments, such as shown in FIG. 4C, the bores 142 can be arranged randomly of can be arranged in various patterns. For example, in embodiments, the bores can be arranged in patterns such as in concentric rings or in groups of substantially same diameter bores, in groups or rows or columns of similar or different diameter bores, or other arrangements. In still other embodiments, a plurality of smaller diameter bores 142 can be provided without a single centrally located bore.

[0139] In some further embodiments, such as illustrated in FIGS. 6A-8C, the bores 142 can be formed with various configurations, for example, including a tapered construction as shown in FIGS. 6A, 6B and 8C. As shown in FIGS. 6A and 8C, in embodiments, a single bore 142 can be provided, having a first or upstream end 144A having a first diameter “d1” and which expands outwardly along the length thereof to a second end 144B having a second diameter “d2” that is greater than the first diameter “d1”. In other embodiments, such as shown in FIG. 6B, a series of bores 142 can be provided, one or more of which can have a tapered construction that expands outwardly from a first end 144A to a second end 144B. In embodiments, other configurations and / or arrangements of bores can be provided, such as including one or more generally straight bores having a substantially consistent diameter can be provided combined with one or more tapered bores.

[0140] Still further, in embodiments, in addition to including bores of different diameters and different configurations of bores, flow obstructions 155, such as screens, flow diverters such as fins, walls or other projections, etc.. can be located along the bores 142 to further help convert the turbulent flow of the pressurized fracturing fluid to a substantially laminar flow. Such flow obstructions 155 can be positioned between the upstream ends of the bores of the flow conditioning device, or along the passages 143 of the bores, and in some embodiments, could potentially be used to reduce the number of bores of the flow conditioning device.

[0141] For example, screens 156 (FIGS. 7A-7B) can be positioned at the first or upstream end 132 of the body 131, in a position to cover the bores 142, and in some embodiments, one or more screens 156 can be positioned passages 143 of the bores 142 (e.g., as indicated in FIGS. 5B and 8B), in addition to or as an alternative to mounting a screen 156 at the upstream end of the body. As shown in FIG. 7B, the screen(s) 156 generally can be configured to cause additional disruptions in the flow of the pressurized fracturing fluid passing into and through the bores of flow conditioning device without substantially blocking the flow of the pressurized fracturing fluid therethrough.

[0142] As shown in FIG. 8A, other flow obstructions, such as flow diverters 157 (e.g., fins, walls or other projections) can be arranged along the passages 143 of the bores. The flow diverters 157 can have various shapes and sizes (e.g., triangular, straight, arcuate, etc..), and generally will be configured to create disruptions in the turbulent flow of the pressurized fracturing fluid. Such disruptions can help reduce turbulence of the flow of the pressurized fracturing fluid through the fluid or frac conduit(s) upstream of the fracturing tree and / or the valves and / or other more expensive components thereof.

[0143] As noted above, in embodiments, the body 131 of the flow conditioning device 130 can comprise a sacrificial wear component that can be formed from an erosion resistant material and which is configured to be removeable and easily replaceable. For example, in embodiments the body 131 can be formed from rubber, metal, metal alloys, ceramic materials, or combinations thereof, such as shown in FIGS. 5A-5B, the body of the flow conditioning device can be formed as a spool of other conduit adapted to be received between a first of upstream component 160 and a second or downstream component 161 of the injection system, with, the flow conditioning device (or multiple flow conditioning devices) can be mounted along or integrated or located within a shortened length of a trunk line, bridge or other fluid conduit(s) extending between various fracturing equipment or components of the hydraulic fracturing system, such as the frac. conduit 23 a manifold of a zipper module 95, and the junctions, valves and other components of the fracturing tree 101.

[0144] In some embodiments, at least one flow conditioning device 130 can be positioned upstream of the flow control valve 122 of the fracturing tree. For example, FIG. 5A shows an example embodiment of a flow conditioning device 130 positioned between the inlet junction 111 and the cross junction 113 of the fracturing tree upstream from the flow control valve. FIG. 5B shows a further embodiment wherein multiple flow conditioning devices 130 are provided, including multiple flow conditioning devices located along an elongated fluid conduit 114 extending between the junction 111 and cross junction 113. It will be understood that the arrangements of the fluid conduits shown in the examples of FIGS. 2A-2B and 5A-5B are for purposes of illustration and that various other, differing arrangements and numbers of flow conditioning devices and fluid conduits can be provided (e.g., each fluid conduit upstream of the fluid control valve can include one, 2, 3 or more sections that each can be configured as a spool or can be otherwise configured).

[0145] In addition, in embodiments, the flow control device 130 can be mounted along a trunk line, bridge line, or fluid conduit between a pair of adjacent pipes with a substantially straight bore extending therethrough, while in some embodiments, two or more flow control devices can be arranged along the fluid conduit in series such as shown in FIGS. 8A-8B, or with an additional conduit section therebetween such as shown in FIG. 5B. In such embodiments, the flow conditioning devices can include different lengths, or can be of a same length, with a total length of the flow conditioning devices (and any intervening conduit sections), and further each can have a reduced overall length so as to substantially fit within the available length or space between the components. By way of example only, in a situation where an available space or length between the components is limited to 16″ or less, a pair of flow conditioning devices can be used, with a total length of each being a combined 16″ or less so as to substantially fit within the available length or space between the components.

[0146] As shown in FIGS. 8A and 8C, in embodiments, the flow control devices can have different lengths, and further can have different configurations, numbers and arrangements of bores 142, which can also include bores hiving different diameters. For example, FIG. 8A shows two flow conditioning devices arranged in series, with a first one 130A having a shorter length than the second one 130B, and with the internal structures of each including different arrangements of bores 142, and the first flow conditioning device 130A. FIG. 8B shows first and second flow conditioning devices 130A and 130B having substantially a same length, but with the first one 130A having multiple bores 142 of a smaller diameter than the bores 142 of the second flow conditioning device 130B, which is shown with fewer bores 142 and having flow obstructions 155 positioned therealong. FIG. 8C shows an embodiment with flow conditioning device 130A located upstream from a straight conduit section 163, having a greater length than the conduit section and further including a single bore 142 shown as having a tapered configuration wherein the bore expands in diameter from the first end to the second end thereof. Other configurations and arrangements also can be provided.

[0147] In addition, in embodiments, the flow conditioning device(s) 130 can be configured as lower cost sacrificial component that converts the turbulent flow of the pressurized fracturing fluid into a substantially laminar flow before it passes through more costly equipment of the fracturing tree. For example, in some embodiments, such as shown in FIG. 3A, the flow conditioning device can include internal structure 140 through which the bores 142 are formed and extend, and which can comprise a sacrificial wear component formed as a removeable and replaceable insert. In such embodiments, the body 131 of the flow conditioning device 130 can be formed as a spool and can be formed from a high strength material such as steel. The center portion 135 of the body 131 can include a chamber or internal passage 170 defined therethrough, and the internal structure 140 can comprise a sleeve or tubular structure that can be formed from an erosion resistant material, such as rubber, metal, metal alloys, ceramic materials, or combinations thereof and will be configured to be received within the chamber 170. The internal structure thus can act as a sacrificial insert of wear component that protects the downstream components of the fracturing tree, such as the valves and other more expensive components, from erosion, and which further can be removed from the body 131 and replaced as needed, saving time and potential costs of servicing the frac equipment and extending the operational life of the valves and other, similar components.

[0148] Alternatively, in embodiments such as shown in FIGS. 9A-9D, the flow conditioning device 130 can include a body that comprises a replaceable insert configured to be received within a chamber of an existing spool or other conduit. The flow conditioning device 130 can act as a sacrificial wear component formed from an erosion resistant material such as rubber, metal, metal alloys, ceramic materials, or combinations thereof configured to protects the downstream components of the fracturing tree, such as the valves and other more expensive components, from erosional wear due to the pressurized fracturing fluid, and which can be removed and replaced more easily and with less labor, leading to a potential reduction in servicing times and costs.

[0149] In embodiments, as discussed above, the flow conditioning device 130 can be installed along a in the trunk line, bridge or conduit extending between a first or upstream component 125A and an adjacent second or downstream component 125B. For example, the flow conditioning device 130 can be installed between along a conduit ahead of the fracturing tree, or between one or more components thereof (e.g., between a lower cost component and a higher cost component that requires greater protection from the effects of erosion by the pressurized fracturing fluid passing therethrough. As shown in FIGS. 9A-9D, the flow conditioning device 130 can be installed between the adjacent first and second components in various ways.

[0150] For example, in embodiments, a method of installing the flow conditioning device 130 can include assembling fracturing equipment for the hydraulic fracturing system at a fracturing site. This can include assembling a manifold assembly 20, including at least one manifold 22, and connecting the at least one manifold to at least one injection system 100 at a well site, such as indicated in FIGS. 1-2B. In embodiments, the injection system 100 can include a fracturing tree 101, and the at least one manifold can be connected to the fracturing tree by the frac. conduit 23. In some embodiments, the injection system 100 also can include at least one zipper module in fluid communication with the at least one injection system, and can be coupled to the frac. conduit 23 at an upstream or inlet portion, and to the fracturing tree at a downstream or outlet portion, such as, for example, by a fluid conduit such as shown at 110 in FIGS. 2A-2B.

[0151] In embodiments, as shown in FIGS. 2A-2B, the fracturing tree 101 can include a series of components including one or more junctions 111 and 113, valves 116-117 and flow control valve 122, and a series of fluid conduits 110, 114, 124, extending between the various components and defining a fluid flow passage for the pressurized fracturing fluid through the fracturing tree from an inlet to an outlet thereof. In embodiments of the method, at least one flow conditioning device 130 will be positioned along the fluid flow passage extending through the fracturing tree, generally being located upstream of the flow control valve.

[0152] In one embodiment of the method, the flow conditioning device 130 can be installed along a fluid conduit such as by the use of fasteners such as threaded retainer pins, bolts, etc.. as shown in FIGS. 2A-2B and 9A. In such an embodiment, the flow conditioning device can include a connector, such as a flange 134, and at least one end portion thereof. In embodiments, such as shown in FIG. 9A, the flow conditioning device can be formed as an insert and can be installed within a chamber of a spool or other conduit section, and can have a body with a T-shaped configuration including a first end portion configured to be engaged between an upstream end of the spool in which it is received and a downstream end of the upstream component 125A. The first end portion can be secured by clamping or by fasteners inserted through the corresponding connectors (e.g., flanges) of the spool and the first component. As further shown in FIG. 9A, the body can extend through the chamber 136 with the second end portion being substantially aligned / matched with an inlet opening of the downstream component 125B.

[0153] In another embodiment of the method, such as shown in FIG. 9B, the flow conditioning device 130 can be formed as an insert and can be installed within a chamber of a spool or other conduit section, and can have a body with a substantially tubular construction. The body generally will be aligned with the fluid flow passage of the pressurized fracturing fluid passing along the fluid conduit. In addition, in some embodiments, the body can have a tapered configuration (e.g., tapering slightly from its upstream to its downstream end or from its downstream to its upstream end), and can be inserted into the chamber 136 of a spool or conduit section 137 with its tapering outer side surface engaging and bearing against a corresponding tapered inner surface of the chamber. The flow conditioning device can be secured within the chamber of its spool or conduit section by the coupling of the spool to the upstream and downstream components 125A / 125B as shown in FIG. 9B.

[0154] In another embodiment of the method, such as shown in FIG. 9C, the flow conditioning device 130 can be formed as an insert and can be installed within a chamber of a spool or other conduit section, and can have a body with a substantially tubular construction. The body generally will be aligned with the fluid flow passage of the pressurized fracturing fluid passing along the fluid conduit. In addition, in this embodiment, the body is shown as having a shoulder or stepped portion 175 along its central portion. The shoulder 175 of the body 131 can be configured to seat against a corresponding shoulder 176 formed along the side wall of the chamber 37 in which the flow conditioning device is received. The flow conditioning device can be secured within the chamber of its spool or conduit section by the coupling of the spool to the upstream and downstream components 125A / 125B as shown in FIG. 9C.

[0155] Still further, in other embodiments, such as shown in FIG. 9D, the flow conditioning device can be installed as an insert received within a chamber of a spool or other conduit section, and can have a body with a substantially tubular construction. The body generally will be aligned with the fluid flow passage of the pressurized fracturing fluid passing along the fluid conduit. The flow conditioning device can be secured within the chamber of its spool or conduit section by engagement of tie-down pins that can be inserted through the body of the spool and into engagement with at least a portion of the body of the flow conditioning device (e.g., in one embodiment, adjacent the first or upstream end thereof, though other locations also can be used). The spool within which the flow conditioning device is inserted then can be secured to the upstream and downstream components 125A / 125B as shown in FIG. 9D.

[0156] In addition, in any of the embodiments of FIGS. 9A-9D illustrating methods of installation of the flow conditioning device, the flow conditioning device can comprise a replaceable insert received within an existing spool or fluid conduit section of a fluid conduit; or, in alternative embodiments, the body of the flow conditioning device can comprise a spool or conduit section and can include an internal structure configured as a replaceable insert received within an internal chamber of the body.

[0157] The configurations, numbers, arrangements and diameters of the bores can vary, and in embodiments, can be selected to divide and divert the flow of the pressurized fracturing fluid moving along the fluid flow passage F along multiple smaller flow paths 145 (FIGS. 3B, 5A-5B, 6B-7A, and 8A-9D) extending through the body 131 (and thus through a chamber 136 and along the length of a conduit, such as a spool 137 the body is received within) so as to substantially convert the turbulent flow of the pressurized fluid to a laminar flow within substantially reduced or minimized available area or within a selected distance.

[0158] For example, for a traditional frac. conduit having about a 7″ bore (e.g., traditionally about 7.062″), a flow conditioning device 130 can be provided with a body 131 that can define a fluid conduit (e.g., being configured as a spool or conduit section) or be received within an internal chamber defined by the bore of a fluid conduit, and can have a first end portion 132 including a fluid flow path inlet 138 that is aligned with and which has a diameter that substantially matches the diameter of an upstream fluid or frac. conduit, or other upstream component, from which the turbulent flow of the pressurized fracturing fluid flow is received. By way of example only, in embodiments, a flow conditioning device can be positioned between the frac. conduit 23 of the manifold assembly, or between an outlet of the cross junction 113 and an inlet of the flow control valve 122 of the injection system 101, with the fluid flow path inlet 138 thereof having a diameter D that substantially matches the diameter of the upstream fluid or frac. conduit (e.g., a diameter approximately matching a 7″ bore of a traditional frac. conduit), and will include a series of smaller diameter bores extending therethrough. In an embodiment, each of the bores can comprise a diameter of about + / −1.625″, which, together, can approximate a 7″ diameter of the frac. conduit and enable conversion of the turbulent flow of pressurized fracturing fluid to a substantially laminar flow in approximately 16.25″.

[0159] As noted, in embodiments, the number, arrangement, diameter(s) and configurations of the bores 142 can be varied. For example greater or lesser numbers of bores and the diameters thereof can be selected based on the diameter of the upstream fluid conduit from which the pressurized fracturing fluid is received into the flow conditioning device, and, in some embodiments, being substantially matched to a desired or available space or area. For example, in embodiments, where the incoming or downstream fluid conduit has a diameter of between 5″-7″ and the available space between the fluid conduit and a component such as a flow control valve of the fracturing tree is limited to, for example, about 20″-16″ or less, a flow conditioning device 130 having number of bores 142 be selected, with the bores having one or more selected diameters that together can approximate a diameter that is substantially equal to that of the diameter of the fluid conduit can be provided to provide the needed reduction in the turbulence of the turbulent flow of pressurized fracturing fluid to create a substantially laminar flow upstream or a protected component (e.g., a valve or junction), but with the length of the fluid conduit along which the flow conditioning device is located being substantially reduced to a fraction of the full length of a fluid conduit without the flow conditioning device located therealong. By way of illustration, for example, based the general industry practice of using a fluid conduit having a length of at least ten times its diameter to achieve a laminar flow, an overall length of the fluid conduit between fracturing equipment or components of the hydraulic fracturing system can be reduced to about ½, and in embodiments, to as low as about ¼th to about ⅕th of this length vs. conventional installations. The selected number of bores, their diameters, the arrangement of the bores, the use of flow obstructions and other features of the flow conditioning devices can be further adjusted to provide different reductions in length.

[0160] When positioned ahead of at least one protected component of the injection system, such as being located along at least a portion of a fluid conduit upstream from a protected component such as a fluid control valve (or other equipment), the turbulence of the flow of pressurized fracturing fluid passing into frac equipment or components, such as fluid control valves, can be greatly reduced by the flow conditioning device prolonging the life thereof. The flow conditioning device thus can provide protection for more expensive components of the fracturing tree that can be more easily serviceable and can act as a sacrificial, lower cost protective component ahead of the valves, junctions and other equipment for which greater protection from erosional wear is needed or desired.

[0161] It should be appreciated that embodiments of the flow conditioning devices may be utilized in other fluid services other than hydraulic fracturing operations. For instance, embodiments of the flow conditioning devices disclosed herein may be utilized in fluid manifolds, lines, or other fluid conveyance systems and devices for transporting pressurized fluids and other fluid services applications both inside and outside of the oil and gas industry. Some further examples can include the use of embodiments of the flow conditioning devices disclosed herein for flowing fluids for other oilfield operations (such as pump down, drilling mud delivery, production operations, etc.).

[0162] The preceding discussion is directed to various exemplary embodiments. However, one of ordinary skill in the art will understand that the examples disclosed herein have broad application, and that the discussion of any embodiment is meant only to be exemplary of that embodiment, and not intended to suggest that the scope of the disclosure, including the claims, is limited to that embodiment.

[0163] This application claims priority to and the benefit of U.S. Provisional Application No. 63 / 779,382, filed Mar. 28, 2025, titled “FLOW CONDITIONING DEVICE FOR HYDRAULIC FRACTURING SYSTEMS AND RELATED METHODS,” the disclosure of which is incorporated herein by reference in its entirety.

[0164] While exemplary embodiments have been shown and described, modifications thereof can be made by one skilled in the art without departing from the scope or teachings herein. The embodiments described herein are exemplary only and are not limiting. Many variations and modifications of the systems, apparatus, and processes described herein are possible and are within the scope of the disclosure. Accordingly, the scope of protection is not limited to the embodiments described herein, but is only limited by the claims that follow, the scope of which shall include all equivalents of the subject matter of the claims. Unless expressly stated otherwise, the steps in a method claim may be performed in any order. The recitation of identifiers such as (a), (b), (c) or (1) , (2), (3) before steps in a method claim are not intended to and do not specify a particular order to the steps, but rather are used to simplify subsequent reference to such steps.

Examples

Embodiment Construction

[0101]Embodiments of the present disclosure are directed to hydraulic fracturing systems, and various components and methods of installation and use thereof. In embodiments, the hydraulic fracturing systems can include a manifold assembly having one or more manifolds (e.g., inlet and outlet manifolds) configured to receive and transport a pressurized fracturing fluid along a flow path to an injection system or assembly, which can include one or more zipper modules and / or fracturing trees, for injection of the pressurized fracturing fluid to one or more wellbores. In various embodiments, one or more flow conditioning devices can be arranged as part of or along one or more fluid conduits or connections between the one or more manifolds and the zipper module(s), the fracturing tree(s), and / or components thereof.

[0102]In embodiments, the flow conditioning devices can be located along a trunk line, bridge or conduit upstream of a fracturing tree and / or components thereof, and will be con...

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and the benefit of U.S. Provisional Application No. 63 / 779,382, filed Mar. 28, 2025, titled “FLOW CONDITIONING DEVICE FOR HYDRAULIC FRACTURING SYSTEMS AND RELATED METHODS,” the disclosure of which is incorporated herein by reference in its entirety.BACKGROUND

[0002] During a hydraulic fracturing operation, a series of pumps supply volumes of a pressurized fracturing fluid to a wellbore or multiple wellbores for injection into a subterranean formation. The fracturing fluid is injected into the subterranean formation at a higher pressure than the fracture pressure of the subterranean formation such that the pressurized fracturing fluid creates fractures therein. The fractures increase a permeability of the subterranean formation so that fluids such as oil, gas, water, etc. may more easily escape the subterranean formation and flow to the surface via the wellbore(s). Proppants (such as sand or other solids) generally may be mixed with the pressurized fracturing fluid prior to injecting the fracturing fluid into the wellbore(s), and will flow into the fractures to hold the fractures open. The pressurized fracturing fluid is delivered to a fracturing tree or other injection equipment at the wellbore(s) through a manifold that typically has a large diameter to accommodate the volume of the pressurized fluid. As the length of the manifold is shortened, such as to provide more compact installations of the hydraulic fracturing system or at locations with limited space, the flow of the pressurized fluid becomes more turbulent. This turbulent pressurized fracturing fluid, with the proppant materials entrained therein, tends to abrade and cause erosion of the conduits, manifolds, valves and other components of the fracturing system, which can damage such components and substantially shorten the operating life thereof. This can result in premature failures or the components and require more frequent maintenance and replacement thereof, causing considerable down time of the hydraulic fracturing system as well as increased costs of maintaining and conducting the overall fracturing operation.

[0003] Accordingly, it can be seen that a need exists for hydraulic fracturing systems, including assemblies, systems and devices for controlling the flow of pressurized fracturing fluids supplied to a wellbore or wellbores, and methods of assembly and use thereof, which are directed to addressing the foregoing and other related and unrelated problems in the art.SUMMARY

[0004] Briefly described, the present disclosure is directed to aspects and embodiments of hydraulic fracturing systems and methods of installation and operation thereof. In embodiments, the hydraulic fracturing system will include a plurality of components configured for delivery of a pressurized fracturing fluid to the injection equipment at one or more wellbores for injection of the pressurized fracturing fluid into a subterranean formation. In addition, in embodiments, the hydraulic fracturing system further can include a flow conditioning device or assembly arranged between one or more components of the hydraulic fracturing system and configured for converting a turbulent flow of the pressurized fracturing fluid passing through the hydraulic fracturing system to a substantially laminar flow upstream of the wellbore(s) to protect one or more selected components of the hydraulic fracturing system from erosional wear due to the turbulent flows of the pressurized fracturing fluid, and do so within a substantially reduced or shortened distance, which can thus enable a reduction of the overall length of a fluid conduit and overall fluid flow path of the pressurized fracturing fluid from a manifold to the wellbore, which in turn can potentially enable a reduction of the overall area or footprint of the hydraulic fracturing system.

[0005] In embodiments, the flow conditioning device may be configured to convert the turbulent flow of the fracturing fluid to a substantially laminar flow within a shortened space / distance (e.g., within about ½ to ⅕th of the amount of space generally required for converting a turbulent flow passing along a manifold of the hydraulic fracturing system) before it passes through the junctions, valve(s), or other costly equipment of an injection system at a wellbore, to substantially reduce the potential effects of erosion due to erosive materials contained within the turbulent fracturing fluid flow. In addition, in embodiments, the flow conditioning device can comprise an internal structure designed to separate and / or change the flow of the pressurized fluid to substantially reduce the turbulence thereof, and in some further embodiments can include one or more replaceable and / or sacrificial wear components.

[0006] In various embodiments, the hydraulic fracturing systems can include one or more manifold assemblies that, in embodiments, can include one or more manifolds (e.g., inlet and outlet manifolds), and one or more pumping systems connected to the one or more manifold for supplying a pressurized fracturing fluid thereto. The one or more manifolds can be connected to one or more injection systems at one or more wellbores, including fracturing equipment such as zipper modules, fracturing trees (“frac tree”), or other components, that will receive the pressurized fracturing fluid and inject it into the subterranean formation. In addition, in embodiments, one or more flow conditioning devices can be arranged along one or more flow paths for the pressurized fracturing fluid extending between the various components, such as, in embodiments, at areas of transition between a fluid conduit of manifold and a conduit, junction or valve of a zipper module or frac tree at a wellbore. The flow conditioning devices will be configured for converting a turbulent flow of the pressurized fracturing fluid received from the manifold to a substantially laminar flow prior to the pressurized fracturing fluid passing into the downstream component (e.g., a valve or other component) so as to enable a significant reduction in the length of the manifold, and, in embodiments, further enabling a reduction in the overall footprint or area of the hydraulic fracturing system.

[0007] According to some aspects, a hydraulic fracturing system is provided comprising fracturing equipment or components, including at least one inlet fluid conduit along which a pressurized fracturing fluid is received and directed to an injection system for injecting the pressurized fracturing fluid into a subterranean formation through one or more wellbores. The pressurized fracturing fluid generally will be received at the injection system from the at least one inlet fluid conduit as a turbulent flow, which will subject the components of the injection system to erosional wear, which can cause faster wearing and premature failure of more sensitive, expensive components such as valves, junctions, etc. In embodiments, the hydraulic fracturing system can include one or more flow conditioning devices configured to convert a turbulent flow of a pressurized fracturing fluid to a substantially laminar flow upstream of a protected component of a fracturing tree within a substantially shortened space or distance.

[0008] In embodiments, the fracturing equipment of components of the hydraulic fracturing system can include a manifold assembly comprising inlet and outlet manifolds, with at least one outlet manifold defining the at least one fluid conduit along which a pressurized fracturing fluid is received and directed to the one or more wellbores. In embodiments, one or more pumping systems can be coupled to the at least one manifold for supplying the pressurized fracturing fluid thereto.

[0009] In embodiments, the flow conditioning device(s) configured for converting a turbulent flow of the pressurized fracturing fluid to a substantially laminar flow can be arranged along one or more fluid conduits, which define an overall fluid flow path along which the pressurized fracturing fluid is directed for injection at the wellbore. The flow conditioning device each generally will be configured with an internal structure designed to substantially reduce the turbulence of the pressurized fracturing fluid so as to convert this turbulent flow to a substantially laminar flow within a substantially shortened space.

[0010] The flow conditioning device is designed to convert the turbulent flow of the fracturing fluid to a substantially laminar flow within a shortened space / distance. For example, generally the length of the fluid conduit should be about 10 times its diameter to enable a transition from a turbulent to a laminar flow. The flow conditioning device will be configured to enable a substantial reduction in the length of the fluid conduit (e.g., by about ½ to about ⅕th the length of the fluid conduit, and, in embodiments, possibly less) along which the pressurized fracturing fluid is transported before it passes through the valve(s), junctions, or other equipment of the injection system that is more susceptible to erosion and wear and which is more costly to replace. As a result, the potential effects of erosion due to erosive materials contained within the turbulent fracturing fluid flow can be substantially reduced, extending a working life of components and reducing the need for maintenance and servicing thereof.

[0011] By way of example, in embodiments, one or more flow conditioning devices can be positioned at various locations, such as at a location or point of transition between the at least one fluid conduit of the at least one manifold and a conduit or an inlet of a junction, valve, or other component of the injection system where the pressurized fracturing fluid is transferred from the at least one fluid conduit of the manifold to the injection system. In addition, in some embodiments, one or more flow conditioning devices can be positioned between the conduits, valves, junctions, gates, etc. of a zipper module or frac tree, and in some further embodiments, multiple flow conditioning devices can be used together, for example, two or more flow conditioning devices can be arranged in series along a flow path, and can be positioned between upstream and downstream portions of various components, or can be arranged in other configurations.

[0012] In some embodiments, each flow conditioning device can comprise a body having a first or upstream end portion, a second or downstream end portion and a central portion located between the first and second end portions. For example, in embodiments, the flow conditioning device can be configured as a conduit, such as a spool, while in other embodiments, can comprise an insert configured to be received within an existing conduit of the injection system, for example within a spool, trunk line or other conduit extending between and defining a fluid flow path between adjacent components such as the fluid conduit of the manifold, valves, junctions, and / or conduits of the injection system.

[0013] In embodiments, the first and / or second end portions can include connectors adapted to couple the flow conditioning device to an adjacent component such as to another spool, a junction, conduit, valve, etc. In embodiments, the central portion can be configured to receive and convert a turbulent flow of the pressurized fracturing fluid (which can include proppant materials entrained therein) to a substantially laminar flow upstream of the wellbore.

[0014] In embodiments, the central portion of the flow conditioning device can be formed with an internal structure configured to divert and / or disrupt the turbulent flow of the pressurized fracturing fluid by creating multiple flow paths for the pressurized fracturing fluid through the flow conditioning device. In embodiments, the internal structure can be formed with or integrated within the central portion, while in some embodiments, the central portion can include a chamber in which the internal structure can be received.

[0015] For example, in embodiments, the internal structure of the central portion can include a plurality of internal bores. The bores can include different diameters and can be arranged in different patterns within the central portion and each can define a flow path having a reduced size or area along which the pressurized fracturing fluid flows.

[0016] In embodiments, the number and size of the bores can be selected to enable the pressurized fracturing fluid to flow therethrough without a significant reduction in a flow volume of the pressurized fracturing fluid. Various numbers, arrangements, and diameters of bores can be calculated to account for particle size, maximum flow area, length of chamber, etc.

[0017] In addition, in embodiments, a number of the bores, an arrangement of the bores about the chamber, a diameter of each bore, or combinations thereof, selected to convert a turbulent flow of the fracturing fluid to a substantially laminar flow of the fracturing fluid based on a diameter of the body, a length of the body, a projected particle size of particulates entrained within the fracturing fluid, a maximum flow area, or combinations thereof.

[0018] Further, in some embodiments, the flow conditioning device can comprise or can include one or more sacrificial wear components that can be formed from rubber, steel, or other erosion resistant material. For example, in embodiments, the flow conditioning device can be formed from an erosion resistant material and can be designed to be easily removed and replaced as a unit. In other embodiments, the internal structure thereof can be formed as a replaceable insert comprising a sacrificial wear component.

[0019] According to some aspects of the present disclosure, a hydraulic fracturing system can be constructed or assembled having at least one flow conditioning device configured to convert a turbulent flow of a pressurized fracturing fluid to a substantially laminar flow upstream of a protected component of a fracturing tree within a substantially shortened space or distance so as to accommodate substantial reductions in the length of the fluid flow path of the pressurized fracturing fluid required for converting the turbulent flow thereof to a substantially laminar flow. The flow conditioning device can be installed as part of the hydraulic fracturing system using a variety of installation methods and / or techniques.

[0020] For example, in embodiments, a flow conditioning device, or multiple flow conditioning devices, can be installed as part of a fluid conduit (e.g., being mounted between or within one or more components of a fluid conduit).

[0021] In embodiments, the flow conditioning can be located within a conduit section such as a spool or, in embodiments, a junction, of the fluid conduit, while in some embodiments, can include a body configured to define the fluid conduit, and will generally be located upstream of a component to be protected. For example, in embodiments, the flow conditioning device can be located along the fluid conduit extending between a first, upstream component and a second, downstream component (e.g., a protected component), and can be coupled to the first and second components attaching connectors (e.g., flanges) at the first and second ends thereof to corresponding connectors (e.g., flanges) of the adjacent components.

[0022] In some embodiments, the flow conditioning device can include a body configured to be received within a chamber or passage of a component. In some configurations, the body can be seated against a shoulder within the chamber or passage of the component.

[0023] In other embodiments, the flow conditioning device can have a body including a first or upstream end portion that can be engaged between a first component and an adjacent second component and a second or downstream end portion configured to be received within a fluid conduit upstream of the second component (e.g., a protected component). The body can be secured within the fluid conduit by attachment of connectors at the upstream and downstream ends of the fluid conduit to corresponding connectors of the first and second components.

[0024] Alternatively, in embodiments, the flow conditioning device can be located along a fluid conduit upstream from a component to be protected. For example, the flow conditioning device can comprise at least a portion of a fluid conduit extending between components of the fracturing tree, such as a junction and a valve (e.g., a protected component). In such embodiments, the body of the flow conditioning device can comprise a conduit section such as a spool or tube with an internal structure including a plurality of bores received therein, or can be configured with a tubular, T-shaped, or other construction and can be at least partially received within a conduit section such as a spool or tube of a fluid conduit..

[0025] In still other embodiments, the flow conditioning device can be engaged clamped between adjacent components, retained with pins, tie-down devices, threaded retainers, or other detachable connectors.

[0026] According to an aspect of the present disclosure, a flow conditioning device comprises a body comprising: a first end portion; a second end portion; and a central portion extending between the first end portion and the second end portion, the central portion having a plurality of longitudinally extending bores, each of the bores configured to define a flow path through the body; wherein the body is configured to: (a) be positioned between an upstream component and a downstream component with the central portion aligned with a flow passage of the upstream component such that a portion of a fracturing fluid moving along the flow passage of the upstream component is received though one or more of the bores; and (b) have a number of the bores, an arrangement of the bores about the central portion, a diameter of each bore, or combinations thereof, selected to convert a turbulent flow of the fracturing fluid to a substantially laminar flow of the fracturing fluid based on a diameter of the body, a length of the body, a projected particle size of particulates entrained within the fracturing fluid, a maximum flow area, or combinations thereof.

[0027] In embodiments, at least one of the first and second end portions of the body comprises a connector configured for coupling to a corresponding connector of the upstream component, the downstream component or a combination thereof.

[0028] In embodiments, each of the first and second end portions comprises a flange having a diameter greater than an overall diameter of the central portion and configured for coupling the body to the upstream component and to the downstream component.

[0029] In embodiments, the central portion further comprises an insert received within a chamber of the central portion and along which the bores extend; and wherein the insert comprises an erosion resistant material.

[0030] In embodiments, the insert is configured as a replaceable sacrificial wear component.

[0031] In embodiments, the erosion resistant material of the insert comprises rubber, metal, metal alloys, ceramic materials, or combinations thereof.

[0032] In embodiments, the plurality of bores comprises at least one bore extending approximately through a center of the central portion, and a series of bores arranged about a periphery of the central portion.

[0033] In embodiments, at least some of the bores have a first bore diameter, and at least some of the bores have a second bore diameter that is different from the first bore diameter.

[0034] In embodiments, the body comprises a substantially T-shaped configuration, a tapered configuration, a substantially straight configuration, an offset configuration, or a substantially I-shaped configuration.

[0035] In embodiments, the body is configured to be received within a chamber of a conduit positioned between the upstream and downstream components.

[0036] In embodiments, the body further comprises one or more screens, one or more flow diverters, tapering bores, different size bores, different arrangements of bores, different configurations of bores, or combinations thereof.

[0037] In embodiments, one or more of the bores comprise a substantially straight configuration, an inwardly tapering configuration, an expanding configuration, or combinations thereof.

[0038] According to another aspect, a hydraulic fracturing system comprises: a first component; a second component; a conduit positioned between the first and second components and configured to transport a fracturing fluid from the first component to the second component; wherein a fluid flow path along which a fracturing fluid is supplied to a wellbore is defined between the first component, the second component, and the conduit; and at least one flow conditioning device positioned along the fluid flow path, the flow conditioning device comprising: a body having a first end portion, a second end portion, and a plurality of bores extending longitudinally though the body; wherein each of the bores defines a separate flow path through the body; wherein each of the plurality of bores is configured to receive a portion of the fracturing fluid flowing through the conduit so as to substantially reduce a turbulence of the fracturing fluid; and wherein a diameter of each of the plurality of bores, a number of the plurality of bores, an arrangement of the plurality of bores, or combination thereof, are selected to create a substantially laminar flow of the fracturing fluid within a substantially reduced length of an overall flow path of the fracturing fluid between the first and second components, prior to introduction of the fracturing fluid into the second component.

[0039] In embodiments, the first component comprises a fluid conduit of a manifold and the second component comprises a valve.

[0040] In embodiments, the body includes an internal structure received within a chamber defined along the body and through which the plurality of bores is formed.

[0041] In embodiments, the internal structure is configured as a sacrificial wear component.

[0042] In embodiments, the plurality of bores comprises at least one central bore extending along a longitudinally extending center axis of the body, and a series of bores arranged about the central bore.

[0043] In embodiments, at least some of the bores have a first bore diameter, and at least some of the bores have a second bore diameter that is different from the first bore diameter.

[0044] In embodiments, at least one of the first and second end portions of the body includes a connector configured to couple to a corresponding connector of the first component or the component with pins, threaded fasteners, locking features, or combinations thereof.

[0045] In embodiments, the body of the flow conditioning device is configured to be at least partially received within the conduit.

[0046] In embodiments, the second end portion of the body has a first diameter and is configured to be received along a chamber extending through the conduit, and the first end portion of the body has a second diameter that is greater than the first diameter and is configured to seat against an upstream end of the conduit so as to be engaged between an inlet of the conduit and an outlet of the first component.

[0047] In embodiments, the body of the flow conditioning device is configured to be received within the conduit and is releasably retained within the conduit by pins, fasteners, threaded retainers, or combinations thereof.

[0048] In embodiments, at least one flow conditioning device comprises a plurality of flow conditioning devices positioned at selected locations along the fluid flow path between the first and second components.

[0049] In embodiments, the plurality of flow conditioning devices comprises at least one flow conditioning device having a first length and at least one flow conditioning device having a second length that is different from the first length.

[0050] In embodiments, the flow conditioning devices of the plurality of flow conditioning devices comprise different arrangements of bores, different sizes of bores, different configurations of bores, different numbers of bores, screens, flow diverters, or combinations thereof.

[0051] According to still another aspect, a system comprises: at least one manifold configured to receive and direct a fracturing fluid along a fluid flow passage; at least one fracturing tree located downstream from the at least one manifold, the at least one fracturing tree having an inlet connected to the manifold at an outlet connected to a wellbore; wherein the at least one fracturing tree is configured to receive the fracturing fluid from the at least one manifold and direct the fracturing fluid to the wellbore for injection into a wellbore; and at least one flow conditioning device positioned between adjacent components of the at least one fracturing tree, the at least one flow conditioning device comprising: a body including a plurality of bores, each of the bores defining a flow path extending through the body; and wherein the bores are configured to create a substantially laminar flow of the fracturing fluid within a substantially reduced length of an overall fluid flow path of the fracturing fluid passing through the at least one manifold and the at least one fracturing tree, prior to introduction of the fracturing fluid into the wellbore.

[0052] In embodiments of the system, the body of the at least one flow conditioning device is configured as an insert configured to be received within a component of the at least one fracturing tree.

[0053] In embodiments of the system, the body comprises a corrosion resistant material replaceable wear resistant material, or a combination thereof.

[0054] In some embodiments of the system, the body includes a replaceable internal structure through which the plurality of bores are formed.

[0055] In embodiments of the system, the at least one flow conditioning device comprises two or more flow conditioning devices arranged in series between the at least one manifold and the at least one fracturing tree.

[0056] In embodiments of the system, at least one of the two or more flow conditioning devices has a first length and another one of the two or more flow conditioning devices has a second length; and wherein the second length is greater than the first length.

[0057] In embodiments of the system, a number of the bores extending through the body, an arrangement of the bores within the body, a diameter of each bore, a taper of each bore, or combinations thereof, are selected to convert a turbulent flow of the fracturing fluid to the substantially laminar flow of the fracturing fluid based on a diameter of the body, a length of the body, a projected particle size of particulates entrained within the fracturing fluid, a maximum flow area, or combinations thereof.

[0058] In embodiments of the system, one or more of the bores include one or more screens, one or more fins, one or more geometric objects, or combinations thereof, positioned along a length of the one or more bores.

[0059] In embodiments of the system, one or more bores comprise a substantially straight configuration, an inwardly tapering configuration, an expanding configuration, or combinations thereof.

[0060] In embodiments of the system, the body is configured to be received within an internal passage of a conduit; and wherein the body comprises an erosion resistant material including rubber, metal, metal alloys, ceramic materials, or combinations thereof.

[0061] In embodiments of the system, the plurality of bores comprises two or more bores having a different diameter; and wherein the bores are arranged with at least one bore extending approximately through a center of the body, and a series of bores arranged about the at least one bore.

[0062] In embodiments of the system, the body comprises a spool including a first flange at a first end and a second flange at a second end; and wherein each of the first and second flanges is configured to couple the body to an adjacent spacer, cross flow junction, manifold, valve, or combinations thereof.

[0063] In embodiments, the system further comprises one or more pumping units connected to the at least one manifold for supplying fracturing fluid under pressure to the at least one manifold.

[0064] According to a further aspect, a method comprises: assembling a manifold at a hydraulic fracturing site; wherein the manifold is configured to receive and deliver a fracturing fluid to a fracturing tree during a hydraulic fracturing operation; and connecting an outlet of the manifold to an inlet of at least one fracturing tree coupled to a wellbore at the hydraulic fracturing site; and locating at least one flow conditioning device along a fluid flow path of the fracturing fluid extending from the manifold through the at least one fracturing tree; wherein the at least one flow conditioning device comprises: a body having a plurality of bores, each of the bores defining a flow path extending through the body parallel to the fluid flow path of the fracturing fluid; and wherein the bores are configured to create a substantially laminar flow of the fracturing fluid within a substantially reduced length of the fluid flow path along which the fracturing fluid is transported prior to introduction of the fracturing fluid into at least one fracturing tree.

[0065] In embodiments of the method, locating the at least one flow conditioning device comprises inserting the body into a chamber of a conduit positioned between adjacent components of the fracturing tree such that the fracturing fluid is converted to a substantially laminar flow upstream of the wellbore.

[0066] In some embodiments of the method, the at least one flow conditioning device is positioned between a junction and a valve of the fracturing tree.

[0067] In some embodiments of the method, the body of the at least one flow conditioning device comprises a first section and a second section, the first section having a diameter that is larger than a diameter of the second section so as to define a shoulder portion configured to seat against a corresponding shoulder portion of the chamber of the conduit.

[0068] In embodiments, the method further comprises inserting one or more retainers, tie-down pins, fasteners, or combinations thereof into the body of the at least one flow conditioning device to substantially secure the body of the at least one flow conditioning device within the conduit.

[0069] In embodiments of the method, the chamber of the conduit comprises a tapered bore and the body of the at least one flow conditioning device comprises a corresponding tapering configuration adapted to seat within the tapered bore of the chamber.

[0070] In embodiments of the method, the body of the at least one flow conditioning device can comprise a first end portion and a second end portion, and a central portion extending between the first and second end portions; and further coupling connectors of the first and second end portions to corresponding connectors of adjacent upstream and downstream components of the fracturing tree.

[0071] In embodiments of the method, the body further comprises a replaceable internal structure received within the central portion and through which the plurality of bores extends; and further comprising removing the internal structure from the body and inserting a new internal structure.

[0072] According to another aspect, a flow conditioning device comprises: a body comprising a plurality of longitudinally extending bores, each of the bores configured to define a flow path through the body; wherein the body is configured to: (a) be positioned between an upstream component and a downstream component and aligned with a fluid flow path extending between the upstream component and the downstream component such that a portion of a fracturing fluid moving along the fluid flow path is received though one or more of the bores; and (b) have a number of the bores, an arrangement of the bores about the, a diameter of each bore, or combinations thereof, selected to convert a turbulent flow of the fracturing fluid to a substantially laminar flow of the fracturing fluid based on a diameter of the body, a length of the fluid flow path, a projected particle size of particulates entrained within the fracturing fluid, a maximum flow area, or combinations thereof.

[0073] In embodiments of the flow conditioning device, the body further comprises a connector located at a first end thereof, the connector configured for coupling to a corresponding connector of the upstream component.

[0074] In embodiments of the flow conditioning device, the body further comprises an internal structure configured as an insert received within a chamber of the body and along which the bores extend; and wherein the internal structure comprises an erosion resistant material.

[0075] In embodiments of the flow conditioning device, the internal structure is configured as a replaceable sacrificial wear component.

[0076] In embodiments of the flow conditioning device, the erosion resistant material of the internal structure comprises rubber, metal, metal alloys, ceramic materials, or combinations thereof.

[0077] In embodiments of the flow conditioning device, the plurality of bores comprises at least one bore extending approximately through a center of the central portion, and a series of bores arranged about the at least one bore.

[0078] In embodiments of the flow conditioning device, at least some of the bores have a first bore diameter, and at least some of the bores have a second bore diameter that is different from the first bore diameter.

[0079] In embodiments of the flow conditioning device, the body comprises a substantially T-shaped configuration, a tapered configuration, a substantially straight configuration, an offset configuration, or a substantially I-shaped configuration.

[0080] In embodiments of the flow conditioning device, the body is configured to be received within a chamber of a conduit positioned between the upstream and downstream components.

[0081] In embodiments of the flow conditioning device, the body includes a second end portion having a first diameter and configured to be received along the chamber extending through the conduit, and a first end portion having a second diameter that is greater than the first diameter and configured to seat against an upstream end of the conduit so as to be engaged between an inlet of the conduit and an outlet of the upstream component.

[0082] In embodiments of the flow conditioning device, the body further comprises one or more screens, one or more flow diverters, tapering bores, different size bores, different arrangements of bores, different configurations of bores, or combinations thereof.

[0083] In some embodiments of the flow conditioning device, the body is configured as a spool having a first end portion, a second end portion and a central portion through which the plurality of bores extend.

[0084] In various embodiments of the flow conditioning device, one or more of the bores comprise a substantially straight configuration, an inwardly tapering configuration, an expanding configuration, or combinations thereof.

[0085] In embodiments of the flow conditioning device, at least one of the first and second end portions of the body includes a connector configured to couple to a corresponding connector of the upstream component or the downstream component with pins, threaded fasteners, locking features, or combinations thereof.

[0086] Various other aspects, features, and advantages of a hydraulic fracturing system, including one or more flow conditioning devices configured for converting a turbulent flow of a pressurized fracturing fluid to a substantially laminar flow of the pressurized fluid along a substantially reduced space or distance so as to substantially shorten the length of the fluid flow path along which the pressurized fracturing fluid is delivered to a wellbore, and methods of use thereof according to exemplary embodiments thereof are discussed herein. The embodiments described herein comprise a combination of features and characteristics intended to address various shortcomings associated with certain prior devices, systems, and methods.

[0087] Moreover, it is to be understood that both the foregoing information and the following detailed description provide merely illustrative examples of various aspects and embodiments and are intended to provide an overview or framework for understanding the nature and character of the claimed aspects and embodiments. It further should be appreciated that this disclosure may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes as the disclosed embodiments, and that such equivalent constructions do not depart from the spirit and scope of the principles disclosed herein. Accordingly, these and other aspects, along with advantages and features of the present disclosure, will become apparent through reference to the following description and the accompanying drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0088] The accompanying drawings, which are included to provide a further understanding of the embodiments of the present disclosure, are incorporated in and constitute a part of this specification, illustrate embodiments of the present disclosure, and together with the detailed description, serve to explain principles of the embodiments discussed herein. No attempt is made to show structural details of this disclosure in more detail than may be necessary for a fundamental understanding of the embodiments discussed herein and the various ways in which they may be practiced. According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate embodiments of the disclosure. For a detailed description of various embodiments, reference will now be made to the accompanying drawings in which:

[0089] FIG. 1 is a schematic diagram of a hydraulic fracturing system including a manifold.

[0090] FIG. 2A is a perspective view of an example embodiment of a fracturing tree of the hydraulic fracturing system of FIG. 1, including one or more flow conditioning devices configured to facilitate the conversion of a turbulent flow of a pressurized fluid to a substantially laminar flow in accordance with the principles of the present disclosure.

[0091] FIG. 2B is an exploded perspective view of the fracturing tree of FIG. 2A, illustrating a series of flow conditioning devices configured to facilitate the conversion of a turbulent flow of a pressurized fluid to a substantially laminar flow located between various components of the fracturing tree in accordance with the principles of the present disclosure.

[0092] FIG. 3A is a perspective view of an example embodiment of a flow conditioning device configured to facilitate the conversion of a turbulent flow of a pressurized fluid to a substantially laminar flow in accordance with the principles of the present disclosure.

[0093] FIG. 3B is a side elevational view taken in partial cross-section of an embodiment of a flow conditioning device configured to facilitate the conversion of a turbulent flow of a pressurized fluid to a substantially laminar flow such as shown in FIG. 3A in accordance with the principles of the present disclosure.

[0094] FIGS. 4A-4C illustrate additional embodiments of flow conditioning devices configured to facilitate the conversion of a turbulent flow of a pressurized fluid to a substantially laminar flow, including different arrangements, numbers and diameters of bores thereof in accordance with the principles of the present disclosure.

[0095] FIG. 5A is a side elevational view schematically illustrating an example embodiment of a fracturing tree, including embodiments of flow conditioning devices configured to facilitate the conversion of a turbulent flow of a pressurized fluid to a substantially laminar flow and having different internal structures in accordance with the principles of the present disclosure.

[0096] FIG. 5B is a side elevational view schematically illustrating another example embodiment of a fracturing tree, including embodiments of flow conditioning devices configured to facilitate the conversion of a turbulent flow of a pressurized fluid to a substantially laminar flow and having different internal structures in accordance with the principles of the present disclosure.

[0097] FIGS. 6A-6B are cross-sectional side elevational views schematically illustrating an example embodiments of flow conditioning devices configured to facilitate the conversion of a turbulent flow of a pressurized fluid to a substantially laminar flow and having tapering internal structures in accordance with the principles of the present disclosure.

[0098] FIGS. 7A-7B illustrate an embodiment of a flow conditioning device including a flow obstruction including a screen at least one end thereof for further facilitating the conversion of a turbulent flow of a pressurized fluid to a substantially laminar flow in accordance with the principles of the present disclosure.

[0099] FIGS. 8A-8C illustrate example embodiments of arrangements of flow conditioning devices arranged as part of or within a fluid conduit assembly and configured to facilitate the conversion of a turbulent flow of a pressurized fluid to a substantially laminar flow in accordance with the principles of the present disclosure.

[0100] FIGS. 9A-9D schematically illustrate various example embodiments of mounting arrangements of flow conditioning devices configured to facilitate the conversion of a turbulent flow of a pressurized fluid to a substantially laminar flow as part of or along a fluid conduit, in accordance with the principles of the present disclosureDETAILED DESCRIPTION

[0101] Embodiments of the present disclosure are directed to hydraulic fracturing systems, and various components and methods of installation and use thereof. In embodiments, the hydraulic fracturing systems can include a manifold assembly having one or more manifolds (e.g., inlet and outlet manifolds) configured to receive and transport a pressurized fracturing fluid along a flow path to an injection system or assembly, which can include one or more zipper modules and / or fracturing trees, for injection of the pressurized fracturing fluid to one or more wellbores. In various embodiments, one or more flow conditioning devices can be arranged as part of or along one or more fluid conduits or connections between the one or more manifolds and the zipper module(s), the fracturing tree(s), and / or components thereof.

[0102] In embodiments, the flow conditioning devices can be located along a trunk line, bridge or conduit upstream of a fracturing tree and / or components thereof, and will be configured to facilitate the conversion of a turbulent flow of a pressurized fracturing fluid to a substantially laminar flow within a substantially reduced length or distance so as to enable a substantial reduction in an overall area or space required for the various components of the hydraulic fracturing system and thus potentially a reduction in the overall area or size required for the hydraulic fracturing system, while protecting components of the fracturing tree(s), such as valves, junctions, and other more expensive components, from wear and erosion, to help prolong the operational life thereof.

[0103] As will be understood, the terms “pressurized fracturing fluid,”“fracturing fluid,”“pressurized fluid,” and “fluid” may be used interchangeably throughout the present disclosure to refer to a fluid injected into a wellbore during operation of embodiments of the hydraulic fracturing systems of the present disclosure.

[0104] As used herein, the terms “comprises,”“comprising,”“includes,”“including,”“has,”“having,” or any other variation thereof, and are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but may include other features not expressly listed or inherent to such process, method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive-or and not to an exclusive-or.

[0105] Dimensional information in the following description should be understood as nominal dimensions that are intended to encompass variations in dimensions that normally occur in the pumping systems and components thereof such as described herein. Terms such as “approximately,”“about,” and “substantially” may be used to qualify dimensional information in the following description but such qualifications are intended merely to reinforce that the dimensions are nominal dimensions and not to differentiate qualified dimensions from unqualified dimensions.

[0106] Also, the terms “couple,”“linked,” and “connect” and any variations thereof will be understood to cover both indirect and direct connections between one or more parts or elements.

[0107] The terminology used herein is for the purpose of description only and is not intended to be limiting of the present disclosure. Spatially relative terms, such as “beneath,”“below,”“lower,”“above,”“upper,” and the like may be used herein for ease of description to describe one element's or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the exemplary term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (e.g., rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0108] In addition, the terms “axial” and “axially” generally mean along or substantially parallel to a given axis (e.g., central axis of a body or a port), while the terms “radial” and “radially” generally mean substantially perpendicular to or extending at a tangent to a given axis.

[0109] As used herein, the singular forms “a,”“an,” and “the” are intended to include the plural forms as well, unless the context indicates otherwise. It will be further understood that the terms “comprises” and / or “comprising” specify the presence of stated features, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof.

[0110] FIG. 1 shows a schematic diagram of a hydraulic fracturing system 10 including various fluid conveyance devices along which flows of a relatively high-pressure fracturing fluid are supplied to one or more injection systems 100 connected to a wellbore 103 extending into a subterranean formation 102. It should be appreciated that the hydraulic fracturing system 10 shown in FIG. 1 schematically depicts some components and assemblies that may be used during a hydraulic fracturing operation, and that in some embodiments additional or fewer components may be used within the hydraulic fracturing system 10. Thus, the particular combination and / or arrangement of components of the system 10 depicted in FIG. 1 is not limiting to other potential embodiments of hydraulic fracturing system 10.

[0111] For instance, in embodiments, the hydraulic fracturing assembly 10 can include a manifold assembly 20, which can include one or more manifolds 22 (e.g., one or more inlet manifolds and one or more outlet manifolds) that each define or include a frac. conduit 23 configured to deliver the pressurized fracturing fluid received from one or more pumping units 40 to an injection system 100. Such manifolds sometimes can be referred to as “missiles,” and in embodiments, can comprise monobore type manifolds with a single fluid conduit, while in other embodiments, can have other configurations including more than one fluid conduit.

[0112] In embodiments, each manifold of the manifold assembly 20 also may include one or more junctions 24 through which the pressurized fracturing fluid is received into the manifold. In an example embodiment, such as shown in FIGS. 2A-2B, a manifold 22 (e.g., an outlet manifold of the manifold assembly 20) will be connected to one or more injection systems 100 located at a wellhead for supplying the pressurized fracturing fluid thereto. In embodiments, the injection system 100 can comprise one or more zipper modules 95 and / or one or more fracturing trees 101 (which also can be referred to as a “frac tree” or a “Christmas tree”), configured for injection of the pressurized fracturing fluid into the subterranean formation 102 via the wellbore as indicated at 103 in FIG. 1.

[0113] In addition, in embodiments, the hydraulic fracturing system 10 generally can include a plurality of storage vessels 12 that are each configured to hold a volume of fracturing fluid therein. The fracturing fluid stored in the storage vessels 12 may include any liquid or semi-liquid (such as a gel) that is suitable for injection into and fracturing of the subterranean formation 103 as previously described. In some embodiments, the fracturing fluid includes an aqueous solution including substantially pure water or water mixed with one or more additives (such as gels or gelling agents, chemicals, etc.). The storage vessels 12 may include any suitable container for holding a volume of fluids (such as liquids) therein. For instance, in some embodiments, storage vessels may include rigid tanks, flexible tanks (such as bladders), open pits, mobile tanks (that may be pulled by a tractor trailer or other vehicle), or a combination thereof.

[0114] A blender 14 can be positioned downstream of the storage vessels 12 that is configured to mix a proppant into the fracturing fluid. The proppant may include sand or other suitable solids. As previously described, the proppant is configured to flow into the fractures within the subterranean formation 102 so as to hold the fractures open after the hydraulic fracturing operation has ended. In some embodiments, additives (such as chemical additives) may be mixed into the fracturing fluid within the blender 14 either in addition or alternatively to the proppant. The blender 14 emits the fracturing fluid, now with proppant mixed therein, to a manifold assembly 20 that communicates the fracturing fluid to and from a plurality of pumping units 40.

[0115] In various embodiments, the manifolds 22 of the manifold assembly 20 include at least one inlet manifold and at least one outlet manifold. However, in other embodiments, different numbers, arrangements, and combinations of inlet manifolds and outlet manifolds may be utilized, such as, for instance, a single outlet manifold, a plurality of outlet manifolds, a single inlet manifold, or a plurality of inlet manifolds. For example, in embodiments, a plurality of inlet conduits 30 can connect at least one inlet manifold at least one to of the pumping units 40. In addition, a plurality of outlet conduits 28 can connect the plurality of pumping units 40 to at least one outlet manifold.

[0116] Each pumping unit 40 can include at least one pump 44 driven by a driver 42 (which may be referred to herein as a “prime mover”). Pump 44 may include any suitable fluid pumping device or assembly for pressurizing the fracturing fluid (with or without proppant and / or other additives entrained therein) to the pressures associated with a hydraulic fracturing operation. For instance, in some embodiments, the pump 44 may be configured to pressurize the fracturing fluid (again, with or without proppant and / or other additives entrained therein) to a pressure of about 9000 pounds per square inch (psi) or higher, and may be referred to herein as a “hydraulic fracturing pump”44.

[0117] In some embodiments, pump 44 may include a positive displacement pump, centrifugal pump, or other suitable pump types. Each driver 42 may include any suitable motor or engine that is configured to drive or actuate the corresponding pump 44 during operations. For instance, in some embodiments, each driver 42 may include a diesel engine, a turbine (such as a gas turbine, steam turbine, etc.), an electric motor, or some combination thereof. During operations, within each pumping unit 40, the driver 42 may drive its associated pump 44 to draw fracturing fluid F into the pump 44 via the corresponding inlet conduit 30 and to pressurize and output the fracturing fluid from the pump 44 via the corresponding outlet conduit 28.

[0118] During a hydraulic fracturing operation, a pressurized fracturing fluid is pumped from the pumping units 40 to the manifold assembly 20, generally being received by an outlet manifold 22 via the outlet conduits 28. The outlet manifold 22 directs the pressurized fracturing fluid toward an injection system 101 at a wellhead for injection into the subterranean formation 102 as previously described. The fracturing fluid further may be emitted from the wellbore 103 via the wellhead and recycled back to the storage vessels 12 through one or more recycle conduits 16. In some embodiments, the fracturing fluid output from the wellhead 103 may be routed through one or more filtering or separation assemblies or devices (not shown) to remove additives, proppant, and / or other fluids or solids (such as, rock chips, formation fluids, etc.) that may be entrained within the fracturing fluid, prior to recycling the fracturing fluid to the storage vessels 12.

[0119] In embodiments of the hydraulic fracturing system 10 as shown in FIGS. 2A-2B, the outlet manifold 22 can include an elongate frac. conduit 23 connecting the outlet manifold 22 to the injection system 100. In embodiments, the manifold 22 can have an upstream end, a plurality of tubular sections 22a with a plurality of junctions 24 interleaved therebetween and defining one or more fluid inlets, and a downstream end coupled to the frac. conduit 23, which is in fluid communication with the injection system 100. The frac. conduit 23 can have a flow passage 50 defined therethrough, extending along a longitudinal central axis 55 and along which a pressurized fracturing fluid is received and is directed for supplying the pressurized fracturing fluid to the injection system 100. As used herein, the terms “upstream” and “downstream” denote a general flow direction of fracturing fluid during hydraulic fracturing operations, according to some embodiments.

[0120] In an example embodiment of the hydraulic fracturing system 10 as shown in FIGS. 2A-2B, the injection system 100 can include a fracturing tree 101 having various components and configured to inject the pressurized fracturing fluid through the wellbore 103 and into the subterranean formation. In addition, in some example embodiments such as illustrated in FIGS. 2A-2B, the injection system further can include at least one zipper module 95 between the frac. conduit 23 and the fracturing tree 101.

[0121] In a typical hydraulic fracturing operation, large volumes of fluids, which further contain proppant materials such as sand and other particulates, are pumped through the manifold and supplied to one or more fluid conduits and into the well bore(s) 103 at high pressures and rates. The fluid conduits generally have diameters of, for example, 5″ 7″ or possibly greater, to accommodate the high flow rates needed for a fracturing operation. The high pressures and high volume of the pressurized fracturing fluids passing though the conduits creates a turbulent flow that is responsible for substantially most of the erosional wear and tear on fracturing equipment, which can lead to premature failure of such equipment of components, shortening their operational life and increasing maintenance and service costs. It therefore is important to reduce the turbulence of the pressurized fluid flows as much as possible and create a substantially laminar flow to reduce such erosional wear.

[0122] It has been recognized that the length of the conduits supplying the pressurized fracturing fluid to the injection systems should be at least about ten times the diameter of the conduit to provide a sufficient length of a flow path to achieve to achieve laminar flow at which point erosional wear is believed to be sufficiently reduced. For a 7″ diameter conduit, the length of the conduit should be at least 70″-84″ (e.g., generally at least about 6-7 feet in length). However oftentimes the space available is much less, for example, limiting the length of the conduits to only about 16″ in length, leaving insufficient space to reduce the turbulent flows of the pressurized fracturing fluid to create the desired laminar flow and therefore exposing the fracturing equipment of components to substantial erosional wear.

[0123] For some fracturing equipment or components, the increased erosion and wear created by the turbulent flows due to the smaller space constraints has been viewed as acceptable collateral damage for lower cost and easier serviceable components such as spools and other fluid conduits and cross junctions. However, for more expensive components such as frac valves, such increased erosional wear can lead to significant costs increases and more downtime for servicing and premature replacement of such components. In addition, the frac valves themselves have been reduced substantially in length (e.g., from 39″ or more to 17″), further shortening the length of the fluid flow path of the pressurized fracturing fluid through the fracturing tree, and increasing the exposure to erosional wear.

[0124] As illustrated in FIGS. 2A-2B, in embodiments, the injection system 100 can include a zipper module 95 or multiple zipper modules, while in other embodiments, a zipper module may not be used. In an example embodiment, the zipper module 95 such as shown in FIGS. 2A-2B, can be positioned between the frac. conduit 23 and the fracturing tree 101 and can receive the pressurized fracturing fluid form the conduit and transfer the pressurized fracturing fluid along a fluid flow path indicated at 105, to the fracturing tree. In embodiments, the zipper module can include a first cross or junction 96, a fluid conduit 97 (which can be formed as a spool) connecting the first cross or junction to a second cross or junction 98, and a spacer spool or conduit 99 that is configured to couple to an upstream or inlet fluid conduit 110 of the fracturing tree 101. Other configurations of a zipper module 95 also can be provided.

[0125] As further illustrated in FIGS. 2A-2B, in embodiments, fracturing tree 101 of the injection system 100 can include a junction 111 connected to the upstream fluid conduit 110. For example, in embodiments, the fluid conduit 110 can include one or more spools 112 coupled together in series so as to define an elongated fluid conduit 110 extending between the cross or junction 98 of the zipper module 95 and the junction 111 of the fracturing tree 101. The junction 111 further can be connected to a cross junction 113 by a downstream fluid conduit 114. In embodiments, one or more valves, such as more or hydraulic gate valves 116 (or other actuator driven valves) and one or more manual valves 117 can be coupled to opposite lateral sides 118 of the cross junction 113, as illustrated in FIG. 2B.

[0126] As further illustrated in FIG. 2A, an outlet fluid conduit 119 can be coupled to a downward side of the cross junction 113 into a bore tube or pipe 121 of the wellbore 103 for delivery of the pressurized fracturing fluid into the wellbore. In embodiments, a flow control valve 122 (e.g., a gate valve or other valve) can be positioned between the cross junction 113 and the pipe 121 of the wellbore 103 along the fluid flow path 105 extending through the fracturing tree 101 to the wellbore 103. In embodiments, the valve 122 can be connected to the cross junction 113 by one or more spools 123 defining a fluid conduit 124, and to the pipe 121 of the wellbore 103 by one or more spools 126 defining a fluid conduit 128. Other configurations of fracturing trees also can be provided.

[0127] As illustrated in FIG. 2B, in embodiments, at least one flow conditioning device 130 can be positioned between various frac. equipment or components of the hydraulic fracturing system 10, such as being mounted within or located along a trunk line, bridge or conduit extending between a first component 125A and a second component 125B of the hydraulic fracturing system 10, as indicated in FIGS. 9A-9D. For example, in some embodiments, such components 125A / 125B can include the frac. conduit 23 (FIGS. 2A-2B) of the manifold assembly of the hydraulic fracturing system and the injection system 100 or the zipper module, or along a conduit 110 extending between the zipper module 95 and the fracturing tree 101 such that the at least one flow conditioning device is positioned ahead of the fracturing tree 101 (e.g., as indicated in FIGS. 5A and 5B).

[0128] In some embodiments, the first and second components can include one or more adjacent components of the fracturing tree 101 (FIGS. 2A-2B, and 5A-5B), such as a junction and one or more of the valves (e.g., at least one flow conditioning device can be located along the fluid flow path between a first, lower cost component 125A (FIGS. 9A-9B), such as a spool or other conduit section, and a second, greater cost component 125A such as the flow control valve 122 or other more component for which greater protection from erosion is needed or required). In such embodiments, at least one flow control device 130 can be positioned along a fluid flow path F of the pressurized fracturing fluid through the injection system, for example, being positioned within or in-line with any of the fluid conduits 110, 114, 124, and / or 128 (FIGS. 2A-2B) of the fracturing tree (each of which fluid conduits can also be referred to as a frac. conduit) located along the fluid flow path extending from the inlet of the fracturing tree to its outlet at the wellbore 103.

[0129] In embodiments, the flow conditioning device(s) 130 will be configured to provide a reduction in turbulence of the incoming pressurized fluid flow so as to convert the turbulent flow of the pressurized fracturing fluid to a substantially laminar flow upstream of the fracturing tree and / or the valves and other more expensive components or equipment of the fracturing tree (e.g., the junctions or valves), while also enabling a substantial reduction of a length of the conduits supplying the pressurized fracturing fluid and an overall fluid flow path of the pressurized fracturing fluid. Thus, the flow conditioning device 130 can help prolong an operational life and reduce required maintenance and servicing of such more expensive components, which can further reduce costs of operation and downtime of the hydraulic fracturing system.

[0130] For example, in embodiments, one or more flow conditioning devices 130 can be positioned along and / or mounted within the inlet fluid conduit 110 extending between the cross or junction 98 of the zipper module 99 and the junction 111 of the fracturing tree, between the junction 111 and the cross junction 113 of the fracturing tree, between the cross junction and the valve 122 of the fracturing tree, or any combinations thereof. In some embodiments, such as shown in FIGS. 2B, 5B and 8A-8C, multiple flow conditioning devices 130 can be located along one or more of the fluid conduits, including having multiple flow conditioning devices arranged in series or spaced on one or both sides of a spool or other conduit section.

[0131] In embodiments, such as shown in FIGS. 3A-3B, 5A-7A, and 8A-9D, the flow conditioning device 130 generally can include a body 131 having a first or upstream end portion 132 and a second or downstream end portion 133, with a central portion 135 extending therebetween. In some embodiments, such as generally illustrated in FIGS. 6A-6B and 8A-8B, the body 131 of each flow conditioning device 133 can be formed as a spool or conduit having a central portion 135 that can be of a smaller diameter than the first and second end portions 132 / 133, and which can be mounted between first and second or upstream and downstream components of the injection system, such as, for example, between the junction 98 of a zipper module 95 and junction 111 of the fracturing tree or between the cross junction 113 and valve 122 of the fracturing tree.

[0132] As shown in FIGS. 2B-3B, and 5A-7A, in embodiments, one or both of the first and second end portions 132 / 133 of the body 131 of the flow conditioning device can be configured with a connector such as a flange 134. The flange 134 can be configured to be coupled to a corresponding connector (e.g., a corresponding flange) of the adjacent first or upstream component 125A (FIG. 9A) and / or the second or downstream component 125B, for example, in some embodiments, including a plurality of fastener openings 139A for receiving threaded retainer pins, bolts, or other fasteners 139B, such as indicated in FIG. 3B.

[0133] In embodiments, the flow conditioning device can include an internal structure 140 that can be received within a chamber 141 of the body 131, such as shown in FIGS. 3A-3B, 6A-6B and 8A-8B. In some embodiments, the body 131 can comprise an internal structure that can be formed as an insert configured to be received within a chamber 136 of a conduit such as a spool 137, while in other embodiments, the body can include or comprise an internal structure 140 of a conduit section such as a spool 137 of a fluid conduit (e.g., one or more of fluid conduits 110, 114, 124). In such embodiments, as shown in FIGS. 3A and 9A-9D, the body can be configured as a sleeve or tubular component adapted to be received within a chamber 136 of a conduit section such as a spool 137 and can extend therethrough. For example, as shown in FIGS. 9A-9D, in embodiments, the flow conditioning device can comprise a tubular body 131 configured to fit into a traditional bore of a fluid conduit (e.g., a fluid conduit such as shown at 110, 114, or 124,) supplying the flow of pressurized fracturing fluid into and / or through the fracturing tree to the wellbore.

[0134] In addition, in various embodiments, an outer sleeve can be formed from an erosion resistant material, and each can comprise a replaceable wear component. For example, in embodiments such as indicated in FIG. 3A, the body 131 can comprise an outer sleeve formed from a first erosion resistant material such as a metal or metal alloy, while the internal structure 141 can be formed as a sleeve or tube that can be received within the outer tubular body 131, and can comprise a second erosion resistant material that can be different form the first erosion resistant material. In embodiments, the body and internal structure could be formed as separate removable and replaceable inserts, while in other embodiments, the body and internal structure can comprise a unitary insert that can be removed and replaced from a spool of other conduit as a unit.

[0135] Still further, in some embodiments, the body and the internal structure will include a fluid flow path inlet 138 defined at the upstream end portion thereof, and which is aligned with an outlet opening of an adjacent upstream component of the injection system. For example, the flow conditioning device 130 (FIGS. 2A and 2B) can be positioned upstream from the fluid control valve 122, such as being located between the cross junction 113 and an inlet of the flow control valve 122, and with its fluid flow path inlet 138 generally aligned with the outlet of the cross junction 113. In some embodiments, the fluid flow path inlet 138 of the body of the flow conditioning device further generally will have a diameter D that substantially matches the overall diameter D of the fluid conduit and the outlet of the upstream component through which the pressurized fluid is received when the flow conditioning device or a spool in which it is received are mated with the outlet of an upstream component such as an upstream fluid conduit or a junction as indicated in FIG. 2B. In other embodiments, the fluid flow path inlet 138 can have a diameter d1 (e.g., as shown in FIG. 6A) that is different from the diameter D of the outlet of the upstream component.

[0136] In embodiments, the internal structure of the body can include one or more bores 142 (FIGS. 3A-5B). The bores 142 generally can be formed as tubes or passages 143 extending from a first or upstream end 144A through the length of the body 131 to a second or downstream end 144B and each having a substantially reduced diameter D′ (FIGS. 4A-4C) as compared to an overall diameter D of the fluid or frac. conduit(s) supplying the pressurized fracturing fluid into the fracturing tree.

[0137] As shown in FIGS. 4A-4B, in various embodiments, the bores 142 can include a center bore 146 that can be generally aligned with a central axis 147 of the body of the flow conditioning device, and a series of additional bores 148 arranged thereabout. As shown in FIGS. 4A-4B, the additional bores 148 can be arranged about a periphery of the body. In addition, in embodiments, the bores 142 can have substantially a same diameter “D”, while in other embodiments, such as indicated in FIG. 3A, the bores 142 can have at least two different diameters.

[0138] In addition, in some embodiments, such as shown in FIG. 4C, the bores 142 can be arranged randomly of can be arranged in various patterns. For example, in embodiments, the bores can be arranged in patterns such as in concentric rings or in groups of substantially same diameter bores, in groups or rows or columns of similar or different diameter bores, or other arrangements. In still other embodiments, a plurality of smaller diameter bores 142 can be provided without a single centrally located bore.

[0139] In some further embodiments, such as illustrated in FIGS. 6A-8C, the bores 142 can be formed with various configurations, for example, including a tapered construction as shown in FIGS. 6A, 6B and 8C. As shown in FIGS. 6A and 8C, in embodiments, a single bore 142 can be provided, having a first or upstream end 144A having a first diameter “d1” and which expands outwardly along the length thereof to a second end 144B having a second diameter “d2” that is greater than the first diameter “d1”. In other embodiments, such as shown in FIG. 6B, a series of bores 142 can be provided, one or more of which can have a tapered construction that expands outwardly from a first end 144A to a second end 144B. In embodiments, other configurations and / or arrangements of bores can be provided, such as including one or more generally straight bores having a substantially consistent diameter can be provided combined with one or more tapered bores.

[0140] Still further, in embodiments, in addition to including bores of different diameters and different configurations of bores, flow obstructions 155, such as screens, flow diverters such as fins, walls or other projections, etc.. can be located along the bores 142 to further help convert the turbulent flow of the pressurized fracturing fluid to a substantially laminar flow. Such flow obstructions 155 can be positioned between the upstream ends of the bores of the flow conditioning device, or along the passages 143 of the bores, and in some embodiments, could potentially be used to reduce the number of bores of the flow conditioning device.

[0141] For example, screens 156 (FIGS. 7A-7B) can be positioned at the first or upstream end 132 of the body 131, in a position to cover the bores 142, and in some embodiments, one or more screens 156 can be positioned passages 143 of the bores 142 (e.g., as indicated in FIGS. 5B and 8B), in addition to or as an alternative to mounting a screen 156 at the upstream end of the body. As shown in FIG. 7B, the screen(s) 156 generally can be configured to cause additional disruptions in the flow of the pressurized fracturing fluid passing into and through the bores of flow conditioning device without substantially blocking the flow of the pressurized fracturing fluid therethrough.

[0142] As shown in FIG. 8A, other flow obstructions, such as flow diverters 157 (e.g., fins, walls or other projections) can be arranged along the passages 143 of the bores. The flow diverters 157 can have various shapes and sizes (e.g., triangular, straight, arcuate, etc..), and generally will be configured to create disruptions in the turbulent flow of the pressurized fracturing fluid. Such disruptions can help reduce turbulence of the flow of the pressurized fracturing fluid through the fluid or frac conduit(s) upstream of the fracturing tree and / or the valves and / or other more expensive components thereof.

[0143] As noted above, in embodiments, the body 131 of the flow conditioning device 130 can comprise a sacrificial wear component that can be formed from an erosion resistant material and which is configured to be removeable and easily replaceable. For example, in embodiments the body 131 can be formed from rubber, metal, metal alloys, ceramic materials, or combinations thereof, such as shown in FIGS. 5A-5B, the body of the flow conditioning device can be formed as a spool of other conduit adapted to be received between a first of upstream component 160 and a second or downstream component 161 of the injection system, with, the flow conditioning device (or multiple flow conditioning devices) can be mounted along or integrated or located within a shortened length of a trunk line, bridge or other fluid conduit(s) extending between various fracturing equipment or components of the hydraulic fracturing system, such as the frac. conduit 23 a manifold of a zipper module 95, and the junctions, valves and other components of the fracturing tree 101.

[0144] In some embodiments, at least one flow conditioning device 130 can be positioned upstream of the flow control valve 122 of the fracturing tree. For example, FIG. 5A shows an example embodiment of a flow conditioning device 130 positioned between the inlet junction 111 and the cross junction 113 of the fracturing tree upstream from the flow control valve. FIG. 5B shows a further embodiment wherein multiple flow conditioning devices 130 are provided, including multiple flow conditioning devices located along an elongated fluid conduit 114 extending between the junction 111 and cross junction 113. It will be understood that the arrangements of the fluid conduits shown in the examples of FIGS. 2A-2B and 5A-5B are for purposes of illustration and that various other, differing arrangements and numbers of flow conditioning devices and fluid conduits can be provided (e.g., each fluid conduit upstream of the fluid control valve can include one, 2, 3 or more sections that each can be configured as a spool or can be otherwise configured).

[0145] In addition, in embodiments, the flow control device 130 can be mounted along a trunk line, bridge line, or fluid conduit between a pair of adjacent pipes with a substantially straight bore extending therethrough, while in some embodiments, two or more flow control devices can be arranged along the fluid conduit in series such as shown in FIGS. 8A-8B, or with an additional conduit section therebetween such as shown in FIG. 5B. In such embodiments, the flow conditioning devices can include different lengths, or can be of a same length, with a total length of the flow conditioning devices (and any intervening conduit sections), and further each can have a reduced overall length so as to substantially fit within the available length or space between the components. By way of example only, in a situation where an available space or length between the components is limited to 16″ or less, a pair of flow conditioning devices can be used, with a total length of each being a combined 16″ or less so as to substantially fit within the available length or space between the components.

[0146] As shown in FIGS. 8A and 8C, in embodiments, the flow control devices can have different lengths, and further can have different configurations, numbers and arrangements of bores 142, which can also include bores hiving different diameters. For example, FIG. 8A shows two flow conditioning devices arranged in series, with a first one 130A having a shorter length than the second one 130B, and with the internal structures of each including different arrangements of bores 142, and the first flow conditioning device 130A. FIG. 8B shows first and second flow conditioning devices 130A and 130B having substantially a same length, but with the first one 130A having multiple bores 142 of a smaller diameter than the bores 142 of the second flow conditioning device 130B, which is shown with fewer bores 142 and having flow obstructions 155 positioned therealong. FIG. 8C shows an embodiment with flow conditioning device 130A located upstream from a straight conduit section 163, having a greater length than the conduit section and further including a single bore 142 shown as having a tapered configuration wherein the bore expands in diameter from the first end to the second end thereof. Other configurations and arrangements also can be provided.

[0147] In addition, in embodiments, the flow conditioning device(s) 130 can be configured as lower cost sacrificial component that converts the turbulent flow of the pressurized fracturing fluid into a substantially laminar flow before it passes through more costly equipment of the fracturing tree. For example, in some embodiments, such as shown in FIG. 3A, the flow conditioning device can include internal structure 140 through which the bores 142 are formed and extend, and which can comprise a sacrificial wear component formed as a removeable and replaceable insert. In such embodiments, the body 131 of the flow conditioning device 130 can be formed as a spool and can be formed from a high strength material such as steel. The center portion 135 of the body 131 can include a chamber or internal passage 170 defined therethrough, and the internal structure 140 can comprise a sleeve or tubular structure that can be formed from an erosion resistant material, such as rubber, metal, metal alloys, ceramic materials, or combinations thereof and will be configured to be received within the chamber 170. The internal structure thus can act as a sacrificial insert of wear component that protects the downstream components of the fracturing tree, such as the valves and other more expensive components, from erosion, and which further can be removed from the body 131 and replaced as needed, saving time and potential costs of servicing the frac equipment and extending the operational life of the valves and other, similar components.

[0148] Alternatively, in embodiments such as shown in FIGS. 9A-9D, the flow conditioning device 130 can include a body that comprises a replaceable insert configured to be received within a chamber of an existing spool or other conduit. The flow conditioning device 130 can act as a sacrificial wear component formed from an erosion resistant material such as rubber, metal, metal alloys, ceramic materials, or combinations thereof configured to protects the downstream components of the fracturing tree, such as the valves and other more expensive components, from erosional wear due to the pressurized fracturing fluid, and which can be removed and replaced more easily and with less labor, leading to a potential reduction in servicing times and costs.

[0149] In embodiments, as discussed above, the flow conditioning device 130 can be installed along a in the trunk line, bridge or conduit extending between a first or upstream component 125A and an adjacent second or downstream component 125B. For example, the flow conditioning device 130 can be installed between along a conduit ahead of the fracturing tree, or between one or more components thereof (e.g., between a lower cost component and a higher cost component that requires greater protection from the effects of erosion by the pressurized fracturing fluid passing therethrough. As shown in FIGS. 9A-9D, the flow conditioning device 130 can be installed between the adjacent first and second components in various ways.

[0150] For example, in embodiments, a method of installing the flow conditioning device 130 can include assembling fracturing equipment for the hydraulic fracturing system at a fracturing site. This can include assembling a manifold assembly 20, including at least one manifold 22, and connecting the at least one manifold to at least one injection system 100 at a well site, such as indicated in FIGS. 1-2B. In embodiments, the injection system 100 can include a fracturing tree 101, and the at least one manifold can be connected to the fracturing tree by the frac. conduit 23. In some embodiments, the injection system 100 also can include at least one zipper module in fluid communication with the at least one injection system, and can be coupled to the frac. conduit 23 at an upstream or inlet portion, and to the fracturing tree at a downstream or outlet portion, such as, for example, by a fluid conduit such as shown at 110 in FIGS. 2A-2B.

[0151] In embodiments, as shown in FIGS. 2A-2B, the fracturing tree 101 can include a series of components including one or more junctions 111 and 113, valves 116-117 and flow control valve 122, and a series of fluid conduits 110, 114, 124, extending between the various components and defining a fluid flow passage for the pressurized fracturing fluid through the fracturing tree from an inlet to an outlet thereof. In embodiments of the method, at least one flow conditioning device 130 will be positioned along the fluid flow passage extending through the fracturing tree, generally being located upstream of the flow control valve.

[0152] In one embodiment of the method, the flow conditioning device 130 can be installed along a fluid conduit such as by the use of fasteners such as threaded retainer pins, bolts, etc.. as shown in FIGS. 2A-2B and 9A. In such an embodiment, the flow conditioning device can include a connector, such as a flange 134, and at least one end portion thereof. In embodiments, such as shown in FIG. 9A, the flow conditioning device can be formed as an insert and can be installed within a chamber of a spool or other conduit section, and can have a body with a T-shaped configuration including a first end portion configured to be engaged between an upstream end of the spool in which it is received and a downstream end of the upstream component 125A. The first end portion can be secured by clamping or by fasteners inserted through the corresponding connectors (e.g., flanges) of the spool and the first component. As further shown in FIG. 9A, the body can extend through the chamber 136 with the second end portion being substantially aligned / matched with an inlet opening of the downstream component 125B.

[0153] In another embodiment of the method, such as shown in FIG. 9B, the flow conditioning device 130 can be formed as an insert and can be installed within a chamber of a spool or other conduit section, and can have a body with a substantially tubular construction. The body generally will be aligned with the fluid flow passage of the pressurized fracturing fluid passing along the fluid conduit. In addition, in some embodiments, the body can have a tapered configuration (e.g., tapering slightly from its upstream to its downstream end or from its downstream to its upstream end), and can be inserted into the chamber 136 of a spool or conduit section 137 with its tapering outer side surface engaging and bearing against a corresponding tapered inner surface of the chamber. The flow conditioning device can be secured within the chamber of its spool or conduit section by the coupling of the spool to the upstream and downstream components 125A / 125B as shown in FIG. 9B.

[0154] In another embodiment of the method, such as shown in FIG. 9C, the flow conditioning device 130 can be formed as an insert and can be installed within a chamber of a spool or other conduit section, and can have a body with a substantially tubular construction. The body generally will be aligned with the fluid flow passage of the pressurized fracturing fluid passing along the fluid conduit. In addition, in this embodiment, the body is shown as having a shoulder or stepped portion 175 along its central portion. The shoulder 175 of the body 131 can be configured to seat against a corresponding shoulder 176 formed along the side wall of the chamber 37 in which the flow conditioning device is received. The flow conditioning device can be secured within the chamber of its spool or conduit section by the coupling of the spool to the upstream and downstream components 125A / 125B as shown in FIG. 9C.

[0155] Still further, in other embodiments, such as shown in FIG. 9D, the flow conditioning device can be installed as an insert received within a chamber of a spool or other conduit section, and can have a body with a substantially tubular construction. The body generally will be aligned with the fluid flow passage of the pressurized fracturing fluid passing along the fluid conduit. The flow conditioning device can be secured within the chamber of its spool or conduit section by engagement of tie-down pins that can be inserted through the body of the spool and into engagement with at least a portion of the body of the flow conditioning device (e.g., in one embodiment, adjacent the first or upstream end thereof, though other locations also can be used). The spool within which the flow conditioning device is inserted then can be secured to the upstream and downstream components 125A / 125B as shown in FIG. 9D.

[0156] In addition, in any of the embodiments of FIGS. 9A-9D illustrating methods of installation of the flow conditioning device, the flow conditioning device can comprise a replaceable insert received within an existing spool or fluid conduit section of a fluid conduit; or, in alternative embodiments, the body of the flow conditioning device can comprise a spool or conduit section and can include an internal structure configured as a replaceable insert received within an internal chamber of the body.

[0157] The configurations, numbers, arrangements and diameters of the bores can vary, and in embodiments, can be selected to divide and divert the flow of the pressurized fracturing fluid moving along the fluid flow passage F along multiple smaller flow paths 145 (FIGS. 3B, 5A-5B, 6B-7A, and 8A-9D) extending through the body 131 (and thus through a chamber 136 and along the length of a conduit, such as a spool 137 the body is received within) so as to substantially convert the turbulent flow of the pressurized fluid to a laminar flow within substantially reduced or minimized available area or within a selected distance.

[0158] For example, for a traditional frac. conduit having about a 7″ bore (e.g., traditionally about 7.062″), a flow conditioning device 130 can be provided with a body 131 that can define a fluid conduit (e.g., being configured as a spool or conduit section) or be received within an internal chamber defined by the bore of a fluid conduit, and can have a first end portion 132 including a fluid flow path inlet 138 that is aligned with and which has a diameter that substantially matches the diameter of an upstream fluid or frac. conduit, or other upstream component, from which the turbulent flow of the pressurized fracturing fluid flow is received. By way of example only, in embodiments, a flow conditioning device can be positioned between the frac. conduit 23 of the manifold assembly, or between an outlet of the cross junction 113 and an inlet of the flow control valve 122 of the injection system 101, with the fluid flow path inlet 138 thereof having a diameter D that substantially matches the diameter of the upstream fluid or frac. conduit (e.g., a diameter approximately matching a 7″ bore of a traditional frac. conduit), and will include a series of smaller diameter bores extending therethrough. In an embodiment, each of the bores can comprise a diameter of about + / −1.625″, which, together, can approximate a 7″ diameter of the frac. conduit and enable conversion of the turbulent flow of pressurized fracturing fluid to a substantially laminar flow in approximately 16.25″.

[0159] As noted, in embodiments, the number, arrangement, diameter(s) and configurations of the bores 142 can be varied. For example greater or lesser numbers of bores and the diameters thereof can be selected based on the diameter of the upstream fluid conduit from which the pressurized fracturing fluid is received into the flow conditioning device, and, in some embodiments, being substantially matched to a desired or available space or area. For example, in embodiments, where the incoming or downstream fluid conduit has a diameter of between 5″-7″ and the available space between the fluid conduit and a component such as a flow control valve of the fracturing tree is limited to, for example, about 20″-16″ or less, a flow conditioning device 130 having number of bores 142 be selected, with the bores having one or more selected diameters that together can approximate a diameter that is substantially equal to that of the diameter of the fluid conduit can be provided to provide the needed reduction in the turbulence of the turbulent flow of pressurized fracturing fluid to create a substantially laminar flow upstream or a protected component (e.g., a valve or junction), but with the length of the fluid conduit along which the flow conditioning device is located being substantially reduced to a fraction of the full length of a fluid conduit without the flow conditioning device located therealong. By way of illustration, for example, based the general industry practice of using a fluid conduit having a length of at least ten times its diameter to achieve a laminar flow, an overall length of the fluid conduit between fracturing equipment or components of the hydraulic fracturing system can be reduced to about ½, and in embodiments, to as low as about ¼th to about ⅕th of this length vs. conventional installations. The selected number of bores, their diameters, the arrangement of the bores, the use of flow obstructions and other features of the flow conditioning devices can be further adjusted to provide different reductions in length.

[0160] When positioned ahead of at least one protected component of the injection system, such as being located along at least a portion of a fluid conduit upstream from a protected component such as a fluid control valve (or other equipment), the turbulence of the flow of pressurized fracturing fluid passing into frac equipment or components, such as fluid control valves, can be greatly reduced by the flow conditioning device prolonging the life thereof. The flow conditioning device thus can provide protection for more expensive components of the fracturing tree that can be more easily serviceable and can act as a sacrificial, lower cost protective component ahead of the valves, junctions and other equipment for which greater protection from erosional wear is needed or desired.

[0161] It should be appreciated that embodiments of the flow conditioning devices may be utilized in other fluid services other than hydraulic fracturing operations. For instance, embodiments of the flow conditioning devices disclosed herein may be utilized in fluid manifolds, lines, or other fluid conveyance systems and devices for transporting pressurized fluids and other fluid services applications both inside and outside of the oil and gas industry. Some further examples can include the use of embodiments of the flow conditioning devices disclosed herein for flowing fluids for other oilfield operations (such as pump down, drilling mud delivery, production operations, etc.).

[0162] The preceding discussion is directed to various exemplary embodiments. However, one of ordinary skill in the art will understand that the examples disclosed herein have broad application, and that the discussion of any embodiment is meant only to be exemplary of that embodiment, and not intended to suggest that the scope of the disclosure, including the claims, is limited to that embodiment.

[0163] This application claims priority to and the benefit of U.S. Provisional Application No. 63 / 779,382, filed Mar. 28, 2025, titled “FLOW CONDITIONING DEVICE FOR HYDRAULIC FRACTURING SYSTEMS AND RELATED METHODS,” the disclosure of which is incorporated herein by reference in its entirety.

[0164] While exemplary embodiments have been shown and described, modifications thereof can be made by one skilled in the art without departing from the scope or teachings herein. The embodiments described herein are exemplary only and are not limiting. Many variations and modifications of the systems, apparatus, and processes described herein are possible and are within the scope of the disclosure. Accordingly, the scope of protection is not limited to the embodiments described herein, but is only limited by the claims that follow, the scope of which shall include all equivalents of the subject matter of the claims. Unless expressly stated otherwise, the steps in a method claim may be performed in any order. The recitation of identifiers such as (a), (b), (c) or (1) , (2), (3) before steps in a method claim are not intended to and do not specify a particular order to the steps, but rather are used to simplify subsequent reference to such steps.

Examples

Embodiment Construction

[0101]Embodiments of the present disclosure are directed to hydraulic fracturing systems, and various components and methods of installation and use thereof. In embodiments, the hydraulic fracturing systems can include a manifold assembly having one or more manifolds (e.g., inlet and outlet manifolds) configured to receive and transport a pressurized fracturing fluid along a flow path to an injection system or assembly, which can include one or more zipper modules and / or fracturing trees, for injection of the pressurized fracturing fluid to one or more wellbores. In various embodiments, one or more flow conditioning devices can be arranged as part of or along one or more fluid conduits or connections between the one or more manifolds and the zipper module(s), the fracturing tree(s), and / or components thereof.

[0102]In embodiments, the flow conditioning devices can be located along a trunk line, bridge or conduit upstream of a fracturing tree and / or components thereof, and will be con...

Claims

1. A flow conditioning device comprising:a body comprising:a first end portion;a second end portion; anda central portion extending between the first end portion and the second end portion, the central portion having a plurality of longitudinally extending bores, each of the bores configured to define a flow path through the body;wherein the body is configured to:(a) be positioned between an upstream component and a downstream component with the central portion aligned with a flow passage of the upstream component such that a portion of a fracturing fluid moving along the flow passage of the upstream component is received though one or more of the bores; and(b) have a number of the bores, an arrangement of the bores about the central portion, a diameter of each bore, or combinations thereof, selected to convert a turbulent flow of the fracturing fluid to a substantially laminar flow of the fracturing fluid based on a diameter of the body, a length of the body, a projected particle size of particulates entrained within the fracturing fluid, a maximum flow area, or combinations thereof.

2. The flow conditioning device of a claim 1, wherein at least one of the first and second end portions of the body comprises a connector configured for coupling to a corresponding connector of the upstream component, the downstream component or a combination thereof.

3. The flow conditioning device of claim 1, wherein each of the first and second end portions comprises a flange having a diameter greater than an overall diameter of the central portion and configured for coupling the body to the upstream component and to the downstream component.

4. The flow conditioning device of claim 1, wherein the central portion further comprises an insert received within a chamber of the central portion and along which the bores extend; and wherein the insert comprises an erosion resistant material, and wherein the insert is configured as a replaceable sacrificial wear component.

5. The flow conditioning device of claim 1, wherein the plurality of bores comprises at least one bore extending approximately through a center of the central portion, and a series of bores arranged about a periphery of the central portion.

6. The flow conditioning device of claim 1, wherein at least some of the bores have a first bore diameter, and at least some of the bores have a second bore diameter that is different from the first bore diameter.

7. The flow conditioning device of claim 1, wherein the body is configured to be received within a chamber of a conduit positioned between the upstream and downstream components, and wherein the body further comprises one or more screens, one or more flow diverters, tapering bores, different size bores, different arrangements of bores, different configurations of bores, or combinations thereof.

8. The flow conditioning device of claim 1, wherein one or more of the bores comprise a substantially straight configuration, an inwardly tapering configuration, an expanding configuration, or combinations thereof.

9. A hydraulic fracturing system comprising:a first component;a second component;a conduit positioned between the first and second components and to transport a fracturing fluid from the first component to the second component and so that a fluid flow path along which a fracturing fluid is supplied to a wellbore is defined between the first component, the second component, and the conduit; andone or more flow conditioning devices positioned along the fluid flow path, each of the one or more flow conditioning devices comprises:a body having a first end portion, a second end portion, and a plurality of bores extending longitudinally though the body, each of the plurality of bores positioned to define a separate flow path through the body and positioned to receive a portion of the fracturing fluid flowing through the conduit so as to substantially reduce a turbulence of the fracturing fluid, and so that a diameter of each of the plurality of bores, a number of the plurality of bores, an arrangement of the plurality of bores, or combination thereof, create a substantially laminar flow of the fracturing fluid within a substantially reduced length of an overall flow path of the fracturing fluid between the first and second components, prior to introduction of the fracturing fluid into the second component.

10. The hydraulic fracturing system of claim 9, wherein the first component comprises a fluid conduit of a manifold and the second component comprises a valve, and wherein the body includes an internal structure received within a chamber defined along the body and through which the plurality of bores is formed.

11. The hydraulic fracturing system of claim 10, wherein the internal structure is configured as a sacrificial wear component.

12. The hydraulic fracturing system of claim 9, wherein the plurality of bores comprises at least one central bore extending along a longitudinally extending center axis of the body, and a series of bores arranged about the central bore, and wherein at least some of the bores have a first bore diameter, and at least some of the bores have a second bore diameter that is different from the first bore diameter.

13. The hydraulic fracturing system of claim 9, wherein at least one of the first and second end portions of the body includes a connector to couple to a corresponding connector of the first component or the component with pins, threaded fasteners, locking features, or combinations thereof.

14. The hydraulic fracturing system of claim 13, wherein the body of the flow conditioning device is at least partially received within the conduit.

15. The hydraulic fracturing system of claim 14, wherein the second end portion of the body has a first diameter and is positioned to be received along a chamber extending through the conduit, and wherein the first end portion of the body has a second diameter that is greater than the first diameter and is configured to seat against an upstream end of the conduit so as to be engaged between an inlet of the conduit and an outlet of the first component.

16. The hydraulic fracturing system of claim 14, wherein the body of the flow conditioning device is positioned to be received within the conduit and is releasably retained within the conduit by pins, fasteners, threaded retainers, or combinations thereof.

17. The hydraulic fracturing system of claim 9, wherein at least one flow conditioning device comprises a plurality of flow conditioning devices positioned at selected locations along the fluid flow path between the first and second components, and whrein the plurality of flow conditioning devices comprises at least one flow conditioning device having a first length and at least one flow conditioning device having a second length that is different from the first length.

18. A method comprising:assembling a manifold at a hydraulic fracturing site so that the manifold is positioned to receive and deliver a fracturing fluid to a fracturing tree during a hydraulic fracturing operation;connecting an outlet of the manifold to an inlet of at least one fracturing tree coupled to a wellbore at the hydraulic fracturing site; andlocating one or more one flow conditioning devices along a fluid flow path of the fracturing fluid extending from the manifold through the at least one fracturing tree, the one or more flow conditioning devices comprises:a body having a plurality of bores, each of the bores defining a flow path extending through the body parallel to the fluid flow path of the fracturing fluid, the bores positioned to create a substantially laminar flow of the fracturing fluid within a substantially reduced length of the fluid flow path along which the fracturing fluid is transported prior to introduction of the fracturing fluid into at least one fracturing tree.

19. The method of claim 18, wherein locating the one or more flow conditioning devices comprises inserting the body into a chamber of a conduit positioned between adjacent components of the at least one fracturing tree such that the fracturing fluid operates in a substantially laminar flow upstream of the wellbore.

20. The method of claim 18, wherein the one or more one flow conditioning devices is positioned between a junction and a valve of the at least one fracturing tree, and wherein the body of the at least one flow conditioning device comprises a first section and a second section, the first section having a diameter that is larger than a diameter of the second section so as to define a shoulder portion configured to seat against a corresponding shoulder portion of the chamber of the conduit.

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