US20220341305A1

US20220341305A1 - Systems and methods for cathodic protection of hydraulic fracturing pump systems

Info

Publication number: US20220341305A1
Application number: US17/764,079
Authority: US
Inventors: Jacob A. Bayyouk; Frazer Craig Brownlie; Trevor Hodgkiess; Brian Witkowski; Benjamin David Engstrom; Collin Garner
Original assignee: SPM Flow Control Inc; SPM Oil and Gas Inc
Current assignee: SPM Oil and Gas Inc
Priority date: 2019-10-21
Filing date: 2020-10-21
Publication date: 2022-10-27
Also published as: WO2021081107A1; CA3153916A1

Abstract

The present disclosure relates, according to some embodiments, to a hydraulic fracturing pump comprising a fluid end assembly, the fluid end assembly comprising a cylinder body configured to receive a respective plunger from a power end; a suction bore configured to house a valve body, a valve seat, and a spring; a suction cap; and a spring retainer, wherein a surface of one or more of the cylinder body, the suction bore, the suction cap, and the spring retaining serves as a cathode, and wherein the fluid end comprises at least one of a plunger anode, a suction cap anode, a spring retainer anode, a valve top anode, a valve seat outer diameter anode, and a valve seat inner diameter anode.

Description

FIELD OF THE DISCLOSURE

The present disclosure relates, in some embodiments, to cathodic protection of steel compositions. In some embodiments, the disclosure relates to systems and methods using cathodic protection to control corrosion of a metal surface of high pressure pump parts (e.g., a fluid end of a hydraulic fracturing pump) and other fracking fluid transporting components.

BACKGROUND

Hydraulic fracturing is an oil well stimulation technique in which bedrock is fractured (i.e., fracked) by the application of a pressurized fracking fluid. The effectiveness of fracking fluid is due not only to pressurization, but also to its composition of one or more proppants (e.g., sand) and chemical additives (e.g., dilute acids, biocides, breakers, pH adjusting agents). The application of pressurized fracking fluid to existing bedrock fissures creates new fractures in the bedrock, as well as, increases the size, extent, and connectivity of existing fractures. This permits more oil and gas to flow out of the rock formations and into the wellbore, from where they can be extracted.
Hydraulic fracturing pumps generally consist of a power end and a fluid end, with the power end pressurizing a fracking fluid and the fluid end directing the pressurized fracking fluid into the wellbore through a series of conduits (e.g., pipes). Hydraulic fracking pump components (e.g., a fluid end) and conduit components (e.g., a check valve) that are exposed to fracking fluid are prone to fluid leakage, failure, and other sustainability issues due to corrosion resulting from their exposure to components of the fracking fluid having corrosive or abrasive properties (e.g., proppant, chemical additives). As a result, hydraulic fracking pump and conduit components require frequent replacement at a substantial cost.
In general, hydraulic pump and conduit components are made of either carbon steel, low alloy steel, or stainless steel. The composition of hydraulic pump and conduit components plays a large role in both the frequency of replacement and cost. While components composed of stainless steel have a life span of around 2000 working hours, the exorbitant cost of stainless steel often makes their use cost prohibitive. By contrast, components composed of low alloy steel and carbon steel offer an inexpensive entry price point, but have a life span of only about 10-15% compared to their stainless steel counterparts (e.g., 200-300 working hours). Accordingly, there is a need for affordable systems and methods for controlling the corrosion rates of low alloy steel and carbon steel components so that they can have an expanded working life span (e.g., more than 400 working hours).
Cathodic protection is a technique used to control corrosion of a metal surface by making the metal surface a cathode of an electrochemical cell. In one embodiment of cathodic protection the anode of the electrochemical cell serves as a sacrificial metal that corrodes while the more precious cathode remains intact. A system could be developed where low alloy steel and carbon steel hydraulic fracturing pump components are coupled with sacrificial anodes so that the low alloy steel and carbon steel hydraulic fracturing components undergo cathodic protection so that they have a life span similar to comparable stainless steel components.

SUMMARY

The present disclosure relates, according to some embodiments, to a hydraulic fracturing pump including a fluid end assembly. A fluid end assembly may include a cylinder body oriented along a longitudinal axis of the fluid end, including a first end and a second end, and configured to receive a respective plunger from a power end through the first end of the cylinder body. A fluid end assembly may include a suction bore oriented along a vertical axis of the fluid end and connected to a cylinder body through the second end of the cylinder body. A suction bore may be configured to house a valve body, a valve seat, and a spring, wherein the valve body having a top, and the valve seat having an inner diameter and an outer diameter. A suction cap may be located at a second end of cylinder body. A spring retainer may be contained within a suction bore. A surface of one or more of a cylinder body, a suction bore, a suction cap, and a spring retaining may be configured to serve as a cathode. At least one of a plunger, a suction cap, a spring retainer, a valve top, a valve seat outer diameter, and a valve seat inner diameter may be configured to serve as an anode.
A fluid end may include an anode configuration selected from a group consisting of a plunger anode, a suction cap anode, a valve top anode, a valve seat outer diameter anode, and a valve seat inner diameter anode; a valve top anode, a valve seat outer diameter anode, and a valve seat inner diameter anode; a plunger anode, a valve seat outer diameter anode, and a valve seat inner diameter anode; and a suction cap anode, a valve seat outer diameter anode, and a valve seat inner diameter anode. At least one of a plunger anode, a suction cap anode, a spring retainer anode, a valve top anode, a valve seat outer diameter anode, and a valve seat inner diameter anode each may include a sacrificial anode fabricated from one or more metals selected from a group consisting of aluminum, aluminum alloys, zinc, zinc alloys, magnesium, and magnesium alloys. A sacrificial anode may be secured by at least one method selected from a group of a mechanical fastener, an adhesive, and a friction fit.
In some embodiments, a plunger anode may be secured onto an end of a plunger by a plunger bolt. A suction cap anode may be secured onto an end of a suction cap by a suction cap bolt. A spring retainer anode may be secured onto an end of a spring retainer by a spring retainer bolt. A valve top anode may be secured onto an end of a valve top by a retainer ring. A valve seat outer diameter anode that clamps onto an outer diameter of a valve seat. A valve seat inner diameter anode that clamps onto an inner diameter of a valve seat. At least one of a plunger bolt, a suction cap bolt, a spring retainer bolt, and a valve top bolt may include brass, bronze, stainless steel, galvanized steel, gold, platinum, and silver. One or more of a plunger bolt, a suction cap bolt, a spring retainer bolt, and a valve top bolt may be substantially inert to corrosion. At least one of a plunger anode, a suction cap anode, a valve top anode, a valve seat outer diameter anode, and a valve seat inner diameter anode may include a mass from about 0.15 ounces to about 0.5 ounces. At least one of a plunger anode, a suction cap anode, a valve top anode, a valve seat outer diameter anode, and a valve seat inner diameter anode may include a surface area from about 1 in²to about 7 in².
In some embodiments, the present disclosure relates to a system for preventing corrosion of a surface of a conduit. A system may include a conduit including a tubular body; an outer surface; an inner surface configured to contain a fracking fluid; and one or more ports configured to receive a bolt or a valve; and a bolt including an anodic end and an corrosion resistant end. A system furar may include a check valve including a check valve anode. A system furar may include a plug valve including a plug valve anode. A check valve anode has a mass from about 100 g to about 2,000 g. A plug valve anode has a mass from about 100 g to about 2,000 g. A check valve anode has a volume from about 25 cm³to about 300 cm³. A plug valve anode has a volume from about 100 g to about 2,000 g. An anodic end may include aluminum, aluminum alloys, zinc, zinc alloys, magnesium, magnesium alloys, and combinations thereof. A corrosion resistant end may include brass, bronze, stainless steel, galvanized steel, gold, platinum, and silver.
In some embodiments, a system for preventing corrosion of a surface of a conduit includes a conduit including a tubular body; an outer surface; an inner surface configured to contain a fracking fluid; and one or more ports configured to receive a bolt or a valve; and a valve including an anode. A valve may include a check valve, and wherein a anode may include a check valve anode. A valve may include a plug valve, and wherein a anode may include a plug valve anode.

BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary embodiments of the present disclosure are described herein with reference to the drawings, wherein like parts are designated by like reference numbers, and wherein:

FIG. 1 illustrates a cross-sectional perspective of a standard hydraulic fracturing pump;

FIG. 2A illustrates a cross-sectional perspective of a fluid end of a hydraulic fracturing pump having sacrificial anodes according to a specific example embodiment of the disclosure;

FIG. 2B illustrates a close-up vantage of a spring retainer anode from the fluid end of FIG. 2A in cross-section, according to a specific example embodiment of the disclosure;

FIG. 2C illustrates a close-up vantage of a suction cover anode from the fluid end of FIGS. 2A-2B in cross-section, according to a specific example embodiment of the disclosure;

FIG. 2D illustrates a close-up vantage of a plunger anode from the fluid end of FIGS. 2A-2C in cross-section, according to a specific example embodiment of the disclosure;

FIG. 3A illustrates a cross-sectional perspective of a fluid end having a plunger anode, a suction cover anode, a spring retainer anode, and valve top anodes secured by threaded fasteners according to a specific example embodiment of the disclosure;

FIG. 3B illustrates a close-up vantage of a hydraulic fracturing pump valve of the fluid end from FIG. 3A in cross-section, the hydraulic fracturing pump valve having a valve top anode secured by threaded fasteners, a seat outer diameter anode, and a seat inner diameter anode according to a specific example embodiment of the disclosure;

FIG. 4A illustrates a cross-sectional perspective of a fluid end having a plunger anode, a suction cover anode, and a spring retainer anode according to a specific example embodiment of the disclosure;

FIG. 4B illustrates a close-up vantage of a hydraulic fracturing pump valve of the fluid end from FIG. 4A in cross-section, the hydraulic fracturing pump valve having a valve top anode, a seat outer diameter anode, and a seat inner diameter anode according to a specific example embodiment of the disclosure;

FIG. 5A illustrates a cross-sectional perspective of a hydraulic fracturing pump valve having an outer diameter anode, an inner diameter anode, and a valve top fastened by a clip ring according to a specific example embodiment of the disclosure;

FIG. 5B illustrates a clip ring for securing the valve top anode to the valve from FIG. 5A according to a specific example embodiment of the disclosure;

FIG. 5C illustrates a cross section of the installed inner diameter anode from FIG. 5A according to a specific example embodiment of the disclosure;

FIG. 5D illustrates a cross section of the installed outer diameter anode from FIG. 5A according to a specific example embodiment of the disclosure;

FIG. 5E illustrates a side perspective of the inner diameter anode from FIG. 5A according to a specific example embodiment of the disclosure;

FIG. 5F illustrates a front perspective of the inner diameter anode from FIG. 5A according to a specific example embodiment of the disclosure;

FIG. 5G illustrates a back perspective of the inner diameter anode from FIG. 5A where it shoes an opening of the outer diameter anode according to a specific example embodiment of the disclosure;

FIG. 5H illustrates a perspective of the inner diameter anode from FIG. 5A according to a specific example embodiment of the disclosure

FIG. 5I illustrates a side perspective of the outer diameter anode from FIG. 5A according to a specific example embodiment of the disclosure;

FIG. 5J illustrates a front perspective of the outer diameter anode from FIG. 5A according to a specific example embodiment of the disclosure;

FIG. 5K illustrates a back perspective of the outer diameter anode from FIG. 5A where it shoes an opening of the outer diameter anode according to a specific example embodiment of the disclosure;

FIG. 5L illustrates a perspective of the outer diameter anode from FIG. 5A according to a specific example embodiment of the disclosure;

FIG. 6A illustrates a cross-sectional perspective of a hydraulic fracturing pump valve having an outer diameter anode, an inner diameter anode, and a valve top fastened by a threaded fastener according to a specific example embodiment of the disclosure;

FIG. 6B illustrates a threaded fastener for securing the valve top anode to the valve of FIG. 6A according to a specific example embodiment of the disclosure;

FIG. 6C illustrates a cross section of the installed inner diameter anode from FIG. 6A according to a specific example embodiment of the disclosure;

FIG. 6D illustrates a cross section of the installed outer diameter anode from FIG. 6A according to a specific example embodiment of the disclosure;

FIG. 6E illustrates a side perspective of the inner diameter anode from FIG. 6A according to a specific example embodiment of the disclosure;

FIG. 6F illustrates a front perspective of the inner diameter anode from FIG. 6A according to a specific example embodiment of the disclosure;

FIG. 6G illustrates a back perspective of the inner diameter anode from FIG. 6A where it shoes an opening of the outer diameter anode according to a specific example embodiment of the disclosure;

FIG. 6H illustrates a perspective of the inner diameter anode from FIG. 6A according to a specific example embodiment of the disclosure

FIG. 6I illustrates a side perspective of the outer diameter anode from FIG. 6A according to a specific example embodiment of the disclosure;

FIG. 6J illustrates a front perspective of the outer diameter anode from FIG. 6A according to a specific example embodiment of the disclosure;

FIG. 6K illustrates a back perspective of the outer diameter anode from FIG. 6A where it shoes an opening of the outer diameter anode according to a specific example embodiment of the disclosure;

FIG. 6L illustrates a perspective of the outer diameter anode from FIG. 6A according to a specific example embodiment of the disclosure;

FIG. 7A illustrates a cross-sectional perspective of a hydraulic fracturing pump valve having an outer diameter anode, an inner diameter anode, and a valve top fastened by four threaded fasteners according to a specific example embodiment of the disclosure;

FIG. 7B illustrates a four threaded fastener for securing the valve top anode to the valve of FIG. 7A according to a specific example embodiment of the disclosure;

FIG. 7C illustrates a cross section of the installed inner diameter anode from FIG. 7A according to a specific example embodiment of the disclosure;

FIG. 7D illustrates a cross section of the installed outer diameter anode from FIG. 7A according to a specific example embodiment of the disclosure;

FIG. 7E illustrates a side perspective of the inner diameter anode from FIG. 7A according to a specific example embodiment of the disclosure;

FIG. 7F illustrates a front perspective of the inner diameter anode from FIG. 7A according to a specific example embodiment of the disclosure;

FIG. 7G illustrates a back perspective of the inner diameter anode from FIG. 7A where it shoes an opening of the outer diameter anode according to a specific example embodiment of the disclosure;

FIG. 7H illustrates a perspective of the inner diameter anode from FIG. 7A according to a specific example embodiment of the disclosure

FIG. 7I illustrates a side perspective of the outer diameter anode from FIG. 7A according to a specific example embodiment of the disclosure;

FIG. 7J illustrates a front perspective of the outer diameter anode from FIG. 7A according to a specific example embodiment of the disclosure;

FIG. 7K illustrates a back perspective of the outer diameter anode from FIG. 7A where it shoes an opening of the outer diameter anode according to a specific example embodiment of the disclosure;

FIG. 7L illustrates a perspective of the outer diameter anode from FIG. 6A according to a specific example embodiment of the disclosure;

FIG. 8 illustrates a cross-sectional perspective of a fluid end designating various sacrificial anode sites including a suction cap, a plunger, a spring retainer, a valve, a valve seat outer diameter and a valve seat inner diameter according to a specific example embodiment of the disclosure;

FIG. 9A illustrates various measurement locations where a fluid end is measured while having anodes at the suction cap, plunger, spring retainer, valve, and valve seat outer diameter according to a specific example embodiment of the disclosure;

FIG. 9B illustrates a graph of measured electrode potentials measured at the various measurement locations shown in FIG. 9A from 0 hours to 48 hours according to a specific example embodiment of the disclosure;

FIG. 10A illustrates various measurement locations where a fluid end is measured while having anodes at the spring retainer, valve, and valve seat outer diameter according to a specific example embodiment of the disclosure;

FIG. 10B illustrates a graph of measured electrode potentials measured at various measurement locations shown in FIG. 10A at 0 hours, 4 hours, 21 hours, and 24 hours according to a specific example embodiment of the disclosure;

FIG. 10C illustrates a graph of measured electrode potentials measured at various measurement locations shown in FIG. 10A at 0 hours, 4 hours, and 24 hours according to a specific example embodiment of the disclosure;

FIG. 11A illustrates various measurement locations where a fluid end is measured while having anodes at the plunger, the valve, and the valve seat outer diameter according to a specific example embodiment of the disclosure;

FIG. 11B illustrates a graph of measured electrode potentials measured at various measurement locations as shown in FIG. 11A from 0 hours to 24 hours according to a specific example embodiment of the disclosure;

FIG. 11C illustrates a graph of measured electrode potentials measured at various measurement locations as shown in FIG. 11A from 0 hours to 63 hours according to a specific example embodiment of the disclosure;

FIG. 12 illustrates various measurement locations where a fluid end is measured while having anodes at the suction cap, the valve, and the valve seat outer diameter according to a specific example embodiment of the disclosure;

FIG. 12B illustrates a graph of measured electrode potentials measured at various measurement locations as shown in FIG. 12A from 0 hours to 24 hours according to a specific example embodiment of the disclosure;

FIG. 12C illustrates a graph of measured electrode potentials measured at various measurement locations as shown in FIG. 12A from 0 hours to 24 hours according to a specific example embodiment of the disclosure;

FIG. 13 illustrates various measurement locations where a fluid end is measured while having anodes at arrangements B, G, H, and I according to a specific example embodiment of the disclosure;

FIG. 13B illustrates a graph of measured electrode potentials measured at various measurement locations as shown in FIG. 13A from 3 hours to 14 hours and 30 minutes according to a specific example embodiment of the disclosure;

FIG. 13C illustrates a graph of measured electrode potentials measured at various measurement locations as shown in FIG. 13A after 24 hours according to a specific example embodiment of the disclosure;

FIG. 14 illustrates various measurement locations where a fluid end is measured while having anodes at arrangements G, H, and I according to a specific example embodiment of the disclosure;

FIG. 14B illustrates a graph of measured electrode potentials measured at various measurement locations as shown in FIG. 14A from 2 hours to 4 hours according to a specific example embodiment of the disclosure;

FIG. 14C illustrates a graph of measured electrode potentials measured at various measurement locations as shown in FIG. 14A after 24 hours according to a specific example embodiment of the disclosure;

FIG. 15A illustrates a valve seat inner diameter anode according to a specific example embodiment of the disclosure;

FIG. 15B illustrates a valve seat outer diameter anode according to a specific example embodiment of the disclosure;

FIG. 15C illustrates a valve seat inner diameter anode having a larger exposed surface than the inner diameter anode from FIG. 15A according to a specific example embodiment of the disclosure;

FIG. 15D illustrates a valve seat outer diameter anode having a larger exposed surface than the outer diameter anode from FIG. 15B according to a specific example embodiment of the disclosure;

FIG. 15E illustrates a suction cap anode according to a specific example embodiment of the disclosure;

FIG. 15F illustrates a spring retainer anode according to a specific example embodiment of the disclosure;

FIG. 15G illustrates a plunger anode according to a specific example embodiment of the disclosure;

FIG. 15H illustrates a suction cap anode having a larger exposed surface than the suction cap anode from FIG. 15E according to a specific example embodiment of the disclosure;

FIG. 15I illustrates a valve top anode according to a specific example embodiment of the disclosure;

FIG. 15J illustrates a valve top anode having four ports for receiving threaded fasteners according to a specific example embodiment of the disclosure;

FIG. 15K illustrates a valve top anode having one port to receive a threaded fastener according to a specific example embodiment of the disclosure;

FIG. 16A is a photograph of a valve top isolated and installed on a valve according to a specific example embodiment of the disclosure;

FIG. 16B illustrates a spring retainer anode isolated and screwed into place on a spring retainer according to a specific example embodiment of the disclosure;

FIG. 16C illustrates a valve seat inner diameter anode isolated and glued into place with a conductive epoxy on the valve seat according to a specific example embodiment of the disclosure;

FIG. 16D illustrates a valve seat outer diameter anode isolated and installed onto a valve seat with a tight interference fit according to a specific example embodiment of the disclosure;

FIG. 16E illustrates a suction seal anode isolated and installed onto a suction cap according to a specific example embodiment of the disclosure;

FIG. 16F illustrates a plunger anode isolated and screwed into place within a plunger according to a specific example embodiment of the disclosure;

FIG. 17A is a graph illustrating the electrode potential measured across various anode locations along a pipe according to a specific example embodiment of the disclosure;

FIG. 17B is a cross-section of the pipe from FIG. 17B according to a specific example embodiments of the disclosure;

FIG. 18 is a photograph of a pipe fitted with various anodes and a reference electrode according to a specific example embodiment of the disclosure;

FIG. 19A is an exploded view of a check valve according to a specific example embodiment of the disclosure; and

FIG. 19B is an exploded view of a plug valve according to a specific example embodiment of the disclosure.

DETAILED DESCRIPTION

The present disclosure relates, to cathodic protection systems and methods for controlling corrosion of hydraulic fracking pump and flow iron components. In disclosed cathodic protection systems, the hydraulic fracking pump or flow iron component serves as a cathode that remains protected from corrosion while a sacrificial anode component succumbs to corrosion. Disclosed hydraulic fracking pump components (e.g., a fluid end) and flat iron components (e.g., a check valve) having a cathodic protection system may resist corrosion better than similar component made of carbon steel or an alloy steel that do not have the same cathodic protection system. Additionally, a disclosed cathodic protection system may have a lower overall manufacturing cost than a stainless steel counterpart while having better corrosion resistance properties than carbon steel alone. In some embodiments, a disclosed cathodic protection system may have similar or better corrosion resistance properties than stainless steel alone.
Flow iron components include valves, swivels, integrals, straight lines, pipes, check valves, fittings, adapters, manifolds, and gates. Valves include ball valves, butterfly valves, choke valves, membrane valves, gate valves, globe valves, knife valves, needle valves, pinch valves, piston valves, plug valves, solenoid valves, spool valves, check valves, flow control valves, poppet valves, pressure reducing valves, thermal expansion valves, safety valves, relief valves, and sampling valves.
FIG. 1 illustrates the basic components of a standard hydraulic fracturing pump 100. As shown in FIG. 1, a hydraulic fracturing pump 100 includes a power end 105 and a fluid end 110. A power end 105 drives reciprocating motion of plungers 115 and a fluid end 110 directs the flow of fracking fluid from a pump to conduits leading to a wellbore. As shown in FIG. 1, a basic power end 105 contains the components of a frame 120, a crank shaft 125, a connecting rod 130, a wrist pin 135, a crosshead 140, a crosshead case 155, a pony rod 145, a pony rod clamp 150, and a plunger 115.
As disclosed in FIG. 1, a crankshaft 125, while contained within a frame 120, is rotated by a power source such as an engine. One or more connecting rods 130 have ends that are rotatably mounted to a crankshaft 125, wherein the opposite end of each connecting rod 130 is pivotally connected to a crosshead 140. Rotary motion of a crankshaft 125 is converted to linear motion by a crosshead 140. Each crosshead 140 may be reciprocally carried within a stationary crosshead case 155. A pony rod 145 may be attached to an end of a crosshead 140 that is opposite to a crank shaft 125. A plunger 115 may be mounted to an end of the pony rod 145 by a pony rod clamp 150. A pony rod 145 moves and strokes a plunger 115 within a cylinder of a fluid end unit. A wrist pin 135 secures a plunger 115 to a connecting rod 130 and provides a bearing for the connecting rod 130 to pivot upon as the plunger 115 moves.
As shown in FIG. 1, a basic fluid end 110 includes a cylinder body 160, a discharge cover 165, valves 170, 172, suction bores 175, 177, springs 180, 182, a valve stop 185, packing 190, a fluid cylinder 195, a cover 197, and an intake 199. A packing 190 and a cylinder body 160 are configured to receive a plunger 115 from a power end 105 side of a hydraulic fracturing pump 100. Insertion and removal of a plunger 115 may create the positive and negative pressure loads within a fluid end 110 component that may draw low pressure fracking fluid from a reservoir and then turn it into high pressure fracking fluid that is purged through a discharge cover 165 to be received by a well bore. An upstroke of plunger 115 puts pressure on spring 180, which opens valve 170 and permits low pressure fracking fluid to be received through intake 199. Fracking fluid travels through intake 199, then through suction bore 175 and into the main body of a fluid end 110. Cover 197 serves as a stopping point for a plunger 115. Valve stop 185 provides for a stopping point enforcer for the maximum open position of a valve 170, which includes a valve body and valve seat. The downstroke of plunger 115 closes valve 170 and opens valve 172. The newly generated high pressure fracking fluid is capable of traveling through open valve 172, fluid cylinder 19, and discharge cover 165 and down a wellbore to create cracks in the deep-rock formations to stimulate flow of natural gas, petroleum, and brine.
In general practice, the fluid end of a hydraulic fracturing pump as shown in FIG. 1 is exposed to high pressure fluids containing corrosive agents, leading to the corrosion of the fluid end components, for example pitting. The present disclosure relates to a high pressure fluid end including sacrificial anodes that prevent the fluid end metal surfaces from corroding. In the electrochemical cell formed by the disclosed system, the fluid end may be a cathode that is protected against corrosion while the sacrificial anodes corrode in its place.
A disclosed fluid end having an anode may have enhanced corrosion resistance when compared to a corresponding fluid end not having the anode. In some embodiments, a fluid end having an anode may have an extended life span when compared to a corresponding fluid end not having the anode. For example, a fluid end having an anode when compared to a fluid end not having the anode when exposed to the same conditions may have an average lifespan that is at least about 25% longer, or at least about 50% longer, or at least about 100% longer, or at least about 125% longer, or at least about 150% longer, or at least about 200% longer, or at least about 250% longer, or at least about 300% longer, or at least about 350% longer, or at least about 400% longer, or at least about 450% longer, or at least about 500% longer than that of the fluid end not having the anode, where about includes plus or minus 25%.
FIGS. 2A-D illustrate a cross-sectional perspective of a fluid end having various sacrificial anodes. For example, as shown in FIG. 2A a fluid end may have one or more of a valve seat anode 205, a suction cap anode 210, a plunger anode 215, a spring retainer anode 220, and a valve top anode 225. An anode may be attached to various fluid end components by any known method in the art, including use of a bolt, an adhesive, a screw, compression, friction, a wire, and combinations thereof. A fluid end may include a suction cap 275 and a spring retainer 285. In some embodiments, a disclosed fluid end may have one or more anodes depending on the level of protection against corrosion that is desired. Since a driving force of the cathodic protection may be the difference in electrode potential between the anode and the cathode, adding additional anodes to a fluid end may provide for additional corrosive protection of the corresponding fluid end metal surface serving as the cathode.
Besides increasing the number of anodes, other methods can be used to increase the difference in electrode potential between the anode and the cathode to therefore increase protection of fracking pump components against corrosion. For example, anodes can be made up of different metals having different electrode potential. In general, the more negative the electrode potential of the anode with respect to the electrode potential of the cathode, the greater the cathodic protection. Therefore, disclosed anodes can be made from metals including aluminum alloys, zinc, zinc alloys, magnesium, magnesium alloys, and combinations thereof.
FIG. 2B-2D illustrate close-up vantages of various anodes from the fluid end of FIG. 2A, shown in cross-section, and illustrating various attachment mechanisms, according to some embodiments of the instant disclosure. As shown in FIG. 2B, a spring retainer anode 220 may be fastened to a fluid end by a spring retainer anode fastener 230. FIG. 2C illustrates an attachment of a suction cap anode 210 to a fluid end component with a suction cap anode fastener 235, according to one embodiment of the instant disclosure. As disclosed in FIG. 2D a plunger anode 215 may be fastened to a fluid end by a plunger anode fastener 240.
Each of a spring retainer anode fastener 230, a suction cap anode fastener 235, and a plunger anode fastener 240 may be a threaded fastener. For example, a threaded fastener may include a screw and a bolt, each including any type of head including a Phillips, slotted, combination, socket, hex, Allen, one-way, square, torx, quadrex, slotted hex, button, pan, truss, oval, round, flat, 6-lobe pin head, and combinations thereof. Threaded fasteners may include lag bolts, lag screws, through bolts, and through screw. Some disclosed embodiments include lag through bolts and through screws that may be coupled with a nut system. For example, a through bolt may be coupled with a hex nut to secure a sacrificial anode to a fluid end component. Nuts include hex, heavy hex, jam, wing, cap, acorn, flange, tee, square, prevailing torque lock, K-lock, coupling, slotted, castle, and combinations thereof. A threaded fastener can be made from any suitable material, such as metal or other materials capable of electrical conductivity or plastic. For example, disclosed threaded fasteners can be made from stainless steel, steel, brass, titanium, bronze, monel, aluminum, nickel, nylon, zinc, magnesium, polyethylene, and combinations thereof.
In some embodiments, more than one fastener may be used to fasten an anode to a fluid end. An anode may be fastened by one to ten fasteners to a fluid end. For example, an anode may be fastened to a fluid end by one fastener, by two fasteners, by four fasteners, by six fasteners, by eight fasteners, and by ten fasteners. FIG. 3A illustrates a fluid end having a suction cap anode 210, a plunger anode 215, and a spring retainer anode 220, each having one fastener. As shown in FIG. 3A, a fluid end may include a suction cap 275 and a spring retainer 285. Additionally, as shown in FIGS. 3A and 3B, a valve top anode 225 can be fastened to a fluid end with more than one valve stop anode fasteners 305. In some embodiments, a valve top anode 225 may fastened to a fluid end with two valve stop anode fasteners 305, three valve stop anode fasteners 305, four valve stop anode fasteners 305, five valve stop anode fasteners 305, six valve stop anode fasteners 305, seven valve stop anode fasteners 305, eight valve stop anode fasteners 305, nine valve stop anode fasteners 305, and ten valve stop anode fasteners 305.
According to some embodiments, an anode may maintain its position relative to a cathodic fluid end component without a fastener. For example, as shown in FIGS. 3A and 3B, a valve seat may include a valve seat outer diameter anode 310 and a valve seat inner diameter anode 315 that may maintain their position without having a fastener. According to some embodiments, an anode, such as a valve seat outer diameter anode 310 and a valve seat inner diameter anode 315, may snap into place.
In some embodiments, disclosed anodes may be secured into place via retaining ring as shown in FIGS. 4A and 4B. For example, valve top anode 425 may be secured to a valve by retaining ring 430. Retaining ring 430 may fit into a groove of the valve so that it maintains the position of valve top anode 425. A retaining ring 425 may be made of any plastic and metal and may be continuous or discontinuous. For example, a retaining ring 425 could be spring steel (e.g., low-alloy manganese, medium-carbon steel or high-carbon steel).
Disclosed valve seat inner diameter anodes 315 and valve seat outer diameter anodes 310 may be continuous or discontinuous. For example, as shown in FIGS. 5A-7L, a valve seat outer diameter anode 310 may be discontinuous in that it has a gap in its annular wall.
As described above, disclosed fluid ends may include one or more anodes in various locations throughout the fluid end. Both the number and location of anodes may affect the corrosive protection garnered to a metal surface of a fluid end. FIGS. 8-14 illustrate various anode configurations that vary both the number and position of the anodes included. Electrode potential data was measured by a reference electrode along five different locations along a fluid end. As shown in FIG. 8, an anode may be included in six different anode locations. FIG. 8 depicts that a disclosed fluid end may include one or more of a suction cap anode 210, a plunger anode 215, a spring retainer anode 220, a valve top anode 225, a valve seat outer diameter anode 310, and a valve seat outer diameter anode 315.
FIG. 9 discloses electrode potential measurement data from a fluid end having a suction cap anode 210, a plunger anode 215, a spring retainer anode 220, a valve top anode 225, and a valve seat outer diameter anode 310. All electrode potential measurement data was measured against an Ag/AgCl reference electrode. Data was measured at five sites by reference electrodes while using a 3.5% sodium chloride solution as an electrolyte that is pumped through the fluid end. As shown in FIG. 9, a measured electrode potential may be below the target threshold of about −800 mV (measured vs an Ag/AgCl reference electrode) at measurement locations 1, 2, and 3 across the active time from 14.5 hours to 48 hours. A measured electrode potential may be below about −750 mV across the times from 14.5 hours to 48 hours. A disclosed fluid end site having electrode potentials below a target threshold of about −800 mV may be substantially protected against corrosion. As a sacrificial anode itself corrodes in place of a surface of a fluid end site, a measured electrode potential may increase at the fluid end site, meaning that protection against corrosion may decrease. If a sacrificial anode is used up past a threshold, it may no longer provide corrosion protection for a fluid end site and the anode may be replaces to provide the fluid end site with protection again.
As shown in FIG. 10, in some embodiments, a disclosed fluid end may include a spring retainer anode 220, a valve top anode 225, and a valve seat outer diameter anode 310. In this configuration, the measured electrode potential may be between about −600 mV and about 875 mV when measured using a 3.5% sodium chloride electrolyte. When measured using a 2% sodium chloride electrolyte, the measured electrode potential may be between about −500 mV and about −750 mV. Disclosed fluid end sites having measured electrode potentials −500 mV and about −750 mV may be protected against corrosion. As shown in FIG. 10, disclosed cathodic protection systems may provide more protection against corrosion as time increases since the average electrode potential is more negative when measured at 4 hours.
In some embodiments, as shown in FIG. 11, a disclosed fluid end may have an anode configuration including a suction cap anode 210, a valve top anode 225, and a valve seat outer diameter anode 310. A configuration such as this may provide for a measured electrode potential from about −600 mV to about −750 mV from about 0 hours to about 63 hours across five measurement locations using a 3.5% sodium chloride electrolyte solution. In a 2% sodium chloride electrolyte solution, a configuration such as this may provide for a measured electrode potential from about −475 mV to about −700 mV from about 0 hours to about 24 hours across five measurement locations.
FIG. 12 discloses a fluid end having three anodes. A fluid end may include a suction cap anode 210, a valve top anode 225, and a valve seat outer diameter anode 310. Disclosed fluid ends having three anodes may provide for a measured electrode potential from about −570 mV to about −650 mV from about 0 hours to about 24 hours across five measurement locations using a 3.5% sodium chloride electrolyte solution. Disclosed fluid ends having three anodes including a suction cap anode 210, a valve top anode 225, and a valve seat outer diameter anode 310, may provide for a measured electrode potential from about −510 mV to about −615 mV from about 0 hours to about 24 hours across five measurement locations using a 2% sodium chloride electrolyte solution.
FIG. 13 illustrates a graphical comparison of the electrode potential data from the various anode configurations shown in FIGS. 9-12 measured in a 3.5% sodium chloride electrolyte solution. Arrangement B corresponds with FIG. 9 for a fluid end having a suction cap anode 210, a plunger anode 215, a spring retainer anode 220, a valve top anode 225, and a valve seat outer diameter anode 310. Arrangement G corresponds with FIG. 10 for a fluid end having a spring retainer anode 220, a valve top anode 225, and a valve seat outer diameter anode 310. Arrangement H corresponds with FIG. 11 for a fluid end having a plunger anode 215, a valve top anode 225, and a valve seat outer diameter anode 310. Arrangement I corresponds with FIG. 12 for a fluid end having a suction cap anode 210, a valve top anode 225, and a valve seat outer diameter anode 310. As shown in FIG. 13, arrangement B may provide for the most protection by reaching the target potential of about −800 mV at measurement locations 1-3 at 14.5 hours and at measurement locations 1-4 after 24 hours. After 24 hours, arrangement G may provide better corrosive protection than arrangement H and arrangement H may provide better corrosive protection than arrangement B.
FIG. 14 illustrates a graphical comparison of the electrode potential data from the various anode configurations shown in FIGS. 10-12 measured in a 2% sodium chloride electrolyte solution. As shown in FIG. 14, after 24 hours, arrangements G and H may provide better corrosive protection to a fluid end than arrangement I. However, at two hours or four hours, arrangement I may provide better corrosive protection in comparison to arrangement G and arrangement H. In some embodiments, anode arrangements can be changed during various periods of fluid end operation to maximize protecting a fluid end from corrosion.
As described in FIGS. 8-14, the position and number of anodes can be varied to alter the electrode potential of a cathodic protection system. Additionally, the shape and sizes of each anode can be changed to alter the electrode potential as well. FIGS. 15A-15K illustrate various anode configurations having different masses and different surface areas. The surface area of each anode may be varied by making an anode larger or smaller, which may increase or decrease the cathodic protection of the fluid end component. An anode may have a mass from about 0.05 ounces to about 0.5 ounces, where about includes plus or minus 0.05 ounces. According to some embodiments, an anode may have a mass of about 0.05 ounces, or of about 0.1 ounces, or of about 0.15 ounces, or of about 0.2 ounces, or of about 0.25 ounces, or of about 0.3 ounces, or of about 0.35 ounces, or of about 0.4 ounces, or of about 0.45 ounces, or of about 0.5 ounces, where about includes plus or minus 0.5 ounces. An anode may have a surface area of about 1 in², or of about 1.5 in², or of about 2 in², or of about 2.5 in², or of about 3 in², or of about 3.5 in², or of about 4 in², or of about 4.5 in², or of about 5 in², or of about 5.5 in², or of about 6 in², or of about 6.5 in², or of about 7 in², where about includes plus or minus 0.5 in².
In some embodiments, varying the surface area of an anode type may increase or decrease the protection of a fluid end component against corrosion. Varying the mass of an anode type may increase or decrease the protection of a fluid end component against corrosion.
FIGS. 15A and 15B illustrate valve seat inner diameter anodes having different exposed surface areas. A valve seat inner diameter anode of FIG. 15A has a mass of 0.058 ounces (oz.) and an exposed surface of 1.97 inches (in)²and a valve seat inner diameter anode from FIG. 15B has a mass of 0.058 oz. and an exposed surface of 2.0 in². FIG. 15C has a valve seat outer diameter anode with a mass of 0.182 oz. and an exposed surface area of 5.55 in²and FIG. 15D has a valve seat outer diameter anode with a mass of 0.193 oz. and an exposed surface area of 6.16 in². A suction cap anode disclosed in FIG. 15E has a mass of 0.065 oz. and an exposed surface area of 0.49 in²and a suction cap anode of FIG. 15F has a mass of 0.25 oz. and an exposed surface area of 0.1.32 in². As shown in FIG. 15G, a plunger anode may have a mass of 0.364 oz. and an exposed surface of 2.19 in². FIG. 15H discloses a spring retainer anode having a mass of 0.198 oz. and an exposed surface area of 1.52 in². As shown in FIG. 15I, a valve top anode may have a mass of 0.202 oz. and an exposed surface area of 1.17 in². FIG. 15J illustrates a valve top anode having four ports, a mass of 0.214 oz. and an exposed surface area of 1.17 in². FIG. 15K illustrates a valve top having a single port, a mass of 0.308 oz. and an exposed surface area of 1.22 in².
FIGS. 16A-16F are photographs of various anode configurations both alone and fitted to a corresponding fluid end component. FIG. 16A is a photograph of a valve top anode isolated and installed on a valve. In disclosed embodiments, and as shown in FIG. 16A, a valve top anode may be installed onto a vale without a fastener. FIG. 16B is a photograph of a spring retainer anode isolated and installed on a spring retainer through the use of a threaded fastener. As shown in FIG. 16C a valve seat inner diameter anode may be isolated and installed onto a valve seat. In some embodiments, a valve seat inner diameter anode may be installed by being glued into place with an electrically conductive epoxy on the valve seat. FIG. 16D is a photograph of a valve seat outer diameter anode both isolated and installed onto a valve seat. In some embodiments, a valve seat outer diameter anode may be installed onto a valve seat with a tight interference fit. FIG. 16E is a photograph of a suction seal anode both isolated and installed onto a suction cap and FIG. 16F is a photograph of a plunger anode isolated and installed onto a plunger. In some embodiments, and as shown in FIG. 16F, a plunger anode may be secured to a plunger with a threaded fastener.
However, even though FIGS. 1-16F disclose fluid end components having sacrificial anodes to protect the components against corrosion, the present disclosure also relates to conduits that are protected by cathodic protection against corrosion in a similar manner to the disclosed fluid ends. Disclosed conduits receive pressurized fracking fluid from a fluid end and transport the fracking fluid from the fluid end to a wellbore. Since an interior surface of a conduit may come into contact with a fracking fluid, it may be prone to corrosion. In some embodiments, sacrificial anodes may be affixed along an interior surface of a conduit, thereby protecting the interior surface from corrosion caused by contacting a fracking fluid.
In some embodiments, a conduit may be affixed with bolts having anodic ends. An anodic end may be disposable and may degrade in place of a conduit. In some embodiments, an anodic end may be a sacrificial anode. A disclosed conduit may include a bolt having an anodic end that may be affixed to or positioned near an inner surface of the conduit. For example, a through bolt may be threaded into a wall of a conduit so that at least a portion of an anodic end of the through bolt is positioned near an inner surface of the conduit. In some embodiments, a bolt may have an anodic end and an end that is substantially corrosion resistant, rust resistant, or both. As an anodic end of a bolt protects a surface of a conduit from corrosion it may degrade as it corrodes in place of the surface. A bolt may have a substantially corrosion resistant end attached to the anodic end so that once the anodic end substantially degrades, the bolt may be removed through interfacing the corrosion resistant end and a new bolt may replace the initial bolt. For example, a bolt may include a stainless steel nut and a zinc alloy anodic end. An anodic end of a bolt may be made from aluminum, aluminum alloys, zinc, zinc alloys, magnesium, magnesium alloys, and combinations thereof. In some embodiments, a corrosion resistant end may be made from brass, bronze, stainless steel, galvanized steel, gold, platinum, and silver.
According to some embodiments, a conduit may include a valve containing an anode. For example, a valve may include a threaded connection into a valve body that may serve as a protection to various conduit components. A valve may include a plug valve, a check valve, a ball valve, a gate valve, a globe valve, a diaphragm valve, a butterfly valve, a needle valve, a pinch valve, a piston valve, and a pressure relief valve. Any component of a valve may either be an anode or have an anode attached to it. For example, a plug valve may include a plug that is an anode or include a lining on the plug where the lining is an anode. In some embodiments, a check valve may include a stem, a ball, a piston, or a plate that is an anode.
FIG. 17 is a graph illustrating electrode potentials measured across various anode locations along a conduit. As shown in FIG. 17, a potential difference is measured at various positions along a 130 inch long conduit from about 20 inches to about 120 inches. In a disclosed conduit, a sacrificial anode is placed at about 9 inches, about 10.5 inches, at about 63 inches, and at about 64.5 inches from a starting or 0 inch position along the conduit. Along a disclosed conduit, an electrode potential may be less than about −800 mV from distance of about 20 inches to about 30 inches and from about 50 inches to about 70 inches. An electrode potential may be from about −750 mV to −800 mV at a distance from about 30 inches to about 50 inches and at a distance from 70 inches to about 75 inches. In some embodiments, an electrode potential may be more negative than about −750 mV at a distance from about 75 inches to about 120 inches. As shown in FIG. 17, an electrode potential of less than about −800 mV may be achieved at a distance of less than 15 inches from a sacrificial anode or in between two anodes. In some embodiments, having an electrode potential of less than about −800 mV may provide for a substantially complete protection from corrosion. Protection from corrosion may also be achieved at distances of about 60 inches away from a sacrificial anode. FIG. 17 shows an electrode potential from about −600 mV to about −750 mV at a distance from about 75 inches to about 120 inches.
Not only do disclosed fluid ends include systems and methods for cathodic protection against corrosion, but other disclosed parts of a hydraulic fracturing process may include similar protection mechanisms. For example, a disclosed conduit may have an anode that protects the conduit from corrosion. A disclosed conduit having an anode may have enhanced corrosion resistance when compared to a corresponding conduit not having the anode. In some embodiments, a conduit having an anode may have an extended life span when compared to a corresponding conduit not having the anode. For example, a conduit having an anode when compared to a conduit not having the anode when exposed to the same conditions may have an average lifespan that is at least 10% longer, at least 25% longer, or at least 50% longer, or at least 100% longer, or at least 125% longer, or at least 150% longer, or at least 200% longer, or at least 250% longer, or at least 300% longer, or at least 350% longer, or at least 400% longer, or at least 450% longer, or at least 500% longer than that of the conduit not having the anode.
FIG. 18 is a photograph of an experimental set up of a flow iron conduit fitted with more than one bolt having an anodic end. As shown in FIG. 18, a conduit may include more than one bolt having a stainless steel nut as a corrosion resistant end and an anodic end, including one made from zinc alloy. In some embodiments, a bolt may have anodic end For example, a bolt may have an anodic end of about 1 cm, or of about 2 cm, or of about 3 cm, or of about 4 cm, or of about 5 cm, or of about 6 cm, or of about 7 cm, or of about 8 cm, or of about 9 cm, or of about 10 cm, with about including plus or minus 1 cm. A bolt may have an anodic end having a diameter of about 0.5 cm, or of about 1 cm, or of about 1.5 cm, or of about 2 cm, or of about 2.5 cm, or of about 3 cm, or of about 3.5 cm, or of about 4 cm, or of about 4.5 cm, or of about 5 cm, where about includes plus or minus 0.5 cm. A reference electrode may be placed near a bolt to serve as a reference when measuring an electrode potential at various parts of a conduit. For example, a reference electrode may be located inside a conduit and potential electrode measurements may be made every one to five inches to determine a relative level of protection against corrosion. For example, an electrode potential measurement may be made about every one inch, or about every two inches, or about every three inches, or about every four inches, or about every five inches, where about includes plus or minus 0.5 inches. As an anodic end of a bolt corrodes and is used up, a reference electrode may detect a drift in electrode potential to more positive values relative to the bolt. At a threshold electrode potential, a bolt having a used up anodic end may be replaced with new bolt so that corrosive protection may be restored.
Not only may a conduit include an anodic bolt or anode affixed to a surface of the conduit, but the conduit may include a valve that includes an anode that may protect the valve and the conduit from corrosion. A disclosed valve having an anode may have enhanced corrosion resistance when compared to a corresponding valve not having the anode. In some embodiments, a valve having an anode may have an extended life span when compared to a corresponding valve not having the anode. A valve having an anode may have an average lifespan that is from at least 10% longer to at least 500% longer when compared to a valve not having the anode. For example, a valve having an anode when compared to a valve not having the anode when exposed to the same conditions may have an average lifespan that is at least about 10% longer, at least about 25% longer, or at least about 50% longer, or at least about 100% longer, or at least about 125% longer, or at least about 150% longer, or at least about 200% longer, or at least about 250% longer, or at least about 300% longer, or at least about 350% longer, or at least about 400% longer, or at least about 450% longer, or at least about 500% longer than that of the valve not having the anode, where about includes plus or minus 25%.
In some embodiments, a check valve or a plug valve that is not protected by a disclosed cathodic protection system may have a life expectancy of about 12 months in a corrosive environment such as one including exposure to a fracking fluid. In a non-corrosive environment or a less corrosive environment such as one including exposure to a) North Sea water, b) non-recycled water, or c) non-produced water may have a life expectancy of about 5 years. Corrosion may cause pitting on a non-repairable area of a check valve and a plug valve that may lead to component failure. In some embodiments, disclosed cathodic protection systems may protect critical areas of a plug valve and a check valve including a sealing area, a sealing surface, and a wetted surface including one exposed to pressurized fluid. A cathodic protection systems may protect a check valve and a plug valve component from at least about 1 week to at least about 8 weeks. For example, a disclosed cathodic protection systems may protect a check valve and a plug valve component for at least about 1 week, or at least about 2 weeks, or at least about 3 weeks, or at least about 4 weeks, or at least about 5 weeks, or at least about 6 weeks, or at least about 7 weeks, or at least about 8 weeks, where about includes plus or minus 0.5 weeks. Disclosed cathodic protection systems may protect a check valve and a plug valve component for at least about 1 month, or at least about 2 months, or at least about 3 months, or at least about 4 months, or at least about 5 months, or at least about 6 months, or at least about 7 months, or at least about 8 months, or at least about 9 months, or at least about 10 months, or at least about 11 months, or at least about 12 months, where about includes plus or minus 0.5 months. Disclosed cathodic protection systems may protect a check valve and a plug valve each having a diameter of about 1 inch, or of about 2 inches, or of about 3 inches, or of about 4 inches, or of about 5 inches, or of about 6 inches, or of about 7 inches, or of about 8 inches, or of about 9 inches, or of about 10 inches, or of about 11 inches, or of about 12 inches, where about includes plus or minus 0.5 inches. Disclosed cathodic protection systems may protect a conduit having a diameter of about 1 inch, or of about 2 inches, or of about 3 inches, or of about 4 inches, or of about 5 inches, or of about 6 inches, or of about 7 inches, or of about 8 inches, or of about 9 inches, or of about 10 inches, or of about 11 inches, or of about 12 inches, where about includes plus or minus 0.5 inches.
As shown in FIG. 19A, a conduit may include a check valve having an anode. In some embodiments, a check valve may include at least one anode. Additionally, a check valve may include a wing nut 1901, a retainer segment 1902, a retainer ring 1903, an RFID ID band 1904, a check valve body 1905, a roll pin 1906, a seat 1907, a union seal 1908, a seat back up ring 1909, a seat O-ring 1910, a clapper 1911, a clapper pin 1912, a hanger 1913, a cover O-ring 1914, a cover back up ring 1915, a cover 1916, bolts 1917, and a lifting eye 1918. A check valve may include a ball check valve, a diaphragm check valve, a swing check valve, a tilting disc check valve, a stop-check valve, a lift-check valve, an in-line check valve, a duckbill valve, and a pneumatic non-return valve. A check valve may be protected from corrosion from an anode of various surface areas and masses depending on the surface area of the check valve. For example, in one embodiment, an anode having a surface area of about 50 cm²(7.8 in.²) may be used to protect a check valve having a surface area of about 1,400 cm²(217 in.²) from corrosion. A check valve anode may have a surface area of about 10 cm², or of about 20 cm², or of about 30 cm², or of about 40 cm², or of about 50 cm², or of about 60 cm², or of about 70 cm², or of about 80 cm², or of about 90 cm², or of about 100 cm², where about includes plus or minus 5 cm².
In some embodiments, as an anode provides cathodic protection for a check valve against corrosion, the anode may degrade and may need to be replaced. A starting volume and mass of an anode may be changed to provide longer or shorter protection times. A check valve may include an anode having a mass of about 100 g, or of about 200 g, or of about 300 g, or of about 400 g, or of about 500 g, or of about 600 g, or of about 700 g, or of about 800 g, or of about 900 g, or of about 1,000 g, or of about 1,100 g, or of about 1,200 g, or of about 1,300 g, or of about 1,400 g, or of about 1,500 g, or of about 1,600 g, or of about 1,800 g, or of about 1,900 g, or of about 2,000 g, where about includes plus or minus 500 g. A check valve may include an anode having a volume of about 25 cm³, or of about 50 cm³, or of about 75 cm³, or of about 100 cm³, or of about 125 cm³, or of about 150 cm³, or of about 175 cm³, or of about 200 cm³, or of about 225 cm³, or of about 250 cm³, or of about 275 cm³, or of about 300 cm³, where about includes plus or minus 12.5 cm³.
An anode having a mass of about 240 g (0.53 lb) and a volume of about 34 cm³(2.07 in³) may protect a check valve having a surface area of about 1,400 cm²for about 4 weeks. An anode having a mass of about 480 g (1.06 lb) and a volume of about 68 cm3 (4.15 in³) may protect a check valve having a surface area of about 1,400 cm²for about 8 weeks. An anode having a mass of about 1,440 g (3.17 lb) and a volume of about 202 cm3 (12.33 in³) may protect a check valve having a surface area of about 1,400 cm²for about 6 months. In some embodiments, a mass or a volume of an anode or anodic material may be divided among more than one anode where a similar mass or volume may similarly protect a check of a given surface area. For example, two anodes each having a mass of about 240 g and a volume of about 34 cm³may protect a check valve having a surface area of about 1,400 cm²for about 8 weeks.
In some embodiments, as shown in FIG. 19B, a conduit may include a plug valve having an anode. Additionally, a plug valve may include a grease fitting 1919, a socket head cap screw 1920, an end plate 1921, a ring backup 1922, a seal 1923, a seal 1924, a backup ring 1925, a plug 1926, a seal segment 1927, a side segment casting 1928, a segment O-ring 1929, a plug valve body 1930, a union seal 1931, a retainer ring 1932, a retainer segment 1933, a wing nut 1934, an adapter 1935, a gear operator assembly 1936, a mounting adapter bolt 1937, a mounting adapter washer 1938, an adapter key 1939, an adapter 1940, a hand wheel 1941, a mounting adapter bolt 1942, and a mounting adapter washer 1943. In some embodiments, a plug valve may include an anode. A plug valve may include a lubricated plug valve, a non-lubricated plug valve, an eccentric plug valve, and an expanding plug valve. A plug valve may be protected from corrosion from an anode of various surface areas and masses depending on the surface area of the plug valve. For example, for a plug valve having a surface area of about 1,770 cm²(274 in.²), an anode having a surface area of about 63 cm²(10 in.²) may be used to protect the plug valve from corrosion. As an anode provides cathodic protection against corrosion, the anode degrades and needs to be replaced. A starting volume and mass of an anode may be changed to provide longer or shorter protection times for a plug valve. A plug valve may include an anode having a mass of about 100 g, or of about 200 g, or of about 300 g, or of about 400 g, or of about 500 g, or of about 600 g, or of about 700 g, or of about 800 g, or of about 900 g, or of about 1,000 g, or of about 1,100 g, or of about 1,200 g, or of about 1,300 g, or of about 1,400 g, or of about 1,500 g, or of about 1,600 g, or of about 1,800 g, or of about 1,900 g, or of about 2,000 g, where about includes plus or minus 500 g. A plug valve may include an anode having a volume of about 25 cm³, or of about 50 cm³, or of about 75 cm³, or of about 100 cm³, or of about 125 cm³, or of about 150 cm³, or of about 175 cm³, or of about 200 cm³, or of about 225 cm³, or of about 250 cm³, or of about 275 cm³, or of about 300 cm³, where about includes plus or minus 12.5 cm³.
In some embodiments, an anode having a mass of about 300 g (0.66 lb) and a volume of about 42 cm³(2.56 in³) may protect a plug valve having a surface area of about 1,770 cm²for about 4 weeks. An anode having a mass of about 600 g (1.32 lb) and a volume of about 84 cm³(5.12 in³) may protect a plug valve having a surface area of about 1,770 cm²for about 8 weeks. An anode having a mass of about 1,800 g (3.97 lb) and a volume of about 252 cm³(15.38 in³) may protect a plug valve having a surface area of about 1,770 cm²for about 6 months. In some embodiments, a mass or a volume of an anode or anodic material may be divided among more than one anode where a similar mass or volume may similarly protect a plug of a given surface area. For example, two anodes each having a mass of about 300 g and a volume of about 42 cm³may protect a plug valve having a surface area of about 1,770 cm²for about 8 weeks.
As will be understood by those skilled in the art who have the benefit of the instant disclosure, other equivalent or alternative compositions, devices, and disclosed systems and methods for cathodic protection of hydraulic fracturing pump systems can be envisioned without departing from the description contained in this application. Accordingly, the manner of carrying out the disclosure as shown and described is to be construed as illustrative only.
Persons skilled in the art can make various changes in the shape, size, number, and/or arrangement of parts without departing from the scope of the instant disclosure. For example, the position and number of anodes can be varied. In some embodiments, valves can be interchangeable. In addition, the size of a device and/or system can be scaled up or down to suit the needs and/or desires of a practitioner. Each disclosed process, system, method, and method step can be performed in association with any other disclosed method or method step and in any order according to some embodiments. Where the verb “may” appears, it is intended to convey an optional and/or permissive condition, but its use is not intended to suggest any lack of operability unless otherwise indicated. Where open terms such as “having” or “comprising” are used, one of ordinary skill in the art having the benefit of the instant disclosure will appreciate that the disclosed features or steps optionally can be combined with additional features or steps. Such option may not be exercised and, indeed, in some embodiments, disclosed systems, compositions, apparatuses, and/or methods can exclude any other features or steps beyond those disclosed in this application. Elements, compositions, devices, systems, methods, and method steps not recited can be included or excluded as desired or required. Persons skilled in the art can make various changes in methods of preparing and using a composition, device, and/or system of the disclosure.
Also, where ranges have been provided, the disclosed endpoints can be treated as exact and/or approximations as desired or demanded by the particular embodiment. Where the endpoints are approximate, the degree of flexibility can vary in proportion to the order of magnitude of the range. For example, on one hand, a range endpoint of about 50 in the context of a range of about 5 to about 50 can include 50.5, but not 52.5 or 55 and, on the other hand, a range endpoint of about 50 in the context of a range of about 0.5 to about 50 can include 55, but not 60 or 75. In addition, it can be desirable, in some embodiments, to mix and match range endpoints. Also, in some embodiments, each figure disclosed (e.g., in one or more of the examples, tables, and/or drawings) can form the basis of a range (e.g., depicted value +/−about 10%, depicted value +/−about 50%, depicted value +/−about 100%) and/or a range endpoint. With respect to the former, a value of 50 depicted in an example, table, and/or drawing can form the basis of a range of, for example, about 45 to about 55, about 25 to about 100, and/or about 0 to about 100. Disclosed percentages are volume percentages except where indicated otherwise.
All or a portion of a disclosed systems and methods for cathodic protection of hydraulic fracturing pump systems can be configured and arranged to be disposable, serviceable, interchangeable, and/or replaceable. These equivalents and alternatives along with obvious changes and modifications are intended to be included within the scope of the present disclosure. Accordingly, the foregoing disclosure is intended to be illustrative, but not limiting, of the scope of the disclosure as illustrated by the appended claims.
The title, abstract, background, and headings are provided in compliance with regulations and/or for the convenience of the reader. They include no admissions as to the scope and content of prior art and no limitations applicable to all disclosed embodiments.

Claims

What is claimed is:

1. A hydraulic fracturing pump comprising a fluid end assembly, the fluid end assembly comprising:

a cylinder body oriented along a longitudinal axis of the fluid end, comprising a first end and a second end, and configured to receive a respective plunger from a power end through the first end of the cylinder body;

a suction bore oriented along a vertical axis of the fluid end and connected to the cylinder body through the second end of the cylinder body, wherein the suction bore is configured to house a valve body, a valve seat, and a spring, wherein the valve body having a top, and the valve seat having an inner diameter and an outer diameter;

a suction cap located at the second end of the cylinder body; and

a spring retainer contained within the suction bore,

wherein a surface of one or more of the cylinder body, the suction bore, the suction cap, and the spring retaining is configured to serve as a cathode, and

wherein at least one of the plunger, the suction cap, the spring retainer, the valve top, the valve seat outer diameter, and the valve seat inner diameter is configured to serve as an anode.

2. The hydraulic fracturing pump of claim 1, wherein the fluid end comprises an anode configuration selected from the group consisting of:

the plunger anode, the suction cap anode, the valve top anode, the valve seat outer diameter anode, and the valve seat inner diameter anode;

the valve top anode, the valve seat outer diameter anode, and the valve seat inner diameter anode;

the plunger anode, the valve seat outer diameter anode, and the valve seat inner diameter anode; and

the suction cap anode, the valve seat outer diameter anode, and the valve seat inner diameter anode.

3. The hydraulic fracturing pump of claim 1, wherein at least one of the plunger anode, the suction cap anode, the spring retainer anode, the valve top anode, the valve seat outer diameter anode, and the valve seat inner diameter anode each comprises a sacrificial anode fabricated from one or more metals selected from the group consisting of aluminum, aluminum alloys, zinc, zinc alloys, magnesium, and magnesium alloys.

4. The hydraulic fracturing pump of claim 3, wherein the sacrificial anode is secured by at least one method selected from the group of a mechanical fastener, an adhesive, and a friction fit.

5. The hydraulic fracturing pump of claim 1, wherein:

the plunger anode is secured onto an end of the plunger by a plunger bolt,

the suction cap anode is secured onto an end of the suction cap by a suction cap bolt,

the spring retainer anode is secured onto an end of the spring retainer by a spring retainer bolt,

the valve top anode is secured onto an end of a valve top by a retainer ring,

the valve seat outer diameter anode that clamps onto an outer diameter of the valve seat, and

the valve seat inner diameter anode that clamps onto an inner diameter of the valve seat.

6. The hydraulic fracturing pump of claim 5, wherein at least one of the plunger bolt, the suction cap bolt, the spring retainer bolt, and the valve top bolt comprises brass, bronze, stainless steel, galvanized steel, gold, platinum, and silver, and wherein one or more of the plunger bolt, the suction cap bolt, the spring retainer bolt, and the valve top bolt is substantially inert to corrosion.

7. The hydraulic fracturing pump of claim 1, wherein at least one of the plunger anode, the suction cap anode, the valve top anode, the valve seat outer diameter anode, and the valve seat inner diameter anode comprises a mass from about 0.15 ounces to about 0.5 ounces.

8. The hydraulic fracturing pump of claim 1, wherein at least one of the plunger anode, the suction cap anode, the valve top anode, the valve seat outer diameter anode, and the valve seat inner diameter anode comprises a surface area from about 1 in²to about 7 in².

9. A system for preventing corrosion of a surface of a conduit, the system comprising:

the conduit comprising a tubular body; an outer surface; an inner surface configured to contain a fracking fluid; and one or more ports configured to receive a bolt or a valve; and

the bolt comprising an anodic end and a corrosion resistant end.

10. The system of claim 8, wherein the system further comprises a check valve comprising a check valve anode.

11. The system of claim 9, wherein the system further comprises a plug valve comprising a plug valve anode.

12. The system of claim 10, wherein the check valve anode has a mass from about 100 g to about 2,000 g.

13. The system of claim 11, wherein the plug valve anode has a mass from about 100 g to about 2,000 g.

14. The system of claim 10, wherein the check valve anode has a volume from about 25 cm³to about 300 cm³.

15. The system of claim 11, wherein the plug valve anode has a volume from about 100 g to about 2,000 g.

16. The system according to claim 9, wherein the anodic end comprises aluminum, aluminum alloys, zinc, zinc alloys, magnesium, magnesium alloys, and combinations thereof.

17. The system according to claim 9, wherein the corrosion resistant end comprises brass, bronze, stainless steel, galvanized steel, gold, platinum, and silver.

18. A system for preventing corrosion of a surface of a conduit, the system comprising:

a valve comprising an anode.

19. The system of claim 18, wherein the valve comprises a check valve, and wherein the anode comprises a check valve anode.

20. The system of claim 18, wherein the valve comprises a plug valve, and wherein the anode comprises a plug valve anode.