A method of manufacturing a flow block for use as a T-Block, tree block, manifold block or valve block, the method including: machining a main bore in a body; forming an opening in the body in a side wall of the main bore; providing an insert including a first bore intersecting with a second bore and being in fluid communication with each other; forming a substantially curved surface on at least part of the intersection between the first bore and the second bore; and inserting the insert into the opening, such that the first bore is substantially aligned with the main bore in order to provide a fluid flow path between the main bore and the second bore.
1. A tubing hanger to support a completion tubing, including:
a body including an exterior, a main bore, and a side bore extending between the main bore and the exterior; and
an insert insertable from the exterior through the side bore and including a first bore and a second bore, the first bore being alignable and concentric with the main bore, the second bore intersecting the first bore at an intersection;
wherein the intersection defines an inside corner and an outside corner of a fluid flow path; and
wherein a substantially curved surface is positioned at one or more of the inside and outside corners.
2. A tubing hanger according to claim 1 , wherein the substantially curved surface is positioned at the outside corner of the fluid flow path.
3. A tubing hanger according to claim 1 , wherein the substantially curved surface is provided around the entire intersection.
4. A tubing hanger according to claim 1 , wherein the radius of the substantially curved surface is greater than approximately 25% of the diameter of the side bore.
5. A tubing hanger according to claim 1 , wherein the radius of curvature of the substantially curved surface is approximately 50% of the diameter of the side bore.
6. A tubing hanger according to claim 1 , wherein the substantially curved surface is a convex surface.
7. A tubing hanger according to claim 1 , further including at least one weld between the body and the insert.
8. A tubing hanger according to claim 1 , wherein the body and the insert are formed from the same material.
9. A tubing hanger according to claim 1 , wherein the body and the insert are formed from different materials.
10. A tubing hanger according to claim 9 , wherein the insert is formed from nickel alloy or Tungsten material.
11. A tubing hanger according to claim 1 , wherein the side bore is perpendicular to the main bore.
12. A tubing hanger according to claim 1 , wherein the side bore is at a non-ninety degree angle to the main bore.
13. A tubing hanger according to any claim 1 , further including a recess in the body in a side wall of the main bore, opposite the side bore.
14. A tubing hanger according to claim 1 , further including a second side bore intersecting the main bore, the second side bore being in fluid communication with the main bore; wherein the substantially curved surface is provided on at least part of the intersection between the main bore and the second side bore.
15. A tubing hanger according to claim 1 , wherein the the substantially curved surface is positioned at the inside corner of the fluid flow path.
16. A tubing hanger assembly to support a completion tubing, including:
a body including an exterior, a main bore, and an opening in the body extending between the main bore and the exterior; and
a preformed insert including a first bore intersecting with a second bore at an intersection for fluid communication between the first bore and the second bore;
wherein the insert is configured for insertion from the exterior through the opening in the body such that the first bore is aligned and concentric with the main bore and the second bore intersects the first bore and is aligned with the opening to establish fluid communication between the main bore and the opening through the insert; and
wherein the insert includes a substantially curved inner surface on at least a part of the intersection between the first bore and the second bore.