U.S. patent application number 16/948290 was filed with the patent office on 2021-03-18 for turbine engine exhaust duct system and methods for noise dampening and attenuation.
This patent application is currently assigned to BJ Energy Solutions, LLC. The applicant listed for this patent is BJ Energy Solutions, LLC. Invention is credited to Heber Martinez-Barron, Ricardo Rodriguez-Ramon, Tony Yeung.
Application Number | 20210079849 16/948290 |
Document ID | / |
Family ID | 1000005167158 |
Filed Date | 2021-03-18 |
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United States Patent
Application |
20210079849 |
Kind Code |
A1 |
Yeung; Tony ; et
al. |
March 18, 2021 |
TURBINE ENGINE EXHAUST DUCT SYSTEM AND METHODS FOR NOISE DAMPENING
AND ATTENUATION
Abstract
A mobile fracking system and methods may include a gas turbine
housed at least partially inside a trailer and an exhaust
attenuation system configured to receive exhaust gas from the gas
turbine. The exhaust attenuation system may include a lower
elongated plenum configured to receive exhaust gas from the gas
turbine and an upper noise attenuation system that is movably
connected relative to a distal end of the lower elongated
plenum.
Inventors: |
Yeung; Tony; (Tomball,
TX) ; Rodriguez-Ramon; Ricardo; (Tomball, TX)
; Martinez-Barron; Heber; (Tomball, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
BJ Energy Solutions, LLC |
Houston |
TX |
US |
|
|
Assignee: |
BJ Energy Solutions, LLC
Houston
TX
|
Family ID: |
1000005167158 |
Appl. No.: |
16/948290 |
Filed: |
September 11, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62899957 |
Sep 13, 2019 |
|
|
|
62704567 |
May 15, 2020 |
|
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F05D 2220/32 20130101;
F02C 6/00 20130101; F01D 25/30 20130101; F05D 2260/4031 20130101;
F02C 7/24 20130101; F05D 2220/70 20130101 |
International
Class: |
F02C 7/24 20060101
F02C007/24; F01D 25/30 20060101 F01D025/30; F02C 6/00 20060101
F02C006/00 |
Claims
1. A mobile fracking system comprising: a trailer including a rear
end, a front end, a bottom end, and a top end defining therebetween
an interior space; a gas turbine at least partially housed inside
the trailer in the interior space; and an exhaust attenuation
assembly configured to receive exhaust gas from the gas turbine,
the exhaust attenuation assembly attached to a portion of the
trailer and including: a lower elongated plenum having a proximal
end and a distal end, the lower elongated plenum extending a first
distance between the respective proximal and distal ends, an inlet
adjacent the proximal end configured to receive exhaust gas from
the gas turbine, and an upper noise attenuation system movably
connected relative to the distal end of the lower elongated plenum,
the upper noise attenuation system being selectively movable
between a stowed position, in which an outlet end portion of the
upper noise attenuation system is positioned proximate to the
distal end of the lower elongated plenum, and an operative
position, in which the upper noise attenuation system defines an
upper elongated plenum in fluid communication with the distal end
of the lower elongated plenum and in which an outlet of the upper
elongated plenum is spaced away from the distal end of the lower
elongated plenum at a second distance that is greater than the
first distance.
2. The mobile fracking system of claim 1, further comprising a
first plenum configured to receive exhaust gas from the gas
turbine, a first end of the first plenum connected to an exhaust
outlet of the gas turbine and a second end of the first plenum
connected to the inlet of the lower elongated plenum.
3. The mobile fracking system of claim 2, wherein the gas turbine
is mounted to a bottom surface of the trailer, and wherein the
first plenum extends longitudinally substantially parallel to the
bottom surface.
4. The mobile fracking system of claim 1, wherein the lower
elongated plenum extends longitudinally away from a bottom surface
of the trailer about an exhaust axis.
5. The mobile fracking system of claim 4, wherein the upper noise
attenuation system, in the operative position, extends
longitudinally away from the distal end of the lower elongated
plenum about the exhaust axis.
6. The mobile fracking system of claim 5, wherein the exhaust axis
is substantially perpendicular relative to the bottom surface of
the trailer.
7. The mobile fracking system of claim 1, wherein the upper noise
attenuation system further comprises at least one array of baffles
configured to attenuate noise.
8. The mobile fracking system of claim 7, wherein the array of
baffles comprises a plurality of baffles that are distributed
parallel to a common axis and that define a plurality of slots
defined by and between the plurality of baffles.
9. The mobile fracking system of claim 8, wherein the at least one
array of baffles is mounted in a portion of the upper elongated
plenum in communication with the exhaust gas passing through the
upper elongated plenum to the outlet.
10. The mobile fracking system of claim 1, wherein: the upper noise
attenuation system further comprises a pair of opposed silencer
hoods, each of the pair of opposed silencer hoods comprising a
planer surface having opposed side edges and a pair of opposing
side surfaces that extend outwardly from portions of respective
side edges of the planer surface, each of the pair of opposed
silencer hoods configured to be hingeably mounted to portions of
the distal end of the lower elongated plenum; and in the operative
position, the pair of opposed silencer hoods are positioned
substantially upright such that the planer surfaces of the
respective side edges are in parallel opposition and that
respective side surface are also in parallel opposition to form the
upper elongated plenum.
11. The mobile fracking system of claim 10, wherein the pair of
opposed silencer hoods comprises an upper silencer hood and a lower
silencer hood that are configured to cooperatively slideably engage
relative to each other when moving between the stowed position and
the operative position.
12. The mobile fracking system of claim 10, wherein the upper noise
attenuation system further comprises one or more of a linear
actuator or a rotary actuator connected to one or more of the pair
of opposed silencer hoods, the one or more of the linear actuator
or the rotary actuator configured to be one of
electrically-actuated, pneumatically-actuated, or
hydraulically-actuated for selective movement of the respective
connected silencer hood between the stowed position and the
operative position.
13. The mobile fracking system of claim 10, wherein the exhaust
attenuation system further comprises a retention brace system
comprising: a first pair of opposing retention braces comprising a
first brace mounted to exterior portions of the distal end of the
lower elongated plenum and a second brace mounted to opposed
exterior portions of the distal end of the lower elongated plenum,
each brace of the first pair of opposing retention braces
comprising a bar extending between a first end mount and an
opposing second end mount such that, when mounted, the bar is
spaced from an exterior surface of the distal end of the lower
elongated plenum and defines a slot sized and shaped for receipt of
portions of respective side surfaces of the pair of silencer hoods;
and a second pair of opposing retention braces comprising a third
brace spaced proximally from the first brace and mounted to
exterior portions of the lower elongated plenum and a fourth brace
spaced proximally from the first brace and mounted to opposed
exterior portions of the lower elongated plenum, each brace of the
second pair of opposing retention braces comprising a bar extending
between a first end mount and an opposing second end mount such
that, when mounted, the bar is spaced from an exterior surface of
the lower elongated plenum and defines a slot sized and shaped for
receipt of respective side surfaces of the pair of silencer hoods
when the pair of silencer hoods is positioned in the stowed
position.
14. The mobile fracking system of claim 10, wherein: the upper
noise attenuation system further comprises at least one array of
baffles configured to attenuate noise; the array of baffles
comprises a plurality of baffles that are distributed parallel to a
common axis and that define a plurality of spacings positioned by
and between the plurality of baffles; and the at least one array of
baffles is mounted in at least a portion of the planer surface of
each of the silencer hoods.
15. The mobile fracking system of claim 1, wherein: the upper noise
attenuation system further comprises an elongated conduit that has
an exterior that is shaped and sized for complementary receipt
therein the distal portion of the lower elongated plenum; and in
the stowed position, the elongated conduit is positioned
substantially in the lower elongated plenum such that an outlet end
of the elongated conduit is positioned proximate to the distal end
of the lower elongated plenum, and, in the operative position, the
elongated conduit extends outwardly away from the distal end of the
lower elongated plenum such that a proximal end of the elongated
conduit is positioned proximate the distal end of the lower
elongated plenum and the outlet end of the elongated conduit forms
the outlet of the upper noise elongated plenum.
16. The mobile fracking system of claim 15, wherein the upper noise
attenuation system further comprises: a guide mounted to an
exterior surface of the lower elongated plenum, the guide defining
an elongated enclosed slot extending parallel to the exhaust axis;
a rod having a distal end mounted to an outermost edge surface of
the outlet end of the elongated conduit, the rod being configured
for operative slideable receipt in the slot of the guide; and one
or more of a plurality of sheaves or wire rope pulleys for movement
of the elongated conduit between the stowed position and the
operative position.
17. The mobile fracking system of claim 15, wherein: the upper
noise attenuation system further comprises at least one array of
baffles configured to attenuate noise; the array of baffles
comprises a plurality of baffles distributed parallel to a common
axis and defining a plurality of spacings positioned by and between
the plurality of baffles; and the at least one array of baffles is
mounted in an outlet end of the elongated conduit.
18. An exhaust attenuation assembly to receive exhaust gas from a
gas turbine attached to a trailer, the exhaust attenuation assembly
to attach to a portion of the trailer and comprising: a lower
elongated plenum having a proximal end and a distal end, the lower
elongated plenum extending a first distance between the respective
proximal and distal ends, an inlet adjacent the proximal end to
receive exhaust gas from the gas turbine; and an upper noise
attenuation system movably connected relative to the distal end of
the lower elongated plenum, the upper noise attenuation system
being selectively movable between a stowed position, in which an
outlet end portion of the upper noise attenuation system is
positioned proximate the distal end of the lower elongated plenum,
and an operative position, in which the upper noise attenuation
system defines an upper elongated plenum in fluid communication
with the distal end of the lower elongated plenum and in which an
outlet of the upper elongated plenum is spaced away from the distal
end of the lower elongated plenum at a second distance that is
greater than the first distance.
19. The exhaust gas attenuation assembly of claim 18, further
comprising a first plenum configured to receive exhaust gas from
the gas turbine, a first end of the first plenum configured to be
connected to an exhaust outlet of the gas turbine and a second end
of the first plenum connected to the inlet of the lower elongated
plenum.
20. The exhaust gas attenuation assembly of claim 19, wherein the
first plenum is configured to be connected to the trailer to extend
longitudinally substantially parallel to a bottom surface of the
trailer.
21. The exhaust gas attenuation assembly of claim 18, wherein the
lower elongated plenum is configured to extend longitudinally away
from a bottom surface of the trailer about an exhaust axis.
22. The exhaust gas attenuation assembly of claim 21, wherein the
upper noise attenuation system, in the operative position, extends
longitudinally away from the distal end of the lower elongated
plenum about the exhaust axis.
23. The exhaust gas attenuation assembly of claim 22, wherein the
exhaust axis is substantially perpendicular relative to the bottom
surface of the trailer.
24. The exhaust gas attenuation assembly of claim 18, wherein the
upper noise attenuation system further comprises at least one array
of baffles configured to attenuate noise.
25. The exhaust gas attenuation assembly of claim 24, wherein the
array of baffles comprises a plurality of baffles distributed
parallel to a common axis and that define a plurality of slots
defined by and between the plurality of baffles.
26. The exhaust gas attenuation assembly of claim 25, wherein the
at least one array of baffles is mounted in a portion of the upper
elongated plenum for communication with the exhaust gas passing
through the upper elongated plenum to the outlet.
27. The exhaust gas attenuation assembly of claim 18, wherein: the
upper noise attenuation system further comprises a pair of opposed
silencer hoods, each of the pair of opposed silencer hoods
comprising a planer surface having opposed side edges and a pair of
opposing side surfaces that extend outwardly from portions of
respective side edges of the planer surface, each of the pair of
opposed silencer hoods configured to be hingeably mounted to
portions of the distal end of the lower elongated plenum; and in
the operative position, the pair of opposed silencer hoods are
positioned substantially upright such that the planer surfaces of
the respective side edges are in parallel opposition and that
respective side surface are also in parallel opposition to form the
upper elongated plenum.
28. The exhaust gas attenuation assembly of claim 27, wherein the
pair of opposed silencer hoods comprises an upper silencer hood and
a lower silencer hood that are configured to cooperatively
slideably engage relative to each other when moving between the
stowed position and the operative position.
29. The exhaust gas attenuation assembly of claim 27, wherein the
upper noise attenuation system further comprises: an anchor point
mounted on a back surface of the planar surface of each silencer
hood proximate a bottom edge of the back surface; a wire connected
to each respective anchor point; and a spooling system operatively
connected to a respective wire for selective movement of the
respective connected silencer hood between the stowed position and
the operative position.
30. The exhaust gas attenuation assembly of claim 27, wherein the
exhaust attenuation system further comprises a retention brace
system comprising: a first pair of opposing retention braces
comprising a first brace mounted to exterior portions of the distal
end of the lower elongated plenum and a second brace mounted to
opposed exterior portions of the distal end of the lower elongated
plenum, each brace of the first pair of opposing retention braces
comprising a bar extending between a first end mount and an
opposing second end mount such that, when mounted, the bar is
spaced from an exterior surface of the distal end of the lower
elongated plenum and defines a slot sized and shaped for receipt of
portions of respective side surfaces of the pair of silencer hoods;
and a second pair of opposing retention braces comprising a third
brace spaced proximally from the first brace and mounted to
exterior portions of the lower elongated plenum and a fourth brace
spaced proximally from the first brace and mounted to opposed
exterior portions of the lower elongated plenum, each brace of the
second pair of opposing retention braces comprising a bar extending
between a first end mount and an opposing second end mount such
that, when mounted, the bar is spaced from an exterior surface of
the lower elongated plenum and defines a slot sized and shaped for
receipt of respective side surfaces of the pair of silencer hoods
when the pair of silencer hoods is positioned in the stowed
position.
Description
PRIORITY CLAIMS
[0001] This U.S. non-provisional patent application claims priority
to and the benefit of, under 35 U.S.C. .sctn. 119(e), U.S.
Provisional Application No. 62/899,957, filed Sep. 13, 2019, and
U.S. Provisional Application No. 62/704,567, filed May 15, 2020,
the disclosures of both of which are incorporated herein by
reference in their entireties.
TECHNICAL FIELD
[0002] In one aspect, the present disclosure relates to noise
attenuation and dampening systems and methods for hydraulic
fracturing and, in particular, to systems and methods for dampening
and directional control of exhaust air flow from a gas turbine of a
direct drive turbine fracturing system.
BACKGROUND
[0003] The present disclosure relates generally to a mobile
fracking system and, more particularly, to a gas turbine-based
mobile fracking system that may provide mechanical power through
gearboxes connected to respective gas turbines and respective
mechanically driven fluid pumps in a fracturing operation (also
referable to as "fracking"). Such a mobile fracking system may
include a plurality of such directly driven turbine (DDT)
fracturing units for use in well stimulation and hydraulic
fracturing operations. In addition to offering potential efficiency
advantages compared to diesel fleets or electric fleets, DDT
fracturing units may offer flexibility in operating on a wide
variety of fuel compositions, while also providing improved
reliability, lower emissions and/or smaller foot prints.
[0004] In a fracturing operation, a fluid mixture is injected under
pressure at a wellbore into a rock formation that bears hydrocarbon
to create fractures within a rock. In operation, the pressurized
fluid mixture is pressure pumped down to fracture the subsurface
geological formation and allows the flow of the hydrocarbon
reserves, such as oil and/or gas. The fluid mixture may include
water, various chemical additives, and proppants (e.g., sand,
ceramic materials, and the like as will be understood by those
skilled in the art). For example, and without limitation, the
fracturing fluid may comprise a liquid petroleum gas, linear gelled
water, gelled water, gelled oil, slick water, slick oil, poly
emulsion, foam/emulsion, liquid carbon dioxide (CO.sub.2), nitrogen
gas (N.sub.2), and/or binary fluid and acid.
[0005] Mechanical power may be generated by the DDT fracturing
units and used to deliver fracturing fluid through mechanically
connected fluid pumps to a wellbore at the fracturing operation
site. Surface pumping systems including fluid pumps are utilized to
accommodate the various fluids and are typically mobilized at well
sites on, for example, skids or tractor-trailers. In one
conventional example, dedicated sources of power may include gas
turbines connected to a source of natural gas that drives the
respective gas turbine to produce mechanical power that may be sent
to one or more of the surface pumping systems through mechanically
connected gearboxes and/or transmission systems to operate the
fluid pumps at desired speeds.
[0006] The fracturing operation site often encompasses a large
footprint with the number of wells or wellheads and supporting
components. The supporting components take time to be transported
and to be setup for utilization at the fracturing operation sites.
Due to the large nature of many fracturing operations, there exists
a continued challenge to reduce the environmental impact resulting
from fracturing operations. Accordingly, there exists a need for
methods and systems for reducing the environmental impact of noise
pollution produced by the fracturing operations.
SUMMARY
[0007] As referenced above, a fracturing operation may include a
large number of gas turbines operating substantially concurrently.
As a result, an undesirably large amount of noise may be generated
by the fracturing operation.
[0008] The present disclosure is generally directed to systems and
methods for dampening and directional control of exhaust air flow
from a gas turbine of, for example, a direct drive turbine
fracturing system. According to some embodiments, a mobile fracking
system may include a trailer including a rear end, a front end, a
bottom end, and a top end defining therebetween an interior space,
a gas turbine housed inside the trailer in the interior space, and
an exhaust attenuation system configured to receive exhaust gas
from the gas turbine via an exhaust duct. The exhaust attenuation
system may be attached to a portion of the trailer and may include
a lower elongated plenum having an inlet adjacent the proximal end
configured to receive exhaust gas from the gas turbine exhaust duct
of the gas turbine and an upper noise attenuation system that is
movably connected relative to the distal end of the lower elongated
plenum. The upper noise attenuation system may be selectively
movable between a stowed position, in which an outlet end portion
of the upper noise attenuation system is positioned proximate to
the distal end of the lower elongated plenum, and an operative
position, in which the upper noise attenuation system defines an
upper elongated plenum in fluid communication with the distal end
of the lower elongated plenum and in which an outlet of the upper
noise elongated plenum is spaced away from the distal end of the
lower elongated plenum at a second distance that is greater than
the first distance.
[0009] According to some embodiments, the upper noise attenuation
system may include a pair of opposed and cooperating silencer
hoods. In such embodiments, each silencer hood may have a planer
surface having opposed side edges and a pair of opposing side
surfaces that extend outwardly from portions of the respective side
edges of the planer surface. Each silencer hood may be configured
to be hingeably mounted to portions of a distal end of the lower
elongated plenum such that, in the operative position, the pair of
opposed silencer hoods are positioned substantially upright, so
that the planer surfaces of the respective back edges are in
parallel opposition and so that the respective side surface are
also in parallel opposition to form the upper elongated plenum.
[0010] According to some embodiments, the upper noise attenuation
system may optionally include an elongated conduit that has an
exterior that is shaped and sized for complementary receipt therein
a distal portion of the lower elongated plenum. In such
embodiments, in the stowed position, the elongated conduit may be
positioned substantially in the lower elongated plenum, such that
an outlet end of the elongated conduit is positioned proximate to
the distal end of the lower elongated plenum. In the operative
position, the elongated conduit may be selectively movable along
and about an exhaust axis outwardly away from the distal end of the
lower elongated plenum, such that a proximal end of the elongated
conduit is positioned proximate the distal end of the lower
elongated plenum and the outlet end of the elongated conduit forms
the outlet of the upper elongated plenum.
[0011] Still other aspects, embodiments, and advantages of these
exemplary aspects and embodiments, are discussed in detail below.
Moreover, it is to be understood that both the foregoing
information and the following detailed description are merely
illustrative examples of various aspects and embodiments, and are
intended to provide an overview or framework for understanding the
nature and character of the claimed aspects and embodiments.
Accordingly, these and other objects, along with advantages and
features of the present disclosure herein disclosed, will become
apparent through reference to the following description and the
accompanying drawings. Furthermore, it is to be understood that the
features of the various embodiments described herein are not
mutually exclusive and may exist in various combinations and
permutations.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The accompanying drawings, which are included to provide a
further understanding of the embodiments of the present disclosure,
are incorporated in and constitute a part of this specification,
illustrate embodiments of the present disclosure, and together with
the detailed description, serve to explain the principles of the
embodiments discussed herein. No attempt is made to show structural
details of this disclosure in more detail than may be necessary for
a fundamental understanding of the exemplary embodiments discussed
herein and the various ways in which they may be practiced.
According to common practice, the various features of the drawings
discussed below are not necessarily drawn to scale. Dimensions of
various features and elements in the drawings may be expanded or
reduced to more clearly illustrate the embodiments of the
disclosure.
[0013] FIG. 1 is a schematic top view of an example of a mobile
fracking system showing an example directly driven turbine
fracturing unit having a gas turbine housed inside a trailer in an
interior space within the trailer and showing a gearbox connected
to the gas turbine for mechanically translating mechanical energy
produced by the gas turbine to at least one fluid pump via a
gearbox according to an embodiment of the disclosure.
[0014] FIG. 2 illustrates an example exhaust attenuation system
configured to receive exhaust gas from a gas turbine, the exhaust
attenuation system including a lower elongated plenum configured to
receive exhaust gas from the gas turbine and an upper noise
attenuation system that is movably connected relative to the distal
end of the lower elongated plenum, the upper noise attenuation
system being shown in the extended operative position according to
an embodiment of the disclosure.
[0015] FIG. 3 illustrates an example exhaust attenuation system
configured to receive exhaust gas from a gas turbine, the exhaust
attenuation system including a lower elongated plenum configured to
receive exhaust gas from the gas turbine and an upper noise
attenuation system that is movably connected relative to the distal
end of the lower elongated plenum, the upper noise attenuation
system being shown in the stowed position according to an
embodiment of the disclosure.
[0016] FIG. 4 shows an example exhaust attenuation system
illustrating an upper noise attenuation system having a pair of
opposed silencer hoods that are configured to be hingeably mounted
to portions of the distal end of the lower elongated plenum and
that are independently movable relative to each other according to
an embodiment of the disclosure.
[0017] FIG. 5 shows an example lower silencer hood being moved to
the operative position and shows an example upper silencer hood
positioned in the operative position according to an embodiment of
the disclosure.
[0018] FIGS. 6A and 6B respectively show a perspective view and an
enlarged perspective view of an example retention brace system
having a first pair of opposing retention braces comprising a first
brace mounted to exterior portions of the distal end of the lower
elongated plenum and a second brace mounted to an opposed exterior
portions of the distal end of the lower elongated plenum, each
brace defining a slot that is sized and shaped for receipt of
portions of respective side surfaces of the pair of silencer hoods
according to an embodiment of the disclosure.
[0019] FIG. 7 shows an example retention brace system according to
an embodiment of the disclosure having a first pair of opposing
retention braces comprising a first brace mounted to exterior
portions of the distal end of the lower elongated plenum and a
second brace mounted to an opposed exterior portions of the distal
end of the lower elongated plenum, each brace defining a slot that
is sized and shaped for receipt of portions of respective side
surfaces of the pair of silencer hoods and a second pair of
opposing retention braces comprising a third brace spaced
proximally from the first brace and mounted to exterior portions
the lower elongated plenum and a fourth brace spaced proximally
from the first brace and mounted to an opposed exterior portions of
the lower elongated plenum, each brace defining a slot that is
sized and shaped for receipt of respective side surfaces of the
pair of silencer hoods when the pair of silencer hoods is
positioned in the stowed position.
[0020] FIG. 8 shows an example upper noise attenuation system
having an elongated conduit that has an exterior that is shaped and
sized for complementary receipt therein the distal portion of the
lower elongated plenum and showing the elongated conduit in the
stored position according to an embodiment of the disclosure.
[0021] FIG. 9 shows an example upper noise attenuation system
having an elongated conduit that has an exterior that is shaped and
sized for complementary receipt therein the distal portion of the
lower elongated plenum and showing the elongated conduit in the
operative position according to an embodiment of the
disclosure.
[0022] FIG. 10 shows an example guide mounted to an exterior
surface of the lower elongated plenum, a rod configured for
operative slideable receipt therein the slot of the guide, and
means for selective axial movement of the rod for movement of the
elongated conduit between the stowed position and the operative
position according to an embodiment of the disclosure.
[0023] FIG. 11 schematically illustrates portions of a means for
selective axial movement of the rod for movement of the elongated
conduit between the stowed position and the operative position
according to an embodiment of the disclosure.
DETAILED DESCRIPTION
[0024] Referring now to the drawings in which like numerals
indicate like parts throughout the several views, the following
description is provided as an enabling teaching of exemplary
embodiments, and those skilled in the relevant art will recognize
that many changes may be made to the embodiments described. It also
will be apparent that some of the desired benefits of the
embodiments described may be obtained by selecting some of the
features of the embodiments without utilizing other features.
Accordingly, those skilled in the art will recognize that many
modifications and adaptations to the embodiments described are
possible and may even be desirable in certain circumstances, and
are a part of the disclosure. Thus, the following description is
provided as illustrative of the principles of the embodiments and
not in limitation thereof.
[0025] The phraseology and terminology used herein is for the
purpose of description and should not be regarded as limiting. As
used herein, the term "plurality" refers to two or more items or
components. The terms "comprising," "including," "carrying,"
"having," "containing," and "involving," whether in the written
description or the claims and the like, are open-ended terms, i.e.,
to mean "including but not limited to." Thus, the use of such terms
is meant to encompass the items listed thereafter, and equivalents
thereof, as well as additional items. Only the transitional phrases
"consisting of" and "consisting essentially of," are closed or
semi-closed transitional phrases, respectively, with respect to any
claims. Use of ordinal terms such as "first," "second," "third,"
and the like in the claims to modify a claim element does not by
itself connote any priority, precedence, or order of one claim
element over another or the temporal order in which acts of a
method are performed, but are used merely as labels to distinguish
one claim element having a certain name from another element having
a same name (but for use of the ordinal term) to distinguish claim
elements.
[0026] As used herein, the term "trailer" refers to any
transportation assembly, including, but not limited to, a
transport, truck, skid, and/or barge used to transport relatively
heavy structures, such as fracturing equipment.
[0027] As used herein, the term "directly driven turbine" DDT
refers to both the gas turbine and the mechanical energy transport
sections of a directly driven turbine fracturing unit. The gas
turbine receives hydrocarbon fuel, such as natural gas, and
converts the hydrocarbon fuel into mechanical energy that is
mechanically transferred via a gearbox to at least one fluid pump.
It is further contemplated that a gas turbine as described herein
may be a gas fueled turbine, a dual-fuel turbine, and the like.
[0028] In one embodiment, a mobile fracking system 10 may include a
trailer 12, a gas turbine 14, and an exhaust attenuation system 20
configured to receive exhaust gas from the gas turbine. FIG. 1 is a
schematic diagram of an embodiment of a mobile fracking system 10
showing the trailer 12 having a rear end, a front end, a bottom
end, and a top end that defines an interior space. As shown, the
gas turbine 14 is housed inside the trailer in the interior space.
To improve mobility over a variety of roadways, the trailer may
have a maximum height, a maximum width, and a maximum length that
would be suitable for passage on conventional roads and
expressways. Further, the trailer may comprise at least three axles
used to support and distribute the weight on trailer. Other
embodiments of the trailer may exceed three axles depending on the
total transport weight and it is contemplated that the dimensions
and the number of axles may be adjusted to allow for the transport
over roadways that typically mandate certain height, length, and
weight restrictions.
[0029] The trailer 12 may house at least one or more of the
following equipment: (1) an inlet plenum; (2) the gas turbine 14;
(3) the exhaust attenuation system 20 to remove exhaust gas from
gas turbine into the atmosphere, (4) a gearbox and/or transmission
16 connected to a rotary output of the gas turbine, and (5) a fluid
pump 18 operatively connected to the output of the gearbox. Other
components not shown in FIG. 1, but which may also be located on
the trailer include a control system, a turbine lube oil system,
and a fire suppression system. The turbine lube oil system may be
configured to selectively operate turbine lube oil filtering and
cooling systems. In one embodiment, the fire suppression system may
also comprise sprinklers, water mist, clean agent, foam sprinkler,
carbon dioxide, and/or other equipment used to suppress a fire or
provide fire protection for the gas turbine. Mounting of the
turbine lube oil systems and the fire suppression system onto the
DDT fracturing unit reduces trailer operative footprint by
eliminating the need for an auxiliary transport and connections for
the turbine and generator lube oil, filtering, cooling systems and
the fire suppression system to the gas turbine generator
transport.
[0030] One skilled in the art will appreciate that the gas turbine
14 may be configured to generate mechanical energy (i.e., rotation
of a shaft) from a hydrocarbon fuel source, such as natural gas,
liquefied natural gas, condensate, and/or other liquid fuels. As
schematically illustrated, the gas turbine shaft is connected to
the gearbox such that the gearbox converts the supplied mechanical
energy from the rotation of the gas turbine shaft to a downstream
shaft assembly that is rotated at a desired speed and torque to the
downstream mechanically connected fluid pump. The gas turbine may
be a gas turbine, such as the GE family of gas turbines, the Pratt
and Whitney family of gas turbines, or any other gas turbine and/or
dual-fuel turbine that generates sufficient mechanical power for
the production of the desired level of brake horsepower to the
downstream fluid pump for fracking operations at one or more well
sites.
[0031] The trailer 12 may also comprise gas turbine inlet filter(s)
configured to provide ventilation air and combustion air via one or
more inlet plenums (not shown) to the gas turbine. Additionally,
enclosure ventilation inlets may be added to increase the amount of
ventilation air, which may be used to cool the gas turbine and
ventilate the gas turbine enclosure. The combustion air may be the
air that is supplied to the gas turbine to aid in the production of
mechanical energy. The inlet plenum may be configured to collect
the intake air from the gas turbine inlet filter and supply the
intake air to the gas turbine.
[0032] In one embodiment and referring to FIGS. 2-11, the exhaust
attenuation system 20 may be attached to a portion of the trailer
and may include a lower elongated plenum 30 and an upper noise
attenuation system 40 that is movably connected relative to the
distal end of the lower elongated plenum. The lower elongated
plenum 30 has a proximal end and a distal end and extends a first
distance between the respective proximal and distal ends. The lower
elongated plenum 30 defines an inlet 32 adjacent the proximal end
of the lower elongated plenum 30 that is configured to receive
exhaust gas from the gas turbine. In one aspect, the lower
elongated plenum extends longitudinally away from a bottom surface
of the trailer about an exhaust axis. The exhaust axis may be
positioned at an angle relative to the bottom surface and, in one
non-limiting example, may be substantially normal to the bottom
surface, substantially vertical, and/or substantially upright.
[0033] It is contemplated that the exhaust attenuation system 20
will be constructed of materials that are capable of withstanding
extreme temperatures, such as for example and without limitation,
to about 1250.degree. F. (676.degree. C.), that are associated with
exhaust gases exiting gas turbines.
[0034] In embodiments, the upper noise attenuation system 40 may be
configured to be selectively movable between a stowed position and
an operative, upright, position. In the stowed position, an outlet
end portion 42 of the upper noise attenuation system is positioned
proximate to the distal end of the lower elongated plenum, and, in
the operative position, the upper noise attenuation system defines
an upper elongated plenum 50 that is in fluid communication with
the distal end of the lower elongated plenum. In this operative
position, an outlet 52 of the upper noise elongated plenum is
spaced away from the distal end of the lower elongated plenum at a
second distance that is greater than the first distance. Further,
it is contemplated that the upper noise attenuation system, in the
operative position, may extend longitudinally away from the distal
end of the lower elongated plenum about the exhaust axis.
[0035] The mobile fracking system affects a reduction in sound
emission by increasing the effective length of the gas turbine
exhaust stack. Attenuation of rectangular duct in the 63 Hz to 250
Hz octave frequency bands may be expressed as:
.DELTA. L duct = 17.0 ( P S ) - .025 f - 0.85 l ( 1 ) .DELTA. L
duct = 1.64 ( P S ) - 0.73 f - 0.58 l ( 2 ) ##EQU00001##
TABLE-US-00001 TABLE 1 Exhaust attenuation with unlined rectangular
duct Exhaust Duct with Exhaust Proposed System Reference Exhaust
Duct .DELTA.L.sub.duct, N - PWL f .DELTA.L.sub.duct, O PWL
.DELTA.L.sub.duct, N .DELTA.L.sub.duct, O PWL dB Hz dB dB dB dB dB
120.0 63.5 2.90 116.1 4.06 1.16 114.9 129.0 125 1.96 127.0 2.74
0.78 126.2 127.0 250 1.31 125.7 1.83 0.52 125.2 127.0 500 0.88
126.1 1.23 0.35 125.8 126.0 1000 0.59 125.4 0.82 0.23 125.2 130.0
2000 0.39 129.6 0.55 0.16 129.4
[0036] For example, and without limitation, and taken from Table 1
above, proposed exhaust system may affect a 40% increase in sound
attenuation and a maximum in 1.2 dB in sound pressure by selective
operative increase in the elongate length of the exhaust plenum
from 16.1 ft. to 22.6 ft.
[0037] In embodiments, the mobile fracking system 10 may include a
first plenum 22 configured to receive exhaust gas from the gas
turbine. In this aspect, a first end of the first plenum is
connected to, and in fluid communication with, an exhaust outlet of
the gas turbine and a second end of the first plenum connected to,
and in fluid communication with, the inlet of the lower elongated
plenum. For example, the gas turbine may be mounted to or otherwise
supported thereon the bottom surface of the trailer and the first
plenum may extend longitudinally substantially parallel to the
bottom surface.
[0038] Optionally, the upper noise attenuation system 40 may
include at least one array of baffles 70 that are configured to
attenuate noise. The array of baffles 70 may include a plurality of
baffles 72 that are distributed parallel to a common axis and that
define a plurality of slots 74 defined by and between the plurality
of baffles. In one exemplary aspect, the at least one array of
baffles 70 may be mounted therein a portion of the upper elongated
plenum in communication with the exhaust gas passing therethrough
the upper elongated plenum to the outlet to supplement the noise
dampening capabilities of the noise attenuation system.
[0039] In embodiments and referring to FIGS. 2-7, the upper noise
attenuation system 40 may include a pair of opposed and cooperating
silencer hoods 46. In this aspect, each silencer hood 46 may have a
planer surface 48 having opposed side edges 50 and a pair of
opposing side surfaces 52 that extend outwardly from portions of
the respective side edges of the planer surface. Each silencer hood
46 may be configured to be hingeably mounted to portions of a
distal end of the lower elongated plenum such that, in the
operative position, the pair of opposed silencer hoods are
positioned substantially upright so that the planer surfaces of the
respective back edges are in parallel opposition and that the
respective side surface are also in parallel opposition to form the
elongated upper elongated plenum.
[0040] As exemplarily shown in the figures, the pair of opposed
silencer hoods 46 may include an upper silencer hood 54 and a lower
silencer hood 56 that are configured to cooperatively slideably
engage relative to each other when moving therebetween the stowed
position and the operative position. In this example, the
respective opposed upper and lower silencer hoods may be opened in
a sequential manner First, the upper silencer hood may be raised
independently from the lower silencer hood. As shown, an anchor
point mounted on a back surface of the planar surface of the upper
silencer hood proximate a bottom edge of the back surface may be
connected to a wire that is operative connected to a spooling
system that is configured for selective movement of the connected
silencer hood between the stowed and operative positions. In
operation, the spooling system is operated to open or otherwise
urge the upper silencer hood to the operative position and may
comprise a winch, such as, for example and without limitation, an
electric winch, a hydraulic winch, a pneumatic winch, and the like.
It is contemplated that, once the upper silencer hood is in the
operative position, tension may be maintained on the wire to aid in
maintaining the upper silencer hood in the operative position until
the upper silencer hood is lowered to the stowed position for
transport. Optionally, a mechanical limit switch on the spooling
system that may be configured to determine distance the wire is
required to move to open and close the respective silencer hoods
46.
[0041] Similarly, the lower silencer hood 56 may be raised
independently from the upper silencer hood 54. As shown, an anchor
point mounted on a back surface of the planar surface of the lower
silencer hood proximate a bottom edge of the back surface may be
connected to a wire that is operative connected to the spooling
system. In operation, after the upper silencer hood is positioned
in the operative position, the spooling system of the lower
silencer hood may be operated to open or otherwise urge the lower
silencer hood to the operative position. It is contemplated that,
once the lower silencer hood is in the operative position, tension
may be maintained on the wire to aid in maintaining the lower
silencer hood in the operative position until the lower silencer
hood is lowered to the stowed position for transport. In this
example, the lower silencer hood would be lowered first in sequence
when the respective opposed upper and lower silencer hoods are
closed or otherwise moved to the stowed position.
[0042] As noted above, the respective upper and lower silencer
hoods 54, 56 may be maneuvered to and about the operative and the
stowed positions through the use of one or more actuators, such as
linear actuators and/or rotary actuators, and in some embodiments,
one or more cables and/or one or more mechanical linkages. In some
embodiments, the one or more actuators may be
electrically-actuated, pneumatically-actuated, and/or
hydraulically-actuated (e.g., via hydraulic cylinders and/or
hydraulic motors). For example, the respective upper and lower
silencer hoods 54, 56 may be maneuvered to and about the operative
and the stowed positions through the use of a spooling system
comprising electrical, mechanical, and/or pneumatic winches that
contain spooled wire that are connected to the anchor points
strategically positioned on the respective upper and lower silencer
hoods 54, 56.
[0043] Optionally, the exhaust attenuation system shown in FIGS.
2-5, 6A, 6B, and 7 may further include a retention brace system 90.
In this aspect, the retention brace system may include a first pair
of opposing retention braces 92 and a second pair of opposing
retention braces 99. The first pair of opposing retention braces 92
may include a first brace 93 mounted to exterior portions of the
distal end of the lower elongated plenum and a second brace 94
mounted to an opposed exterior portions of the distal end of the
lower elongated plenum. Each brace of the first pair of opposing
retention braces includes a bar 95 that extends between a first end
mount 96 and an opposing second end mount 97 such that, when the
respective first and second end mounts are positioned therein the
lower elongated plenum, the bar is spaced from an exterior surface
of the distal end of the lower elongated plenum and defines a slot
98 that is sized and shaped for receipt of portions of respective
side surfaces of the pair of silencer hoods.
[0044] Similarly, the second pair of opposing retention braces 99
includes a third brace 100 spaced proximally from the first brace
and mounted to exterior portions the lower elongated plenum and a
fourth brace 102 spaced proximally from the first brace and mounted
to an opposed exterior portions of the lower elongated plenum. In
this aspect, each brace of the second pair of opposing retention
braces includes a bar 95 extending between a first end mount 96 and
an opposing second end mount 97 such that, when the respective
first and second end mounts are positioned therein the lower
elongated plenum, the bar is spaced from an exterior surface of the
lower elongated plenum and defines a slot 98 that is sized and
shaped for receipt of respective side surfaces of the pair of
silencer hoods when the pair of silencer hoods is positioned in the
stowed position.
[0045] In embodiments, the upper noise attenuation system 40 may
include at least one array of baffles configured to attenuate noise
that is mounted therein at least a portion of the planer surface of
at least one or in each of the opposed silencer hoods.
[0046] In other embodiments and referring to FIGS. 8-11, the upper
noise attenuation system 40 may optionally include an elongated
conduit 110 that has an exterior surface shape that is shaped and
sized for complementary receipt therein a distal portion of the
lower elongated plenum 30. In this aspect, in the stowed position,
the elongated conduit 110 is positioned substantially therein the
lower elongated plenum such that an outlet end 112 of the elongated
conduit is positioned proximate to the distal end of the lower
elongated plenum. In the operative position, the elongated conduit
110 is selectively movable about and along an about an exhaust axis
outwardly away from the distal end of the lower elongated plenum
such that a proximal end 114 of the elongated conduit is positioned
proximate the distal end of the lower elongated plenum and the
outlet end 112 of the elongated conduit forms the outlet of the
upper elongated plenum.
[0047] In this aspect, to operatively move or otherwise urge the
elongated conduit 110 about and between the stowed and operative
positions, the upper noise attenuation system 40 may include at
least one guide 120 mounted to an exterior surface (e.g., at an
upper end thereof) of the lower elongated plenum 30. As will be
appreciated, the guide 120 may define an elongated enclosed slot
extending parallel to the exhaust axis. A rod 122 having a distal
end mounted to an outermost edge surface of the outlet end 112 of
the elongated conduit 110 may be provided that is configured for
operative slideably receipt therein the slot of the guide 120. To
operatively move the rod 122 and thereby move the elongated conduit
110 relative to the lower elongated plenum 30, a means for
selective axial movement of the rod 122 and thus for movement of
the elongated conduit 110 may be provided for selective movement of
the elongated conduit 110 between the stowed position (see, e.g.,
FIGS. 8 and 10) and the operative position (see, e.g., FIG. 9).
[0048] As illustrated in FIGS. 8-11, selective axial movement of
the rod 122 may be provided by an extension assembly 124. In some
examples, the extension assembly 124 may include pairs of pulleys
126 connected to opposing sides 128 of the lower elongated plenum
30, and a drive shaft 130 coupled to the lower elongated plenum 30.
The extension assembly 124 may also include a pair of cables 132,
each of which is anchored to a lower end of the lower elongated
plenum 30. A pair of drive wheels 134 may be connected to each end
of the drive shaft 130, and each of the drive wheels 134 may be
configured to retract or extend a respective one of the pair of
cables 132, for example, such that retraction of the pair of cables
132 causes the rod 122 to push the elongated conduit 110 to extend
from the lower elongated plenum 30 and into the operative position
(see FIG. 9), and extension of the pair of cables 132 causes the
rod 122 to return to a lowered position, thereby allowing the
elongated conduit 110 to return to the stowed position (see FIGS. 8
and 10). In some examples, at ends of the respective rods 122
remote from the outlet end 112 of the elongated conduit 110, a rod
pulley 136 may be provided for engaging a respective cable 132 to
facilitate movement of the elongated conduit 110 relative to the
lower elongated plenum 30. As shown in FIG. 11, in some examples, a
drive gear 138 may be connected to the drive shaft 130 to
facilitate rotation of the drive shaft 130 via an actuator
including a mating gear, such as a linear actuator and/or a rotary
actuator, for example, a gear shaft and a prime mover such as, for
example, and without limitation, a winch. As one skilled in the art
will appreciate, when such a prime mover is activated, the
illustrated drive gear 138 of the drive shaft 130 rotates, which
causes the complementary rotation of the drive wheels 134 connected
to the respective ends of the drive shaft 130. In turn, the cables
132 will spool onto each of the drive wheels 134 and via the
pulleys 126, will affect the translation of the proximal end of the
respective rods 122 to extend the elongated conduit 110 into the
operative position.
[0049] In this embodiment, the upper noise attenuation system may
include at least one array of baffles configured to attenuate noise
that may be mounted therein an outlet end of the elongated
conduit.
[0050] It is contemplated that the means for selective axial
movement of the rod for selective movement of the elongated conduit
110 between the stowed position and the operative position of the
elongated conduit 110 may comprise one or more actuators, such as
linear actuators and/or rotary actuators, and in some embodiments,
one or more cables and/or one or more mechanical linkages. In some
embodiments, the one or more actuators may be
electrically-actuated, pneumatically-actuated, and/or
hydraulically-actuated (e.g., via hydraulic cylinders and/or
hydraulic motors). For example, selective movement of the elongated
conduit 110 between the stowed position and the operative position
of the elongated conduit 110 may be provided by the spooling system
described above. In this aspect, the spooling system may comprise
electrical, mechanical, and/or pneumatic winches that contain
spooled wire and that are configured to spool wire onto each drum
via the pulleys to affect the axial movement of the rod.
[0051] Optionally, the exhaust attenuation system 20 may further
comprise a supervisory control system that is configured to utilize
a series of digital input and output signals that will result in
the controlled operation of the upper noise attenuation system 40.
In this aspect, the exhaust attenuation system 20 may comprise a
plurality of positional feedback sensors in communication with the
supervisory control system. The positional feedback sensors are
operatively mounted to respective portions of the upper noise
attenuation system 40 such that the sensors may actuate when the
upper noise attenuation system 40 is positioned in the stowed
position and when in the operative, upright, position.
[0052] Each positional feedback sensor may comprise, for example
and without limitation, a digital proximity switch that is
configured to actuate when the positional feedback sensor's
electromagnetic detection field comes in contact with a portion of
the metallic surface of the exhaust stack. Upon actuation, each
digital proximity switch is configured to send a digital signal to
the supervisory control system indicative of the position of the
respective upper and lower silencer hoods 54, 56 or, optionally,
the respective position of the elongated conduit 110 relative to
the distal end of the lower elongated plenum.
[0053] Optionally, it is contemplated that the positional feedback
sensor may be an analog position sensor that is configured to
provide positional feedback to the supervisory control system of
the positions of the respective upper and lower silencer hoods 54,
56 or, optionally, the respective position of the elongated conduit
110 relative to the distal end of the lower elongated plenum. In
this exemplary aspect, the analog position sensor may be configured
to transmit a scaled current or voltage signal that depending on
the value allows the control system to identify the accurate
position of the upper noise attenuation system 40. An exemplary
analog position sensor, such as a Sick absolute encoder, models
AFS/AFM60 SSI, would be suitable for this application.
[0054] The positional feedback sensors allow the operator to know
the position of the respective upper and lower silencer hoods 54,
56 or, optionally, the respective position of the elongated conduit
110 relative to the distal end of the lower elongated plenum and to
further allow for the protection of equipment on the gas turbine
skid. For example, the supervisory control system may generate an
interlock signal that would prohibit the ignition of the gas
turbine engine upon receipt of a signal from the respective
positional feedback sensors that indicates that the upper noise
attenuation system 40 is in the closed position. Thus, the
interlock signal preventing turbine operation into a sealed cavity
prevents the possibility of serious damage to the turbine engine
due to undesired backpressure.
[0055] In operational aspects, it is contemplated that the upper
noise attenuation system 40 may be actuated to move between the
stowed and operative positions by manual operation of a physical
lever. In this aspect, and if the spooling system includes a
pneumatic winch, the selective actuation of the manual level may
allow for the flow of air to the pneumatic motor resulting in
rotary motion at the winch. Optionally, if the spooling system
includes a hydraulic winch, the selective actuation of the manual
level may allow for the flow of hydraulic oil into the stator of
the hydraulic motor to produce the desired rotary motion and torque
to actuate the upper noise attenuation system 40. In a further,
exemplary aspect, if the spooling system includes an electrical
winch, a switching device may be provided that is configured to
allow for the selective application of current to the electric
winch motor. The switching device may exemplarily be in the form of
a toggle switch that allows the electrical circuit to the motor to
be completed upon actuation such that the electric motor performs
the desired rotary motion.
[0056] In a further optional aspect, the supervisory control system
of the exhaust attenuation system 20 may comprise a SCADA
(supervisory control and data acquisition) system. Exemplarily, if
pneumatic and/or hydraulic winches are used, a directional control
valve with an electrical coil may be positioned between the
respective pressurized sources of air or oil and the downstream
pneumatic or hydraulic motors. Operationally, an operation signal
transmitted or outputted to the directional control valve from the
SCADA system upon operator input. In this aspect, the operation
signal could be a PWM signal with reverse polarity. For example,
when the operator pushes an input on a human machine interface,
which is identified by the programmable logistical controller, and
the necessary output operation signal is sent to the directional
control valve that allows for proportional flow of the required air
or oil media to the winch motor. Optionally, this methodology may
also be used for an electrical winch but, in this aspect, the
output operation signal would energize a relay that allows for low
voltage, high current power to reach the electrical motor and
perform the proportional operation function. It is contemplated
that these actuation functions may be made fully autonomous by
implementing a start-up sequence such that, when the operator
selects to start the unit, a series of sequenced signal outputs are
driven around the frac pump trailer that will verify that the
exhaust attenuation system 20 is in the open, operative position,
the auxiliary power is verified to be on line, the necessary safety
and communication checks performed, and then the gas turbine is
allowed to start. In this exemplary aspect, a single input to
actuate the exhaust attenuation system 20 to move to the open,
operative position may initiate the issuance of a series of outputs
from the SCADA system, which may save the operator time and may
reduce complexity of how to individually perform these sequential
outputs.
[0057] Although only a few exemplary embodiments have been
described in detail herein, those skilled in the art will readily
appreciate that many modifications are possible in the exemplary
embodiments without materially departing from the novel teachings
and advantages of the embodiments of the present disclosure.
Accordingly, all such modifications are intended to be included
within the scope of the embodiments of the present disclosure as
defined in the following claims.
* * * * *