U.S. patent application number 14/735745 was filed with the patent office on 2016-08-11 for fracturing system layouts.
The applicant listed for this patent is PROSTIM LABS, LLC. Invention is credited to AUDIS BYRD, ROBERT LESTZ, NORMAN MYERS.
Application Number | 20160230525 14/735745 |
Document ID | / |
Family ID | 56566639 |
Filed Date | 2016-08-11 |
United States Patent
Application |
20160230525 |
Kind Code |
A1 |
LESTZ; ROBERT ; et
al. |
August 11, 2016 |
FRACTURING SYSTEM LAYOUTS
Abstract
Systems for stimulation a formation include a plurality of
variable frequency drives, each in communication with at least two
high pressure pumps. A variable frequency drive actuates at least
two electric motors associated with the high pressure pumps, such
that the pumps pressurize fracturing fluid, proppant, or
combinations thereof for flowing the fracturing fluid, proppant, or
combinations thereof into the formation.
Inventors: |
LESTZ; ROBERT; (MISSOURI
CITY, TX) ; BYRD; AUDIS; (BIG SANDY, TX) ;
MYERS; NORMAN; (HOUSTON, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
PROSTIM LABS, LLC |
HOUSTON |
TX |
US |
|
|
Family ID: |
56566639 |
Appl. No.: |
14/735745 |
Filed: |
June 10, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14199461 |
Mar 6, 2014 |
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14735745 |
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14511858 |
Oct 10, 2014 |
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14199461 |
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62010302 |
Jun 10, 2014 |
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62036284 |
Aug 12, 2014 |
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62036297 |
Aug 12, 2014 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E21B 43/267 20130101;
Y02P 20/123 20151101; E21B 43/26 20130101; Y02P 20/10 20151101;
C09K 8/60 20130101 |
International
Class: |
E21B 43/267 20060101
E21B043/267; E21B 41/00 20060101 E21B041/00 |
Claims
1. A system for stimulating a formation, the system comprising: a
source of fracturing fluid in communication with the formation; a
source of proppant in communication with the formation; a power
source; a plurality of variable frequency drives in communication
with the power source; and at least two high pressure pumps in
communication with each of said variable frequency drives, wherein
a variable frequency drive receives power from the power source and
actuates at least two electric motors associated with said at least
two high pressure pumps, and wherein said at least two high
pressure pumps pressurize fracturing fluid, proppant, or
combinations thereof for flowing said fracturing fluid, proppant,
or combinations thereof into the formation.
2. The system of claim 1, wherein the power source comprises a
medium voltage power source.
3. The system of claim 1, wherein the plurality of variable
frequency drives comprises four variable frequency drives.
4. The system of claim 3, wherein said four variable frequency
drives are transportable on a single trailer.
5. The system of claim 3, wherein said four variable frequency
drives are in association with at least eight high pressure pumps,
and wherein said at least eight high pressure pumps are
transportable on three or fewer trailers.
6. The system of claim 1, wherein the plurality of variable
frequency drives are spaced a distance from said at least two high
pressure pumps sufficient to minimize ignition of fracturing fluid
pressurized by said at least two high pressure pumps by said
plurality of variable frequency drives.
7. The system of claim 6, wherein the distance comprises at least
30 meters.
8. The system of claim 6, wherein the source of fracturing fluid
comprises propane.
9. The system of claim 1, further comprising a wellhead in
association with the formation, wherein said at least two high
pressure pumps are spaced a distance from the wellhead sufficient
to minimize ignition of fracturing fluid pressurized by said at
least two high pressure pumps.
10. The system of claim 9, wherein the distance comprise at least
30 meters.
11. A system for stimulating a formation, the system comprising: a
source of fracturing fluid in communication with the formation; a
source of proppant in communication with the formation; at least
one power source; at least one mobile platform comprising a
variable frequency drive and at least two high pressure pumps
mounted thereon, wherein said at least two high pressure pumps are
coupled to the variable frequency drive, wherein the variable
frequency drive receives power from said at least one power source
and actuates at least two electric motors associated with said at
least two high pressure pumps, and wherein said at least two high
pressure pumps pressurize fracturing fluid, proppant, or
combinations thereof for flowing said fracturing fluid, proppant,
or combinations thereof into the formation.
12. The system of claim 11, wherein the power source comprises a
medium voltage power source.
13. The system of claim 11, wherein said at least one mobile
platform comprises four mobile platforms, each of said mobile
platforms having a variable frequency drive and at least two high
pressure pumps mounted thereon.
14. The system of claim 11, wherein said at least two high pressure
pumps engage the variable frequency drive via a single tie
line.
15. The system of claim 11, further comprising a wellhead in
association with the formation, wherein said at least two high
pressure pumps are spaced a distance from the wellhead sufficient
to minimize ignition of fracturing fluid pressurized by said at
least two high pressure pumps.
16. The system of claim 15, wherein the distance comprise at least
30 meters.
17. The system of claim 11, wherein at least one of said high
pressure pumps comprises a breakway feature adapted to decouple
said at least one of said high pressure pumps from the variable
frequency drive to enable substantially all output from the
variable frequency drive to be provided to at least one other of
said high pressure pumps.
18. The system of claim 17, wherein said at least two high pressure
pumps comprise a first high pressure pump of a first type and a
second high pressure pump of a second type different than the first
type.
19. The system of claim 18, wherein the first type comprises a
qunitplex pump and the second type comprises a triplex pump.
20. The system of claim 18, wherein the first type, the second
type, or combinations thereof is selectable to reduce harmonic
resonance, vibration, or combinations thereof generated by said at
least two high pressure pumps, the variable frequency drive, or
combinations thereof.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority to the U.S.
Provisional Patent Application Ser. No. 62/010,302, filed Jun. 10,
2014; U.S. Provisional Patent Application Ser. No. 62/036,284,
filed Aug. 12, 2014; U.S. Provisional Patent Application Ser. No.
62/036,297, filed Aug. 12, 2014; is a continuation-in-part of
United States Application for Patent having the application Ser.
No. 14/199,461, filed Mar. 6, 2014; and is a continuation-in-part
of United States Application for Patent having the application Ser.
No. 14/511,858, filed Oct. 10, 2014. Each of the above-referenced
applications is incorporated by reference herein in its entirety.
Additionally incorporated by reference in their entirety, but not
claimed for priority, are U.S. Provisional Patent Application Ser.
No. 61/774,237, filed Mar. 7, 2013, U.S. Provisional Patent
Application Ser. No. 61/790,942, filed Mar. 15, 2013, U.S.
Provisional Patent Application Ser. No. 61/807,699, filed Apr. 2,
2013, and U.S. Provisional Patent Application Ser. No. 61/870,350,
filed Aug. 27, 2013.
FIELD
[0002] Embodiments usable within the scope of the present
disclosure relate, generally, to systems and methods for flowing
fluid in association with a wellbore, and more specifically, to
systems and methods usable for performing fracturing operations on
a formation to stimulate production (e.g., of hydrocarbons)
therefrom.
BACKGROUND
[0003] To stimulate and/or increase the production of hydrocarbons
from a well, a process known as fracturing (colloquially referred
to as "fracing") is performed. In brief summary, a pressurized
fluid--often water--is pumped into a producing region of a
formation at a pressure sufficient to create fractures in the
formation, thereby enabling hydrocarbons to flow from the formation
with less impedance. Solid matter, such as sand, ceramic beads,
and/or similar particulate-type materials, can be mixed with the
fracturing fluid, this material generally remaining within the
fractures after the fractures are formed. The solid material, known
as proppant, serves to prevent the fractures from closing and/or
significantly reducing in size following the fracturing operation,
e.g., by "propping" the fractures in an open position. Some types
of proppant can also facilitate the formation of fractures when
pumped into the formation under pressure.
[0004] Non-aqueous fracturing fluids have been used as an
alternative to water and other aqueous media, one such successful
class including hydrocarbon-based fluids (e.g., crude/refined oils,
methanol, diesel, condensate, liquid petroleum glass (LPG) and/or
other aliphatic or aromatic compounds). Hydrocarbon-based
fracturing fluids are inherently compatible with most reservoir
formations, being generally non-damaging to formations while
creating acceptable fracture geometry. However, due to the
flammability of hydrocarbon-based fluids, enhanced safety
preparations and equipment are necessary when using such fluids for
wellbore operations. Additionally, many hydrocarbon-based fluids
are volatile and/or otherwise unsuitable for use at wellbore
temperatures and pressures, while lacking the density sufficient to
carry many types of proppant. As such, it is common practice to use
chemical additives (e.g., gelling agents, viscosifiers, etc.) to
alter the characteristics of the fluids. An example a system
describing use of liquid petroleum gas is described in U.S. Pat.
No. 8,408,289, which is incorporated by reference herein in its
entirety.
[0005] Independent of the type of fracturing fluid and proppant
used, a fracturing operation typically requires use of one or more
high pressure pumps to pressurize the fracturing fluid that is
pumped into a wellbore. Conventionally, such equipment is
driven/powered using diesel engines, which can be responsible for
significant quantities of noise, pollution, and expense at a
worksite. Electric drive systems have been contemplated as an
alternative to diesel engines; however, such systems require
numerous pieces of equipment, extensive cabling and/or similar
conduits, and typically utilize on-site power generation, such as a
natural gas turbine. Use of turbine prime movers and similar
equipment may be unsuitable when utilizing fracturing fluids that
include flammable components. An exemplary electrically powered
system for use in fracturing underground formations is described in
published United States Patent Application 2012/0255734, which is
incorporated by reference herein in its entirety.
[0006] A need exists for systems and methods for fracturing and/or
stimulating a subterranean formation that can overcome issues of
formation damage/compatibility, flammability, proppant delivery,
and/or power supply.
SUMMARY
[0007] Embodiments usable within the scope of the present
disclosure include systems and methods usable to perform fracturing
operations on a formation using an electrically powered fracturing
spread. FIG. 1 enumerates numerous benefits relating to safety,
economy, and sustainability of electrically powered fracturing
systems.
[0008] A power source (e.g., a turbine generator and/or a
grid-based power source) can be used to provide electrical power to
one or more Variable Frequency Drives (VFDs), which in turn actuate
electric motors, used to power associated high pressure pumps
(e.g., fracturing pumps). The pumps are usable to pressurize a
fracturing fluid (e.g., water, propane, or other suitable media,
typically combined with proppant) prior to injection of the
pressurized fluid into a wellbore to fracture the underlying
formation.
[0009] A high pressure pump can be subject to a maximum rate and/or
torque at which the pump can be operated without damaging
components thereof, and as such, a single VFD or set of VFDs may
provide horsepower in excess of what is required by a pump to
operate the pump at a maximum rate. As such, embodiments usable
within the scope of the present disclosure can include multiple
high pressure pumps associated with a single VFD. In an embodiment,
pumps can be provided with a "breakaway" usable to disconnect a
selected pump from a VFD to enable the full power thereof to be
provided to one or more pumps that remain connected therewith. In a
further embodiment, a VFD can be associated with different types of
pumps (e.g., a qunitiplex and/or a triplex pump), to enable
selective use of one or both types of pumps in a manner that
minimizes harmonic resonance.
[0010] In various embodiments, disclosed systems can be used with
medium voltage (e.g., 4160 volts), enabling smaller, lighter power
conduits to be used, facilitating transport, installation, and
safety, while minimizing line loss and the required amperage to
operate the system.
[0011] In various embodiments, VFDs and/or similar components can
be positioned a selected distance (e.g., 30 meters) from the high
pressure pumps, thereby minimizing risks of ignition when pumping a
flammable medium, such as propane and/or other hydrocarbon-based
fracturing fluids. Separation of potential ignition sources from
flammable components can eliminate the need to utilize
explosion-proof measures (e.g., explosion-proof housings,
pressurized environments, etc.)
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] In the detailed description of various embodiments usable
within the scope of the present disclosure, presented below,
reference is made to the accompanying drawings, in which:
[0013] FIG. 1 depicts a list describing benefits attainable through
use of embodiments of systems usable within the scope of the
present disclosure.
[0014] FIG. 2 depicts a diagrammatic view of an embodiment of a
system usable within the scope of the present disclosure.
[0015] FIG. 3 depicts a diagrammatic view of an embodiment of a
system usable within the scope of the present disclosure.
[0016] One or more embodiments are described below with reference
to the listed Figures.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0017] Before describing selected embodiments of the present
invention in detail, it is to be understood that the present
invention is not limited to the particular embodiments described
herein. The disclosure and description herein is illustrative and
explanatory of one or more presently preferred embodiments of the
invention and variations thereof, and it will be appreciated by
those skilled in the art that various changes in the design,
organization, order of operation, means of operation, equipment
structures and location, methodology, and use of mechanical
equivalents may be made without departing from the spirit of the
invention.
[0018] As well, it should be understood the drawings are intended
illustrate and plainly disclose presently preferred embodiments of
the invention to one of skill in the art, but are not intended to
be manufacturing level drawings or renditions of final products and
may include simplified conceptual views as desired for easier and
quicker understanding or explanation of the invention. As well, the
relative size and arrangement of the components may differ from
that shown and still operate within the spirit of the invention as
described throughout the present application.
[0019] Moreover, it will be understood that various directions such
as "upper", "lower", "bottom", "top", "left", "right", and so forth
are made only with respect to explanation in conjunction with the
drawings, and that the components may be oriented differently, for
instance, during transportation and manufacturing as well as
operation. Because many varying and different embodiments may be
made within the scope of the inventive concept(s) herein taught,
and because many modifications may be made in the embodiments
described herein, it is to be understood that the details herein
are to be interpreted as illustrative and non-limiting.
[0020] FIG. 2 depicts a diagrammatic view of an embodiment of a
system usable within the scope of the present disclosure, usable to
perform fracturing operations on a formation associated with a
wellhead. The diagram depicts a cleared zone (e.g., having a radius
of about 30 meters) about the wellhead, outside of which the
depicted system can be positioned. At the far left of the diagram a
plurality of fracturing fluid storage vessels are shown (e.g., six
propane storage tanks; however any number and/or type of storage
vessel can be used without departing from the scope of the present
disclosure), in association with a proppant storage vessel (which
can be representative of any number or type of proppant sources
and/or containers).
[0021] It should be understood that while the depicted system
describes use of propane storage tanks (e.g., containing propane
for use as a fracturing fluid), the depicted system can incorporate
use of water or any other fracturing fluid without departing from
the scope of the present disclosure.
[0022] The fracturing fluid and proppant storage vessels are shown
proximate to the low pressure manifold of the system, where the
fracturing fluid and/or proppant can be injected (e.g., as a
slurry). A plurality of high pressure pumps (each powered using an
associated electric motor) is shown, the pumps being usable to
pressurize the fracturing fluid and/or proppant (e.g., at the high
pressure manifold of the system) prior to flowing the fracturing
fluid and/or proppant to the wellhead (and subsequently into the
wellbore to the formation). While the depicted diagram shows eight
high pressure pumps and associated motors, it should be understood
that any number of high pressure pumps can be used depending on the
nature of the operation. Conceptually, FIG. 2 depicts the eight
high pressure pumps divided into three groups--two sets of three
pumps and one set of two pumps--each grouping of pumps
representative of a single transport load (e.g., the number of
pumps that could be transported to an operational site on a single
trailer.) It should be understood that this division of pumps is
merely conceptual, and that depending on the means of transport
and/or the characteristics of the pumps, motors, and/or associated
equipment, any number of transport loads could be used without
departing from the scope of the present disclosure.
[0023] A plurality of Variable Frequency Drives (VFDs) is shown
spaced a selected distance (e.g., 30 meters) from the high pressure
pumps. Placement of the VFDs a safe distance from the high pressure
pumps can allow propane or a similar flammable medium to be used as
a fracturing fluid while minimizing the risk of ignition created by
the proximity of VFDs or similar potential ignition sources. By
placing the VFDs remote from the high pressure pumps, the need for
explosion proof housings, pressurized environments, and/or use of
similar explosion-proof measures can be eliminated.
[0024] While FIG. 2 depicts four VFDs (used in association with the
eight depicted high pressure pumps and associated electric motors),
it should be understood that any number of VFDs or similar devices
can be used depending on the nature and/or requirements of an
operation and/or characteristics of equipment being used.
Conceptually, FIG. 2 depicts the four VFDs as a single grouping of
devices, representative of a single transport load--e.g., it is
contemplated that four VFDs could be transported to an operational
site on a single trailer. As noted above, depending on the means of
transport and/or the characteristics of the equipment utilized, any
number of transport loads could be used without departing from the
scope of the present disclosure. In the depicted embodiment, four
transport loads could be used to position each of the depicted
pumps, motors, and VFDs, which is one half the number of loads
required to deploy such a quantity of equipment using conventional
configurations.
[0025] Each VFD is shown in operative association with two high
pressure pumps (via the associated electric motors). As described
above, the maximum rate at which a high pressure pump can be
operated is typically limited to the maximum torque able to be
withstood by the components thereof. As such, a single VFD may
produce horsepower in excess of that which is required to operate a
high pressure pump at its maximum rate, and in an embodiment, the
horsepower output of a VFD can be generally sufficient to operate
two high pressure pumps at a rate suitable for performing a
fracturing operation. For example, four conventional VFDs may
output approximately 10,000 horsepower, which would be sufficient
to operate eight high pressure pumps at approximately their maximum
rate. It should be understood that the type and quantity of VFDs
and/or pumps and/or electric motors can be selected such that the
output of the VFDs is generally equal to the horsepower
requirements to operate the associated pumps.
[0026] As described above, in various embodiments, one or both
pumps coupled with a VFD can include a breakaway or similar means
for decoupling from the VFD, such that the entirety of the output
from the VFD can be used to drive a single pump (e.g., at an
enhanced rate), and/or to enable a second pump to be used as a
backup/redundant pump in the case of a fault or failure of a first
pump. Additionally or alternatively, two pumps associated with a
single VFD can include different types of pumps, such that a
desired type of pump can be selected for use (e.g., depending on
operational conditions, wellbore conditions, types of equipment
present/available, etc.). For example, selection between a
quintiplex and/or a triplex pump can be used to minimize harmonic
resonance.
[0027] The depicted VFDs are shown in communication with a power
source, which can include one or more generators, one or more power
storage devices, one or more grid power sources, or combinations
thereof. In an embodiment, the incoming power can include a medium
voltage source (e.g., 4160 volts), allowing use of smaller and
lighter conduits, less line loss, lower amperage, etc. Depending on
the characteristics of the VFDs, power source, motors, and/or pumps
used, the need for a separate transformer (e.g., to alter the
incoming voltage and/or the voltage transmitted between components)
can be obviated.
[0028] It should be understood that while FIG. 2 depicts eight high
pressure pumps and associated electric motors, and four VFDs,
independent from trailers or similar transport vehicles (e.g.,
frame-mounted on the ground or an operational platform or similar
surface), in various embodiments, system components could remain in
association with trailers or similar transport vehicles to
facilitate mobility thereof.
[0029] FIG. 3 depicts a diagrammatic view of an embodiment of a
system usable within the scope of the present disclosure, usable to
perform fracturing operations on a formation associated with a
wellhead. The diagram depicts a cleared zone (e.g., having a radius
of about 30 meters) about the wellhead, outside of which the
depicted system can be positioned. At the bottom of the diagram, a
plurality of fracturing fluid storage vessels are shown (e.g., six
water storage tanks; however any number and/or type of storage
vessel can be used without departing from the scope of the present
disclosure), in association with a proppant storage vessel (which
can be representative of any number or type of proppant sources
and/or containers). It should be understood that while the depicted
system describes use of water storage tanks (e.g., containing water
for use as a fracturing fluid), the depicted system can incorporate
use of any fracturing fluid without departing from the scope of the
present disclosure. Due to the close proximity of the depicted VFDs
to the depicted high pressure pumps, the depicted configuration is
contemplated to be of particular use with non-flammable fracturing
fluids.
[0030] The fracturing fluid and proppant storage vessels are shown
proximate to the low pressure manifold of the system, where the
fracturing fluid and/or proppant can be injected (e.g., as a
slurry). A plurality of high pressure pumps, each powered using an
associated electric motor and each mounted on an associated
trailer, is shown, the pumps being usable to pressurize the
fracturing fluid and/or proppant (e.g., at the high pressure
manifold of the system) prior to flowing the fracturing fluid
and/or proppant to the wellhead (and subsequently into the wellbore
to the formation). While the depicted diagram shows eight high
pressure pumps and associated motors, it should be understood that
any number of high pressure pumps can be used depending on the
nature of the operation.
[0031] A plurality of Variable Frequency Drives (VFDs) is shown in
association with the depicted high pressure pumps. Specifically,
each trailer is shown having one VFD mounted thereon, adjacent to
two high pressure pumps and associated motors. While FIG. 3 depicts
four VFDs (each used in association with two high pressure pumps
and associated electric motors), mounted on four trailers, it
should be understood that any number of VFDs or similar devices,
and any number of trailers, can be used depending on the nature
and/or requirements of an operation and/or characteristics of
equipment being used. In the depicted embodiment, four transport
loads could be used to position each of the depicted pumps, motors,
and VFDs, which is one half the number of loads required to deploy
such a quantity of equipment using conventional configurations.
[0032] Due to the horsepower limitations of a typical high pressure
pump, described previously, each VFD is shown in operative
association with two high pressure pumps. As described above, in
various embodiments, one or both pumps coupled with a VFD can
include a breakaway or similar means for decoupling from the VFD,
such that the entirety of the output from the VFD can be used to
drive a single pump (e.g., at an enhanced rate), and/or to enable a
second pump to be used as a backup/redundant pump in the case of a
fault or failure of a first pump. Additionally or alternatively,
two pumps associated with a single VFD can include different types
of pumps, such that a desired type of pump can be selected for use
(e.g., depending on operational conditions, wellbore conditions,
types of equipment present/available, etc.).
[0033] The depicted VFDs are shown in communication with one or
more power sources, which can include one or more generators, one
or more power storage devices, one or more grid power sources, or
combinations thereof. In an embodiment, the incoming power can
include a medium voltage source (e.g., 4160 volts), allowing use of
smaller and lighter conduits, less line loss, lower amperage, etc.
Depending on the characteristics of the VFDs, power sources,
motors, and/or pumps used, the need for a separate transformer
(e.g., to alter the incoming voltage and/or the voltage transmitted
between components) can be obviated.
[0034] It should be understood that while FIG. 3 depicts four
mobile trailers, each trailer having two high pressure pumps and a
single VFD mounted thereon, in various embodiments, system
components could be removed from trailers (e.g., frame mounted on
the ground or a similar operational platform) to reduce the
footprint of the system and allow use of the trailers for other
purposes while the system is deployed.
[0035] In the depicted embodiment, use of two high pressure pumps
and a single VFD on a single trailer can enable the two pumps to be
operated via the VFD using a single tie line. Using a reduced
number of lines for the system in this manner enables the manifold
trailer to be reduced in size (e.g., one half of its conventional
length), reducing the footprint of the system and facilitating
transport thereof.
[0036] While various embodiments usable within the scope of the
present disclosure have been described with emphasis, it should be
understood that within the scope of the appended claims, the
present invention can be practiced other than as specifically de
scribed herein.
* * * * *