ELECTRIC FRACTURING SYSTEM, FRACTURING TRANSPORT FOR FRACTURING OPERATIONS AND METHOD FOR DISTRIBUTI

专利摘要:
providing electrical power distribution for fracturing operations comprising receiving, in a transport element, electrical power from a mobile source of electricity at a first voltage level and supplying, from the transport element, electrical power to a transport element of frac pump on the first stress level using only a single cable first connection. the first voltage level falls within a range of 1000v to 35kv. the transport element also supplies electrical power to a second transport element at the first voltage level using only a second single cable connection.
公开号:BR112019028085B1
申请号:R112019028085-5
申请日:2018-06-28
公开日:2021-06-01
发明作者:Jeffrey G. Morris；Adrian Benjamin Bodishbaugh；Neal Jensen
申请人:Typhon Technology Solutions, Llc；
IPC主号:

专利说明:

FUNDAMENTALS
[001] Hydraulic fracturing has been commonly used by the oil and gas industry to stimulate the production of hydrocarbon production wells, such as oil and/or gas wells. Hydraulic fracturing, sometimes called "fracing" or "fracking" is the process of injecting fracturing fluid into a wellbore to fracture underground geological formations and release hydrocarbons. Fracture fluid is pumped into a wellbore at a pressure sufficient to cause cracks within underground geological formations. Once inside the wellbore, the fracturing fluid fractures the underground formation. Fracturing fluid can include water, various chemical additives and proppants that promote the extraction of hydrocarbon reserves such as oil and/or gas. Propants, such as frac sand, prevent cracks and fractures in the underground formation from closing; thereby allowing the formation to remain open for hydrocarbons to flow through the hydrocarbon wells.
[002] The implementation of fracturing operations at well sites requires extensive investment in equipment, labor and fuel. A typical fracturing operation uses fracturing equipment, personnel to operate and maintain the fracturing equipment, large amounts of fuel to power fracturing operations and relatively large volumes of fracturing fluids. As such, planning for fracturing operations is complex and encompasses a variety of logistical challenges that include minimizing the area on site or the "footprint" of fracturing operations by providing adequate energy and/or fuel to continuously power fracturing operations , increasing the efficiency of hydraulic fracturing equipment, and reducing the environmental impact resulting from fracturing operations. Thus, numerous innovations and improvements to existing fracturing technology are needed to address the variety of complex and logistical challenges faced in today's fracturing operations. SUMMARY
[003] The following presents a simplified summary of the disclosed matter in order to provide a basic understanding of some aspects of the matter disclosed in this document. This summary is not an exhaustive overview of the technology disclosed herein and is not intended to identify key or critical elements of the invention or to delineate the scope of the invention. Its sole purpose is to present concepts in simplified form as a prelude to the more detailed description that will be discussed later.
[004] In one embodiment, an apparatus comprising a hydration tank, a frac mixer and an internal collector system. The internal manifold system couples the hydration tank and frac mixer to direct fluid between the hydration tank and frac mixer. The apparatus also comprises a single transport frame that couples the hydration tank, frac mixer and internal manifold system to form a single transport.
[005] In another embodiment, a method for producing fracturing fluid, comprising receiving source fluid from one or more inlet manifolds of a single transport and driving a first pump mounted on the single transport to direct the source fluid from the inlet manifolds to a hydration tank mounted on the single transport. The method also drives the second pump mounted on the single carriage to direct the hydrated fluid produced by the hydration tank to a mixing tub mounted on the single carriage and discharges the fracturing fluid produced by the mixing tub to one or more conveyor outlet headers. single.
[006] In yet another modality, a transport comprising a transport frame, an internal collector system coupled to the transport frame, and a hydration tank coupled to the transport frame. The hydration tank is configured to receive a source fluid from the internal collector system, produce a hydrated fluid with a target viscosity based on the source fluid, and send the hydrated fluid to the internal collector system. The transport also comprises a mixer coupled to the transport frame, where the mixer is configured to receive the hydrated fluid from the internal manifold system, produce a fracturing fluid based on the hydrated fluid, and discharge the hydrated fluid to the manifold system internal. The delivery rate of hydrated fluid to the hydration tank corresponds to an amount of fracturing fluid that the mixer delivers to one or more fracturing pump carriers.
[007] In another embodiment, an electrical fracturing system comprises a switching gear transport electrically connected to a power generation source to provide electrical energy at a first voltage level. The electrical frac system also comprises an electrical cable that supplies electrical power at the first voltage level and a frac pump conveyor electrically connected to the switching gear conveyor via the electrical cable only. The frac pump transport comprises a transformer that reduces the electrical energy received at the first voltage level to a lower voltage level. The frac pump transport is not electrically connected to the switching gear transport by another electrical cable at a voltage level that differs from the first voltage level.
[008] In another modality, a transport comprising a single transport frame and an electrical primary drive mounted on the single transport frame. The pump is coupled to the electric prime mover and mounted on the single transport frame and a transformer is coupled to the electric prime mover and mounted on the single transport frame. The transformer is configured to receive electrical energy at a first voltage level from a power source through a single set of cables and to reduce electrical energy at the first voltage level to a lower voltage level. The transformer is also configured to supply electrical power at the lowest voltage level to the electrical primary driver, where the transport is not connected to any other set of cables that supply electrical power at the first voltage level and at other voltage levels.
[009] In yet another modality, a method for distributing electrical energy used for fracturing operations. The method comprises receiving, in a transport, electrical energy from a mobile source of electricity at a first voltage level, where the first voltage level falls within a range of 1,000 V to 35 kilovolts and supplying, from the transport , electrical power to a frac pump transport at the first voltage level using only a single cable first connection. The method also includes providing, from the transport, the electrical power for a second transport at the first voltage level using only a second single-cable connection.
[0010] In yet another embodiment, each of the above described embodiments and variations thereof may be implemented as a method, apparatus and/or system. BRIEF DESCRIPTION OF THE DRAWINGS
[0011] For a more complete understanding of this disclosure, reference is now made to the following brief description taken in connection with the accompanying drawings and the detailed description, in which like reference numbers represent like parts.
[0012] Figure 1 is a schematic diagram of an embodiment of a well site comprising a wellhead and a mobile fracturing system.
[0013] Figure 2 is a schematic diagram of a modality of a medium and low voltage power distribution system for the mobile fracturing system.
[0014] Figure 3 is a schematic diagram of another modality of a medium voltage power distribution system for the mobile fracturing system.
[0015] Figure 4A illustrates a side view of one embodiment of a hydration mixer transport.
[0016] Figure 4B illustrates a cross-sectional view of the hydration mixer transport tank.
[0017] Figure 4C illustrates a cross-sectional view of the hydration mixer transport representing the interior of the hydration tank.
[0018] Figure 4D illustrates a top view of the hydration mixer transport representing the top of the hydration tank.
[0019] Figure 4E illustrates a cross-sectional view of the hydration mixer transport that corresponds to the section A-A section shown in Figure 4D.
[0020] Figure 4F illustrates a cross-sectional view of the tank of another embodiment of a hydration mixer carriage.
[0021] Figure 5 illustrates an embodiment of a hydration mixer carriage that includes a single mixing tub.
[0022] Figure 6 is a flowchart of one embodiment of a method for providing fracturing fluid using a single hydration mixer carriage.
[0023] Figure 7 is a flowchart of one modality of a method for providing electrical energy to fracturing equipment.
[0024] Although certain embodiments are described in connection with the illustrative embodiments shown herein, the invention is not limited to those embodiments. Rather, all alternatives, modifications and equivalents are included within the spirit and scope of the invention as defined by the claims. In the figures, which are not to scale, the same reference numbers are used throughout the description and in the figures for components and elements with the same structure, and primary reference numbers are used for components and elements with similar function and construction to the components. and elements with the same non-primary reference numbers. DETAILED DESCRIPTION
[0025] The term "fracturing sand" is used in this disclosure to serve as a non-limiting example of a proppant used as a component of the fracturing fluid. "Fracking sand" is also used here to collectively refer to both wet and dry frac sand. Modalities in this disclosure are not limited to frac sand and any other type of proppant, such as artificial ceramics, aluminum beads and sintered bauxite, can be used with the various modalities presented in the disclosure. Unless otherwise specified in the disclosure, the term "fracturing sand" may be exchanged throughout this disclosure with the term "propans".
[0026] As used herein, the term "wet frac sand" refers to an amount of frac sand that contains a moisture content of about one percent or more, which is normally determined on a weight basis. "Dry frac sand" refers to quantities of frac sand that contain a moisture content of less than about one percent. As used herein, the term "liquefied wet frac sand" refers to improving and transforming the flow properties of wet frac sand to be substantially similar to dry frac sand in order to accurately control the amount of frac sand. measured fracturing. Wet frac sand can liquefy and flow when shaken vigorously.
[0027] As used herein, the term "transport" refers to any transport assembly, including, but not limited to, a trailer, truck, wedge, wagon and/or barge used to transport relatively heavy structures and/or other types of articles such as fracturing equipment and fracturing sand. A transport can be moved independently of another transport. For example, a first transport can be mounted or connected to a motor vehicle that independently moves the first transport, while an unconnected second transport remains stationary.
[0028] As used in this document, the term "trailer" refers to a transport assembly used to transport relatively heavy structures and/or other types of articles (such as fracturing equipment and frac sand) that can be connected and/ or disconnected from a transport vehicle used to pull or tow the trailer. As an example, the transport vehicle is able to independently move and tow a first trailer, while an unconnected second trailer remains stationary. In one or more embodiments, the trailer includes mounts and collector systems to connect the trailer to other fracturing equipment within a frac system or fleet. The term "laying trailer" refers to a specific form of trailer that includes two sections with different vertical heights. One of the sections or the upper section is positioned on or above the trailer axles and another section or the lower section is positioned on the trailer axles or below them. In one embodiment, the main tow beams of the laying trailer may be resting on the ground when in operational mode and/or when uncoupled from a transport vehicle such as a tractor.
[0029] As used herein, the term "low voltage" refers to a voltage range of about 50 volts (V) to 1000 V for alternating current (AC) electrical power. The term "medium voltage" refers to a voltage range from about 1000V to about 35 kilovolts (kV) for AC electrical power, and the term "high voltage" refers to a voltage range greater than 35 kV for AC power. Although the terms “low voltage”, “medium voltage” and “high voltage” generally refer to voltage ranges in AC electrical power, the disclosure is not limited to AC electrical power and may also use current (DC) voltage.
[0030] Unless otherwise specified in the disclosure, the term "electrical connection" refers to the connection of one transport to another transport using one or more electrical cables. The term "power cord" may be interchanged throughout this disclosure with the term "power cord" "power cord connection", "cable connection" or "power cord connection". The terms "power cord", "power cord", "power cord connection", "cable connection" and "power cord connection" refer to a single set of cables that bundle one or more wires together (for example, copper wires) that carry AC or DC electrical current to provide electrical power. In one or more embodiments, the single cable assembly also includes other types of wires, such as fiber optic wires that perform functions other than providing electrical power. For example, fiber optic wires are capable of carrying light for the purpose of transferring communication signals.
[0031] Several exemplary embodiments are disclosed herein for performing mobile fracturing operations using a hydration mixer conveyor. Instead of having a separate hydration transport independent of the mixer transport, a frac fleet can replace two or more different transports with a single hydration mixer transport. The hydration mixer carriage includes a hydration tank and a mixer unit (eg, a single configuration mixer or a dual configuration mixer) interconnected with each other using the hydration mixer carriage's internal manifold system. The internal manifold system directly couples the hydration tank and the mixer unit so that the hydration tank is able to supply fracturing fluid to the mixer unit without the need for manifolds or other fluid connections (eg, pipes or hoses ) which are external to the hydration mixer transport. To draw source fluid, such as water or a mixture of fluids (e.g., water with chemical additives), through one or more inlet manifolds, the hydration mixer transport comprises a plurality of electrical primary actuators that drive a plurality of bombs. Based on how an operator configures the inlet valves of the internal manifold system, the hydration mixer conveyor can transfer source fluid to the hydration tank and mixer unit, or completely bypass the hydration tank and unit. of mixer and transport the source fluid directly to one or more outlet manifolds. In so doing, the hydration mixer conveyor is capable of performing a variety of operations including, but not limited to, direct operations, hydration mixer operations, and split-flow operations.
[0032] Several examples of modalities that distribute electricity from a mobile source of electricity are also disclosed. In one modality for fracturing operations, a power distribution system positions the stress-reducing operation downstream and close to the fracturing equipment within a mobile fracturing system. As an example, the frac pump and hydration mixer transport both include transformers that reduce the supplied tension level to one or more lower tension levels than fracturing equipment (eg, electrical prime movers) utilizes. Transports can also include inverters (eg variable frequency inverters (VFDs)) to control and monitor electrical primary drives. In doing so, the mobile fracturing system is able to reduce the number of transports by eliminating the use of an auxiliary unit transport (eg auxiliary unit transport 106 in Figure 2) and/or drive power transport (by example, drive power transport 104 in Figure 2). A switching gear transport within the mobile fracturing system is then able to supply directly to other transports, such as the hydration mixer transport and the frac pump transport, electrical energy at a relatively high medium voltage level (for example , 13.8 kV);, reducing the number of electrical cables to power fracturing equipment. For example, the switching gear carrier can connect to each frac pump carrier using a single electrical cable that provides electrical power at 13.8 kV. Each transformer mounted on the frac pump conveyor can reduce the electrical energy supplied to different voltage levels (eg 4.2 kV and 480 V) and provide sufficient electrical current to power the fracturing equipment.
[0033] Figure 1 is a schematic diagram of an embodiment of a well site 100 comprising a wellhead 101 and a mobile fracturing system 103. Generally, a mobile fracturing system 103 can perform fracturing operations to complete a well and/or transforming a drilled well into a production well. For example, well site 100 may be a location where operators are in the process of drilling and completing a well. Operators can begin the well completion process with vertical drilling, production casing, and in-well cementation. Operators can also insert a variety of downhole tools into the well and/or as part of a tool string used to drill the well. After operators drill the well to a certain depth, a horizontal portion of the well can also be drilled and subsequently encased in cement. Operators can subsequently pack the rig and move a mobile fracturing system 103 to well site 100 to perform fracturing operations that force relatively high pressure fracturing fluid through wellhead 101 into subsurface geological formations to create cracks and cracks within the rock. Mobile fracturing system 103 can then be moved off well site 100 when operators complete fracturing operations. Typically, fracturing operations for well site 100 can take several days or weeks.
[0034] As shown in Figure 1, the mobile fracturing system 103 includes a mobile source of electricity 102 configured to generate electricity by converting hydrocarbon fuel, such as natural gas, obtained from one or more other sources (e.g., a wellhead production, collection tube systems and/or pipelines) at the well site 100, from a remote location and/or other relatively convenient location near the mobile electricity source 102. The mobile electricity source 102 supplies the generated electricity to the fracturing equipment to power fracturing operations at one or more well sites. In particular, mobile electricity source 102 can supply electrical power to fracturing equipment within mobile fracturing system 103 which includes but is not limited to switching gear transport 112, drive power transport 104, unit transport auxiliary 106, mixer transport 110, data van 114, hydration transport 118, auxiliary power transport 120 and frac pump transport 108 to deliver fracturing fluid through wellhead 101 to subsurface geological formations.
[0035] The conveyor switching gear 112 can receive electricity generated from the mobile source of electricity 102 through one or more electrical connections. In one embodiment, the switching gear transport 112 uses 13.8 kilovolt (kV) electrical connections to receive power from the mobile source of electricity 102. The switching gear transport 112 may comprise a plurality of disconnect switches, fuses, transformers and/or protective circuits to protect other equipment from fracturing within the mobile fracturing system 103. The switching gear transport 112 can then transfer the electricity received from the mobile electricity source 102 to the drive power transports 104 and the auxiliary unit transports 106. The power distribution system for supplying power from the mobile source of electricity 102 to the mobile fracturing system 103 is discussed in more detail in Figure 2.
[0036] The auxiliary unit transport 106 may comprise a transformer and a control system to control, monitor and supply power to electrically connected fracturing equipment. In one embodiment, the auxiliary unit transport 106 receives a relatively higher medium voltage electrical connection (eg 13.8 kV) and reduces electrical energy to a lower voltage. For example, the auxiliary unit transport 106 reduces the voltage level from 13.8 kV to 480 V. The auxiliary unit transport 106 can then supply the reduced voltage to other fracturing equipment such as the mixer transport 110, sand storage and conveyor, data van 114 and lighting equipment.
[0037] Drive power transports 104 can be configured to monitor and control one or more electrical primary drives located on frac pump transports 108 through a plurality of connections, such as electrical connections (e.g., copper wires), optical fiber, wireless, and/or combinations thereof. Drive power transports 104 can also receive power from the switching gear transport 112 and reduce the electrical connection from 13.8 kV to lower voltages. In one embodiment, the drive power transport 104 can reduce the voltage to 4.2 kV instead of other lower voltage levels, such as 600 V, in order to reduce the electrical cable size and the number of electrical cables used. to connect the mobile fracturing system 103. In Figure 1, the frac pump transport 108 uses the electrical energy received from the drive power transport 104 to power one or more electrical primary drives that convert electrical energy to mechanical energy to drive a or more bombs.
[0038] To form fracturing fluid, hydration transport 118 combines a fluid, such as water from a frac tank, with a polymer-based slurry to produce a hydrated fluid with a target viscosity. The polymer-based paste can be a viscous paste concentrate that contains hydratable polymers including, but not limited to, guar gum, hydroxypropyl guar (HPG), carboxymethyl HPG, carboxymethyl hydroxyethyl cellulose, and combinations thereof. As the polymer-based slurry has a specified hydration rate, the viscosity level of the hydrated fluid after the initial combination of the polymer-based slurry with the fluid may not equal the target viscosity. Typically, the hydrated fluid requires a certain amount of mixing time (also known as residence time) to hydrate the polymer-based slurry so that the hydrated fluid reaches the target viscosity. For example, after combining the source fluid with the polymer-based slurry, the viscosity of the hydrated fluid increases as the degree of hydration of the polymer-based slurry increases.
[0039] In one embodiment, the mixer conveyor 110 receives electrical energy from the auxiliary unit conveyor 106 to power a plurality of electrical prime movers to perform a variety of mixing operations. For example, some of the electrical primary drives can drive one or more pumps to direct source fluid to the mixer conveyor 110 to produce fracturing fluid. Non-limiting examples include directing source fluid (eg hydrated fluid from hydration transport 118) received in one or more inlet manifolds in one or more mixing tubs and/or discharging fracturing fluid through one or more outlet manifolds to supply fracturing fluid to frac pump conveyors 108. Other electrical primary drives can drive other mixing operations such as measuring frac sand in mixing tubs and mixing hydrated fluid with frac sand to form frac fluid fracture.
[0040] The data van 114 may be part of a control network system, wherein the data van 114 acts as a control center configured to monitor and provide operational instructions to remotely operate the hydration transport 118, the transport of mixer 110, mobile source of electricity 102, transport frac pump 108 and/or other fracturing equipment within mobile frac system 103. For example, data van 114 can communicate via control network system with the VFDs located on the 104 drive power transports that operate and monitor the health of the electric motors used to drive the pumps on the 108 frac pump transports. Other fracturing equipment shown in Figure 1, such as gas conditioning transport, fuel tanks. fracturing, chemical storage of chemical additives, sand conveyor, and sand container storage are known by habilit people. in the art and therefore are not discussed in further detail.
[0041] In one embodiment, rather than having a separate hydration transport 118 and the mixer transport 110, the mobile fracturing system 103 may include a single hydration mixer transport (not shown in Figure 1). Using Figure 1 as an example, the hydration mixer conveyor receives electrical power from the auxiliary unit conveyor 106 to power a plurality of electrical prime movers to perform a variety of hydration and mixing operations. As an example, the hydration tank of the hydration mixer transport can be configured to perform a continuous hydration process to hydrate a polymer-based slurry with the source fluid to achieve the target viscosity. Implementing a continuous hydration process, rather than a batch process, allows the hydration tank to produce hydrated fluid as needed or in real time, where the hydrated fluid production rate corresponds to the amount of fracturing fluid that the unit of mixer provides the frac pump conveyor 108. To provide an adequate amount of residence time to hydrate the polymer-based slurry, the hydration tank can direct the hydrated fluid to travel a tortuous flow path that delays the delivery of the polymer. hydrated fluid to the mixer unit.
[0042] The tortuous flow path can be configured to provide a minimum amount of dwell time for a given flow rate to produce hydrated fluid with the target viscosity. In addition, the tortuous flow path is configured to retain a target volume of hydrated fluid to sustain a delivery rate of hydrated fluid to the mixer unit. For example, to provide a directed flow rate of about 80 to 100 barrels per minute (bpm) and a dwell time of about three minutes, the tortuous flow path or hydration tank volume would need to contain at least about about 240 barrels. As the hydrated fluid travels through the crooked flow path, the crooked flow path can also be configured to mix, agitate, and apply shear forces that improve the hydration of the polymer-based slurry. The tortuous flow path to the hydration tank can be implemented using a variety of methods known to persons skilled in the art.
[0043] One or more pumps in the hydration mixer conveyor can then direct the hydrated fluid with the target viscosity to the mixer unit to mix frac sand with the hydrated fluid. In one embodiment, the hydration mixer conveyor may include a dual configuration mixer comprising electrical prime movers (eg, electric motors) for the rotating machinery. The dual configuration mixer can have two separate mixing tubs configured to be independent and redundant, where either or both mixing tubs can receive hydrated fluid that originated from either inlet manifold. In other words, source fluid received from either inlet manifold can subsequently be hydrated and then mixed by either or both of the mixing tubs. Subsequently, the combined fracturing fluid is discharged from either outlet manifold. In one embodiment, when both mixing tubs are operational, the dual configuration mixer can have a mixing capacity of up to about 240 bpm. Other modes of hydration mixer transport may utilize a single configuration mixer that has only a single mixing tub.
[0044] Combining the hydration tank and mixer in a single hydration mixer transport also allows the hydration mixer transport to support a variety of operating modes, such as direct operating mode, hydration operating mode and/ or split-stream mode of operation. In a direct operating mode, the hydration mixer transport receives source fluid from one or more inlet manifolds and directly discharges source fluid to one or more outlet manifolds, causing the source fluid to bypass the tank of hydration and the mixing tubs of the mixer unit. In doing so, the hydration mixer transport supplies source fluid, which may also be called clean fluid, to one or more frac pump transports 108. In the hydration mode of operation, the hydration mixer transport directs the source fluid to the hydration tank, pumps the hydrated fluid into the mixing tubs to form fracturing fluid and discharges fracturing fluid, which may also be called dirty fluid, to one or more outlet manifolds. In a split-flow mode of operation, the hydration mixer transport is capable of discharging both clean fluid and dirty fluid to different outlet manifolds. To provide a split current to the frac pump transports, a portion of the source fluid bypasses the hydration tank and mixing tubs and flows directly to the outlet manifolds, and a remaining portion of the source fluid is directed to the tank of hydration to generate the dirty fluid.
[0045] Having a hydration mixer carriage with different modes of operation provides operators flexibility in using a variety of fracturing fluids. Specifically, the hydration mixer conveyor is flexible enough to deliver clean fluid, dirty fluid, or both based on the operator's desired fracturing operation. Using Figure 1 as an example, the mobile fracturing system 103 may have part of the frac pump transports 108 pumping clean fluid and other frac pump transports 108 pumping dirty fluid as frac fluid. An operator may wish to use clean fluid as the frac fluid because of the potential benefits of extending and improving the life of frac pumps. Due to the additional wear that frac sand and polymer-based slurry can cause, pumps and collector equipment exposed to dirty fluid are often susceptible to higher maintenance costs and/or shorter service life when compared to pumps and collector equipment that operates with clean fluid. As such, by having part of the pump 108 pump fracturing transports pumping clean fluid, an operator can reduce fracturing operating costs. Power distribution from a mobile source of electricity
[0046] Figure 2 is a schematic diagram of a modality of a medium and low voltage power distribution system for the mobile fracturing system 103. Although the voltage and current levels mentioned in Figure 2 generally refer to electrical energy AC, other embodiments may have the mobile fracturing system 103 configured to be powered using DC electrical power. As shown in Figure 2, the mobile electricity source 102 supplies power by connecting to the switching gear transport 112 using three medium voltage cable connections (eg 13.8 kV). In one or more embodiments, the mobile source of electricity 102 includes an electric turbine generator transport that compresses and mixes combustion air with hydrocarbon gas to rotate and generate mechanical energy and then converts the mechanical energy to electricity. The mobile electricity source 102 may also include an inlet and exhaust conveyor that provides ventilation and combustion air to the electric turbine generator conveyor when generating electricity. The configuration and use of an electric turbine generator transport and an inlet and exhaust transport are discussed and shown in more detail in US Patent 9,534,473, filed December 16, 2015 by Jeffrey G. Morris et al. and entitled "Mobile Electric Power Generation for Hydration Fracture of Underground Geological Formations", which is incorporated by reference as if reproduced in its entirety. In other embodiments, mobile electricity source 102 can include other transport configurations to employ a centralized source of electricity that powers fracturing equipment.
[0047] The 112 switching gear conveyor contains a transformer that reduces the medium voltage electrical energy (eg 13.8 kV) to a low voltage level (eg 480 V) and provides a low voltage electrical connection (eg 480V) to other transports. Using Figure 2 as an example, the switching gear transport 112 connects to the drive power transports 104 and the auxiliary unit transport 106 using the 480V electrical connection. Figure 2 also illustrates that the switching gear transport 112 utilizes four 480V cable connections from an auxiliary power transport 120 that provides electrical power to ignite, start or energize the mobile source of electricity 102 and/or provide auxiliary power where peak electrical power demand exceeds the production of electrical power from the mobile electricity source 102. Although not shown in Figure 2, in other embodiments, the switching gear transport 112 may also include a transformer to reduce electrical power from a medium voltage level (eg, 13.8 kV) to a relatively lower medium voltage level (eg 4.2 kV) and provide the relatively lower medium voltage level (eg 4.2 kV) directly nt for drive power transports 104.
[0048] As shown in Figure 2, the dehydration transport 118, the mixer transport 110 and the frac pump transport 108 do not contain transformers to reduce the voltage of the electrical energy of the switching gear transport 112. voltages supplied to power fracturing equipment (eg, electrical primary drives) are reduced upstream in different transports within the mobile frac system 103. As an example, the driving power transports 104 may be operable to decrease a level of medium voltage (eg 13.8 kV) that the switching gear transport 112 provides for a relatively lower medium voltage level (eg 4.2 kV), and the auxiliary unit transport 106 may be able to reduce a medium voltage level (eg 13.8 kV) that the switching gear transport 112 provides for a low voltage level (eg 480 V). In other examples, the switching gear transport 112 may include other transformers that reduce voltage to other voltages. The drive power transports 104 and the auxiliary unit transport 106 then provide the reduced voltages to power transport-mounted electrical primary drives (e.g., mixer transport 110 and frac pump transports 108) and other transport equipment. fracture. In one or more embodiments, transformers and/or drives (eg, VFDs) to control the electrical primary drives can be placed on drive power transports 104 and/or auxiliary unit transport 106, because frac pump transports 108 and/or mixer carriage 110 may not have sufficient space or may exceed a specific weight limit.
[0049] In Figure 2, the switching gear transport 112 provides a medium voltage electrical connection (eg 13.8 kV) and a low voltage electrical connection (eg 480 V) to the drive power transports 104. Specifically, each drive power transport 104 receives a single medium voltage cable connection (eg 13.8 kV) from the switching gear transport 112 and uses transformers to reduce the voltage level of the electrical power received from the medium voltage level (eg 13.8 kV) to a relatively lower medium voltage level (eg 4.2 kV). Each drive power transport 104 also receives a single low voltage cable connection (eg 480 V) from the switching gear transport 112. After the drive power transports 104 receive electrical energy from the transport of switching gear 112, each drive power transport 104 supplies electrical power to two different frac pump transports 108. In other words, the mobile frac system 103 implements a 2:1 ratio to the number of frac pump transports 108 that receive electrical power from a drive power transport 104. Other embodiments may have different ratios where the drive power transport 104 supplies power to a single frac pump transport 108 (e.g., 1:1 ratio ) or more than two 108 frac pump transports (eg 3:1 or 4:1 ratio).
[0050] As shown in Figure 2, each drive power transport 104 provides one low voltage cable connection (eg 480V) and two relatively lower medium voltage cable connections (eg 4.2kV) for power each frac pump transport 108. The low voltage cable connection can supply electrical power to drives (eg VFDs) and/or other electrical equipment (eg sensors) mounted on the frac pump transport 108. two medium voltage cable connections (eg 4.2 kV) supply electrical power to one or more electrical primary drivers that drive one or more pumps that pump fracturing fluid to a wellbore. As an example, the 108 frac pump transport contains a 5,000 horsepower (HP) double-rod electric motor that uses approximately 600 amps (A) of electrical current to operate. The double rod electric motor may be a double rod electric motor which is discussed and shown in more detail in US Patent 9,534,473, filed December 16, 2015 by Jeffrey G. Morris et al. and entitled “Generation of mobile electrical energy for fracturing hydration of underground geological formations”. To provide sufficient electrical power, each of the medium voltage cable connections (eg 4.2 kV) could provide about 300 amps of electrical current. Having a single medium voltage electrical cable (eg 4.2 kV) that supplies 600 amps of electrical current to the double rod electric motor may not be desirable due to safety concerns with relatively high current flow. In addition to safety concerns regarding relatively high current flow (eg 600 A), having a single electrical cable can also cause connection and/or disconnection problems due to the thicker size of the cable used to support a current flow. relatively high.
[0051] Figure 2 also illustrates that the switching gear carrier 112 provides a single medium voltage cable connection (eg 13.8 kV) and a single low voltage cable connection (eg 480 V) to an auxiliary unit transport 106. The auxiliary unit transport 106 includes at least one transformer to reduce the voltage from the medium voltage level (13.8 kV) to the low voltage level (e.g., 480 V). The auxiliary unit transport 106 provides a low voltage level electrical connection (eg 480V) to the hydration transport 118 and the mixer transport 110. In Figure 2 the hydration transport 118 and the mixer transport 110 are separate and independent of each other, where the hydration transport 118 receives two low voltage cable connections (eg 480V) and the mixer transport 110 receives eight low voltage cable connections (eg 480V) from the transport of auxiliary unit 106. Other modalities of the power distribution system may cause the auxiliary unit transport 106 to provide a low voltage electrical connection (e.g., 480V) (e.g., ten cable connections) to a single transport. Hydration Mixer Unit for modalities when Mixer Carrier 110 and Hydration Carrier 118 are integrated into a single carrier.
[0052] Figure 3 is a schematic diagram of another mode of a medium voltage power distribution system for the mobile fracturing system 302. In contrast to Figure 2, the power distribution system moves the voltage lower to downstream by placing transformers 310 and/or 312 in frac pump transports 304 and hydration mixer transport 306. As shown in Figure 3, mobile fracturing system 302 reduces the number of transports by eliminating the need for a transport of auxiliary unit (eg auxiliary unit transport 106 in Figure 2) and/or drive power transport (eg drive power transport 104 in Figure 2). Instead, drives (eg VFDs) to control and monitor the electrical primary drives of the 304 frac pump transports and the 310 and/or 312 transformers to reduce electrical power voltage are mounted on the frac pump transport 304 and in the transport of hydration mixer 306.
[0053] Figure 3 illustrates that the transport of switching gear 308 connects to a mobile source of electricity 102 with six medium voltage cable connections (eg 13.8 kV). The switching gear transport also connects to an auxiliary power transport 120 with a medium voltage cable connection (eg 13.8 kV). The switching gear transport 308 also includes a transformer 312 which reduces the electrical energy received to a medium voltage level (eg 13.8 kV) from the auxiliary power transport 120 to a low voltage level (eg , 480V). The low voltage level connection (eg 480V) can supply electrical power to turn on, start, or turn on the mobile source of electricity 102. In contrast to Figure 2, the 308 switching gear carrier does not emit or provide electrical connections low voltage (eg 480V) for other transports. Specifically, the 308 Switch Gear Carrier issues and provides medium voltage (eg 13.8 kV) cable connections directly to the 306 Hydration Mixer Carrier and the 304 Fracture Pump Carrier without connecting to any intermediate carriers ( for example, drive power transport 104 and auxiliary unit transport 106 in Figure 2). Figure 3 shows that the switching gear transport 308 generates seven total medium voltage cable connections (eg 13.8 kV), where each frac pump transport 304 is directly connected to the switching gear transport 308 with a single medium voltage cable connection (eg 13.8 kV). The 308 Switch Gear Carrier also connects directly to the 306 Hydration Mixer Carrier using a single medium voltage cable connection (eg 13.8 kV).
[0054] The medium voltage power distribution system shown in Figure 3 is capable of reducing the number of electrical cables used to supply electrical power to the 304 frac pump transport and 306 hydration mixer transport when compared to the distribution system medium-low power distribution system shown in Figure 2. Specifically, when compared to the medium-low power distribution system shown in Figure 2, the medium voltage power distribution system in Figure 3 is able to reduce the number of electrical cables that provide power to each 304 frac pump transport. As shown in Figure 3, the 302 mobile frac system reduces the number of electrical cables from three electrical cables to one electrical cable for each 304 frac pump transport. An additional reduction of electrical cables is shown providing an electrical cable to the hydration mixer transport 306 instead of the ten electrical cables used for there. improve mixer transport 110 and hydration transport 118. One reason the medium voltage power distribution system is able to use fewer electrical cables is that each electrical cable does not need to supply a relatively high current (eg 600 A) for each of the 304 frac pump transports and 306 hydration mixer transports. Supplying electrical power at relatively lower current levels avoids the safety concerns and/or connection/disconnection issues associated with using a single electrical cable that delivers relatively high current (eg 600 A).
[0055] Each frac pump transport 304 may include one or more transformers to reduce the voltage received from the switching gear transport 308 to different voltage levels. Using Figure 3 as an example, each frac pump transport 304 can include two separate and independent transformers, a first transformer 310 stepping down to a voltage level of 4.2 kV and a second transformer 312 stepping down to a voltage level of voltage of 480V. In other examples, each 304 frac pump transport may include a single transformer that produces multiple voltage levels. For example, the 304 frac pump conveyor can mount a three-phase transformer or three windings to reduce voltage to two different voltage levels. Keep in mind that the 4.2 kV voltage level supplies electrical power to one or more electrical primary drives that drive one or more pumps, and the 480 V provides electrical power to the drives and/or other control instrumentation mounted on the transport of 304 frac pump. Transformers 310 and 312 are configured to provide sufficient electrical current to power primary drivers, controllers, and/or other control instruments.
[0056] Figure 3 also illustrates that the hydration mixer transport 306 can include a transformer that reduces the voltage level to 480 V. The hydration mixer transport 306 can use the reduced voltage levels to supply electrical power to the drives electrical primers for the 306 hydration mixer transport, drives and/or other control instrumentation mounted on the 306 hydration mixer transport. The 306 hydration mixer transport can also be configured to supply electrical power at the voltage level of 480V. to other downstream fracturing equipment such as the sand conveyor. In Figure 3, the medium voltage power distribution system can utilize two electrical connections to supply electrical power to the sand conveyor. Although Figure 3 illustrates that the switching gear transport 308 supplies electrical power to a hydration mixer transport 306, other embodiments could have the switching gear transport 308 connected separately to a hydration transport and a mixer transport. In such a modality, the switching gear transport 308 can connect to the hydration transport using a single medium voltage cable connection (eg 13.8 kV) and another single medium voltage cable connection (eg 13.8 kV) to connect to the mixer transport.
[0057] By mounting the 310 and/or 312 drives and transformers in the 304 frac pump transport and 306 hydration mixer transport, the transports become individually autonomous, removing the need for other separate support-based trailers, such as transport auxiliary drive and drive power transports that provide power conversion and/or drive control. Having standalone trailers allows the 302 mobile frac system to become scalable and flexible, where each frac pump transport can be interchangeable with each other. For example, if the well is relatively small, the mobile frac system 302 may have a reduced number of frac pump transports 304 (eg, four transports instead of six transports). On the other hand, if the well is large and/or the well site is located at high elevations and/or temperatures, more 304 frac pump transports can be stacked to increase pumping capacity without using additional support-based transports ( for example, drive power transports 104 shown in Figures 1 and 2).
[0058] Although Figures 2 and 3 illustrate specific modalities of mobile fracturing system 103 and 302 that use electrical energy for operations, the disclosure is not limited to these particular modalities. For example, with reference to Figure 3, the disclosure describes a switching gear transport 308 receiving electrical power from a mobile source of electrical power. However, other embodiments can cause the switching gear transport 308 to receive electrical energy from other types of power sources, such as a utility grid or a stationary power source. Additionally or alternatively, the mobile fracturing system 302 shown in Figure 3 may utilize a separate hydration conveyor and mixer conveyor instead of the hydration mixer conveyor 306. The use and discussion of Figures 2 and 3 are only examples to facilitate ease of use. description and explanation. Hydration Mixer Transport
[0059] Figure 4A illustrates a side view of an embodiment of a hydration mixer carriage 400 comprising a hydration tank 402, a mixer unit 404, an electrical prime mover 406, a pump 408 and various groups of collectors 410 , 412 and 414. Figure 4A also depicts the transport of hydration mixer 400 as a trailer that includes four axles. Other modalities of hydration mixer carriage 400 may vary the number of shafts depending on the weight of the fracturing equipment and/or the size of hydration tank 402. For example, the hydration mixer carriage 400 may include three shafts to allow for assembly of a 402 hydration tank with greater volume. By removing the axle 401 from the trailer, the hydration mixer carriage 400 has more space available to mount a larger hydration tank 402.
[0060] Depending on the operating modes, the manifold groups 410, 412 and 414 can be configured as inlet manifolds that receive source fluid and/or outlet manifolds that supply fracturing fluid to one or more frac pump transports . Manifold groups 410, 412, and 414 are coupled to the internal manifold system 400 of the hydration mixer transport to direct fluid into the hydration mixer transport 400. Electric prime movers 406 (eg, electric motors) can drive the 408 pumps to pull and supply source fluid to the 402 hydration tank, 404 mixer unit and/or directly to another group of manifolds based on the configuration of the internal manifold system. To implement a variety of modes of operation, the internal manifold system includes a plurality of valves (not shown in Figure 4A) configured to isolate different sections of the internal manifold system.
[0061] The internal manifold system may comprise a hydration tank manifold system 416, a hydration mixer manifold system 418, a mixer output manifold system 420, an interconnector manifold system 424, and a system of lower tank manifold 430. Interconnector manifold system 424 can connect manifold groups 410, 412, and 414, pumps 408, hydration tank manifold system 416, hydration mixer manifold system 418, and the 430 lower tank manifold system with each other. To connect the interconnector collector system 424 to the collector groups 410 and 412, connection points 426 and 432, respectively, can be used to connect the interconnector collector system 424 to the lower tank collector system 430. Hydration tank manifold 416 may be configured to receive source fluid from one or more of manifold groups 410, 412, and 414 through interconnector manifold system 424 to transport source fluid within hydration tank 402.
[0062] After hydration tank 402 hydrates the polymer-based slurry with the source fluid, hydration mixer manifold system 418 transports the hydrated fluid from hydration tank 402 to mixing tubs 454. Since the mixing tubs 454 mix fracturing sand with the hydrated fluid to form fracturing fluid, the mixer outlet manifold system 420 can then transport the fracturing fluid from the mixer unit 404 to one or more groups of manifolds 410, 412 and 414. A return manifold system 428 can be configured to return liquid into hydration tank 402 to maintain a desired level of hydrated fluid. The 430 lower tank manifold system can be configured to connect manifold groups 410, 412, and 414 to each other. Although not illustrated, the internal manifold system shown in Figure 4 may include other components known to those skilled in the art to monitor properties of fluids and/or direct fluids within the hydration mixer transport 400, such as flow meters, densitometers and valves.
[0063] As shown in Figure 4A, the hydration mixer carriage 400 may include a power and control system 436. In one embodiment, the power and control system 436 may include a drive (eg, a VFD) to control 406 electric primes and a transformer to reduce input voltage. For example, the transformer is configured to receive a relatively higher voltage (eg 13.8 kV) and reduce the voltage level to 480 V. The 436 power and control system can also be configured to supply electrical energy at the level voltage of 480V for other downstream fracturing equipment such as the sand conveyor. In another embodiment, the power and control system 436 may include the drive to control the electrical primary drives 406, but may not include the transformer and instead receives power at reduced voltage (eg, 480V) from other transport.
[0064] Figure 4A illustrates that the demixer unit 404 is a dual configuration mixer that includes two separate mixing modules for producing fracturing fluid. Each mixing module includes a mixing tub 454, a hopper 450 (also known as surge tanks), and a metering component 452 (eg, an auger). To power the mixing operations, the mixer unit 404 may also include primary drives 456 and 458. As shown in Figure 4A, each of the mixing modules includes an electrical primary drive 456 for feeding the metering component 452 which measures the sand of fracturing to the mixing tub 454, and an electric primary driver 458 to drive pumps to feed the mixing tub. Mixing tub 454 mixes fracturing sand and hydrated fluid received from hydration mixer manifold system 418 to produce fracturing fluid that discharges through mixer outlet manifold system 420. Mixer tub 454 can discharge the fracturing fluid using a pump (not shown in Figure 4A) driven by a primary driver.
[0065] In Figure 4A, the measuring component 452 is an auger positioned on an incline to measure frac sand in a mixing tub 454. Other embodiments of the mixer unit 404 may have the measuring component 452 positioned in an orientation straight or horizontal. Correct control and measurement of the frac sand in the mixing bath 454 affects the overall proppant concentration of the frac fluid (eg paste weight). Controlling the general proppant concentration is advantageous because the general proppant concentration can affect the proppant transport and proppant fracture dimensions of subsurface geological formations and the performance of hydraulic fracturing treatment.
[0066] Mixer unit 404 can be configured to produce fracturing fluid using dry frac sand and/or wet frac sand. In one embodiment, to be able to produce fracturing fluid using wet fracturing sand, the mixer unit 404 may include one or more vibrating components (eg, mechanical vibrators, vibrating screens, and acoustic generators), which are not shown in the Figure 4A, to liquefy the sand and improve the flow properties of wet frac sand. Vibrator components can be powered by a variety of power sources including, but not limited to, air pressure, hydraulics and/or electricity. When powering the vibrator components by electricity, the 404 mixer unit includes electric motors to drive hydraulic pumps that operate the vibrator components. By controlling electric motors, an operator can indirectly control one or more vibrator components through hydraulic pressure. In another example, operators can control the one or more vibrator components directly by connecting one or more electric motors to one or more vibrator components. Adjusting the attributes of electric motors, such as frequency, voltage and/or amperage, can vary the operation of vibrator components. To reduce vibration and disturbance to other components of the hydration mixer 400 transport, the mixer unit 404 may include a vibration isolation system that includes springs, air pockets, rubber-based dampers (e.g., rubber bushings ) and/or other vibration isolation components. In modalities where a vibrating screen and/or acoustic waves are used to directly liquefy the sand without vibrating the mixing tub, the vibration isolation system can dampen and reduce the amount of vibration experienced by the mixing tub. The processing and liquefaction of wet frac sand is discussed in more detail in US Patent Application 15/452,415, filed March 7, 2017 by Jeffrey G. Morris et al. and entitled "Using Wet Fracture Sand for Hydraulic Fracking Operations", which is incorporated by reference as if reproduced in its entirety.
[0067] Figure 4B illustrates a cross-sectional view of the hydration mixer transport tank 400. Specifically, Figure 4B represents the CC cross-sectional view illustrated in Figure 4A that highlights the lower tank collector system 430. How shown in Figure 4B, bottom tank collector system 430 includes two redundant sides that are coupled using crossover collectors 440 and 442. Mixer output collector system 420 discussed in Figure 4A connects to both sides of the system. bottom tank manifold 430 at connection points 444 so that the outlet of one of the mixing tubs connects to one side of the bottom tank manifold system 430. Crossover manifolds 440 and 442 allow the fracturing fluid to be discharged to one or both sides of the hydration mixer transport 400 and also allows the hydration tank to receive source fluid from both sides of the trans. hydration mixer sport 400. Each side of the 430 lower tank pickup system also includes pickup groups 410, 412, and 414, where each pickup group can be isolated using values (not shown in Figure 4B). Crossover manifolds 440 and 442 may include valves to allow or prevent fluid from flowing to either side of the lower tank manifold system 430.
[0068] Figure 4B also illustrates that the lower tank manifold system 430 includes three pump connection points 446, connection points 426 and one connection point 432. The three pump connection points 446 interconnect the manifold system from lower tank 430 to pumps 408 shown in Figure 4A. Figure 4A illustrates that the electric primary drivers 406 are positioned above the pumps 408 so that one or more of the main electric motors 406 can drive one or more pumps 408. The pumps 408 are then able to direct the source fluid and/ or the fracturing fluid to and out of the lower tank manifold system 430. For example, pumps 408 may be capable of pumping source fluid received from one or more manifold groups 410, 412 and 414 to the manifold system. interconnector 424 through connection points 426. One or more valves can be defined according to the mode of operation for transporting hydration mixer 400. For example, to implement split flow operation, a valve associated with the connection point 432 can be configured for an open position so that source fluid received from collector groups 410, 412 and 414 is sent directly to other collector groups 410, 412 and 414 (by and example, collector group 412) and bypasses hydration tank 402. In other words, connection point 432 can be used to bypass hydration tanks 402 and mixing tubs 454 and directly pump source fluid received from one or more collector groups 410, 412, and 414 back to other collector groups 410, 412, and 414.
[0069] Figure 4C illustrates a cross-sectional view of the hydration mixer carriage 400 representing the interior of the hydration tank 402. As shown in Figure 4C, the interior of the hydration tank 402 includes the interconnector collector system 424 which allows the pumps, driven by 406 electrical prime movers, to direct fluid to different sections of the internal manifold system. In particular, interconnector manifold system 424 connects to hydration tank manifold system 416 through connection points 462 and 438 and connects to hydration mixer manifold system 418 through connection point 464. Using the system of interconnector manifold 424, the pumps are capable of directing source fluid received in one or more manifold groups 410, 412 and 414 to the hydration tank through the hydration tank manifold system 416 and/or pumping hydrated fluid to the 454 mixing tubs through the 418 hydration mixer collector system.
[0070] Figure 4D illustrates a top view of hydration mixer transport 400 representing the top of hydration tank 402. In Figure 4D, hydration tank collector system 416 receives source fluid and directs that fluid from source to a diffuser located on top of hydration tank 402. The diffuser combines the source fluid with the polymer-based slurry and feeds the hydrated fluid to a tortuous flow path within hydration tank 402. The hydrated fluid travels through the tortuous flow path, the 418 Hydration Mixer Collector System obtains the hydrated fluid through the 424 Interconnector Collector System and delivers the hydrated fluid to the 454 mixing tubs. In one embodiment, the Collector System The 418 hydration mixer includes two different manifold connections, where each manifold connection supplies hydrated fluid to one of the 454 mixing tubs. ture discharges the fracturing fluid through the 420 mixer outlet manifold system.
[0071] Figure 4E illustrates a cross-sectional view of the hydration mixer transport 400 that corresponds to the section A-A section shown in Figure 4D. In Figure 4E, the combination of electric prime driver 406 and pump 408 is mounted in the vertical position so that electric prime mover 406 is mounted on top of pump 408. The 408 pumps are also connected to the lower tank manifold system 430. Three different electric prime mover 406 and pump 408 combinations can be used to provide enough power to simultaneously pump source fluid to the hydration mixer 400 transport, pump the hydrated fluid to the mixing tubs 454, and/ or pumping fluid out of the hydration mixer transport 400. In one embodiment, the pumps 408 may be centrifugal pumps.
[0072] Figure 4F illustrates a cross-sectional view of the tank of another embodiment of a hydration mixer transport 400. Specifically, Figure 4F is an illustration of the CC cross-sectional view of a bottom tank collector system 480 that is substantially similar to the lower tank manifold system 430 shown in Figure 4B. The 480 Lower Tank Collector System is similar to the 430 Lower Tank Collector System, except the 480 Lower Tank Collector System includes a crankcase 482 to collect and remove fluid from the hydration tank 402. For example, when an operator completes a frac job, the operator can empty the stored fluid into the hydration tank 402 prior to transport. An operator is able to divert fluid stored within hydration tank 402 to crankcase 482 by discharging fluid out of hydration tank 402.
[0073] Figure 5 illustrates an embodiment of a hydration mixer 500 carrier that includes a single mixing tub. Figure 5 illustrates a top view of the hydration mixer carriage 500 representing the top of the hydration tank. Figure 5 is similar to Figure 4D, except that the manifolds within the hydration mixer manifold system 418 and the manifold output manifold system 420 that correspond to the missing mixing tub have been removed. For example, in Figure 4D, as the hydrated fluid travels through the tortuous flow path, the 418 Hydration Mixer Collector System delivers the hydrated fluid to only one mixing tub 454. The Hydration Mixer Collector System 418 only includes a manifold connection to supply hydrated fluid to the single mixing tub 454. Thereafter, the mixing tub 454 discharges the fracturing fluid through the mixer outlet manifold system 420 (for example, using a pump not shown in Figure 5), which has only one outlet manifold connection to the mixing tub 454. Although Figure 5 illustrates that three electrical primary drivers 406 can be used to drive three pumps 408, other modes of hydration mixer 500 transport may include two 406 electric primes that drive two 408 pumps.
[0074] Figure 6 is a flowchart of an embodiment of a method 600 for providing fracturing fluid using a single hydration mixer carriage. Method 600 can correspond to the hydration mixer mode of operation and the split-flow mode of operation. The use and discussion of Figure 6 is an example only for ease of explanation and is not intended to limit disclosure to this specific example. For example, although Figure 6 illustrates that the blocks within method 600 are implemented in a sequential order, method 600 is not limited to that sequential order. For example, one or more of the blocks, such as blocks 604 and 606, can be implemented in parallel.
[0075] Method 600 may start at block 602 receiving source fluid from one or more inlet/outlet manifolds. To implement block 602, method 600 can set one or more values within the hydration mixer transport such that some of the inlet/outlet headers are configured to receive source fluid and some of the inlet/outlet headers discharge fluid of fracturing. Method 600 can then move to block 604 and drive one or more pumps to direct source fluid from the inlet/outlet manifolds to a hydration tank. In one embodiment, method 600 can use electrical prime movers to drive pumps to direct source fluid.
[0076] Method 600 continues at block 606 and hydrates a polymer-based slurry with the source fluid to produce hydrated fluid with a target viscosity. In one embodiment, method 600 can utilize a tortuous flow path that provides sufficient residence time and a flow rate to deliver fracturing fluid to a mixer unit. Subsequently, method 600 moves to block 608 and triggers one or more pumps to direct the hydrated fluid to one or more mixing tubs. Method 600 then moves to block 610 and mixes the hydrated fluid with metered frac sand to produce frac fluid. Subsequently, method 600 continues at block 612 and drives one or more pumps to discharge fracturing fluid from the mixing tubs. Prior to discharging fracturing fluid, Method 600 can configure one or more valves to direct which inlet/outlet manifolds receive fracturing fluid.
[0077] Figure 7 is a flowchart of an embodiment of a method 700 for providing electrical energy to fracturing equipment using a medium voltage power distribution system. For example, the medium voltage power distribution system that includes switching gear transport 308 and transformers 310 and 312 shown in Figure 3 can implement method 700. The use and discussion of Figure 7 is just an example to facilitate the explanation and are not intended to limit disclosure to this specific example. For example, although Figure 7 illustrates that blocks within method 700 are implemented in a sequential order, method 700 is not limited to that sequential order. For example, one or more of the blocks, such as blocks 704 and 706, can be implemented in parallel.
[0078] Method 700 can start at block 702 by receiving electrical energy from a mobile source of electricity at an average voltage level. As an example, method 700 receives electrical power at 13.8 kV or some other relatively higher medium voltage level from the mobile source of electricity. In one or more other embodiments, method 700 can receive electrical energy from other power sources, such as a utility grid or a power plant. Method 700 can then move to block 704 and supply electrical power to one or more frac pump transports at the medium voltage level (eg 13.8 kV). In block 704, method 700 does not reduce the electrical energy received from the mobile source of electricity to a lower voltage level using transformers. Instead, method 700 in block 706 supplies electrical power to one or more transports at the medium voltage level. As discussed with reference to Figure 3, method 700 is able to reduce the number of electrical cables used to supply electrical power to transports, such as the frac pump transport 304 and the hydration mixer transport 306, when compared to the frac system. medium-low energy distribution shown in Figure 2.
[0079] Method 700 continues at block 708 and reduces the medium stress level received on the frac pump conveyors to one or more lower stress levels. In one embodiment, method 700 can reduce the voltage level to a lower medium voltage level (eg 4.2 kV) or a low voltage level (eg 600 V or 480 V). By reducing the stress on the frac pump transport, method 700 is able to reduce the number of transports by eliminating drive power transports (for example, drive power transports 104 in Figure 2). Subsequently, method 700 moves to block 710 and reduces the medium voltage level received on other transports to one or more lower voltage levels. For example, method 700 can reduce stress on a hydration transport, a mixer transport, a hydration mixer transport or combinations thereof. Reducing the stress on different transports also reduces the number of transports by eliminating auxiliary unit transport. Subsequently, method 700 can move to block 712 and supply electrical power to one or more electrical primary drives mounted on frac pump carriers and other carriers with the lowest voltage levels.
[0080] At least one modality is disclosed variations, combinations and/or modifications of the modality(s) and/or features of the modality(s) made by a person skilled in the art are within the scope of the disclosure. Alternative modalities that result from the combination, integration and/or omission of features of the modality(s) are also within the scope of the disclosure. Where numerical ranges or limitations are expressly stated, such express ranges or limitations may be understood to include iterative ranges or limitations of similar magnitude within the expressly stated ranges or limitations (eg, from about 1 to about 10 includes, 2, 3, 4, etc.; greater than 0.10 includes 0.11.0.12, 0.13 etc.). The use of the term "about" means ± 10% of the subsequent number, unless otherwise indicated.
[0081] The use of the term "optionally" in relation to either element of a claim means that the element is required or, alternatively, the element is not required, both alternatives being within the scope of the claim. The use of broader terms, such as comprising, including, and having, may be understood to support narrower terms, such as consisting of, consisting essentially of, and comprising substantially of. Therefore, the scope of protection is not limited by the description set out above, but is defined by the following claims, which include all equivalents of the subject matter of the claims. Any and all claims are incorporated as further disclosure in the specification and the claims are embodiment(s) of the present disclosure.
[0082] Although various modalities have been provided in the present disclosure, it should be understood that the disclosed systems and methods may be incorporated in many other specific forms without departing from the spirit or scope of the present disclosure. The present examples are to be considered illustrative and not restrictive, and the intent is not to be limited to the details provided herein. For example, various elements or components may be combined or integrated into another system, or certain features may be omitted or not implemented.
[0083] In addition, techniques, systems, subsystems and methods described and illustrated in the various modalities as discrete or separate can be combined or integrated with other systems, modules, techniques or methods without departing from the scope of this disclosure. Other items shown or discussed as coupled or directly coupled or communicating may be indirectly coupled or communicated through some interface, device or intermediate component, whether electrically, mechanically or otherwise.

权利要求:
Claims (23)
[0001]
1. Electrical fracturing system (302) for use with at least one power generating source (102) to provide an electrical source power, characterized in that it comprises: a switching gear carrier (308) electrically connected to the at least one power generation source (102) and configured to receive electrical source power at a first average voltage level; an electrical cable connected to the switching gear carrier (308) that supplies a first electrical power at the first level voltage average from the commutation gear transport (308); and a first frac pump transport (304) comprising: at least one transformer (310, 312), at least one controller, at least one electrical prime mover, and at least one pump, each being disposed on the first frac pump transport. fracturing (304), wherein the at least one first transformer (310, 312) is electrically connected to the switching gear carrier via the first electrical cable only, wherein the at least one first transformer (310, 312) is further connected electrically to the at least one electrical primary driver and the at least one controller, wherein the at least one first transformer (310, 312) is configured to reduce the first electrical power received at the first average voltage level to a first average voltage level lowest that powers the at least one electrical primary driver, where each of the at least one controller and the at least one pump is coupled to the at least one primary driver. electrical device, wherein the at least one first transformer (310, 312) is further configured to reduce the first electrical power at the first average voltage level to a first low voltage level that is lower than the first average voltage level lower and that feeds the at least one controller.
[0002]
2. System according to claim 1, characterized in that the switching gear transport (308) comprises a second transformer (312) electrically connected to an auxiliary power source (120) that supplies second electrical power of the first medium voltage level, where the second transformer (312) is configured to reduce the first medium voltage level to a second low voltage level that falls in the range of 50 volts to 1000 volts.
[0003]
3. System according to claim 2, characterized in that it further comprises a second electrical cable arranged in electrical communication with the second transformer (312) and configured to supply the second electrical power at the second low voltage level from the switching gear conveyor (308), wherein the second low voltage level is a voltage to turn on and start the at least one power generation source (102).
[0004]
4. System according to claim 1, characterized in that it further comprises: a second electrical cable connected to the switching gear transport (308) that provides second electrical power at the first average voltage level from the gear transport switching (308); and a hydration mixer carriage (306) connected to the switching gear carriage (308) via the second electrical cable and without having a trailer connected between the switching gear carriage (308) and the hydration mixer carriage (306) wherein the hydration mixer conveyor (306) comprises a hydration tank and at least one mixing tub mounted on a single conveyor frame.
[0005]
5. System according to claim 4, characterized in that the hydration mixer transport (306) additionally comprises a second transformer that reduces the second electrical power from the first average voltage level to a second average level of lowest voltage which is a voltage lower than the first average voltage level.
[0006]
6. System according to claim 1, characterized in that it further comprises: a second electrical cable connected to the switching gear conveyor (308) that supplies second electrical power at the first average voltage level from the gear conveyor switching (308); and a hydration mixer carrier (306) electrically connected to the switch gear carrier (308) via the second electrical cable.
[0007]
7. System according to claim 1, characterized in that it further comprises: a second electrical cable connected to the switching gear transport (308) that provides second electrical power at the first average voltage level from the mixer transport of hydration; and a hydration carrier (306) electrically connected to the shift gear carrier (308) via the second electrical cable.
[0008]
8. System according to claim 1, characterized in that the first average voltage level and the lowest first average voltage level fall within a range of 1000 volts to 35 kilovolts.
[0009]
9. System according to claim 8, characterized in that the first average voltage level is set to be 13.8 kilovolts.
[0010]
10. System according to claim 8, characterized in that the first low voltage level falls within a range of 50 volts to 1000 volts.
[0011]
11. System according to claim 1, characterized in that the first at least one transformer (310, 312) comprises one of: a single transformer (310/312) configured to reduce the first average voltage level for the lowest first medium voltage level and for first low voltage level; and one transformer (310) configured to reduce the first average voltage level to the lowest first average voltage level and another transformer (312) configured to reduce the first average voltage level to the first low voltage level.
[0012]
12. Fracture transport (304) for fracturing operations, characterized in that it is used with a switching gear transport (308) which provides electrical power and comprises: a single transport frame; at least one electrical actuator mounted on the single transport frame; a controller mounted on a single transport frame and coupled to the at least one electric prime mover; a plurality of pumps coupled to the electric prime mover and mounted on the single transport frame; and at least one transformer (310, 312) coupled through the controller to the electrical primary driver and mounted on the single transport frame, wherein the transformer (310, 312) is configured to: receive electrical power at a first average voltage level from of the commutation gear transport (308) through a single set of cables; reducing (310) the electrical power at the first average voltage level to a lower average voltage level and providing electrical power at the lower average voltage level through from the controller to the electrical primary drive to drive the pumps; and reduce (312) the electrical power at the first medium voltage level to a low voltage level, and supply the electrical power at the low voltage level to the controller, where the fracturing conveyor (304) is not connected to any other set of cables that provide electrical power at the first medium voltage level and other voltage levels.
[0013]
13. Fracture transport according to claim 12, characterized in that the first average voltage level is at a level of 13.8 kilovolts.
[0014]
14. Fracture transport according to claim 12, characterized in that the lowest first average voltage level is at a level less than 13.8 kilovolts.
[0015]
15. Fracture transport, according to claim 12, characterized in that the electric primary driver is a double-rod electric motor.
[0016]
16. Fracture transport according to claim 12, characterized in that the low voltage level falls within a range between 50 volts and 1000 volts.
[0017]
17. Fracture transport according to claim 12, characterized in that the at least one transformer comprises a single transformer (310/312) having a first transformer winding configured to reduce electrical power at the first average voltage level to the lowest average voltage level that falls within a first range of 1000 volts to 35 kilovolts, and having a second transformer winding configured to reduce electrical power at the first average voltage level to the low voltage level that falls within from a range of 50 volts to 1000 volts.
[0018]
18. Fracture transport according to claim 12, characterized in that the commutation gear transport receives electrical power at the first average voltage level from at least one power source.
[0019]
19. Method for distributing electrical power for fracturing operations characterized in that it comprises: receiving, in a switching gear transport (308), source electrical power from at least one mobile source of electricity (102) in a first average voltage level; supply, from the switching gear transport (308), a first electrical power at the first average voltage level using only a first cable connection; receive, in a frac pump transport (304) , the first electrical power at the first average voltage level supplied directly using the first cable connection; reduce, with at least one first transformer (310, 312) arranged in the frac pump transport (304), the first average voltage level for both a lower mean stress level and a low stress level; feed an electrical primary drive disposed on the frac pump conveyor (304) with the mean te level. n is lower; feeding a controller arranged in the frac pump conveyor (304) with the low level of tension; and control the output of the electric prime mover powered with the controller powered.
[0020]
20. Method according to claim 19, characterized in that it further comprises: supplying, from the switching gear transport (308), a second electrical power at the first average voltage level using only a second cable connection ; and receive, in one of a mixer carriage (306), a hydration mixer (306), and a hydration mixer carriage (306), the second electrical power at the first medium voltage level supplied directly using the second cable connection .
[0021]
21. Method according to claim 19, characterized in that the first average voltage level and the lowest average voltage level fall within a range of 1000 volts to 35 kilovolts.
[0022]
22. Method according to claim 19, characterized in that the low voltage level falls within a range of 50 volts to 1000 volts.
[0023]
23. Method according to claim 19, characterized in that it further comprises: reducing, with a second transformer (312) arranged in the commutation gear conveyor (308), the first average voltage level to a second low level of tension; and supply, from the switching gear conveyor (308), electrical power at the second low voltage level to the mobile source of electricity to ignite and start the at least one mobile source of electricity.

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同族专利:

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公开号 | 公开日

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AR112484A1|2019-11-06|

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WO2019006108A1|2019-01-03|

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EP3645832A1|2020-05-06|

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WO2019006106A1|2019-01-03|

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CA3068067A1|2019-01-03|

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BR112019028085A2|2020-06-09|

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CA3123640A1|2019-01-03|

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US20190003329A1|2019-01-03|

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AR112485A1|2019-11-06|

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BR112019028081A2|2020-04-14|

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US20200087997A1|2020-03-19|

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CA3067854A1|2019-01-03|

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EP3645833A4|2021-06-09|

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EP3645832A4|2021-06-09|

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EP3645833A1|2020-05-06|

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US10519730B2|2019-12-31|

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US20190003272A1|2019-01-03|

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BR112019028081B1|2021-01-26|

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US10415332B2|2019-09-17|

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法律状态:
2020-11-03| B06A| Notification to applicant to reply to the report for non-patentability or inadequacy of the application [chapter 6.1 patent gazette]|

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2021-03-09| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2021-06-01| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 28/06/2018, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

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申请号 | 申请日 | 专利标题

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US201762526869P| true| 2017-06-29|2017-06-29|

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US62/526,869|2017-06-29|

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