U.S. patent application number 17/084899 was filed with the patent office on 2021-05-06 for mobile pump system.
The applicant listed for this patent is Red Lion Capital Partners, LLC. Invention is credited to Christopher Combs, Matthew Curry, Neal Jensen.
Application Number | 20210131410 17/084899 |
Document ID | / |
Family ID | 1000005191951 |
Filed Date | 2021-05-06 |
United States Patent
Application |
20210131410 |
Kind Code |
A1 |
Curry; Matthew ; et
al. |
May 6, 2021 |
Mobile Pump System
Abstract
A mobile pump system includes: a trailer movable by a vehicle; a
first pump and a second pump mounted to the trailer and in fluid
communication with an outlet configured to flow a fluid to a
destination and with a fluid source; a power source mounted to the
trailer and directly coupled to the first pump and/or the second
pump, where the power source includes a turbine and/or a natural
gas fired reciprocating engine; and a control system configured to:
activate the second pump, with the first pump deactivated, with a
flow rate of the mobile pump system below a first set point; in
response to the flow rate of the mobile pump system reaching the
first set point, activate the first pump; and deactivate the second
pump, with the first pump activated, in response to the flow rate
of the mobile pump system reaching a second set point, where the
second set point is greater than or equal to the first set
point.
Inventors: |
Curry; Matthew; (McMurray,
PA) ; Combs; Christopher; (Spring, TX) ;
Jensen; Neal; (Henderson, NV) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Red Lion Capital Partners, LLC |
McMurray |
PA |
US |
|
|
Family ID: |
1000005191951 |
Appl. No.: |
17/084899 |
Filed: |
October 30, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62929343 |
Nov 1, 2019 |
|
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F04D 13/12 20130101;
F04B 47/02 20130101; F04B 17/06 20130101; F04D 1/06 20130101; E21B
43/26 20130101; F04B 17/03 20130101; F04D 29/605 20130101; F04B
13/00 20130101 |
International
Class: |
F04B 17/06 20060101
F04B017/06; F04B 17/03 20060101 F04B017/03; F04B 47/02 20060101
F04B047/02; F04D 29/60 20060101 F04D029/60; F04D 13/12 20060101
F04D013/12; F04B 13/00 20060101 F04B013/00; F04D 1/06 20060101
F04D001/06 |
Claims
1. A mobile pump system, comprising: at least one trailer movable
by a vehicle; a plurality of pumps comprising a first pump and a
second pump, wherein the first pump and the second pump are each
mounted to the at least one trailer, wherein the first pump and the
second pump are each in fluid communication with an outlet
configured to flow a fluid from the mobile pump system to a
destination and with a fluid source configured to hold a pumping
fluid; a power source mounted to the at least one trailer and
directly coupled to the first pump and/or the second pump, wherein
the power source comprises a turbine and/or a natural gas fired
reciprocating engine; and a control system configured to: activate
the second pump, with the first pump deactivated, with a flow rate
of the mobile pump system below a first set point to cause the
second pump to pump the pumping fluid; in response to the flow rate
of the mobile pump system reaching the first set point, activate
the first pump to cause the first pump to pump the pumping fluid;
and deactivate the second pump, with the first pump activated, in
response to the flow rate of the mobile pump system reaching a
second set point, wherein the second set point is greater than or
equal to the first set point.
2. The mobile pump system of claim 1, wherein the first pump is
configured to pump fluid at a flow rate as low as 1.5 bpm and at a
flow rate of up to 30 bpm, and wherein the second pump is
configured to pump fluid a flow rate as low as 0.1 bpm.
3. The mobile pump system of claim 1, wherein the first pump
comprises a multi-stage centrifugal injection pump.
4. The mobile pump system of claim 1, wherein the first pump
comprises a pressure-balanced pump.
5. The mobile pump system of claim 1, wherein the second pump
comprises a positive displacement pump.
6. The mobile pump system of claim 5, wherein the positive
displacement pump is a reciprocating triplex or quintuplex
pump.
7. The mobile pump system of claim 1, wherein the control system
comprises an electronic governor configured to control at least one
of a rotational speed of the power source, a flow rate of the first
pump and/or the second pump, and a pumping pressure of the first
pump and/or the second pump.
8. The mobile pump system of claim 7, wherein the electronic
governor is configured to adjust the flow rate of the first pump
and/or the second pump by an incremental amount as low as 0.1
bpm.
9. The mobile pump system of claim 1, wherein the power source is
directly coupled to the first pump, wherein the direct coupling
comprises a non-variable, fixed ratio direct-coupled connection or
a direct-coupled gear connection including a speed reducer.
10. The mobile pump system of claim 1, wherein the second pump is
powered by an electric motor receiving power generated by the power
source.
11. The mobile pump system of claim 6, wherein the control system
is configured to initiate a start-up protocol by: activating the
second pump, with the first pump deactivated, until the flow rate
of the mobile pump system is at least 1.5 bpm; and activating the
first pump, while the second pump is still activated, once the flow
rate of the mobile pump system is at the first set point, wherein
the first set point is at least 1.5 bpm.
12. The mobile pump system of claim 1, wherein the mobile pump
system is not permanently installed at a site for performing a
pressure pumping application.
13. The mobile pump system of claim 1, wherein the power source is
operated using field gas.
14. The mobile pump system of claim 1, wherein the first pump
and/or the second pump are configured to pump fluid at a pressure
of 15,000 psi or greater.
15. The mobile pump system of claim 1, further comprising a fluid
storage tank mounted to the at least one trailer and a third pump
mounted to the at least one trailer and in fluid communication with
the fluid storage tank, the first pump, and the second pump,
wherein the third pump is configured to pump fluid from the fluid
storage tank to the first pump and/or the second pump.
16. The mobile pump system of claim 1, wherein the pumping fluid is
pumped to the outlet by the second pump and not the first pump with
the flow rate of the mobile pump system below the first set point,
and the pumping fluid is pumped to the outlet by the first pump and
optionally the second pump with the flow rate of the mobile pump
system at or above the first set point.
17. A method for performing a pressure pumping application,
comprising: positioning the mobile pump system of claim 1 on a pump
site.
18. The method of claim 17, further comprising: activating the
second pump, with the first pump deactivated, until the flow rate
of the mobile pump system is at least 1.5 bpm; and activating the
first pump, while the second pump is still activated, once the flow
rate of the mobile pump system is at the first set point, wherein
the first set point is at least 1.5 bpm.
19. The method of claim 18, further comprising: deactivating the
second pump, while the first pump is still activated, once the flow
rate flow rate of the mobile pump system is at the second set
point.
20. A mobile pump system, comprising: a trailer movable by a
vehicle; a plurality of pumps comprising a first pump and a second
pump, wherein the first pump and the second pump are each mounted
to the trailer, wherein the first pump and the second pump are each
in fluid communication with an outlet configured to flow a pumping
fluid from the mobile pump system to a destination and configured
to be in fluid communication with a fluid storage tank configured
to hold the pumping fluid, wherein the first pump comprises a
pressure-balanced multi-stage centrifugal injection pump, wherein
the second pump comprises a reciprocating triplex or quintuplex
positive displacement pump; a power source mounted to the trailer
and directly coupled to the first pump, wherein the power source
comprises a turbine and/or a natural gas fired reciprocating
engine, wherein the direct coupling comprises a non-variable, fixed
ratio direct-coupled connection or a direct-coupled gear connection
including a speed reducer; a third pump mounted to the trailer and
configured to be placed in fluid communication with the fluid
storage tank, wherein the third pump is in fluid communication with
the first pump and the second pump, wherein the third pump is
configured to pump the pumping fluid from the fluid storage tank to
the first pump and/or the second pump and a control system
configured to: activate the second pump, with the first pump
deactivated, with a flow rate of the mobile pump system below a
first set point to cause the third pump to pump the pumping fluid
from the fluid storage tank to the second pump which is configured
to pump the pumping fluid to the outlet; in response to the flow
rate of the mobile pump system reaching the first set point,
activate the first pump to cause the third pump to pump the pumping
fluid from the fluid storage tank to the first pump which is
configured to pump the pumping fluid to the outlet; and deactivate
the second pump, with the first pump activated, in response to the
flow rate of the mobile pump system reaching a second set point,
wherein the second set point is greater than or equal to the first
set point.
Description
BACKGROUND
1. Field
[0001] The present disclosure relates to a mobile pump system and a
method for performing a pressure pumping application including the
mobile pump system.
2. Technical Considerations
[0002] Pressure pumping includes a propagation of fractures through
layers of rock using pressurized fluid and/or pumping cement into a
wellbore to complete it.
[0003] In one non-limiting example of pressure pumping, to extract
oil and/or gas trapped in formations beneath the Earth's surface,
drilling of a wellbore is required, and the oil and/or gas may be
recovered and extracted through the wellbore. Various pumps may be
used during the drilling and oil and/or gas recovery process.
[0004] In some non-limiting oilfield applications, drilling may
include forming horizontal laterals extending out from a vertical
section of the wellbore. The formation defining the vertical or
lateral section may be fractured in sections, such that a fracture
stimulation treatment is completed in the first section before
moving on to apply a fracture stimulation treatment on a second
section. This may be performed using a plug-and-perf technique in
which a perforating gun is used to initiate fractures in the
formation in the section after a plug is positioned between the
first section and the second section. The plug seals the first
section of the lateral from the other sections. This plug-and-perf
technique is repeated for each section of the lateral until all
intended sections of the lateral are perforated and fracture
stimulated.
[0005] The plug may be positioned at a predetermined location along
the lateral by utilizing a pump system to pump a fluid into the
wellbore, which exerts a pressure on the plug. The pressure on the
plug moves the plug along the lateral to the desired position.
Positioning the plug using the pump is considered an ancillary
application, commonly referred to as "pumpdown".
[0006] Existing pumps used in pressure pumping application, such as
in ancillary pumpdown applications have numerous drawbacks. For
example, existing pumps use an internal combustion engine driven by
diesel fuel, which have high carbon footprints. In addition, these
existing pumps are cumbersome and require considerable room at the
well site. Further, these existing pumps do not allow for
sufficiently precise control of flow rate, making it difficult to
move the plug to the desired position. Existing pumps are expensive
to acquire and maintain, and they create significant noise at a
decibel level that is known to harm human hearing without adequate
ear protection.
[0007] Further, existing pumping systems utilized in pressure
pumping applications, including ancillary pressure pumping
applications, are not capable of sufficiently low flow rates or
precise control of the flow rate or pump pressure. The existing
pump systems lack precise control and the ability to operate at
lower flow rates because they utilize conventional transmissions
that are incapable of smooth increase or decrease in pumping rates.
This may be the result of hesitation and slugging common when
primary gears disengage and engage the secondary shaft. As a
result, existing pressure pumping systems do not effectively remedy
screen outs occurring during hydraulic fracturing applications.
[0008] Further, higher rates may oftentimes be required for certain
pumping applications. Many existing single pump systems are
required to be located at a well site which take up considerable
room, thereby affecting the standards of safety with increased
personnel and more treating equipment like hoses and high pressure
treating irons, affecting the cost of the well pad and causing
large expenditures in construction of the well pad to accommodate
the multiple pumping systems, and requiring increased amounts of
diesel fuel to be trucked to location and dispersed among the pumps
as they are engaged in high pressure and/or high rate
operations.
[0009] Further, existing pumping systems utilized in pressure
pumping applications are costly to build and to operate.
Traditional diesel-powered pumps require regular repair and
maintenance which can inflate operational costs. Diesel is a
comparatively expensive fuel and is a cause of a variety of
pollutants and greenhouse gases when burned when compared to an
alternate fuel source like natural gas, and diesel engines also
require certain maintenance that leads to significant waste streams
and monetary expenditure being required.
[0010] Therefore, a pump suitable for pressure pumping applications
that overcomes some or all of the disadvantages of existing pumps
is desired.
SUMMARY
[0011] The present disclosure is directed to a mobile pump system
including: at least one trailer movable by a vehicle; a plurality
of pumps including a first pump and a second pump, where the first
pump and the second pump are each mounted to the at least one
trailer, where the first pump and the second pump are each in fluid
communication with an outlet configured to flow a fluid from the
mobile pump system to a destination and with a fluid source
configured to hold a pumping fluid; a power source mounted to the
at least one trailer and directly coupled to the first pump and/or
the second pump, where the power source includes a turbine and/or a
natural gas fired reciprocating engine; and a control system
configured to: activate the second pump, with the first pump
deactivated, with a flow rate of the mobile pump system below a
first set point to cause the second pump to pump the pumping fluid;
in response to the flow rate of the mobile pump system reaching the
first set point, activate the first pump to cause the first pump to
pump the pumping fluid; and deactivate the second pump, with the
first pump activated, in response to the flow rate of the mobile
pump system reaching a second set point, where the second set point
is greater than or equal to the first set point.
[0012] The first pump may configured to pump fluid at a flow rate
as low as 2.5 bpm and at a flow rate of up to 30 bpm, and the
second pump may be configured to pump fluid a flow rate as low as
0.1 bpm. The first pump may include a multi-stage centrifugal
injection pump. The first pump may include a pressure-balanced
pump. The second pump may include a positive displacement pump. The
positive displacement pump may be a reciprocating triplex or
quintuplex pump. The control system may include an electronic
governor configured to control at least one of a rotational speed
of the power source, a flow rate of the first pump and/or the
second pump, and a pumping pressure of the first pump and/or the
second pump. The electronic governor may be configured to adjust
the flow rate of the first pump and/or the second pump by an
incremental amount as low as 0.1 bpm. The power source may be
directly coupled to the first pump, where the direct coupling may
include a non-variable, fixed ratio direct-coupled connection or a
direct-coupled gear connection including a speed reducer. The
second pump may be powered by an electric motor receiving power
generated by the power source. The control system may be configured
to initiate a start-up protocol by: activating the second pump,
with the first pump deactivated, until the flow rate of the mobile
pump system is at least 1.5 bpm; and activating the first pump,
while the second pump is still activated, once the flow rate of the
mobile pump system is at the first set point, where the first set
point is at least 1.5 bpm. The mobile pump system may not be
permanently installed at a site for performing a pressure pumping
application. The power source may be operated using field gas. The
first pump and/or the second pump may be configured to pump fluid
at a pressure of 15,000 psi or greater. The mobile pump system may
include a fluid storage tank mounted to the at least one trailer
and a third pump mounted to the at least one trailer and in fluid
communication with the fluid storage tank, the first pump, and the
second pump, where the third pump is configured to pump fluid from
the fluid storage tank to the first pump and/or the second pump.
The pumping fluid may be pumped to the outlet by the second pump
and not the first pump with the flow rate of the mobile pump system
below the first set point, and the pumping fluid may be pumped to
the outlet by the first pump and optionally the second pump with
the flow rate of the mobile pump system at or above the first set
point.
[0013] The present disclosure is also directed to a method for
performing a pressure pumping application, including positioning a
mobile pump system on a pump site. The mobile pump system includes:
at least one trailer movable by a vehicle; a plurality of pumps
including a first pump and a second pump, where the first pump and
the second pump are each mounted to the at least one trailer, where
the first pump and the second pump are each in fluid communication
with an outlet configured to flow a fluid from the mobile pump
system to a destination and with a fluid source configured to hold
a pumping fluid; a power source mounted to the at least one trailer
and directly coupled to the first pump and/or the second pump,
where the power source includes a turbine and/or a natural gas
fired reciprocating engine; and a control system configured to:
activate the second pump, with the first pump deactivated, with a
flow rate of the mobile pump system below a first set point to
cause the second pump to pump the pumping fluid; in response to the
flow rate of the mobile pump system reaching the first set point,
activate the first pump to cause the first pump to pump the pumping
fluid; and deactivate the second pump, with the first pump
activated, in response to the flow rate of the mobile pump system
reaching a second set point, where the second set point is greater
than or equal to the first set point.
[0014] The method may include activating the second pump, with the
first pump deactivated, until the flow rate of the mobile pump
system is at least 1.5 bpm; and activating the first pump, while
the second pump is still activated, once the flow rate of the
mobile pump system is at the first set point, where the first set
point is at least 1.5 bpm. The method may include deactivating the
second pump, while the first pump is still activated, once the flow
rate flow rate of the mobile pump system is at the second set
point. The method may include positioning a plug in a lateral of a
wellbore using fluid pumped into the wellbore via the mobile pump
system. The method may include performing, using the mobile pump
system, a toe prep application, a drill-out application, an
industrial purging application, a pipeline pressure testing
application, and/or a hydro-blasting application.
[0015] Further embodiments are set forth in the following numbered
clauses:
[0016] Clause 1: A mobile pump system, comprising: at least one
trailer movable by a vehicle; a plurality of pumps comprising a
first pump and a second pump, wherein the first pump and the second
pump are each mounted to the at least one trailer, wherein the
first pump and the second pump are each in fluid communication with
an outlet configured to flow a fluid from the mobile pump system to
a destination and with a fluid source configured to hold a pumping
fluid; a power source mounted to the at least one trailer and
directly coupled to the first pump and/or the second pump, wherein
the power source comprises a turbine and/or a natural gas fired
reciprocating engine; and a control system configured to: activate
the second pump, with the first pump deactivated, with a flow rate
of the mobile pump system below a first set point to cause the
second pump to pump the pumping fluid; in response to the flow rate
of the mobile pump system reaching the first set point, activate
the first pump to cause the first pump to pump the pumping fluid;
and deactivate the second pump, with the first pump activated, in
response to the flow rate of the mobile pump system reaching a
second set point, wherein the second set point is greater than or
equal to the first set point.
[0017] Clause 2: The mobile pump system of clause 1, wherein the
first pump is configured to pump fluid at a flow rate as low as 2.5
or 1.5 bpm and at a flow rate of up to 30 bpm, and wherein the
second pump is configured to pump fluid a flow rate as low as 0.1
bpm.
[0018] Clause 3: The mobile pump system of clause 1 or 2, where the
first pump comprises a multi-stage centrifugal injection pump.
[0019] Clause 4: The mobile pump system of any of clauses 1-3,
wherein the first pump comprises a pressure-balanced pump.
[0020] Clause 5: The mobile pump system of any of clauses 1-4,
wherein the second pump comprises a positive displacement pump.
[0021] Clause 6: The mobile pump system of clause 5, wherein the
positive displacement pump is a reciprocating triplex or quintuplex
pump.
[0022] Clause 7: The mobile pump system of any of clauses 1-6,
wherein the control system comprises an electronic governor
configured to control at least one of a rotational speed of the
power source, a flow rate of the first pump and/or the second pump,
and a pumping pressure of the first pump and/or the second
pump.
[0023] Clause 8: The mobile pump system of clause 7, wherein the
electronic governor is configured to adjust the flow rate of the
first pump and/or the second pump by an incremental amount as low
as 0.1 bpm.
[0024] Clause 9: The mobile pump system of any of clauses 1-8,
wherein the power source is directly coupled to the first pump,
wherein the direct coupling comprises a non-variable, fixed ratio
direct-coupled connection or a direct-coupled gear connection
including a speed reducer.
[0025] Clause 10: The mobile pump system of any of clauses 1-9,
wherein the second pump is powered by an electric motor receiving
power generated by the power source.
[0026] Clause 11: The mobile pump system of any of clauses 6-10,
wherein the control system is configured to initiate a start-up
protocol by: activating the second pump, with the first pump
deactivated, until the flow rate of the mobile pump system is at
least 1.5 bpm; and activating the first pump, while the second pump
is still activated, once the flow rate of the mobile pump system is
at the first set point, wherein the first set point is at least 1.5
bpm.
[0027] Clause 12: The mobile pump system of any of clauses 1-11,
wherein the mobile pump system is not permanently installed at a
site for performing a pressure pumping application.
[0028] Clause 13: The mobile pump system of any of clauses 1-12,
wherein the power source is operated using field gas.
[0029] Clause 14: The mobile pump system of any of clauses 1-13,
wherein the first pump and/or the second pump are configured to
pump fluid at a pressure of 15,000 psi or greater.
[0030] Clause 15: The mobile pump system of any of clauses 1-14,
further comprising a fluid storage tank mounted to the at least one
trailer and a third pump mounted to the at least one trailer and in
fluid communication with the fluid storage tank, the first pump,
and the second pump, wherein the third pump is configured to pump
fluid from the fluid storage tank to the first pump and/or the
second pump.
[0031] Clause 16: The mobile pump system of any of clauses 1-15,
wherein the pumping fluid is pumped to the outlet by the second
pump and not the first pump with the flow rate of the mobile pump
system below the first set point, and the pumping fluid is pumped
to the outlet by the first pump and optionally the second pump with
the flow rate of the mobile pump system at or above the first set
point.
[0032] Clause 17: A method for performing a pressure pumping
application, comprising: positioning the mobile pump system of any
of clauses 1-16 on a pump site.
[0033] Clause 18: The method of clause 17, further comprising:
activating the second pump, with the first pump deactivated, until
the flow rate of the mobile pump system is at least 1.5 bpm; and
activating the first pump, while the second pump is still
activated, once the flow rate of the mobile pump system is at the
first set point, wherein the first set point is at least 1.5
bpm.
[0034] Clause 19: The method of clause 18, further comprising:
deactivating the second pump, while the first pump is still
activated, once the flow rate flow rate of the mobile pump system
is at the second set point.
[0035] Clause 20: The method of any of clauses 17-19, further
comprising: positioning a plug in a lateral of a wellbore using
fluid pumped into the wellbore via the mobile pump system.
[0036] Clause 21: The method of any of clauses 17-20, further
comprising: performing, using the mobile pump system, a toe prep
application, a drill-out application, an industrial purging
application, a pipeline pressure testing application, and/or a
hydro-blasting application.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] Additional advantages and details are explained in greater
detail below with reference to the exemplary embodiments that are
illustrated in the accompanying schematic figures, in which:
[0038] FIG. 1 shows a schematic cross-sectional view of the Earth
at an oil and/or gas production site utilizing horizontal drilling
techniques;
[0039] FIG. 2 shows another schematic cross-sectional view of the
Earth at an oil and/or gas production site utilizing horizontal
drilling techniques and a mobile pump system;
[0040] FIG. 3 shows a schematic aerial view of a well pad at an oil
and/or gas production site, the well pad including a mobile pump
system;
[0041] FIG. 4 shows a schematic side view of a mobile pump system
including a trailer and a cab for moving the mobile pump
system;
[0042] FIG. 5 shows a schematic top view of a mobile pump system
including the trailer and the electrically-driven pump or
turbine-driven pump;
[0043] FIG. 6 shows a schematic side view of an auger-style pump of
a mobile pump system;
[0044] FIG. 7 shows a controller for controlling a mobile pump
system;
[0045] FIG. 8 shows a schematic top view of a mobile pump system
including a pump driven by an electric motor;
[0046] FIG. 9 shows a schematic perspective view of a mobile pump
system including a pump driven by a turbine and/or a natural gas
fired reciprocating engine;
[0047] FIG. 10 shows a schematic perspective view of a mobile pump
system including a pump driven by a turbine and/or a natural gas
fired reciprocating engine, with the trailer including a fuel
tank;
[0048] FIG. 11 shows a schematic top view of a mobile pump system
including a secondary pump;
[0049] FIG. 12 shows a schematic side view of a mobile pump system
including multiple pumps and a turbine and/or a natural gas fired
reciprocating engine;
[0050] FIG. 13 shows a schematic top view of a mobile pump system
including multiple pumps and a turbine and/or a natural gas fired
reciprocating engine;
[0051] FIG. 14 shows a cross-sectional view of a non-limiting
example of the first pump being a multi-stage centrifugal injection
pump;
[0052] FIG. 15 shows a cross-sectional view of a non-limiting
example of the second pump being a positive displacement triplex or
quintuplex pump;
[0053] FIG. 16 shows a cross-sectional view of a non-limiting
example of the turbine and/or a natural gas fired reciprocating
engine including a speed reducer; and
[0054] FIG. 17 shows a side view of a non-limiting example of the
second pump being a positive displacement triplex or quintuplex
pump.
DETAILED DESCRIPTION
[0055] For purposes of the description hereinafter, the terms
"end," "upper," "lower," "right," "left," "vertical," "horizontal,"
"top," "bottom," "lateral," "longitudinal," and derivatives thereof
shall relate to the invention as it is oriented in the drawing
figures. However, it is to be understood that the invention may
assume various alternative variations and step sequences, except
where expressly specified to the contrary. It is also to be
understood that the specific devices and processes illustrated in
the attached drawings, and described in the following
specification, are simply exemplary embodiments or aspects of the
invention. Hence, specific dimensions and other physical
characteristics related to the embodiments or aspects disclosed
herein are not to be considered as limiting.
[0056] No aspect, component, element, structure, act, step,
function, instruction, and/or the like used herein should be
construed as critical or essential unless explicitly described as
such. Also, as used herein, the articles "a" and "an" are intended
to include one or more items and may be used interchangeably with
"one or more" and "at least one."
[0057] The present disclosure is directed to a mobile pump system
that includes: a trailer movable by a vehicle; and a pump mounted
to the trailer, the pump configured to pump a fluid, wherein the
pump comprises an electrically-driven motor mounted to the trailer
or is turbine powered by a turbine mounted to the trailer. The
mobile pump system described herein may be suitable for pressure
pumping applications.
[0058] The present disclosure is also directed to a mobile pump
system, comprising: at least one trailer movable by a vehicle; a
plurality of pumps comprising a first pump and a second pump,
wherein the first pump and the second pump are each mounted to the
at least one trailer, wherein the first pump and the second pump
are each in fluid communication with an outlet configured to flow a
fluid from the mobile pump system to a destination and with a fluid
source configured to hold a pumping fluid; a power source mounted
to the at least one trailer and directly coupled to the first pump
and/or the second pump, wherein the power source comprises a
turbine and/or a natural gas fired reciprocating engine; and a
control system configured to: activate the second pump, with the
first pump deactivated, with a flow rate of the mobile pump system
below a first set point to cause the second pump to pump the
pumping fluid; in response to the flow rate of the mobile pump
system reaching the first set point, activate the first pump to
cause the first pump to pump the pumping fluid; and deactivate the
second pump, with the first pump activated, in response to the flow
rate of the mobile pump system reaching a second set point, wherein
the second set point is greater than or equal to the first set
point.
[0059] Referring to FIG. 1, an oil and/or gas production site 10 is
shown. At the production site 10, the surface 11 (Earth's surface)
includes wellbore 12 created by drilling. The wellbore 12 includes
a wellhead 13, which is a structural component at the surface 11 of
the wellbore 12 which provides a structural and pressure-containing
interface for various drilling and production equipment. The
production site 10 may be a site for conducting hydraulic
fracturing.
[0060] With continued reference to FIG. 1, the production site 10
may utilize a horizontal drilling technique in which at least one
lateral 14 is used. For the horizontal drilling technique, the
wellbore 12 may include a vertical region of 2,500 to 25,000, such
as 6,000 to 15,000 or 6,000 to 10,000 feet in depth, although the
length of this vertical region is not limited to this range. The
wellbore 12 may include a leveling-off point 16 in which the
vertical region ends and the lateral 14 is drilled horizontally in
the Earth (the lateral 14 may have approximately the same depth
from the surface 11 at all points). Each lateral 14 may have a
length of 2,500-25,000, such as 3,000 to 10,000 feet, as measured
from the leveling-off point 16 to an end 18 of the lateral 14,
although the length of the lateral 14 is not limited to this range.
It will be appreciated that FIG. 1 is not drawn to scale, but
merely provides a useful schematic of a production site 10
performing horizontal drilling.
[0061] The lateral 14 may include a plurality of regions, which are
of a predetermined length. Hydraulic fracture stimulation treatment
may be performed in the lateral 14 individually at each region.
Hydraulic fracture stimulation treatment includes pumping a
fracturing fluid into the formation. The lateral 14 of the
schematic in FIG. 1 includes a first region 20, a second region 22,
a third region 24, a fourth region 26, a fifth region 28, and a
sixth region 30.
[0062] With continued reference to FIG. 1, the production site 10
may utilize a "plug-and-perf" method for hydraulic fracture
stimulation treatment. In FIG. 1, hydraulic fracture stimulation
treatment has been completed for the first region 20. A fractured
first region 32 was created in the formation at the first region
20. After the hydraulic fracture stimulation treatment was
completed in the first region 20, a first plug 34 was positioned at
an end of the first region 20 closest to the wellhead 13 (a
proximal end of the first region 20). Once in place, this first
plug 34 may prevent fluid subsequently pumped into the wellbore 12
from entering the first region 20.
[0063] With continued reference to FIG. 1, hydraulic fracture
stimulation treatment in the second region 22 of the formation may
be initiated by lowering a perforating gun 36 (hereinafter "perf
gun") into the wellbore 12 and positioning the perf gun 36 in the
second region 22. The perf gun 36 may be lowered into the wellbore
12 using a perf trailer 37. Once positioned correctly, charges of
the perf gun 36 may be detonated so as to create multiple
connection points from the wellbore 12 to the formation in the
second region 22. Oil and/or gas may be extracted by escaping from
fractures and extracted to the surface 11 via the wellbore 12.
[0064] Referring to FIG. 2, the production site 10 is shown at a
time after that depicted in FIG. 1. The fractured second region 38
is shown, which was created by the perf gun 36 from FIG. 1. It will
be appreciated that FIG. 2 is also not drawn to scale, but merely
provides a useful schematic of a production site 10 performing
horizontal and/or vertical drilling.
[0065] In FIG. 2, a second plug 40 is being lowered into the
wellbore 12 by a plug trailer 41 to be positioned at a proximal
position of the second region 22 (on the end of the second region
22 closer to the wellhead 13). The second plug 40 is spaced apart
from the first plug 34 by approximately the length of the second
region 22. The second plug 40 may be positioned using positioning
fluid 42 to provide pressure to the second plug 40 to move the
second plug along the length of the wellbore 12 (including the
lateral 14). The positioning fluid 42 may include water and/or a
chemical additive. The chemical additive may include a friction
reducer to reduce surface tension. The chemical additive may reduce
tension or pipe friction along the wellbore 12 associated with
positioning the second plug 40.
[0066] The second plug 40 may be positioned using the mobile pump
system 44 of the present disclosure. The mobile pump system 44 may
be used to position the second plug 40 as merely one non-limiting
example of how the mobile pump system 44 may be used in a pressure
pumping application. However, it will be appreciated that the
mobile pump system 44 may be used to complete other pressure
pumping applications using the components of the mobile pump system
44 described hereinafter.
[0067] The mobile pump system 44 may include a trailer 46 movable
by a vehicle (e.g., a cab having a fifth wheel). The trailer 46 may
be movable by a vehicle, such as a cab, to and from the production
site 10. In this way, the mobile pump system 44 may be conveniently
moved from location to location, such as to and from the production
site 10, and the mobile pump system 44 does not need to be
permanently installed at the production site 10. The trailer 46 may
be separable/detachable from the vehicle such that the trailer 46
may be left at the production site 10 and the vehicle driven away,
or the trailer 46 may be integrated with the vehicle, such that the
vehicle remains at the production site 10 while the mobile pump
system 44 is in use and drives away after use of the mobile pump
system 44 is completed.
[0068] With continued reference to FIG. 2, the mobile pump system
44 may further include at least one pump 48 mounted to the trailer
46. The at least one pump 48 may be configured to pump the
positioning fluid 42 into the wellbore 12. The at least one pump 48
may include an electric motor 50 mounted to the trailer 46 or may
be powered by a turbine and/or a natural gas fired reciprocating
engine 50 mounted to the trailer 46. The trailer 46 may include
multiple pumps 48 in some embodiments and may include multiple
electric motors and/or turbines and/or natural gas fired
reciprocating engine 50 for driving the pumps 48. As used herein,
the term "electric motor" or "electrically-driven motor" refers to
a motor in which electrical energy is converted into mechanical
energy. As used herein, the term "turbine" refers to a rotary
mechanical device that extracts energy from a fluid (e.g., liquid
and/or gas) flow and converts it into useful work. The trailer 46
may also include a power generator 52 in connection with the at
least one pump 48 to fuel the electrically-driven motor or the
turbine 50 of the at least one pump 48. The power generator 52 may
be battery, natural gas, diesel fuel, or gasoline fueled. The at
least one pump 48 may be driven by the electric motor or the
turbine 50 and not by an internal combustion engine. The pump 48
may be driven by a natural gas fired reciprocating engine.
[0069] The at least one pump 48 may be configured to pump the
positioning fluid 42, or any other fluid, at a flow rate of up to
30 barrels per minute (bpm), such as up to 60 bpm, up to 80 bpm, up
to 100 bpm, up to 120 bpm, up to 140 bpm or higher. A barrel is
defined as 42 US gallons, which is approximately 159 Liters. The at
least one pump 48 may be configured to pump the positioning fluid
42 at far lower flow rates, and may pump the positioning fluid 42
at a flow rate as low as 0.1 bpm (when the pump is not turned off
such that it's flow rate would be 0 bpm). The at least one pump 48
may be controlled such that its flow rate may be controlled within
0.1 bpm, resulting in a flow rate within 0.1 bpm compared to a
predetermined flow rate. The pump may be configured to adjust the
flow rate by 0.1 bpm (e.g., adjust the flow rate of the at least
one pump 48 from 60.0 bpm to 59.9 bpm or from 0.2 bpm to 0.1 bpm).
Existing pressure pumping systems, including ancillary pressure
pumping applications, are not capable of such low flow rates or
such precise control of the flow rate. The existing pump systems
lack precise control and the ability to operate at lower flow rates
because they utilize conventional transmissions that are incapable
of smooth increase or decrease in pumping rates. This may be the
result of hesitation and slugging common when primary gears
disengage and engage the secondary shaft.
[0070] The ability to pump at lower rates and to more precisely
control the flow rate of the at least one pump 48 may be especially
useful in post-occurrence remedying of "screen outs," which are
common in hydraulic fracturing applications. A screen out occurs
when proppant and fluid (of the positioning fluid 42, for example)
can no longer be injected into the formation. This may be due to
resistant stresses of the formation becoming too excessive or
surface-originated reasons resulting in loss of viscosity to carry
proppant so that it falls out of suspension and plugs perforations
in the wellbore 12. In this way, the wellbore 12 becomes "packed"
with proppant, which does not allow any further operations to
continue due to high pressures that cannot be overcome from these
blockages.
[0071] In response to screen outs, the wellbore 12 may be opened at
the surface 11 to relieve pressure and to carry at least some of
the proppant out of the wellbore 12 and create a pathway to
continue fluid injection to clear the wellbore 12 and allow
operations to continue, which is a dangerous operation. An attempt
to continue pumping operations at low rates to avoid reaching
maximum pressure so that the proppant that is packed is forced
through perforations and into the wellbore 12 may be attempted.
However, due to the limitations of existing pumps with conventional
engines and transmissions, the pump cannot pump at low enough rates
to avoid again reaching maximum pressure. As a result, existing
systems are often required to switch to a coiled tubing procedure
to wash the proppant out and carry it back to the surface so that
the wellbore 12 is finally clear. The coiled tubing procedure
results in shutdown of operations for 3-4 days and is additionally
expensive to complete.
[0072] In contrast to existing systems, the mobile pump system 44
is able to overcome these screen outs successfully without
reverting to the coiled tubing procedure because the electric motor
and/or the turbine and/or the natural gas fired reciprocating
engine 50 of the at least one pump 48 allows the at least one pump
48 to inject fluid for displacement at lower rates (as low as 0.1
bpm) over the course of hours or days without the risks posed by
existing systems.
[0073] The ability to pump fluids at lower rates and to more
precisely control the flow rate of the at least one pump 48 may be
especially useful in prevention or mitigation of the adiabatic
effect which can cause wireline cable melting and/or failure during
pumpdown operations, which are common in hydraulic fracturing
applications. On pumpdowns and related jobs involving wireline
operations with pump assist, the wellhead is equipped with a
lubricator and flow tubes to enable operations in a wellbore that
can have pressure of several thousand pounds or more of pressure.
The process of bringing the lubricator and the wellbore to the same
pressure is known as "equalization." When the air in the lubricator
compresses faster than it can be evacuated, the adiabatic
compression can cause the temperature to rise to as much as
1,200.degree. F. (.about.650.degree. C.). At high temperatures, the
insulating material of the cable would melt and the metallurgy of
the steel in the cable would change, causing the actual wire in the
wireline to become brittle and break, even to the point of severing
the wireline within the lubricator. A common name for this
condition is "wireline burn up" though other colloquialisms and
phrases (such as "E-line burn") describe the same condition.
[0074] In practice, to avoid wireline burn-up, the lubricator may
first be filled with fluid prior to equalizing; this practice can
mitigate much of the air and therefore most of the energy to cause
damage. In order to fill the lubricator with fluid without inducing
wireline burn-up, the fluid must be introduced at very low rates so
that the air can be evacuated at an equivalent rate so as not to
introduce temperature increases caused by compressing air rapidly.
However, due to the limitations of existing pump systems with
conventional engines and transmissions, the pump cannot pump at low
enough rates to completely avoid against reaching damaging high
temperatures. In contrast, the at least one pump 48 would be able
to overcome this situation successfully because the electric motor
and/or the turbine and/or the natural gas fired reciprocating
engine 50 of the at least one pump 48 allows the at least one pump
48 to inject fluid for displacement of the air in the lubricator at
lower rates (as low as approximately 0.1 bpm) without the risks
posed by existing systems.
[0075] The at least one pump 48 may be configured to pump fluid at
a pressure of up to 20,000 psi, such as up to 15,000 psi, up to
12,000 psi, up to 10,000 psi, up to 8,000 psi, or up to 6,000 psi,
although higher pressures are also contemplated.
[0076] With continued reference to FIG. 2, a fluid tank 54
containing the positioning fluid 42 may be in fluid communication
with the at least one pump 48. The at least one pump 48 may pump
the positioning fluid 42 from the fluid tank 54 into the wellbore
12 to position the second plug 40 at a predetermined position in
the wellbore 12.
[0077] With continued reference to FIG. 2, the mobile pump system
44 may position the second plug 40 at a predetermined position in
the wellbore 12. The second plug 40 may be positioned in the
wellbore by providing the previously-described mobile pump system
44. The at least one pump 48 of the mobile pump system 44 may be
placed in fluid communication with the wellbore 12. The positioning
fluid 42 may be pumped from the fluid tank 54 into the wellbore 12
using the at least one pump 48. The positioning fluid 42 pumped
into the wellbore 12 may exert a pressure on the second plug 40 so
as to move the second plug 40 along the lateral 14 and into the
predetermined position. The position of the second plug 40 may be
monitored from the surface by any means known in the art. The flow
rate of the positioning fluid 42 pumped by the at least one pump 48
may be adjusted and controlled to position the second plug 40. The
flow rate may be increased or decreased to adjust the rate at which
the second plug 40 is moved. For example, when the second plug 40
is proximate the predetermined position, the flow rate of
positioning fluid 42 may be lowered so that the position of the
second plug 40 can be more precisely selected.
[0078] The mobile pump system 44 described herein may be used for
any pressure pumping in which its characteristics are suitable and
is not limited to the above-described application. For example, the
mobile pump system 44 may be used in hydraulic fracturing
applications. Hydraulic fracturing applications include any
application associated with hydraulic fracturing performed at a
production site. Hydraulic fracturing refers to fluid injected down
the wellbore through perforations exceeding the minimum fracture
pressure needed to fracture the rock in the formation. An example
of a hydraulic fracturing application includes ancillary
applications ("pumpdown"), such as positioning a plug (previously
described), drillout applications, injecting acid into the
formation, pressure testing casing, injecting diverter materials,
"toe preps" involving initiating the first fracture network in a
well, and the like. Drillout applications may include applications
performed after the drilling and fracturing process has concluded
and the well is being prepared to deliver hydrocarbon production.
As one example, a drillout application may include milling or
drilling out plugs previously positioned in the laterals and
removing debris from the milled plugs by pumping the debris from
the plug location to the surface.
[0079] The mobile pump system 44 allows for the reduction of
capital costs compared to existing pump systems as the mobile pump
system 44 requires less capital costs to build and operate. The
mobile pump system 44 also significantly reduces repair and
maintenance costs compared to existing systems. The use of the
electric motor and/or turbine and/or natural gas fired
reciprocating engine 50 to drive the at least one pump 48 helps to
reduce repair and maintenance costs. The electric motor and/or
turbine and/or natural gas fired reciprocating engine 50 has a
higher run time before requiring repairs compared to conventional
internal combustion diesel engines (motors) used in existing pumps,
which are diesel driven, for example. Keeping the electric motor
and/or turbine and/or natural gas fired reciprocating engine 50
cool and lubricated allows the electric motor and/or turbine and/or
natural gas fired reciprocating engine 50 to have a longer running
life compared to the motors used in existing systems. The electric
motor and/or turbine and/or natural gas fired reciprocating engine
50 also run more efficiently compared to the motors used in
existing systems, such as in terms of emissions and consumption of
fuel.
[0080] The mobile pump system 44 using the electric motor and/or
turbine and/or natural gas fired reciprocating engine 50 to drive
the at least one pump 48 also requires significantly less fuel,
monetary expenditure to maintain, and results in less environmental
waste from maintenance, compared to existing systems. The electric
motor and/or turbine and/or natural gas fired reciprocating engine
50 may utilize natural gas-powered electric generation, such as the
field gas available at a production site. Thus, sulfur and other
pollutants that arise from diesel combustion in conventional
internal combustion motors are not present in the combustion of
natural gas powered electric generation. The inclusion of the
electric motor and/or the turbine and/or the natural gas fired
reciprocating engine 50 in the mobile pump system 44 also reduces
the noise associated with the mobile pump system 44 as pumps used
in existing systems provide significant noise pollution and make it
difficult to operate such pumps in residential areas (e.g., near
housing plans, schools, hospitals, and the like).
[0081] The mobile pump system 44 includes a more compact design of
the pumps 48 compared with existing systems. Multiple pumps 48 may
be included on the trailer 46. The more compact system contributes
to a safer production site 10 as there are less components at the
production site 10 to cause a navigational and/or tripping hazard.
This compact design also allows for the mobile pump system 44 to be
set-up faster, resulting in less wasted time and faster time to
production. Moreover, the mobile pump system 44 may include
multiple of at least one component included in the system, such as
multiple pumps 48, multiple electric motors and/or turbines and/or
natural gas fired reciprocating engines 50, multiple controllers
80, and the like. The redundancy associated with certain of the
components mounted on the trailer 46 of the mobile pump system 44
allows the system to avoid stopping operation of the pressure
pumping application should one of the redundant components
fail.
[0082] Referring to FIG. 3, an aerial view of the production site
10 is shown. The production site 10 includes a well pad 56. The
well pad 56 includes six wellbores 12A-12F, each wellbore having a
vertical region and at least one lateral traversing a direction
different from the other wellbores of the well pad 56. In the
schematic in FIG. 3, the non-limiting example of a pressure pumping
application is being conducted at only the first wellbore 12A;
however, multiple well heads may be in production (e.g., conducting
oilfield activity) simultaneously.
[0083] The production site 10 may include at least one fracturing
trailer 58A-58F, each including at least one fracturing pump
60A-60F. The production site 10 may further include sand and
fracturing fluid storage tanks 62, which include sand and
fracturing fluid used to keep fractures in the formation open. The
production site 10 may further include a water tank 64 for pumping
water into the first wellbore 12A. The water tank 64 may be in
addition to or the same as the fluid tank 54 containing the
positioning fluid 42. The production site 10 may further include a
chemical storage tank 66, which may store any useful chemical, such
as a friction reducer (e.g., polyacrylamide or a guar-based
chemical). The fracturing pumps 60A-60F may be in fluid
communication with at least one of the sand and fracturing fluid
storage tanks 62, the water tank 64, and the chemical storage tank
66 to pump the various materials and/or fluids contained therein
into the first wellbore 12A via piping 70. The piping 70 may
include an isolation valve 72 for isolating the fracturing pumps
60A-60F from the first wellbore 12A when the fracturing pumps
60A-60F are not pumping fluid/material into the first wellbore
12A.
[0084] With continued reference to FIG. 3, the production site 10
may further include a data monitoring station 68, which may be used
to monitor all operations conducted at the production site 10 and
control those operations accordingly. In some non-limiting
examples, the data monitoring station 68 may be remote from the
production site 10.
[0085] With continued reference to FIG. 3, production site 10 may
further include the mobile pump system 44A. The production site may
include a single mobile pump system 44A or multiple mobile pump
systems 44A-44B, as necessary. In the non-limiting example of FIG.
3, a first mobile pumping system 44A is used to pump positioning
fluid 42 into the first wellbore 12A. The first mobile pumping
system 44A may include a first trailer 46A, a first power generator
52A, and a first pump 48A having a first electric motor 50A. The
production site 10 may utilize a second mobile pumping system 44B
in addition to or in lieu of the first mobile pumping system 44A.
The second mobile pumping system 44B may include a second trailer
46B, a second power generator 52B, and two pumps 48B, 48C, each
having an electric motor and/or turbine and/or natural gas fired
reciprocating engine 50B, 50C. The production site 10 may include
the fluid tank 54 containing the positioning fluid 42, and the
fluid tank 54 may be in fluid communication with the first pump 48A
of the first mobile pumping system 44A. The first mobile pumping
system 44A and the second mobile pumping system 44B may be moved to
and from the production site 10 without being permanently installed
at the pumping site 10.
[0086] With continued reference to FIG. 3, the first pump 48A may
be in fluid communication with the first wellbore 12A so as to pump
the positioning fluid 42 into the first wellbore 12A. The first
pump 48A may be in fluid communication with the piping 70 so as to
be in fluid communication with the first wellbore 12A, and the
first pump 48A may intersect with the piping 70 at a tie-in point
74. The tie-in point 74 may be upstream of the wellhead of the
first wellbore 12A (e.g., before the piping 70 reaches the wellhead
of the first wellbore 12A).
[0087] Referring to FIG. 4, a non-limiting example of the mobile
pump system 44 may include a cab 76. The cab 76 may be a truck
capable of attaching the trailer 46 thereto (such as via a fifth
wheel), so that the trailer 46 may be hauled to and from the
production site 10. The trailer 46 may be detachable from the cab
76 so that it may be left at the job site, or the trailer 46 may be
an integrated part of the cab 76 (not detachable therefrom). In
some examples, the cab 76 is the power generator 52 because the cab
may fuel the electric motor and/or turbine and/or natural gas fired
reciprocating engine 50 used to drive the at least one pump 48.
[0088] Referring to FIG. 5, a top view of a non-limiting example of
the mobile pump system 44 is shown, with the mobile pump system 44
including the trailer 46, the at least one pump 48 having the
electric motor and/or turbine and/or natural gas fired
reciprocating engine 50, and the power generator 52. The power
generator 52 may be connected to the at least one pump 48 (e.g.,
the electric motor 50) to fuel the electric motor and/or turbine
and/or natural gas fired reciprocating engine 50, such that the
electric motor and/or turbine and/or natural gas fired
reciprocating engine 50 may drive the at least one pump 48.
[0089] Referring to FIG. 6, a non-limiting example of the at least
one pump 48 is shown. The at least one pump 48 may be any pump
suitable for pumping the positioning fluid 42 as previously
described. In one example, the at least one pump 48 may be an
auger-style pump that includes an auger or impeller 78 driven by
the electric motor and/or the turbine and/or natural gas fired
reciprocating engine 50 to move the positioning fluid 42 into the
wellbore 12. The auger-style pump may provide certain advantages,
including allowing for a more precise control of flow rate, reduced
maintenance, and ease of maintenance (based on the reduced number
and simplicity of components).
[0090] Referring to FIG. 7, the at least one pump 48, the electric
motor and/or the turbine and/or natural gas fired reciprocating
engine 50, the generator 52, and/or other components ("controllable
components") of the mobile pump system 44 may be controlled
remotely by a controller 80. As used herein, "remotely" refers to a
geographic location separate from the controllable component. The
at least one pump 48 may be controlled from the data monitoring
station 68 or other location at the production site 10 (shown in
FIG. 3), or the at least one pump 48 may be controlled off-site
(not at the production site 10). The at least one pump 48 may be
controlled by the controller 80 that is a portable computing
device, such that the portable computing device may be moved
between locations and is still able to control the at least one
pump 48. The portable computing device may be, for instance, a
laptop computer, a tablet computer, or a smartphone. Thus, relevant
data associated with the mobile pump system 44 may be communicated
to the controller 80 remote from the controllable component(s).
[0091] An exemplary graphical user interface (GUI) displayed on the
controller 80 is shown in FIG. 7, and a user may control the
controllable components by interacting with the GUI on the
controller 80. The GUI may allow the user to control various
features of the controllable components. Non-limiting examples
include controlling the pump's 48 flow rate or the pressure of the
at least one pump 48. The GUI may display the flow rate and
pressure of the at least one pump 48. The GUI may allow the user to
turn the at least one pump 48 on or off. The GUI may display the
fill level of the fluid tank 54 or provide a status of the electric
motor and/or the turbine and/or natural gas fired reciprocating
engine 50, such as whether any issues are identified with the
electric motor and/or the turbine and/or natural gas fired
reciprocating engine 50. It will be appreciated that other aspects
of the mobile pump system 44 may be controlled by interacting with
the GUI, and any suitable layout of the GUI may be used. Multiple
controllable components (e.g., multiple pumps) may be controllable
from the same controller 80.
[0092] Beyond providing the capability to adjust certain parameters
of the system, the GUI may display on the controller various
diagnostic and monitoring information. As non-limiting examples,
the GUI may display electric motor and/or the turbine and/or the
natural gas fired reciprocating engine temperature, fluid levels,
and pump revolutions per minute.
[0093] Referring to FIG. 8, a mobile pump system 82 is shown. The
mobile pump system 82 may include a trailer 84 attachable to a
vehicle for moving the trailer 84 to various locations. The mobile
pump system 82 may include a controller 86 mounted on the trailer
84, the controller 86 in electrical communication with other
components of the mobile pump system 82 (e.g., an electrical
transformer 88, a variable frequency drive 90, a heat exchanger 92,
an electric motor 94, a pump 96, a secondary pump 98, and a
secondary electric motor 100). The controller 86 may communicate
control signals to the other components to cause the other
components to perform a predetermined action (e.g., activating or
deactivating a component, changing a pump rate, changing a heat
exchanger temperature, and the like).
[0094] The mobile pump system 82 may include an electrical
transformer 88 mounted on the trailer 84. The electrical
transformer 88 may increase or decrease a voltage from an external
power source for use by one of the components of the mobile pump
system 82. This may allow components of the mobile pump system 82
to be powered by an external power source not included on the
trailer 84 by electrically connecting the external power source to
the transformer 88, which may be electrically connected to the
other components.
[0095] The mobile pump system 82 may include the variable frequency
drive 90 mounted on the trailer 84. The variable frequency drive 90
may include an electro-mechanical drive system to control motor
speed and/or torque of the electric motor 94 by varying motor input
frequency and/or voltage.
[0096] The mobile pump system 82 may include the heat exchanger 92
mounted on the trailer 84 to regulate temperature of at least one
of the other components (e.g., the electric motor 94 and/or the
pump 96), such that the component can operate more efficiently. The
heat exchanger 92 may function as a cooler to prevent a component
of the mobile pump system 82 from overheating.
[0097] The mobile pump system 82 may include the electric motor 94
mounted on the trailer 84, the electric motor 94 as previously
described herein. The mobile pump system 82 may also include the
pump 96a, 96b (a single or multiple pumps may be included) mounted
on the trailer 84. The pump 96a, 96b may include the features
previously described herein in connection with at least one pump
48. The pump 96a, 96b may be driven by the electric motor 94.
[0098] With continued reference to FIG. 8 and referring to FIG. 11,
the mobile pump system 82 may include a secondary pump 98 and/or a
secondary motor 100 (e.g., an electric motor) mounted on the
trailer 84. The secondary pump 98 may include a triplex or
quintuplex pump. The secondary pump 98 may be configured for
pumping fluid at higher pressure compared to the pump 96a, 96b of
the mobile pump system 82. The secondary pump 98 may be selectively
activated in situations in which the mobile pump system 82 is
required to operate at a higher pressure. The secondary pump 98 may
be isolated from the pump 96a, 96b of the mobile pump system. The
secondary motor 100 may drive the secondary pump 98. The pump 96a,
96b and/or the secondary pump 98 may be in fluid communication with
the wellbore 12 (see FIG. 2).
[0099] Referring to FIG. 9, a mobile pump system 102 may include
any of the components discussed in connection with the mobile pump
system 82 from FIG. 8 and may include any additional or alternative
components as hereinafter described. The trailer 84 may include a
connection portion 104 configured to engage with an engagement
portion of a cab (e.g., a fifth wheel). The connection portion 104
may engage with a cab, such that the mobile pump system 102 may be
transported by the cab to various locations, such as to and from a
production site.
[0100] The mobile pump system 102 may include an inlet filter
silencer 106 mounted on the trailer 84 to reduce noise emitted by
any of the components included in the mobile pump system 102.
[0101] The mobile pump system 102 may include a turbine and/or a
natural gas fired reciprocating engine 108a, 108b (a single or
multiple turbines and/or natural gas fired reciprocating engines
may be included) mounted on the trailer 84 and connected to the
pump 96a, 96b. The turbine and/or natural gas fired reciprocating
engine 108a, 108b may be enclosed in a housing. The turbine and/or
natural gas fired reciprocating engine 108a, 108b may be an
on-board (on the trailer 84) turbine and/or natural gas fired
reciprocating engine to generate power on the trailer 84 for
driving the pumps 96a, 96b. The turbine and/or natural gas fired
reciprocating engine 108a, 108b may be directly coupled to the pump
96a, 96b via a gearbox 110a, 110b (a speed reduction mechanism may
be included), which may include gear reduction components. The
turbine and/or natural gas fired reciprocating engine 108a, 108b
may be powered by using field gas (e.g., natural gas) e.g.,
introduced to the turbine to spin the turbine blades to create
power to rotate the pump 96a, 96b. The power generated by the
turbine and/or the natural gas fired reciprocating engine 108a,
108b may drive the pump 96a, 96b. The turbine and/or natural gas
fired reciprocating engine 108a, 108b may be included in the mobile
pump system 102 in addition to or in lieu of the electric motor
94a, 94b shown in the mobile pump system 82 shown in FIG. 8.
[0102] Referring to FIG. 10, a mobile pump system 112 may include
all of the components from the mobile pump system 102 of FIG. 9
with the following additions or alterations. The mobile pump system
112 may include a fuel tank 114 (or multiple fuel tanks) mounted on
the trailer. The fuel tank 114 may include any type of fuel
suitable to fuel any of the components of the mobile pump system
112. Non-limiting examples of suitable fuels for the fuel tank 114
include compressed natural gas (CNG), liquefied natural gas (LNG),
diesel fuel, gasoline, propane, butane, and other suitable
hydrocarbons and the like. The fuel tank 114 may be in fluid
communication with any of the components of the mobile pump system
112 capable of being fueled by the fuel contained in the fuel tank
114. The fuel tank 114 may include any pumps, pipes, hoses, and/or
valves required to carry the fuel to the relevant components of the
mobile pump system 112.
[0103] The fuel tank 114 may be used as a backup fuel supply in the
event of a fuel supply interruption. A fuel supply interruption may
include the interruption of field gas (e.g., natural gas supplied
directly from the production site at which the mobile pump system
112 is located) to the mobile pump system 112. Inclusion of the
fuel tank 114 on the trailer 84 allows the mobile pump system 112
to continue operation even in the event of such a fuel supply
interruption, without the deployment of an emergency backup power
supply to the production site.
[0104] The mobile pump system 112 may include a conditioning system
116 configured to condition the gas from the fuel tank 114 or the
field gas supplied to the mobile pump system 112. The conditioning
system 116 may include a gas heater to drop out solids and/or water
from the gas and return it to the supply line. The conditioning
system 116 may include at least one filter to filter out impurities
in the fuel that could cause the system to malfunction.
[0105] Referring to FIGS. 12 and 13, another non-limiting example
of a mobile pump system 200 is shown. The mobile pump system 200
may include at least one trailer 202 movable by a vehicle, such as
a truck. The mobile pump system 200 may include a single trailer,
as shown, but a mobile pump system including a plurality of
trailers to mount the plurality of pumps and the turbine and/or
natural gas fired reciprocating engine (as described hereinafter)
is also contemplated. Certain components (e.g., the pumps) of the
mobile pump system described herein may be mounted to a first
trailer while other of the components (e.g., the turbine and/or
natural gas fired reciprocating engine) of the mobile pump system
may be mounted to a second trailer. As such, the mobile pump system
200 may be positioned at a site for performing a pressure pumping
application without permanently installing the mobile pump system
200 at the site. A turbine and/or natural gas fired reciprocating
engine 204 may be mounted to the trailer 202. The mobile pump
system 200 may include a plurality of pumps 206a, 206b, 208, 218,
each mounted to the trailer 202. The pumps may be in fluid
communication with one another by a conduit 214. The conduit 214
may be configured to be placed in fluid communication with an
outlet, which is in fluid communication with the intended
destination of the fluid being pumped by the mobile pump system
200. For example, the conduit 214 may be configured to be placed in
fluid communication with a wellbore in non-limiting scenarios in
which fluid is being pumped into the wellbore by the mobile pump
system 200.
[0106] The plurality of pumps 206a, 206b, 208, 218 may include at
least one first pump 206a, 206b. In the non-limiting example of the
mobile pump system 200 shown in FIGS. 12 and 13, two first pumps
206a, 206b are included; however, the mobile pump system 200 may
include a single first pump or three or more first pumps. The first
pump 206a may be a multi-stage centrifugal injection pump (one
example of which is shown in FIG. 14), each stage allowing for an
increase in the flow rate and/or the pressure pumped. The first
pump 206a may be a pressure-balanced pump, so as to reduce the
torque loading on the first pump 206a, 206b. In one non-limiting
example of a pressure-balanced pump, a twelve stage pump may
include a fluid inlet or suction port, such that when the fluid
enters the fluid inlet or suction port, the fluid is flowed to
stages 1-6. Before entering stages 7-12, the fluid may redirect
around stages 7-12 and enter stage 12, followed by stage 11, stage
10, stage 9, stage 8, and stage 7, in that order, and discharge the
fluid proximate to where the fluid inlet or suction port is
located. Such an arrangement may create a more pressure load
balanced pump, such that the torque from operation of the pumps is
reduced. The reduced torque means that the system is not required
to withstand high torques, leading to reduced design and
maintenance costs. The first pump 206a may be configured to pump
fluid at a flow rate as low as 1.5 bpm or as low as 2.5 bpm or as
low as 3.5 bpm. The first pump 206a may be configured to pump fluid
at a flow rate of up to 25 bpm, up to 30 bpm, up to 40 bpm, up to
50 bpm, up to 60 bpm, up to 70 bpm, or up to 80 bpm. The first pump
206a may be configured to pump fluid at a flow rate of from 1.5-30
bpm, such as 2.5-30 bpm or from 1.5-60 bpm, such as from 2.5-60
bpm. The first pump 206a may be configured to pump fluid at a
pressure of 15,000 psi or greater, such as 16,000 psi or greater,
or 20,000 psi or greater.
[0107] The inclusion of the first pump 206a as a multi-stage
centrifugal injection pump in combination with the positive
displacement second pump 208 (described hereinafter) allows for
costs of including a multiple high-cost pressure displacement pumps
capable of operating at relatively higher flow rates (those flow
rates associated with the first pump 206a ) to be avoided.
[0108] The plurality of pumps 206a, 206b, 208, 218 may include at
least one second pump 208. In the non-limiting example of the
mobile pump system 200 shown in FIGS. 12 and 13, one second pump
208 is included; however, the mobile pump system 200 may include
multiple second pumps. The second pump 208 may be a positive
displacement pump. The positive displacement pump may be a
reciprocating triplex or quintuplex pump (non-limiting examples of
which are shown in FIGS. 15 and 17). The second pump 208 may be
configured to pump fluid at a flow rate as low as 0.1 bpm. The
second pump 208 may be configured to pump fluid at a flow rate at
or below 2.5 bpm or below 1.5 bpm. The second pump 208 may be
configured to pump fluid at a flow rate of from 0.1-2.5 bpm or from
0.1-1.5 bpm. The second pump 208 may be configured to pump fluid at
a pressure of up to 15,000 psi.
[0109] The first pump 206a may have a higher flow rate capability
and/or a higher pumping pressure capability compared to the second
pump 208. The second pump 208 may have a lower flow rate capability
and/or a lower pumping pressure capability compared to the first
pump 206a . The flow rate capability and/or the pumping pressure
capability of the first pump 206a and the second pump 208 may
include an overlap. The first set point and/or the second set point
(described hereinafter) may fall within the overlap.
[0110] With continued reference to FIGS. 12 and 13, the turbine
and/or the natural gas fired reciprocating engine 204 may be
directly coupled to the first pump 206a, 206b and/or the second
pump 208. In some non-limiting examples, the turbine and/or the
natural gas fired reciprocating engine 204 may be directly coupled
to the first pump 206a, 206b. The turbine and/or the natural gas
fired reciprocating engine 204 may be directly coupled to the first
pump 206a, 206b and/or the second pump 208 by a non-variable fixed
ratio direct-coupled connection. The turbine and/or the natural gas
fired reciprocating engine 204 may be directly coupled to the first
pump 206a, 206b and/or the second pump 208 by a direct-coupled gear
connection including a speed reducer 210. The direct coupling
eliminates the need for a transmission, thus eliminating moving
parts that may require maintenance or result in additional
operating costs. In some non-limiting examples, the turbine and/or
the natural gas fired reciprocating engine 204 is connected to the
speed reducer 210, which is connected to a plurality of first pumps
206a, 206b. The turbine and/or the natural gas fired reciprocating
engine 204 may be powered using field gas, such that the mobile
pump system 200 has a lower carbon footprint compared to systems
using diesel engines, for example. The use of a turbine and/or
natural gas fired reciprocating engine 204 on the mobile pump
system 200 (as opposed to, for example, a diesel engine) allows the
mobile pump system 200 to operate at lower decibels. The mobile
pump system 200, when in operation, may emit less than 85 decibels,
less than 80 decibels, less than 75 decibels, less than 70
decibels, or less than 65 decibels (compared to the at least 115
decibels emitted by certain existing systems utilizing a diesel
engine.)
[0111] With continued reference to FIGS. 12 and 13, the mobile pump
system 200 may include an electric motor 212. The electric motor
212 may be in electrical communication with the turbine and/or the
natural gas fired reciprocating engine 204, such that that the
turbine and/or the natural gas fired reciprocating engine 204
provides electrical energy to the electric motor 212. The electric
motor 212 may be connected to the second pump 208 to power the
second pump 208.
[0112] With continued reference to FIGS. 12 and 13, the mobile pump
system 200 may include a fluid storage tank mounted on the trailer
202, and the fluid storage tank may be filled with a fluid to be
pumped by the mobile pumping system 200. In some non-limiting
examples, a fluid storage tank may be positioned at the site off of
the trailer 202, in addition to or in lieu of the fluid storage
tank mounted on the trailer 202.
[0113] The mobile pump system 200 may include a third pump 218
mounted on the trailer 202. The third pump 218 may be in fluid
communication with at least one of the fluid storage tank, the
first pump 206a, 206b, and the second pump 208 by the conduit 214.
The third pump 218 may be configured to pump fluid from the fluid
storage tank to at least one of the first pump 206a, 206b and the
second pump 208. The third pump 218 may be a volute-type
centrifugal pump and may pump fluid from the at least one of the
fluid storage tank to the first pump 206a, 206b and/or the second
pump 208 by the conduit 214 at a flow rate of from 0-3.5 bpm, such
as 0-2.5 bpm and at a pressure of up to 15,000 psi.
[0114] With continued reference to FIGS. 12 and 13, the mobile pump
system 200 may include a control system 216 comprising at least one
processor programmed or configured to control at least one of the
components of the mobile pump system 200 (and may be in electrical
communication therewith). The control system 216 may receive input
data from a user, such as via a graphical user interface, or may
collect data from other sources, such at least one pressure sensor,
flow sensor, temperature sensor, and the like, to communicate
instructions to the components of the mobile pump system 200 (e.g.,
the first pump 206a, 206b, the second pump 208, and/or the turbine
and/or the natural gas fired reciprocating engine 204). The control
system 216 may communicate with the components of the mobile pump
system 200 to control, for example, a rotational speed of the
turbine and/or the natural gas fired reciprocating engine 204, a
flow rate of the first pump 206a, 206b and/or the second pump 208,
and a pumping pressure of the first pump 206a, 206b and/or the
second pump 208. The control system 216 may use an advanced control
algorithm to generate instructions to control the components of the
mobile pump system 200. The advanced control algorithm may consider
at least one of the following: pump properties, fluid properties,
on-site atmospheric properties, and the like, to enable the control
system 216 to generate the instructions to control the components
of the mobile pump system 200.
[0115] The control system 216 may include an electronic governor
configured to control at least one of the rotational speed of the
turbine and/or the natural gas fired reciprocating engine 204, the
flow rate of the first pump 206a, 206b and/or the second pump 208,
and the pumping pressure of the first pump 206a, 206b and/or the
second pump 208. The control system 216 may communicate the
instructions for the components of the mobile pump system 200 to
the electronic governor to cause the electronic governor to
communicate with the components to cause the instructions to be
effected by the components. The control system 216 enables the
mobile pump system 200 to control small incremental adjustments in
the rotational speed of the turbine and/or the natural gas fired
reciprocating engine 204, the flow rate of the first pump 206a,
206b and/or the second pump 208, and the pumping pressure of the
first pump 206a, 206b and/or the second pump 208 without
transmission or gear-based controls, which lack the capability for
the highly precise controls of the mobile pump system 200.
[0116] The control system 216 may receive set point data from a
user that specifies a desired a rotational speed of the turbine
and/or the natural gas fired reciprocating engine 204, a flow rate
of the first pump 206a, 206b and/or the second pump 208, and/or a
pumping pressure of the first pump 206a, 206b and/or the second
pump 208, such as by the user entering the set point data into a
graphical user interface. Based on the user specifying a desired
rotational speed of the turbine and/or the natural gas fired
reciprocating engine 204, the control system 216 may automatically
generate instructions (based on the advanced control algorithm, for
example) to cause the first pump 206a, 206b and/or the second pump
208 to operate at a flow rate and/or a pumping pressure, such that
the desired rotational speed may be changed or maintained. Based on
the user specifying a flow rate of the first pump 206a, 206b and/or
the second pump 208, the control system 216 may automatically
generate instructions (based on the advanced control algorithm, for
example) to cause the first pump 206a, 206b and/or the second pump
208 to operate at a pumping pressure and/or the turbine and/or the
natural gas fired reciprocating engine 204 to operate a rotational
speed, such that the desired flow rate may be maintained. Based on
the user specifying a pumping pressure of the first pump 206a, 206b
and/or the second pump 208, the control system 216 may
automatically generate instructions (based on the advanced control
algorithm, for example) to cause the first pump 206a, 206b and/or
the second pump 208 to operate at a flow rate and/or the turbine
and/or the natural gas fired reciprocating engine 204 to operate a
rotational speed, such that the desired pumping pressure may be
maintained. Therefore, a deviation of the actual data value from
the set point data value may cause the control system 216 to
generate instructions to the relevant components to cause the
components of the mobile pump system 200 to automatically adjust to
return to the set point value.
[0117] The control system 216 may be configured to communicate
(e.g., via the electronic governor) with the turbine and/or the
natural gas fired reciprocating engine 204 to control the
rotational speed of the turbine and/or the natural gas fired
reciprocating engine 204. The control system 216 may adjust the
rotational speed of the turbine and/or the natural gas fired
reciprocating engine 204 by an incremental amount as low as the rpm
required to change the flow rate by 0.1 bpm.
[0118] The control system 216 may be configured to communicate
(e.g., via the electronic governor) with the first pump 206a, 206b
and/or the second pump 208 to control the flow rate thereof. The
control system 216 may adjust the flow rate of the first pump 206a,
206b and/or the second pump 208 by an incremental value as low as
0.1 bpm. In some non-limiting examples, the control system 216 may
automatically adjust the flow rate of the first pump 206a, 206b
and/or the second pump 208 to reach or maintain a pressure pumping
set point value specified by the user for the first pump 206a, 206b
and/or the second pump 208.
[0119] The control system 216 may be configured to communicate
(e.g., via the electronic governor) with the first pump 206a, 206b
and/or the second pump 208 to control the pumping pressure thereof.
In some non-limiting examples, the control system 216 may
automatically adjust the pumping pressure of the first pump 206a,
206b and/or the second pump 208 to reach or maintain a flow rate
set point value specified by the user for the first pump 206a, 206b
and/or the second pump 208.
[0120] With continued reference to FIGS. 12 and 13, the control
system 216 may be configured to perform a "hand-off" operation. The
hand-off operation may include the control system 216 being
configured to activate the second pump 208, with the first pump
206a, 206b deactivated, with a flow rate of the mobile pump system
200 below a first set point to cause the second pump 208 to pump a
pumping fluid from the fluid storage tank to the outlet. The
control system 216 may be configured to, in response to the flow
rate of the mobile pump system 200 reaching the first set point,
activate the first pump 206a, 206b to cause the first pump 206a,
206b to pump the pumping fluid. The control system 216 may be
configured to deactivate the second pump 208, with the first pump
206a, 206b still activated, in response to the flow rate of the
mobile pump system 200 reaching a second set point, with the second
set point greater than or equal to the first set point. In some
non-limiting examples, the control system 216 may cause the pumping
fluid to be pumped to the outlet by the second pump 208 and not the
first pump 206a, 206b with the flow rate of the mobile pump system
200 below the first set point, and the pumping fluid to be pumped
to the outlet by the first pump 206a, 206b and optionally the
second pump 208 with the flow rate of the mobile pump system at or
above the first set point.
[0121] In one non-limiting illustrative example, the mobile pump
system 200 may initially be deactivated, having a flow rate
associated therewith of 0 bpm. The mobile pump system 200 may be
activated to begin pumping the pumping fluid, and the control
system 216 may activate the second pump 208 to begin the pumping
application. The second pump 208 may pump the pumping fluid with
the first pump 206a, 206b deactivated at lower flow rates (below
the first set point and/or below the minimum flow rate pumping
capability of the first pump 206a, 206b). Thus, the third pump 218
may flow the pumping fluid from the fluid storage tank to the
second pump 208 when the flow rate of the mobile pump system 200 is
below the first set point, such that the second pump 208 moves the
pumping fluid to the outlet. Upon the flow rate of the mobile pump
system 200 reaching the first set point, the control system 216 may
activate the first pump 206a, 206b to cause the first pump 206a,
206b to pump pumping fluid. Thus, the third pump 218 may flow the
pumping fluid from the fluid storage tank to the first pump 206a,
206b when the flow rate of the mobile pump system 200 reaches the
first set point, such that the first pump 206a, 206b moves the
pumping fluid to the outlet. At a second set point equal to or
higher than the first set point, the control system 216 may
deactivate the second pump 208 so that only the first pump 206a,
206b (of the first 206a, 206b and second pumps 208) is moving
pumping fluid to the outlet. The first pump 206a, 206b may pump the
pumping fluid at a flow rate above the capabilities of the second
pump 208. In some non-limiting examples, the first set point is
equal to the second set point, such that as the control system 216
activates the first pump 206a, 206b, the second pump 208 is
deactivated (at the same set point). In some non-limiting examples,
the second set point is higher than the first set point such as
between the first set point and the second set point, the first
pump 206a, 206b and the second pump 208 work in tandem to flow
pumping fluid to the outlet.
[0122] With continued reference to FIGS. 12 and 13, the control
system 216 may be configured to initiate a start-up protocol to run
the mobile pump system 200. The start-up protocol may include the
control system 216 causing the second pump 208 to be activated,
while the first pump 206a, 206b remains deactivated, until a flow
rate effected by the mobile pump system 200 is at least 1.5 bpm.
The control system 216 may be configured to activate the first pump
206a, 206b, while the second pump 208 is still activated, once the
flow rate effected by the mobile pump system 200 is at a first set
point. The first set point may be at least 1.5 bpm, such as at
least 2.5 bpm. The first set point may range from 1.5-3.5 bpm, such
as from 1.5-2.5 bpm or 2.5-3.5 bpm. Further, the control system 216
may be configured to deactivate the second pump 208, while the
first pump 206a, 206b is still activated, once the flow rate
effected by the mobile pump system is at a second set point. The
second set point may range from 1.5-3.5 bpm, such as from 1.5-2.5
bpm. The second set point may be equal to or higher than the first
set point. The flow rate associated with the second pump 208 may be
phased out as the flow rate associated with the first pump 206a,
206b increases.
[0123] As illustrated by the above-described operation of the
control system 216 controlling activation and deactivation of the
first pump 206a, 206b and the second pump 208, the mobile pump
system 200 has been designed to handle ancillary pressure pumping
applications associated with hydraulic fracturing, which often
require the full range of low rate/high pressure pumping
applications to high rate/high pressure pumping applications. The
combination of the first pump 206a, 206b and the second pump 208 on
the mobile pump system 200 enables these pumping parameters to be
achieved using a mobile system with lower capital costs. Further,
the above-described activation and deactivation of the first pump
206a, 208 and the second pump 208 (e.g., in the operating order
described) allows for the second pump 208 capable of operating at
lower flow rates to hand-off the pumping application to the first
pump 206a, 206b, which is capable of operating at higher flow
rates.
[0124] The utilization of the first pump 206a, 206b in the mobile
pump system 200, which may be a multi-stage centrifugal injection
pump, at pump rates above 1.5 bpm, such as above 2.5 bpm, above 3.5
bpm, or above 5 bpm allows for fracture propagation to occur more
efficiently compared to a pumping system only including a positive
displacement pump. The multi-stage centrifugal injection pump
allows for an almost instantaneous response to formation breakdown
and is capable of increasing flow rate relatively more seamlessly
to achieve a target pressure. Thus the combination of the first
pump 206a, 206b with the second pump 208 of a different style on
the trailer 202 allow for the pump more suitable for the particular
pumping application (or stage thereof) to be seamlessly used on the
mobile pumping system 200.
[0125] The mobile pump system 200 may include a fuel buffering
system, which may be positioned to remove undesired liquids,
solids, and other debris from the chamber of the turbine 204 and/or
the natural gas fired reciprocating engine and/or to prevent such
products from entering the chamber of the turbine and/or the
natural gas fired reciprocating engine 204.
[0126] The turbine and/or natural gas fired reciprocating engine
204 may generate excess power, in excess of the power needed to
power the mobile pump system 200, such that the excess power may be
transferred to other on-site locations to power other on-site
components. For example, the excess power may be directed to other
on-site needs, such as wireline needs, water transfer needs, and
the like. The turbine 204 may include a shaft on a side opposing
the side of the mobile pump system 200 which may rotate a standard
electric motor and/or generator and send the excess power (at a
specified wattage) through a cable to the other on-site components
to provide the necessary power requirement.
[0127] The mobile pump system 200, may be positioned on a pump site
to perform a pressure pumping application thereon. The pressure
pumping application may be an oil/gas-field or
non-oil/gas-field-related application.
[0128] The mobile pump system 200 positioned on a pump site may be
used to perform the previously-described "plug-and-perf" method in
which a plug is positioned in a lateral of a wellbore using the
fluid pumped into the wellbore by the mobile pump system 200.
[0129] The mobile pump system 200 positioned on a pump site may be
used to perform a toe prep application. Toe prep applications
prepare the well for the commencement of fracture stimulation
operations. Toe preps involve establishing an initial pathway for
fracture propagation into the reservoir from the well, thereby
allowing fluid communication from inside the wellbore into the
target formation. Toe preps may involve shifting casing sleeves
through building pressure using fluid pumped by the mobile pump
system 200 to provide the pathway for fluid to exit the casing into
the formation. Toe preps may also involve tubing-conveyed
perforating (TCP) and other wireline conveyed perforating, for
example, in conjunction with the fluid pumped by the mobile pump
system 200. Injection tests, like Diagnostic Fracture Injection
Tests (DFIT), are commonly performed at the beginning of fracture
stimulation operations and can be designed for low-rate/high
pressure and/or high-rate/high pressure through the range of
capabilities of the mobile pump system 200.
[0130] The mobile pump system 200 may be positioned at an
agricultural site to move water or other fluid for an agricultural
application. The mobile pump system 200 may be positioned at a
mining site to move water or other fluid for a mining application,
such as dewatering and or supplying water in coal and/or precious
metal mining operations.
[0131] The mobile pump system 200 positioned on a pump site may be
used to perform a drill-out application. Drill-out applications are
performed after a well is fracture stimulated. During multi-stage
fracture stimulation operations, plugs are placed in the lateral
for zonal isolation prior to the performance of additional fracture
stimulation stages. Typically plugs are spaced 150 ft to 300 ft
apart in a wellbore but are not limited to those distances. At a
time after fracture stimulations have been completed, these plugs
are drilled out. A bit or mill is commonly placed at the end of a
tubing string or coiled tubing, for instance, and is rotated to
drill up each plug in succession. During drill-out operations,
fluid may be circulated to keep the wellbore clean and to carry
cuttings and debris out of the wellbore. This fluid is circulated
by the mobile pump system 200 at potentially very low rates, such
as 1-2 bpm (or lower), and higher rates, such as 8-9 bpm (or
higher), depending on tubing and casing sizes, for instance, or
condition of the well as regards sand from fracture stimulation
operations and debris.
[0132] The mobile pump system 200 positioned on a pump site may be
used to perform an industrial purging application. In industrial
purging, piping associated with plant or factory operations, for
instance, may require treatments that can include flushing debris,
cleansing the system, or clearing blockages utilizing a fluid
pumped by the mobile pump system 200.
[0133] The mobile pump system 200 positioned on a pump site may be
used to perform a pipeline pressure testing application. Before
pipelines are placed into service, pipeline pressure testing
operations are utilized to assure that the system safely meets the
maximum allowable operating pressures (MAOP). Additionally,
pipelines are tested at regular intervals to assure safe operations
with regard to pressure. Fluid is pumped into the pipeline(s) by
the mobile pump system 200 and held at a designated pressure for a
determined period of time. The mobile pump system's 200 precise
controls can achieve designed pressures more accurately than
conventional pumps, as in those involving diesel engines and
transmissions.
[0134] The mobile pump system 200 positioned on a pump site may be
used to perform a hydro-blasting application. Whereas sand blasting
and dry blasting introduces particulate matter into the air,
hydro-blasting utilizes no abrasives but utilizes fluid pressure
(as in pressure washing) instead. Fluid pumped at a variety of
pressures by the mobile pump system 200 with its precise controls
can be utilized in a variety of applications, such as stripping old
paint from metal surfaces, for example.
[0135] The mobile pump system 200 may perform a pressure pumping
application by activating the second pump 208, with the first pump
206a, 206b deactivated, until a flow rate effected by the mobile
pump system 200 is at least 1.5 bpm; and activating the first pump
206a, 206b, while the second pump 208 is still activated, once the
flow rate effected by the mobile pump system 200 is at a first set
point, the first set point being at least 1.5 bpm. Performing the
pressure pumping application may further include deactivating the
second pump 208, while the first pump 206a, 206b is still
activated, once the flow rate effected by the mobile pump system
200 is at a second set point, the second set point being equal to
or higher than the first set point.
[0136] Although the invention has been described in detail for the
purpose of illustration based on what is currently considered to be
the most practical and preferred embodiments, it is to be
understood that such detail is solely for that purpose and that the
invention is not limited to the disclosed embodiments, but, on the
contrary, is intended to cover modifications and equivalent
arrangements that are within the spirit and scope of the appended
claims. For example, it is to be understood that the present
invention contemplates that, to the extent possible, one or more
features of any embodiment can be combined with one or more
features of any other embodiment.
* * * * *