U.S. patent application number 11/396918 was filed with the patent office on 2007-06-07 for method and apparatus for providing pressure for well treatment operations.
This patent application is currently assigned to HALLIBURTON ENERGY SERVICES, INC.. Invention is credited to Leonard Case, James E. Curry, Lloyd McNeel, Lonnie R. Robinson.
Application Number | 20070125544 11/396918 |
Document ID | / |
Family ID | 38110096 |
Filed Date | 2007-06-07 |
United States Patent
Application |
20070125544 |
Kind Code |
A1 |
Robinson; Lonnie R. ; et
al. |
June 7, 2007 |
Method and apparatus for providing pressure for well treatment
operations
Abstract
An apparatus for providing pressure for a well fracturing
operation is disclosed. The apparatus includes one or more docking
areas for docking one or more pumping units to a pressure manifold
wherein the one or more docking areas are operable to provide
access between one or more pumping units, and a structure operable
to enclose the one or more docking areas and pumping units. An
apparatus for providing pressure for a well fracturing operation is
disclosed. The apparatus includes one or more pumping units, a
central fueling system connected to the one or more pumping units,
a central power system connected to the one or more pumping units,
a central lubrication system connected to the one or more pumping
units, and a central cooling system connected to the one or more
pumping units.
Inventors: |
Robinson; Lonnie R.;
(Duncan, OK) ; Curry; James E.; (Duncan, OK)
; Case; Leonard; (Duncan, OK) ; McNeel; Lloyd;
(Green River, WY) |
Correspondence
Address: |
JOHN W. WUSTENBERG
P.O. BOX 1431
DUNCAN
OK
73536
US
|
Assignee: |
HALLIBURTON ENERGY SERVICES,
INC.
DUNCAN
OK
|
Family ID: |
38110096 |
Appl. No.: |
11/396918 |
Filed: |
April 3, 2006 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
11291496 |
Dec 1, 2005 |
|
|
|
11396918 |
Apr 3, 2006 |
|
|
|
Current U.S.
Class: |
166/308.3 ;
166/305.1; 166/90.1 |
Current CPC
Class: |
E21B 43/26 20130101;
E21B 43/30 20130101 |
Class at
Publication: |
166/308.3 ;
166/305.1; 166/090.1 |
International
Class: |
E21B 43/267 20060101
E21B043/267; E21B 43/26 20060101 E21B043/26 |
Claims
1. An apparatus for providing pressure for a well fracturing
operation comprising: one or more docking areas for docking one or
more pumping units to a pressure manifold wherein the one or more
docking areas are operable to provide access between one or more
pumping units; and a structure operable to enclose the one or more
docking areas and pumping units.
2. The apparatus of claim 1 further comprising a crane system
surrounding the one or more docking areas.
3. The apparatus of claim 1 further comprising a central
lubrication system connected to the one or more pumping units.
4. The apparatus of claim 1 further comprising a central power
system connected to the one or more pumping units.
5. The apparatus of claim 4 wherein the central power system
comprises a hydraulic power system.
6. The apparatus of claim 1 further comprising a central cooling
system connected to the one or more pumping units.
7. The apparatus of claim 6 wherein the central cooling system
comprises a cooling tower.
8. The apparatus of claim 1 wherein at least one of the one or more
docking areas extend outside of the structure.
9. The apparatus of claim 1 further comprising a ventilation
system.
10. The apparatus of claim 1 further comprising a central fueling
system connected to the one or more pumping units for supplying
fuel to the one or more pumping units.
11. The apparatus of claim 10 wherein the central fueling system
supplies one or more fuels from the group consisting of: diesel,
gasoline, and natural gas.
12. The apparatus of claim 1 wherein the structure comprises one or
more structures from the group consisting of a supported fabric
structure, a collapsible structure, a prefabricated structure, a
retractable structure, a composite structure, a temporary
structure, a prefabricated wall and roof structure, a deployable
structure, a modular structure, a preformed structure, a mobile
accommodation structure, and combinations thereof.
13. The apparatus of claim 1 wherein the one or more docking areas
comprise walkways.
14. The apparatus of claim 1 wherein the one or more docking areas
comprise one or more lubrication connections, coolant connections,
fuel connections, power connections, and pressure connections.
15. The apparatus of claim 1 wherein the one or more pumping units
comprise heaters.
16. An apparatus for providing pressure for a well fracturing
operation comprising: one or more pumping units connected to a
manifold; a central fueling system connected to the one or more
pumping units; a central power system connected to the one or more
pumping units; a central lubrication system connected to the one or
more pumping units; and a central cooling system connected to the
one or more pumping units.
17. The apparatus of claim 16 wherein the central power system
comprises a hydraulic power system.
18. The apparatus of claim 16 wherein the central cooling system
comprises a cooling tower.
19. The apparatus of claim 16 further comprising a ventilation
system.
20. The apparatus of claim 16 wherein the central fueling system
supplies one or more fuels from the group consisting of: diesel,
gasoline, natural gas, or electricity.
21. A method for operating one or more pumping units for a well
fracturing operation from a land based location comprising:
providing fuel to the one or more pumping units from a central
location; providing lubrication to the one or more pumping units
from a central location; providing power to the one or more pumping
units from a central location; and providing coolant to the one or
more pumping units from a central location.
22. The method of claim 21 wherein the power is provided from a
hydraulic power system.
23. The method of claim 21 wherein the coolant is provided from a
cooling tower.
24. The method of claim 21 further comprising providing ventilation
to the one or more pumping units.
25. The method of claim 21 wherein the fuel comprises of one or
more fuels from the group consisting of: diesel, gasoline, natural
gas, or electricity.
26. The method of claim 21 further comprising enclosing the one or
more pumping units in a structure.
27. An apparatus for providing well treatment fluid to a production
site comprising: a well treatment operations factory comprising an
auxiliary pumping system; and a pumping grid connected to the
auxiliary pumping system; wherein the pumping grid is located
remotely from the well treatment operations factory.
28. A method for providing well treatment fluid to a production
site comprising: producing well treatment fluid at a central
location; pumping the well treatment fluid from the central
location to a remote pumping grid; and pumping the well treatment
fluid from the remote pumping grid to the production site.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of application
Ser. No. 11/291,496 filed Dec. 1, 2005.
FIELD OF THE INVENTION
[0002] The present invention relates generally to well operations,
and more particularly to methods and apparatuses for manufacturing
well treatment fluid so as to conserve labor, infrastructure, and
environmental impact.
BACKGROUND
[0003] In the production of oil and gas in the field, it is often
required to stimulate and treat several well locations within a
designated amount of time. Stimulation and treatment processes
often involve mobile equipment that is set up and put in place at a
pad and then moved by truck from pad to pad within short time
periods. Only during non-stimulation activities, such as water
flood operations, can some operations occur simultaneously.
[0004] This movement of equipment and personnel can involve complex
logistics. The servicing and stimulation of wells can require a
series of coordinated operations that begin with the supply by
truck of equipment, supplies, fuel, and chemicals to the wellhead.
The equipment is then set up and made ready with proppant and
chemicals. After completion of the well services, equipment must be
broken down and made ready for transport to the next pad for
service. Often, the next pad will be less than 500 feet away from
the previously treated pad. In addition, due to the limited storage
capacity of the moving equipment for chemicals and equipment,
additional trucks are often required to resupply and reequip an
existing operation. This movement of equipment and supplies has
environmental impacts, and the exposure of mobile equipment to
adverse weather conditions can jeopardize well treatment operations
and worker safety.
SUMMARY
[0005] In general, an apparatus for providing pressure for a well
fracturing operation is disclosed. The apparatus can include one or
more docking areas for docking one or more pumping units to a
pressure manifold wherein the one or more docking areas are
operable to provide access between one or more pumping units, and a
structure operable to enclose the one or more docking areas and
pumping units. The apparatus can also include a crane system, a
central lubrication system connected to the one or more pumping
units for providing lubrication fluid to the one or more pumping
units, and a central power system connected to the one or more
pumping units for starting the one or more pumping units. The
central power system can include a hydraulic power system. The
apparatus can include a central cooling system connected to the one
or more pumping units for cooling the one or more pumping units.
The central cooling system can include a cooling tower. The at
least one of the one or more docking areas can extend outside of
the structure. The apparatus can include a ventilation system. The
apparatus can include a central fueling system connected to the one
or more pumping units for supplying fuel to the one or more pumping
units. The central fueling system supplies one or more fuels from
the group consisting of: diesel, gasoline, natural gas, or
electricity. The structure can include one or more structures from
the group consisting of a supported fabric structure, a collapsible
structure, a prefabricated structure, a retractable structure, a
composite structure, a temporary structure, a prefabricated wall
and roof structure, a deployable structure, a modular structure, a
preformed structure, a mobile accommodation structure, and
combinations thereof. The one or more docking areas can include
walkways. The one or more docking areas can include one or more
lubrication connections, coolant connections, fuel connections,
power connections, and pressure connections. The one or more
pumping units can include heaters.
[0006] An apparatus for providing pressure for a well fracturing
operation is disclosed. The apparatus can include one or more
pumping units, a central fueling system connected to the one or
more pumping units, a central power system connected to the one or
more pumping units, a central lubrication system connected to the
one or more pumping units, and a central cooling system connected
to the one or more pumping units. The central power system can
include a hydraulic power system. The central cooling system can
include a cooling tower. The apparatus can include a ventilation
system. The central fueling system can supply one or more fuels
from the group consisting of: diesel, gasoline, natural gas, or
electricity.
[0007] A method for operating one or more pumping units for a well
fracturing operation from a central land based location is
disclosed. The method includes providing fuel to the one or more
pumping units from the central location, providing lubrication to
the one or more pumping units from the central location, providing
power to the one or more pumping units from the central location,
and providing coolant to the one or more pumping units from the
central location. The power can be provided from a hydraulic power
system. The coolant can be provided from a cooling tower. The
method can include providing ventilation to the one or more pumping
units. The fuel can include of one or more fuels from the group
consisting of: diesel, gasoline, natural gas, or electricity. The
method can also include enclosing the one or more pumping units in
a structure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] A more complete understanding of the present disclosure and
advantages thereof may be acquired by referring to the following
description taken in conjunction with the accompanying drawings.
The drawings illustrate only exemplary embodiments and are not
intended to be limiting against the invention.
[0009] FIG. 1 is a diagram of a centralized well treatment
facility.
[0010] FIG. 2 is a flow diagram of a centralized well treatment
facility.
[0011] FIG. 3 is a flow diagram of central manifold used to treat
wells and recover production fluid.
[0012] FIG. 4 is a diagram of a multiple manifold well treatment
system.
[0013] FIG. 5 is a schematic of a manifold apparatus for directing
treatment fluid.
[0014] FIG. 6 is a schematic of a manifold apparatus for directing
treatment fluid.
[0015] FIG. 7 is a schematic of a simultaneous fracturing
method.
[0016] FIG. 8 is an aerial view of the pumping grid apparatus.
[0017] FIG. 9 is an aerial view of a structure that can enclose the
pumping grid apparatus.
[0018] FIG. 10 is a side view of the pumping grid apparatus.
[0019] FIG. 11 is an aerial view of the fracturing operations
factory and a remote pumping grid apparatus.
DETAILED DESCRIPTION
[0020] The details of the methods and apparatuses according to the
present invention will now be described with reference to the
accompanying drawings.
[0021] In reference to FIG. 1, in one embodiment, a well treatment
operations factory 100 includes one or more of the following: a
centralized power unit 103; a pumping grid 111; a central manifold
107; a proppant storage system 106; a chemical storage system 112;
and a blending unit 105. In this and other embodiments, the well
treatment factory may be set upon a pad from which many other
wellheads on other pads 110 may be serviced. The well treatment
operations factory may be connected via the central manifold 107 to
at least a first pad 101 containing one or more wellheads via a
first connection 108 and at least a second pad 102 containing one
or more wellheads via a second connection 109. The connection may
be a standard piping or tubing known to one of ordinary skill in
the art. The factory may be open, or it may be enclosed at its
location in various combinations of structures including a
supported fabric structure, a collapsible structure, a
prefabricated structure, a retractable structure, a composite
structure, a temporary building, a prefabricated wall and roof
unit, a deployable structure, a modular structure, a preformed
structure, or a mobile accommodation unit. The factory may be
circular and may incorporate alleyways for maintenance access and
process fluid flow. The factory, and any or all of its components
can be climate controlled, air ventilated and filtered, and/or
heated. The heating can be accomplished with radiators, heat
plumbing, natural gas heaters, electric heaters, diesel heaters, or
other known equivalent devices. The heating can be accomplished by
convection, radiation, conduction, or other known equivalent
methods.
[0022] In one embodiment of the centralized power unit 103, the
unit provides electrical power to all of the subunits within the
well operations factory 100 via electrical connections. The
centralized power unit 103 can be powered by liquid fuel, natural
gas, or other equivalent fuel and may optionally be a cogeneration
power unit. The unit may comprise a single trailer with subunits,
each subunit with the ability to operate independently. The unit
may also be operable to extend power to one or more outlying
wellheads.
[0023] In one embodiment, the proppant storage system 106 is
connected to the blending unit 105 and includes automatic valves
and a set of tanks that contain proppant. Each tank can be
monitored for level, material weight, and the rate at which
proppant is being consumed. This information can be transmitted to
a controller or control area. Each tank is capable of being filled
pneumatically and can be emptied through a calibrated discharge
chute by gravity. Gravity can be the substantial means of
delivering proppant from the proppant tank. The tanks may also be
agitated in the event of clogging or unbalanced flow. The proppant
tanks can contain a controlled, calibrated orifice. Each tank's
level, material weight, and calibrated orifice can be used to
monitor and control the amount of desired proppant delivered to the
blending unit. For instance, each tank's orifice can be adjusted to
release proppant at faster or slower rates depending upon the needs
of the formation and to adjust for the flow rates measured by the
change in weight of the tank. Each proppant tank can contain its
own air ventilation and filtering. In reference to FIG. 8, the
tanks 106 can be arranged around each blending unit 105 within the
enclosure, with each tank's discharge chute 803 located above the
blending unit 105. The discharge chute can be connected to a surge
hopper 804. In one embodiment, proppant is released from the
proppant storage unit 106 through a controllable gate in the unit.
When the gate is open, proppant travels from the proppant storage
unit into the discharge chute 803. The discharge chute releases the
proppant into the surge hopper. In this embodiment, the surge
hopper contains a controlled, calibrated orifice or aperture 807
that releases proppant from the surge hopper at a desired rate. The
amount of proppant in the surge hopper is maintained at a
substantially constant level. Each tank can be connected to a
pneumatic refill line 805. The tanks' weight can be measured by a
measurement lattice 806 or by weight sensors or scales. The weight
of the tanks can be used to determine how much proppant is being
used during a well stimulation operation, how much total proppant
was used at the completion of a well stimulation operation, and how
much proppant remains in the storage unit at any given time. Tanks
may be added to or removed from the storage system as needed. Empty
storage tanks may be in the process of being filled by proppant at
the same time full or partially full tanks are being used, allowing
for continuous operation. The tanks can be arranged around a
calibrated v-belt conveyor. In addition, a resin-coated proppant
may be used by the addition of a mechanical proppant coating
system. The coating system may be a Muller System.
[0024] In one embodiment, the chemical storage system 112 is
connected to the blending unit and can include tanks for breakers,
gel additives, crosslinkers, and liquid gel concentrate. The tanks
can have level control systems such as a wireless hydrostatic
pressure system and may be insulated and heated. Pressurized tanks
may be used to provide positive pressure displacement to move
chemicals, and some tanks may be agitated and circulated. The
chemical storage system can continuously meter chemicals through
the use of additive pumps which are able to meter chemical
solutions to the blending unit 105 at specified rates as determined
by the required final concentrations and the pump rates of the main
treatment fluid from the blending unit. The chemical storage tanks
can include weight sensors that can continuously monitor the weight
of the tanks and determine the quantity of chemicals used by mass
or weight in real-time, as the chemicals are being used to
manufacture well treatment fluid. Chemical storage tanks can be
pressurized using compressed air or nitrogen. They can also be
pressurized using variable speed pumps using positive displacement
to drive fluid flow. The quantities and rates of chemicals added to
the main fluid stream are controlled by valve-metering control
systems. The valve-metering can be magnetic mass or volumetric mass
meters. In addition, chemical additives could be added to the main
treatment fluid via aspiration (Venturi Effect). The rates that the
chemical additives are aspirated into the main fluid stream can be
controlled via adjustable, calibrated apertures located between the
chemical storage tank and the main fluid stream. In the case of
fracturing operations, the main fluid stream may be either the main
fracture fluid being pumped or may be a slip stream off of a main
fracture fluid stream. In one embodiment, the components of the
chemical storage system are modularized allowing pumps, tanks, or
blenders to be added or removed independently.
[0025] In reference to FIG. 2, in one embodiment, the blending unit
105 is connected to the chemical storage system 112, the proppant
storage system 106, a water source 202, and a pumping grid 111 and
may prepare a fracturing fluid, complete with proppant and chemical
additives or modifiers, by mixing and blending fluids and chemicals
at continuous rates according to the needs of a well formation. The
blending unit 105 comprises a preblending unit 201 wherein water is
fed from a water supply 202 and dry powder (guar) or liquid gel
concentrate can be metered from a storage tank by way of a screw
conveyor or pump into the preblender's fluid stream where it is
mixed with water and blended with various chemical additives and
modifiers provided by the chemical storage system 112. These
chemicals may include crosslinkers, gelling agents, viscosity
altering chemicals, PH buffers, modifiers, surfactants, breakers,
and stabilizers. This mixture is fed into the blending unit's
hydration device, which provides a first-in-first-out laminar flow.
This now near fully hydrated fluid stream is blended in the mixer
202 of the blending unit 105 with proppant from the proppant
storage system to create the final fracturing fluid. This process
can be accomplished at downhole pump rates. The blending unit can
modularized allowing its components to be easily replaced. In one
embodiment, the mixing apparatus is a modified Halliburton Growler
mixer modified to blend proppant and chemical additives to the base
fluid without destroying the base fluid properties but still
providing ample energy for the blending of proppant into a near
fully hydrated fracturing fluid. The final fluid can be directed to
a pumping grid 111 and subsequently directed to a central manifold
107, which can connect and direct the fluid via connection 109,
204, or 205 to multiple wells 110 simultaneously. In one
embodiment, the fracturing operations factory can comprise one or
more blending units each coupled to one or more of the control
units, proppant storage system, the chemical storage system, the
pre-gel blending unit, a water supply, the power unit, and the
pumping grid. Each blending unit can be used substantially
simultaneously with any other blending unit and can be blending
well treatment fluid of the same or different composition than any
other blending unit.
[0026] In one embodiment, the blending unit does not comprise a
pre-blending unit. Instead, the fracturing operations factory
contains a separate pre-gel blending unit. The pre-gel blending
unit is fed from a water supply and dry powder (guar) can be
metered from a storage tank into the preblender's fluid stream
where it is mixed with water and blended and can be subsequently
transferred to the blending unit. The pre-gel blending unit can be
modular, can also be enclosed in the factory, and can be connected
to the central control system.
[0027] In one embodiment, the means for simultaneously flowing
treatment fluid is a central manifold 107. The central manifold 107
is connected to the pumping grid 111 and is operable to flow
stimulation fluid, for example, to multiple wells at different pads
simultaneously. The stimulation fluid can comprise proppant,
gelling agents, friction reducers, reactive fluid such as
hydrochloric acid, and can be aqueous or hydrocarbon based. The
manifold 107 is operable to treat simultaneously two separate
wells, for example, as shown in FIG. 2 via connections 204 and 205.
In this example, multiple wells can be fractured simultaneously, or
a treatment fluid can be flowed simultaneously to multiple wells.
The treatment fluid flowed can be of the same composition or
different. These flows can be coordinated depending on a well's
specific treatment needs. In addition, in reference to FIG. 3, the
connection 109 between the central manifold 107 and a well location
can be used in the opposite direction as shown in FIG. 2 to flow a
production fluid, such as water or hydrocarbons, or return the well
treatment fluid 301 from the well location to the manifold. From
the central manifold 107, the production fluid can be directed to a
production system 303 where it can be stored or processed or, in
the case of the returning well treatment fluid, to a reclamation
system that can allow components of returning fluid to be reused.
The manifold is operable to receive production fluid or well
treatment fluid from a first well location 101 while simultaneously
flowing treatment fluid 302 using a second connection 108 to a
second well location 102. The central manifold 107 is also operable
to receive production fluid from both the first well location and
the second well location simultaneously. In this embodiment, the
first and second well locations can be at the same or different
pads (as shown in FIG. 3). The manifold is also operable to extend
multiple connections to a single well location. In reference to
FIG. 2, in one embodiment, two connections are extended from the
manifold to a single well location. One connection 109 may be used
to deliver well treatment fluid to the well location while the
other connection 203 may be used to deliver production fluid or
return well treatment fluid from the well location to the central
manifold 107.
[0028] In reference to FIG. 4, in one embodiment, the central
manifold 107 can be connected to one or more additional manifolds
405. The additional manifolds are operable to connect to multiple
well locations 401-404 and deliver well treatment fluids and
receive production fluids via connections 406-409, respectively, in
the same way as the central manifold 107 described above in
reference to FIGS. 2 and 3. The additional manifolds can be located
at the well pads.
[0029] In reference to FIG. 5, in one embodiment, the central
manifold has an input 501 that accepts pressurized stimulating
fluid, fracturing fluid, or well treatment fluid from a pump truck
or a pumping grid 111. The fluid flows into input 501 and through
junctions 502 and 503 to lines 504 and 505. Line 504 contains a
valve 506, a pressure sensor 507, and an additional valve 508. The
line is connected to well head 101. Line 505 contains a valve 511,
a pressure sensor 512, and an additional valve 513. These valves
may be either plug valves or check valves and can be manually or
electronically monitored and controlled. The pressure sensor may be
a pressure transducer and may also be manually or electronically
monitored or controlled. Line 504 is connected to well head 101 and
line 505 is connected to well head 102. This configuration allows
wells 101 and 102 to be stimulated individually and at a higher
rate, by opening the valves along the line to the well to be
treated while the valves along the other line are closed, or
simultaneously at a lower rate, by opening the valves on both lines
at the same time. As shown in FIG. 5, this architecture can be
easily expanded to accommodate additional wells by the addition of
junctions, lines, valves, and pressure sensors as illustrated. This
architecture also allows monitoring the operations of the manifold
and detecting leaks. By placing pressure sensors 507 and 512
between valves 506 and 508 and valves 511 and 513 respectively, the
pressure of lines 504 and 505 can be readily determined during
various phases of operation. For instance, when the manifold is
configured to stimulate only well 101, valves 511 and 513 are
closed. Pressure sensor 507 can detect the pressure within the
active line 504, and pressure sensor 512 can be used to detect if
there is any leakage, as it would be expected that the pressure in
line 505 in this configuration would be minimal. In another
embodiment, only a single valve is used along each of lines 504 and
505. This embodiment can be used to stimulate wells simultaneously
or singly as well. Furthermore, as described in reference to FIG.
4, the manifold of this embodiment can also work in reverse and
transfer fluid from the wellhead back through the manifold and to
the central location. In this configuration, input 501 can be
connected to a production system or reclamation system, for
example, and the valves along the line connected to the wellhead in
which it is desirable to recover fluid are open. The valves along
the other lines may be open or closed depending on whether it is
desirable to recover fluids from the wellheads connected to those
lines. Production fluid or stimulation fluid can be returned from
the wellhead to those systems respectively. This manifold can be
located at the central location or at a remote pad.
[0030] In reference to FIG. 6, in one embodiment, the central
manifold contains two inputs 601 and 602 that accept pressurized
stimulating fluid, fracturing fluid, or well treatment fluid from
pump trucks or a pumping grid 111. Inputs 601 and 602 can accept
fluid of different or the same compositions at similar or different
pressures and rates. The fluid pumped through input 602 travels
through junctions 603 and 605. The junctions are further connected
to lines 610 and 611. The fluid pumped through input 601 travels
through junctions 604 and 615. The junctions are further connected
to lines 609 and 612. Lines 609, 610, 611, and 612 may each contain
a valve 606, a pressure sensor 607, and an additional valve 608, or
may contain only a single valve. These valves may be either plug
valves or check valves and can be manually or electronically
monitored and controlled. The pressure sensor may be a pressure
transducer and may also be manually or electronically monitored or
controlled. When, for example, the fluid from input 602 is desired
to be delivered to well 101 only, the valves on line 610 are open
and the valves on line 611 are closed. When the fluid from input
601 is desired to be delivered to well 101 only, the valves on line
609 are open and the valves on line 612 are closed. When it is
desired that fluid from both inputs 601 and 602 are to be delivered
to well 101 only, the valves on lines 609 and 610 are open and the
valves on lines 611 and 612 are closed. Lines 609 and 610 are
coupled to wellhead 101 through junction 616. When it is desired
that fluid from input 602 be delivered to both wells 101 and 102
simultaneously, the valves on lines 610 and 611 are both open.
Fluid from input 601 can be delivered to well 101 and fluid from
input 602 can be delivered to well 102 simultaneously by closing
the valves on lines 610 and 612 and opening the valves on lines 611
and 609. The delivery of fluid to well 102 works analogously. As
shown in FIG. 6, the manifold can be easily expanded to include
additional wells through additional junctions, lines, and valves.
Furthermore, as described in reference to FIG. 4, the manifold of
this embodiment can also work in reverse and transfer fluid from
the wellhead back through the manifold and to the central location.
In this configuration, either or both inputs 601 and 602 can be
connected to a production system or reclamation system, for
example, and the valves along the line connected to the wellhead in
which it is desirable to recover fluid are open. The valves along
the other lines may be open or closed depending on whether it is
desirable to recover fluids from the wellheads connected to those
lines. Production fluid or stimulation fluid can be returned from
the wellhead to those systems respectively. This manifold can be
located at the central location or at a remote pad.
[0031] In reference to FIG. 7, in one embodiment, multiple manifold
trailers 701 and 702 may be used at the central location where the
stimulation fluid is manufactured and pressurized. The manifold
trailers themselves are well known in the art. Each manifold
trailer is connected to pressurized stimulating fluid through pump
trucks 703 or a pumping grid 111. A line from each manifold trailer
can connect directly to a well head to stimulate it directly, or it
can further be connected to the manifolds described that are
further connected to well locations.
[0032] In one embodiment, of the pumping grid system 111, pumping
modules can be hauled to the fracturing operation factory site by
truck, and pinned or bolted or otherwise located together on the
ground. Pumping equipment grid modules can be added or taken away
to accommodate the number of pumping units to be used on site. The
pressure manifold will interface with the pumping equipment grid
modules and support a crane. The grid system can be configured with
various piping or electrical connections that each pumping unit may
require for power, fuel, cooling, and lubrication. The grid system
would incorporate space to allow access to the pumping units' main
components for easy maintenance. In reference to FIG. 8, in one
embodiment of the pumping grid 111, the grid comprises one or more
pumps 801 that can be electric, gas, diesel, or natural gas
powered. The grid can also contain spaces or docks 810 operable to
receive equipment, such as pumps and other devices, modularized to
fit within such spaces. The pumping grid 111 can include walkways
807 that provide access to pumps or any other equipment docked in
the grid spaces. The grid's spaces or docks 810 can be prewired and
preplumbed and can contain lube oil, fueling, power, and cooling
capabilities and connections for the pumps 801 to manifold 107
(shown in FIG. 10). The pumps 801 that connect to the grid 111 can
be freestanding such as pumps 801, or the pumps 809 can be attached
to trucks 808. Pumps 809 can each contain its own fueling, cooling,
lubrication, and power sources. Pumps 801 can rely on centralized
fuel, coolant, lubrication, and power sources. The fuel for the
pumps 801 can be supplied to the pumps 801 from a single central
fueling system 803 through piping or tubing well known in the art.
The pumps 801 can include hydraulic starting mechanisms. Hydraulic
power for the starting mechanisms can be supplied to the pumps 801
from a single central power system 804 using tubing or piping well
known in the art. In the event electric pumps are used, the power
system 804 can provide electricity to the pumps via wires. The
lubrication of the pumps 801 can also be centralized. Lubrication
fluid can be supplied from a central lubrication system 805 to the
pumps 801 using tubing or piping well known in the art. Coolant for
the pumps can be provided from a central source such as a coolant
or water tower that can generate less noise than local fans. The
grid is operable to accept connections to proppant storage and
metering systems, chemical storage and metering systems, and
blending units. The pumping grid can also have a crane 806 that can
assist in the replacement or movement of pumps, manifolds, or other
equipment. In reference to FIG. 9, the pumping grid 111 can be
enclosed in a structure 901. The structure can be a supported
fabric structure, a collapsible structure, a prefabricated
structure, a retractable structure, a composite structure, a
temporary structure, a prefabricated wall and roof structure, a
deployable structure, a modular structure, a preformed structure, a
mobile accommodation structure, and combinations thereof. The
pumping grid 111 can also be partially enclosed by structure 901
and partially exposed, as shown by pump trucks 808, which are
connected to the pumping grid outside of the structure 901. The
pumping grid 111 can also include a ventilation system 902 that can
release exhaust from the pumps and/or ventilate the inside of the
structure 901. FIG. 10 shows the pumping grid 111, the crane 806,
the pressure manifold 107, and the enclosing structure 901. A
central manifold 107 can accept connections to wells and can be
connected to the pumping grid. In one embodiment, the central
manifold and pumping grid are operable to simultaneously treat both
a first well head connected via a first connection and a second
well head connected via a second connection with the stimulation
fluid manufactured by the factory and connected to the pumping
grid.
[0033] In reference to FIG. 11, in some embodiments, the pumping
grid can be located at a different pad miles away from the
fracturing operations factory 100. An auxiliary pumping system
1102, which itself can include pumping trucks, manifold trailers
703 shown in FIG. 7, or standalone pumps, can pump fracturing fluid
from the fracturing operations factory 100 through connection 1101
to the pumping grid 111. The pumping grid 111 can next pump the
fluid to production site 101, for example. In this way, the
operations of the fracturing factory 100 can be extended to remote
pads through assembly and reassembly of the pumping grid 111 and
connection 1101.
[0034] In some embodiments, the operations of the chemical storage
system, proppant storage system, blending unit, pumping grid, power
unit, and manifolds are controlled, coordinated, and monitored by a
central control system. The central control system can be an
electronic computer system capable of receiving analog or digital
signals from sensors and capable of driving digital, analog, or
other variety of controls of the various components in the
fracturing operations factory. The control system can be located
within the factory enclosure, if any, or it can be located at a
remote location. The central control system may use all of the
sensor data from all units and the drive signals from their
individual subcontrollers to determine subsystem trajectories. For
example, control over the manufacture, pumping, gelling, blending,
and resin coating of proppant by the control system can be driven
by desired product properties such as density, rate, viscosity,
etc. Control can also be driven by external factors affecting the
subunits such as dynamic or steady-state bottlenecks. Control can
be exercised substantially simultaneously with both the
determination of a desired product property, or with altering
external conditions. For instance, once it is determined that a
well treatment fluid with a specific density is desired, a well
treatment fluid of the specific density can be manufactured
virtually simultaneously by entering the desired density into the
control system. The control system will substantially
simultaneously cause the delivery of the proppant and chemical
components comprising a well treatment fluid with the desired
property to the blending unit where it can be immediately pumped to
the desired well location. Well treatment fluids of different
compositions can also be manufactured substantially simultaneously
with one another and substantially simultaneously with the
determination of desired product properties through the use and
control of multiple blending units each connected to the control
unit, proppant storage system, chemical storage system, water
source, and power unit. The central control system can include such
features as: (1) virtual inertia, whereby the rates of the
subsystems (chemical, proppant, power, etc.) are coupled despite
differing individual responses; (2) backward capacitance control,
whereby the tub level controls cascade backward through the system;
(3) volumetric observer, whereby sand rate errors are decoupled and
proportional ration control is allowed without steady-state error.
The central control system can also be used to monitor equipment
health and status. Simultaneously with the manufacture of a well
treatment fluid, the control system can report the quantity and
rate usage of each component comprising the fluid. For instance,
the rate or total amount of proppant, chemicals, water, or
electricity consumed for a given well in an operation over any time
period can be immediately reported both during and after the
operation. This information can be coordinated with cost schedules
or billing schedules to immediately compute and report incremental
or total costs of operation.
[0035] The present invention can be used both for onshore and
offshore operations using existing or specialized equipment or a
combination of both. Such equipment can be modularized to expedite
installation or replacement. The present invention may be enclosed
in a permanent, semipermanent, or mobile structure.
[0036] As those of ordinary skill in the art will appreciate, the
present invention can be adapted for multiple uses. By way of
example only, multiple well sites may be treated, produced, or
treated and produced sequentially or simultaneously from a single
central location. The invention is capable of considerable
additional modification, alteration, and equivalents in form and
function, as will occur to those ordinarily skilled in the art
having the benefit of this disclosure. The depicted and described
embodiments of the invention are exemplary only, and are not
exhaustive of the scope of the invention. Consequently, the
invention is intended to be limited only by the spirit and scope of
the appended claims.
* * * * *