U.S. patent application number 15/983623 was filed with the patent office on 2018-09-20 for plant for controlling delivery of pressurized fluid in a conduit, and a method of controlling a prime mover.
The applicant listed for this patent is IMPACT SOLUTIONS AS. Invention is credited to Oddgeir HUSOY, Terje STOKKEV G.
Application Number | 20180266412 15/983623 |
Document ID | / |
Family ID | 61187799 |
Filed Date | 2018-09-20 |
United States Patent
Application |
20180266412 |
Kind Code |
A1 |
STOKKEV G; Terje ; et
al. |
September 20, 2018 |
PLANT FOR CONTROLLING DELIVERY OF PRESSURIZED FLUID IN A CONDUIT,
AND A METHOD OF CONTROLLING A PRIME MOVER
Abstract
A plant for delivering a fluid in a conduit (10) comprises a
prime mover (2), for example a gas turbine, which is configured to
drive one or more fluid delivery systems (34a-c, 35a1-c1, 35a2-c2)
for delivering a fluid in the conduit (10). A first sensor (16) is
configured for sensing pressure variations in the pipe (10) and is
connected to a first controller (7). The first controller (7) is
configured to provide control signals to control valves (36a-c,
37a-c) for at least one fluid delivery system and to a control
system (4, 3) for the prime mover (2). One or more hydraulic pumps
(9a-c) are configured to operate the fluid delivery systems and are
driven by the prime mover, whereby interaction between the
hydraulic pumps and the prime mover is controlled based on sensed
pressure in the pipe (10).
Inventors: |
STOKKEV G; Terje;
(Ulsteinvik, NO) ; HUSOY; Oddgeir; (Fosnavaag,
NO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
IMPACT SOLUTIONS AS |
ULSTEINVIK |
|
NO |
|
|
Family ID: |
61187799 |
Appl. No.: |
15/983623 |
Filed: |
May 18, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
PCT/NO2017/050307 |
Nov 28, 2017 |
|
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15983623 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F04B 49/08 20130101;
F04B 17/03 20130101; F04B 47/04 20130101; E21B 43/26 20130101; F04B
11/0058 20130101; F04B 17/06 20130101; F04B 9/1172 20130101; F04B
9/117 20130101; F04B 17/05 20130101; F04B 49/20 20130101; F04B
49/22 20130101 |
International
Class: |
F04B 49/22 20060101
F04B049/22; F04B 11/00 20060101 F04B011/00; F04B 17/05 20060101
F04B017/05; F04B 17/03 20060101 F04B017/03; F04B 17/06 20060101
F04B017/06; F04B 49/20 20060101 F04B049/20 |
Foreign Application Data
Date |
Code |
Application Number |
Nov 30, 2016 |
NO |
20161911 |
Claims
1. A method of controlling a plant for delivering a pressurized
fluid in a conduit, the plant comprising: a prime mover configured
to supply torque to one or more hydraulic pumps, each hydraulic
pump being configured to supply hydraulic pressure to a respective
positive displacement fluid delivery system via a respective
control valve, each positive displacement fluid delivery system
being configured to deliver the pressurized fluid in the conduit; a
first sensor configured for sensing pressure variations in the
conduit; and a first controller in data communication with the
first sensor, the first controller being configured to provide
control signals to the control valve for at least one of the fluid
delivery systems and to a control system for the prime mover; the
method comprising: sensing pressure variations in the pressurized
fluid in the conduit; and based on the sensed pressure variations:
(a) controlling at least one of the positive displacement fluid
delivery systems; and (b) controlling power output of the prime
mover.
2. The method of claim 1, further comprising determining an
estimated power consumption.
3. The method of claim 2, wherein controlling power output of the
prime mover comprises controlling a fuel supply of the prime
mover.
4. The method of claim 3, further comprising controlling the at
least one positive displacement fluid delivery system based on a
set-point, the set-point being identified and set by an operator or
an overall control system.
5. The method of claim 4, further comprising: the first controller
providing control signals to the one or more hydraulic pumps; and
controlling interaction between the hydraulic pumps and the prime
mover based on sensed pressure variations in the conduit.
6. The method of claim 1, wherein the control valve for at least
one of the fluid delivery systems is a plurality of control
valves.
7. A plant for controlling delivery of a pressurized fluid in a
conduit, the plant comprising: a prime mover configured to supply
torque to one or more hydraulic pumps, each hydraulic pump being
configured to supply hydraulic pressure to a respective positive
displacement fluid delivery system via a respective control valve,
each positive displacement fluid delivery system being configured
to deliver the pressurized fluid in the conduit; a first sensor
configured for sensing pressure variations in the conduit; and a
first controller in data communication with the first sensor, the
first controller being configured to provide control signals to the
control valve for at least one of the fluid delivery systems and to
a control system for the prime mover.
8. The plant of claim 7, wherein: the one or more hydraulic pumps
are each configured to communicate with a hydraulic pump controller
and a valve controller and to operate the fluid delivery systems;
the one or more hydraulic pumps are each driven by the prime mover;
and interaction between the one or more hydraulic pumps and the
prime mover is controlled based on sensed pressure variations in
the conduit.
9. The plant of claim 8, further comprising: valve outlet feedback
pressure sensors connected to respective control valves; and a
valve inlet pressure sensor connected to a respective control
valve.
10. The plant of claim 9, wherein the first valve controller is
configured for: receiving signals from the first sensor, the valve
outlet feedback pressure sensors, and the valve inlet pressure
sensor; receiving position feedback from the positive displacement
fluid delivery systems; and providing the control signals to the
control valves.
11. The plant of claim 10, wherein the prime mover is a gas turbine
engine.
12. The plant of claim 11, further comprising a gear unit arranged
between the gas turbine engine and the hydraulic pump.
13. The plant of claim 10, wherein the prime mover is a
reciprocating engine.
14. The plant of claim 10, wherein at least one of the positive
displacement fluid delivery systems comprises a positive
displacement pump.
15. The plant of claim 10, further comprising at least one trailer;
the prime mover, each hydraulic pump, and each positive
displacement fluid delivery system being positioned on the at least
one trailer.
16. The plant of claim 7, further comprising: valve outlet feedback
pressure sensors connected to respective control valves; and a
valve inlet pressure sensor connected to a respective control
valve.
17. The plant of claim 7, further comprising: a respective valve
outlet feedback pressure sensor connected to each control valve;
and a valve inlet pressure sensor connected to a respective control
valve.
18. The plant of claim 7, wherein the prime mover is selected from
the group consisting of: a gas turbine engine, a reciprocating
engine, and an electric motor.
19. The plant of claim 7, wherein at least one of the positive
displacement fluid delivery systems comprises a positive
displacement pump.
20. The plant of claim 7, further comprising at least one trailer;
the prime mover, each hydraulic pump, and each positive
displacement fluid delivery system being positioned on the at least
one trailer.
21. The plant of claim 7, wherein the control valve for at least
one of the fluid delivery systems is a plurality of control valves.
Description
RELATED APPLICATIONS
[0001] This application is a continuation under 35 U.S.C. .sctn.
365 to International PCT Application No. PCT/NO2017/050307 filed
Nov. 28, 2017, which claims priority to Norwegian Application No.
20161911 filed Nov. 30, 2016; the disclosure of each is
incorporated herein in its entirety by reference.
FIELD OF THE INVENTION
[0002] Embodiments of the invention generally concern methods of
controlling a prime mover which is configured to drive one or more
fluid delivery systems for delivering a fluid in a conduit. This
may be particularly useful in the extraction of shale oil and/or
gas by means of pressure pumping equipment for well stimulation,
commonly known as "hydraulic fracturing" or "fracking", but is not
limited to such operations.
BACKGROUND OF THE INVENTION
[0003] The majority of the equipment used for pressure pumping has
been following the same principle for several decades: a trailer or
truck mounted power pack (diesel-powered reciprocating engine, or a
gas turbine engine) drives a pressure pump through a multi-speed
transmission gear box. All parts are mechanically connected.
[0004] A typical pressure pump comprises two major parts: a "fluid
end" and a "power end". The fluid end is the actual pressure pump,
pressurizing the fracturing fluid. It is normally a plunger/piston
pump, typically operating at 150-300 strokes per minute, and is an
exchangeable unit. The power end is part of the drivetrain, and it
is connected to a multi-speed transmission. One of the primary
functions of the power end is to convert rotational force to
reciprocating force. The power end has a reduction gear box on the
inlet, and is connected to the plunger on the fluid end via a
crankshaft and a crosshead. The power is normally provided by a
reciprocating engine, although gas turbine engines are also
used.
[0005] Some of the problems associated with the prior art are
shortened expected lifecycles of the equipment, as well as high
maintenance costs during the lifecycle of the drivetrain. In
addition, the prior art plants have a large surface footprint.
[0006] The prior art includes CN 104806220 A, which describes
"fully-hydraulic driven" fracturing equipment with a power unit and
a fracturing pump. The power unit comprises an engine unit, a
transfer case unit, and a hydraulic pump unit. Three hydraulic
pumps are installed on each transfer case, and the hydraulic pump
unit is connected through hydraulic pipelines. The fracturing pump
has a left and a right pump head, and three two-way hydraulic oil
cylinders arranged in parallel are installed on the fracturing
pump. The fracturing pump is driven by the two-way hydraulic oil
cylinders so that the equipment power is increased, the equipment
discharge flow is increased, and the equipment weight and size are
reduced.
[0007] The prior art also includes CN 104727797 A and CN 204552723
U, which describe a system where an engine, a transfer case, a
plurality of variable displacement plunger pumps, and a
double-acting fracturing pump are arranged on a chassis. The output
end of the engine is connected with the input end of the transfer
case, and the output end of the transfer case includes a plurality
of power take-off ports. Each power take-off port is connected with
one variable displacement plunger pump. The plunger pumps drive the
double-acting fracturing pump through a hydraulic system.
[0008] The prior art also includes CN 104728208 A, which describes
a high-power hydraulic driving fracturing-pump pump station system,
in which the hydraulic cylinders are connected with the fracturing
cylinders. An electric motor driven hydraulic pump provides
high-pressure oil, and a fluid outlet, manifold outputs a
high-pressure fracturing fluid.
[0009] The prior art also includes CN 104453825 A, which describes
a modularized fracturing pump set which has a power unit and a
fracturing pump unit. An auxiliary engine is arranged on the power
unit and is connected to a hydraulic pump. A torque converter is
arranged in the fracturing pump, and the input end of the torque
converter is connected to the main engine. The output end of the
torque converter is connected to a gearbox, and the output end of
the gearbox is connected to the fracturing pump.
[0010] The prior art also includes WO 2014/078236 A1, which
describes a turbo-shaft engine having a drive shaft and a high
pressure (and high-RPM) centrifugal pump coupled to the drive
shaft.
SUMMARY OF THE INVENTION
[0011] The following presents a simplified summary of the
disclosure in order to provide a basic understanding of some
aspects of the disclosure. This summary is not an extensive
overview of the disclosure. It is not intended to identify critical
elements of the disclosure or to delineate the scope of the
disclosure. Its sole purpose is to present some concepts of the
disclosure in a simplified form as a prelude to the more detailed
description that is presented elsewhere.
[0012] According to an embodiment, a plant for controlling delivery
of a pressurized fluid in a conduit includes a prime mover, a
sensor, and a first controller. The prime mover is configured to
supply torque to one or more hydraulic pumps, and each hydraulic
pump is configured to supply hydraulic pressure to a respective
positive displacement fluid delivery system via respective control
valves. Each positive displacement fluid delivery system is
configured to deliver the pressurized fluid in the conduit. The
first sensor is configured for sensing pressure variations in the
conduit, and the first controller is in data communication with the
first sensor. The first controller is configured to provide control
signals to the control valve for at least one of the fluid delivery
systems and to a control system for the prime mover.
[0013] According to another embodiment, a plant for controlling the
delivery of a pressurized fluid in a conduit is characterized by a
prime mover which is configured to supply torque to one or more
hydraulic pumps, each hydraulic pump configured to supply hydraulic
pressure to respective positive displacement fluid delivery
systems, each positive displacement fluid delivery system
configured to deliver said fluid in the conduit, a first sensor
configured for sensing pressure variations in the conduit and
connected to a first controller. The first controller is configured
to provide control signals to the control valves for at least one
fluid delivery system and to a control system for the prime
mover.
[0014] In an embodiment, the plant has one or more hydraulic pumps
driven by the prime mover. The hydraulic pumps are configured to
communicate with a controller to operate the fluid delivery
systems. Interaction between the hydraulic pumps and the prime
mover is controlled based on sensed pressure variations in the
conduit.
[0015] In an embodiment, the plant further includes valve outlet
feedback pressure sensors connected to respective control valves,
and a valve inlet pressure sensor connected to the control valve.
The plant may further include a valve controller configured for
receiving signals from the pressure sensors and the first sensor
and position feedback from the positive displacement fluid delivery
systems. The valve controller is configured for providing control
signals to the control valves.
[0016] In an embodiment, the prime mover is a gas turbine engine
and a gear unit is arranged between the gas turbine engine and the
hydraulic pump.
[0017] In an embodiment, the prime mover is a reciprocating
engine.
[0018] In an embodiment, at least one positive displacement fluid
delivery system includes a positive displacement pump.
[0019] In an embodiment, the plant is positioned on a trailer.
[0020] According to still another embodiment, a method is provided
for controlling a prime mover which is configured to drive one or
more positive displacement fluid delivery systems for delivering a
fluid in a conduit. The method is characterized by sensing the
pressure variations in the fluid in the conduit and, based on the
sensed pressure variations, controlling at least one of the
positive displacement fluid delivery system and controlling the
power output of the prime mover.
[0021] In an embodiment, the method includes determining an
estimated power consumption.
[0022] In an embodiment, the method includes controlling the prime
mover fuel supply based on variations in sensed pressure.
[0023] In an embodiment, at least one positive displacement fluid
delivery system is controlled based on a set-point identified and
set by an operator or an overall control system.
[0024] In an embodiment, a first controller provides control
signals to hydraulic pumps that are configured to operate the fluid
delivery systems and that are driven by the prime mover, whereby
the interaction between the hydraulic pumps and the prime mover is
controlled based on sensed pressure variations in the conduit.
[0025] Although embodiments of the invention are particularly
useful in hydraulic fracturing ("fracking") operations, embodiments
may also be applicable for all positive displacement pumping
processes in which control is based on at least one of: flow
measurements, pressure settings, and feedback pressures. The
invention shall therefore not be limited to fracking operations
unless such is specifically claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 schematically illustrates one embodiment of a plant
for controlling delivery of pressurized fluid in a conduit, in
accordance with an embodiment of the current invention.
[0027] FIG. 2 is a perspective view of a mobile embodiment of the
plant of FIG. 1, in a transportation configuration.
[0028] FIG. 3 is a perspective view of the mobile embodiment of
FIG. 2, in a pumping (operational) configuration.
[0029] FIG. 4 is a perspective view of the mobile embodiment of
FIG. 3, shown with the housing removed for illustration.
DETAILED DESCRIPTION OF AN EMBODIMENT
[0030] The following description may use terms such as
"horizontal", "vertical", "lateral", "back and forth", "up and
down", "upper", "lower", "inner", "outer", "forward", "rear", etc.
These terms generally refer to the views and orientations as shown
in the drawings and that are associated with a normal use of the
invention. The terms are used for the reader's convenience only and
shall not be limiting.
[0031] Referring initially to FIGS. 2, 3, and 4, the invented plant
is in this illustrated embodiment arranged as a mobile unit 18 on a
trailer 19 and enclosed by a housing 20. Doors in the housing
provide access to the plant, and rear doors may allow the movable
unit comprising fluid end 21 with its double-acting cylinders 22 to
be moved out and down (see FIG. 3) when the plant is in operation.
Pipes 21a are configured for connection to well piping (not
shown).
[0032] Referring to FIG. 4, the mobile plant in the illustrated
embodiment includes a gas turbine 26 connected via a duct 27a to an
air inlet 27, and also connected to an exhaust opening 26a. The gas
turbine 26 receives fuel from a fuel tank 32. Supply lines and
hoses, power lines and control lines, etc., are not shown, as these
components are commonly known in the art.
[0033] The gas turbine 26 is connected to a set of single or
tandem-mounted hydraulic pumps 30 via a gearbox 28. Reference
numbers 31 and 29 denote a hydraulics tank and accumulator tanks,
respectively. Louvers and air filtration container 23 is arranged
towards the rear of the mobile unit, behind oil cooler gearbox 25
and hydraulics cooler 24.
[0034] The hydraulic pumps 30 operate hydraulic cylinders 22 in the
plant's fluid ends 21. Each hydraulic cylinder operates one
plunger, in each of the plant's two fluid ends 21.
[0035] A typical configuration of the invented plant will now be
described with reference to the diagram in FIG. 1.
[0036] In FIG. 1, three systems are shown--denoted A, B, C,
respectively. It should be understood that only system C is
illustrated in detail in FIG. 1, for clarity of illustration. The
skilled person will understand that the components and functions
illustrated and described with reference to system C also can be
applied to systems A and B. It should also be understood that the
invention shall not be limited to the number of systems shown in
FIG. 1.
[0037] Reference number 1 denotes a power source having a prime
mover 2. The prime mover 2 may be, for example, a gas turbine
engine or a reciprocating engine, controlled via a throttle 3
(controlling fuel supply F and receiving information regarding
rotation speed R). The prime mover 2 is connected, and configured
to transfer torque T, to a gear unit 8. The gear unit 8 transfers
torque T` to individual hydraulic pumps 9a-c, and each pump has
respective pump pressure sensors 13a-c.
[0038] If the prime mover 2 is a gas turbine, the gear unit 8 may
be configured to reduce high-rpm output from the turbine. If the
prime mover is of another type of engine (e.g. a reciprocating
engine), the hydraulic pumps may be driven directly by the engine,
and the gear unit 8 may be omitted.
[0039] Each hydraulic pump 9a-c supplies hydraulic pressure to
respective positive displacement fluid delivery systems (in the
illustrated embodiment, double-acting hydraulic cylinders 34a-c)
via respective control valves 36a-c, 37a-c. A reservoir tank 11 and
a cooler 17 are fluidly connected between the hydraulic pump 9c and
the control valves 36c, 37c. The circuit also comprises an
accumulator 33 for mitigating pressure pulses.
[0040] Each hydraulic cylinder 34a-c is operably connected to
respective sets of fluid plungers 35a1-c1, 35a2-c2. The fluid
plungers 35a1-c1, 35a2-c2 force fluid to the well via the fluid
supply line 10. The invention shall, however, not be limited to
such fluid plungers. Reference number 12 denotes a supply line from
a fluid blending system.
[0041] Well feedback pressure sensor 16 is connected to, and
configured to sense the pressure in (and hence pressure variations
in) the supply line 10. Valve outlet feedback pressure sensors 15
are connected to respective control valves 36c, 37c. Valve inlet
pressure sensor 14 is connected to control valve 36c. A valve
controller 7 (typically a programmable logic controller--PLC)
receives signals from the pressure sensors 14, 15, 16, position
feedback Cp from the hydraulic cylinders, and provides control
signals Vf to the control valves 36c, 37c.
[0042] A main control system 4 controls the throttle 3 based on
power request Pr and provides power feedback Pf. The main control
system 4 also receives transport security interlock feedback Ts
from the gear unit 8, and estimated power consumption data EPC from
the PLC 7, based on the sensed pressure variations by well feedback
pressure sensor 16. A louver controller 5 is also in communication
with the main control system 4, to open and close louvers (for e.g.
ventilation and fire control). The main control system 4 receives
data from a hydraulic pump controller 6 (e.g. a PLC) and provides a
power command Ac to the hydraulic pump controller 6. The hydraulic
pump controller 6 in turn provides the required displacement
command Dc to the hydraulic pump 9c based on pump pressure feedback
Pp (from the pressure sensor 13c). The main control system 4 also
provides data regarding requested cylinder speed RCS to the valve
controller 7, which in turn determines and provides the valve flow
control signal Vf to the control valves 36c, 37c, as described
above.
[0043] The plant thus includes a hydraulic-pressure/flow-controlled
power transmission, in which all power from the prime mover is
transformed into hydraulic power by the hydraulic pumps. The
hydraulic pumps enable the prime mover to start against little or
no load, and the hydraulic pumps may start the positive
displacement fluid delivery system under varying load
conditions.
[0044] When the plant is in use in a fracking operation, the prime
mover 2 and the hydraulic pumps 9a-c operate the hydraulic
cylinders 34a-c and fluid plungers 35a1-c1, 35a2-c2 to supply
pressurized fracturing fluid to the line 10 (and thus the
subterranean well). The hydraulic fracturing pressure generated in
the well is a result of the well pressure and the hydraulic
pressure generated by the plungers. The well pressure (which is
sensed by the sensor 16) is communicated to the valve controller
PLC 7, which controls the control valves 36a-c, 37a-c and also
determines the estimated power consumption EPC, which is
transmitted to the main control system 4. The prime mover fuel
supply (e.g., turbine fuel injection) may thus be governed by the
well pressure, or rather the variations in pressure, as sensed
continuously by the sensor 16. The turbine fuel control receives
pressure reading from the hydraulic control system, based on the
pressure and rate reading from the hydraulic fracturing pressure.
The hydraulic control system then performs a control action based
on a set-point (rate/pressure) identified and set by the
operator.
[0045] The delay which is inherent in hydraulic components, or
which may be provided (controlled) by the main control system 4,
provides sufficient time for the turbine fuel control to predict
what is going to happen, and take action before it happens.
[0046] This means that the prime mover can--before the requirement
arises--either increase the fuel injection (open throttle) to be
ready for higher demand from the hydraulic pumps, or lower the fuel
injection (restrict throttle) to adapt to the estimated future
requirement of torque, and thereby accommodate the change in
rate/pressure. This function may be particularly useful in
embodiments where the prime mover is a gas turbine engine, as such
turbines normally operate at high rotational speeds, and have low
torque. The control system may in this fashion prevent the gas
turbine engine from over-speeding, and further give the gas turbine
engine a head-start on a predicted increase in torque demand.
[0047] When the requirement for fracturing fluid in the well
changes, or actual consumption of fracturing fluid is changing and
not complying with the set point as set by the operator or as
determined by an overall control system, the valve controller 7 and
pressure sensor 16 are sensing this, based on sensed pressure
variations. The set point may also be defined based on a
prioritized list, defined by an overall control system, of how
deviating conditions are to be handled. Based on rate/pressure
difference between the set point and the actual pressure reading
(as sensed by 16), there will occur a situation that the actual
power command Ac (fed to main controller 4 by the pump controller
6) differs from (less or more) the estimated power consumption EPC
(fed to the main controller 4 by the valve controller 7). This will
lead to a situation where the main controller 4 will be able to
give appropriate control signals, and be able to control the
instant in which the control signals are given, to both the pump
controller 6 and to the prime mover throttle control 3--whether
simultaneously or at a controlled difference to have the prime
mover act in a predictive manner.
[0048] Although an embodiment of the invention has been described
with reference to three hydraulic pumps, it should be understood
that other embodiments may utilize fewer or more hydraulic
pumps.
[0049] Although an embodiment of the invention has been described
with reference to a mobile unit, it should be understood that other
embodiments may be formed as a stationary plant.
[0050] Although an embodiment of the invention has been described
with reference to driving fluid ends (double-acting hydraulic
cylinders), it should be understood that other embodiments may
utilize other pumping principles driven by hydraulic flow and
pressure, i.e. positive displacement pumps. The invention shall
thus not be limited to the double-acting hydraulic cylinders.
[0051] Many different arrangements of the various components
depicted, as well as components not shown, are possible without
departing from the spirit and scope of the present disclosure.
Embodiments of the present disclosure have been described with the
intent to be illustrative rather than restrictive. Alternative
embodiments will become apparent to those skilled in the art that
do not depart from its scope. A skilled artisan may develop
alternative means of implementing the aforementioned improvements
without departing from the scope of the present disclosure. It will
be understood that certain features and subcombinations are of
utility and may be employed without reference to other features and
subcombinations and are contemplated within the scope of the
claims. The specific configurations and contours set forth in the
accompanying drawings are illustrative and not limiting.
* * * * *