U.S. patent number RE49,140 [Application Number 17/221,176] was granted by the patent office on 2022-07-19 for methods of performing well treatment operations using field gas.
This patent grant is currently assigned to Halliburton Energy Services, Inc.. The grantee listed for this patent is Halliburton Energy Services, Inc.. Invention is credited to Leonard R. Case, Ed B. Hagan, Ron Hyden, Calvin L. Stegemoeller.
United States Patent |
RE49,140 |
Case , et al. |
July 19, 2022 |
Methods of performing well treatment operations using field gas
Abstract
Methods and systems for integral storage and blending of the
materials used in oilfield operations are disclosed. A modular
integrated material blending and storage system includes a first
module comprising a storage unit, a second module comprising a
liquid additive storage unit and a pump for maintaining pressure at
an outlet of the liquid additive storage unit. The system further
includes a third module comprising a pre-gel blender. An output of
each of the first module, the second module and the third module is
located above a blender and gravity directs the contents of the
first module, the second module and the third module to the
blender. The system also includes a pump that directs the output of
the blender to a desired down hole location. The pump may be
powered by natural gas or electricity.
Inventors: |
Case; Leonard R. (Duncan,
OK), Hagan; Ed B. (Hastings, OK), Stegemoeller; Calvin
L. (Duncan, OK), Hyden; Ron (Spring, TX) |
Applicant: |
Name |
City |
State |
Country |
Type |
Halliburton Energy Services, Inc. |
Houston |
TX |
US |
|
|
Assignee: |
Halliburton Energy Services,
Inc. (Houston, TX)
|
Family
ID: |
1000006343206 |
Appl.
No.: |
17/221,176 |
Filed: |
April 2, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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16537070 |
Aug 9, 2019 |
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15853076 |
Nov 5, 2019 |
RE47695 |
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15079027 |
Feb 20, 2018 |
RE46725 |
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12557730 |
May 12, 2013 |
8444312 |
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16537124 |
Aug 9, 2019 |
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Reissue of: |
12774959 |
May 6, 2010 |
8834012 |
Sep 16, 2014 |
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Reissue of: |
12774959 |
May 6, 2010 |
8834012 |
Sep 16, 2014 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E21B
21/062 (20130101); E21B 21/062 (20130101) |
Current International
Class: |
E21B
21/06 (20060101) |
Field of
Search: |
;366/141,181.8,183.1,154.1 |
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Jul 1994 |
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EP |
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Jul 1994 |
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EP |
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2474335 |
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Jul 1981 |
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FR |
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2474335 |
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FR |
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Sep 1994 |
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WO |
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WO |
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May 2009 |
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WO |
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WO2011/150486 |
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Dec 2011 |
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WO |
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|
Primary Examiner: Doerrler; William C
Attorney, Agent or Firm: Wustenberg; John Baker Botts
L.L.P.
Parent Case Text
.Iadd.Notice: More than one reissue application has been filed for
the reissue of U.S. Pat. No. 8,834,012. The reissue applications
are U.S. patent application Ser. No. 15/079,027, now U.S. Pat. No.
RE46,725, which is a reissue application of U.S. Pat. No.
8,834,012; U.S. patent application Ser. No. 15/853,076, now U.S.
Pat. No. RE47,695, which is a reissue of U.S. Pat. No. 8,834,012
and is a divisional reissue application of U.S. patent application
Ser. No. 15/079,027, now U.S. Pat. No. RE46,725; U.S. patent
application Ser. No. 16/537,070, which is a continuation reissue
application of U.S. patent application Ser. No. 15/853,076, now
U.S. Pat. No. RE47,695, and a reissue of U.S. Pat. No. 8,834,012;
U.S. patent application Ser. No. 16/537,124, which is a
continuation reissue application of U.S. patent application Ser.
No. 15/853,076, now U.S. Pat. No. RE47,695, and a reissue of U.S.
Pat. No. 8,834,012; the present U.S. patent application Ser. No.
17/221,176, which is a continuation reissue application of U.S.
patent application Ser. Nos. 16/537,070 and 16/537,124 and a
reissue of U.S. Pat. No. 8,834,012; and the following co-pending
U.S. patent application Ser. Nos. 17/221,152, 17/221,186,
17/221,204, 17/221,221, 17/221,242, 17/221,267, 17/221,281,
17/221,317, 17/352,956, and 17/353,091, each of which is a
continuation reissue application of U.S. patent application Ser.
Nos. 16/537,070 and 16/537,124 and a reissue of U.S. Pat. No.
8,834,012. .Iaddend.
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a .Iadd.continuation reissue of U.S. patent
application Ser. No. 16/537,070 and U.S. patent application Ser.
No. 16/537,124, both filed on Aug. 9, 2019, which are reissue
applications of U.S. Pat. No. 8,834,012 and continuation reissue
applications of U.S. patent application Ser. No. 15/853,076, filed
on Dec. 22, 2017, now U.S. Pat. No. RE47,695, which is a reissue of
U.S. Pat. No. 8,834,012 and a divisional reissue application of
U.S. patent application Ser. No. 15/079,027, filed on Mar. 23,
2016, now U.S. Pat. No. RE46,725, which is a reissue of U.S. patent
application Ser. No. 12/744,959, filed on May 6, 2010, now U.S.
Pat. No. 8,834,012, issued on Sep. 16, 2014, entitled "Electric or
Natural Gas Fired Small Footprint Fracturing Fluid Blending and
Pumping Equipment," which is a .Iaddend.continuation-in-part of
U.S. patent application Ser. No. 12/557,730, filed Sep. 11, 2009,
now U.S. Pat. No. 8,444,312, issued on May 21, 2013, entitled
"Improved Methods and Systems for Integral Blending and Storage of
Materials," the entire disclosures of which are incorporated herein
by reference.
Claims
What is claimed is:
.[.1. An integrated material blending and storage system
comprising: a storage unit; a blender located under the storage
unit; wherein the blender is operable to receive a first input from
the storage unit through a hopper; a liquid additive storage module
having a first pump to maintain constant pressure at an outlet of
the liquid additive storage module; wherein the blender is operable
to receive a second input from the liquid additive storage module;
and a pre-gel blender, wherein the pre-gel blender comprises at
least a pre-gel storage unit resting on a leg, further wherein the
pre-gel storage unit comprises a central core and an annular space,
wherein the annular space hydrates the contents of the pre-gel
blender; wherein the blender is operable to receive a third input
from the pre-gel blender; wherein gravity directs the contents of
the storage unit, the liquid additive storage module and the
pre-gel blender to the blender; a second pump; and a third pump;
wherein the second pump directs the contents of the blender to the
third pump; and wherein the third pump directs the contents of the
blender down hole; wherein at least one of the second pump and the
third pump is powered by one of natural gas and electricity..].
.[.2. The system of claim 1, wherein the storage unit comprises a
load sensor..].
.[.3. The system of claim 1, wherein the pre-gel blender comprises:
a feeder coupling the pre-gel storage unit to a first input of a
mixer; a fourth pump coupled to a second input of the mixer;
wherein the pre-gel storage unit contains a solid component of a
well treatment fluid; wherein the feeder supplies the solid
component of the well treatment fluid to the mixer; wherein the
fourth pump supplies a fluid component of the well treatment fluid
to the mixer; and wherein the mixer outputs a well treatment
fluid..].
.[.4. The system of claim 3, wherein the well treatment fluid is a
gelled fracturing fluid..].
.[.5. The system of claim 4, wherein the solid component is a gel
powder..].
.[.6. The system of claim 4, wherein the fluid component is
water..].
.[.7. The system of claim 3, wherein the central core contains the
solid component of the well treatment fluid..].
.[.8. The system of claim 3, wherein the well treatment fluid is
directed to the annular space..].
.[.9. The system of claim 3, wherein the annular space comprises a
tubular hydration loop..].
.[.10. The system of claim 9, wherein the well treatment fluid is
directed from the mixer to the tubular hydration loop..].
.[.11. The system of claim 3, wherein the well treatment fluid is
selected from the group consisting of a fracturing fluid and a sand
control fluid..].
.[.12. The system of claim 3, further comprising a power source to
power at least one of the feeder, the mixer and the pump..].
.[.13. The system of claim 12, wherein the power source is selected
from the group consisting of a combustion engine, an electric power
supply and a hydraulic power supply..].
.[.14. The system of claim 13, wherein one of the combustion
engine, the electric power supply and the hydraulic power supply is
powered by natural gas..].
.[.15. The system of claim 1, further comprising a load sensor
coupled to one of the storage unit, the liquid additive storage
module or the pre-gel blender..].
.[.16. The system of claim 15, further comprising an information
handling system communicatively coupled to the load sensor..].
.[.17. The system of claim 15, wherein the load sensor is a load
cell..].
.[.18. The system of claim 15, wherein a reading of the load sensor
is used for quality control..].
.[.19. The system of claim 1, wherein the electricity is derived
from one of a power grid and a natural gas generator set..].
.[.20. A modular integrated material blending and storage system
comprising: a first module comprising a storage unit; a second
module comprising a liquid additive storage unit and a first pump
for maintaining pressure at an outlet of the liquid additive
storage unit; and a third module comprising a pre-gel blender,
wherein the pre-gel blender comprises at least a pre-gel storage
unit resting on a leg, further wherein the pre-gel storage unit
comprises a central core and an annular space, wherein the annular
space hydrates the contents of the pre-gel blender; wherein an
output of each of the first module, the second module and the third
module is located above a blender; and wherein gravity directs the
contents of the first module through a hopper, the second module
and the third module to the blender; a second pump; wherein the
second pump directs the output of the blender to a desired down
hole location; and wherein the second pump is powered by one of
natural gas and electricity..].
.[.21. The system of claim 20, wherein each of the first module,
the second module and the third module is a self erecting
module..].
.[.22. The system of claim 20, wherein the third module comprises:
a feeder coupling the pre-gel storage unit to a first input of a
mixer; a third pump coupled to a second input of the mixer; wherein
the pre-gel storage unit contains a solid component of a well
treatment fluid; wherein the feeder supplies the solid component of
the well treatment fluid to the mixer; wherein the third pump
supplies a fluid component of the well treatment fluid to the
mixer; and wherein the mixer outputs a well treatment fluid..].
.[.23. The system of claim 22, wherein the well treatment fluid is
directed to the blender..].
.[.24. The system of claim 20, wherein the blender mixes the output
of the first module, the second module and the third module..].
.[.25. The system of claim 20, further comprising a fourth pump for
pumping an output of the blender down hole..].
.[.26. The system of claim 25, wherein the fourth pump is selected
from the group consisting of a centrifugal pump, a progressive
cavity pump, a gear pump and a peristaltic pump..].
.Iadd.27. A method of performing a fracturing operation comprising:
using a blender to prepare a fracturing fluid comprising a liquid
and a solid material; transferring the fracturing fluid from the
blender to at least one pump; pumping the fracturing fluid into a
down hole location using the at least one pump; and powering the at
least one pump with only one or both of: (a) one or more generators
using only conditioned field gas, or (b) one or more engines using
conditioned field gas and without using diesel. .Iaddend.
.Iadd.28. The method of claim 27, wherein the solid material is
transferred from a storage unit to the blender using at least
gravity. .Iaddend.
.Iadd.29. The method of claim 27, wherein the solid material is
sand or proppant. .Iaddend.
.Iadd.30. The method of claim 27, wherein the blender is powered
using electricity. .Iaddend.
.Iadd.31. The method of claim 28, wherein the storage unit is
supported by a plurality of legs. .Iaddend.
.Iadd.32. The method of claim 28, further comprising using one or
more load sensors to monitor a change in weight, mass and/or volume
of the solid materials in the storage unit. .Iaddend.
.Iadd.33. The method of claim 27, wherein the fracturing fluid
further comprises a liquid additive transferred to the blender
using at least gravity. .Iaddend.
.Iadd.34. The method of claim 27, further comprising using a
transfer pump to transfer the fracturing fluid from the blender to
the at least one pump. .Iaddend.
.Iadd.35. The method of claim 28, further comprising monitoring a
change in weight, mass and/or volume of the solid material in the
storage unit. .Iaddend.
.Iadd.36. The method of claim 27, further comprising using a
pre-gel blender and pre-gel storage unit for hydrating materials
used in the fracturing fluid. .Iaddend.
.Iadd.37. The method of claim 28, further comprising providing an
alert when the solid material in the storage unit reaches a
threshold level. .Iaddend.
.Iadd.38. A method of performing a fracturing operation comprising:
using a blender to prepare a fracturing fluid comprising a solid
material and a liquid; transferring the fracturing fluid from the
blender to at least one pump; pumping the fracturing fluid into a
down hole location using the at least one pump; and powering the
blender and the at least one pump with only one or both of: (a) one
or more generators using only conditioned field gas, or (b) one or
more engines using conditioned field gas and without using diesel.
.Iaddend.
.Iadd.39. A method of performing a fracturing operation comprising:
using a blender to prepare a fracturing fluid comprising a liquid
and a solid material; transferring the fracturing fluid from the
blender to at least one pump; pumping the fracturing fluid into a
down hole location using the at least one pump; and powering the at
least one pump with only one or more generators using only
conditioned field gas obtained from a field on which the fracturing
operation is being performed. .Iaddend.
.Iadd.40. The method of claim 28, wherein the solid material is
transferred from the storage unit to the blender using at least
gravity and without a conveyor. .Iaddend.
.Iadd.41. The method of claim 38, wherein only the one or more
generators using only conditioned field gas is used to power the
blender and the at least one pump. .Iaddend.
.Iadd.42. The method of claim 41, wherein the conditioned field gas
is compressed. .Iaddend.
.Iadd.43. The method of claim 38, wherein the solid material is
transferred from a storage unit to the blender using at least
gravity and without a conveyor. .Iaddend.
.Iadd.44. The method of claim 38, further comprising using one or
more load sensors to monitor a change in weight, mass and/or volume
of the solid materials in a storage unit. .Iaddend.
.Iadd.45. The method of claim 38, wherein the solid material is
sand or proppant. .Iaddend.
.Iadd.46. The method of claim 39, wherein the solid material is
transferred from a storage unit to the blender without a conveyor.
.Iaddend.
.Iadd.47. The method of claim 39, further comprising powering the
blender with only the one or more generators using only conditioned
field gas obtained from a field on which the fracturing operation
is being performed. .Iaddend.
.Iadd.48. The method of claim 39, wherein the solid material is
sand or proppant. .Iaddend.
Description
BACKGROUND
The present invention relates generally to oilfield operations, and
more particularly, to methods and systems for integral storage and
blending of the materials used in oilfield operations.
Oilfield operations are conducted in a variety of different
locations and involve a number of equipments, depending on the
operations at hand. The requisite materials for the different
operations are often hauled to and stored at the well site where
the operations are to be performed.
Considering the number of equipments necessary for performing
oilfield operations and ground conditions at different oilfield
locations, space availability is often a constraint. For instance,
in well treatment operations such as fracturing operations, several
wells may be serviced from a common jobsite pad. In such
operations, the necessary equipment is not moved from well site to
well site. Instead, the equipment may be located at a central work
pad and the required treating fluids may be pumped to the different
well sites from this central location. Accordingly, the bulk of
materials required at a centralized work pad may be enormous,
further limiting space availability.
Typically, in modem well treatment operations, equipment is mounted
on a truck or a trailer and brought to location and set up. The
storage units used are filled with the material required to prepare
the well treatment fluid and perform the well treatment. In order
to prepare the well treatment fluid, the material used is then
transferred from the storage units to one or more blenders to
prepare the desired well treatment fluid which may then be pumped
down hole.
For instance, in conventional fracturing operations a blender and a
pre-gel blender are set between the high pressure pumping units and
the storage units which contain the dry materials and chemicals
used. The dry materials and the chemicals used in the fracturing
operations are then transferred, often over a long distance, from
the storage units to the mixing and blending equipments. Once the
treating process is initiated, the solid materials and chemicals
are typically conveyed to the blender by a combination of conveyer
belts, screw type conveyers and a series of hoses and pumps.
The equipment used for transferring the dry materials and chemicals
from the storage units to the blender occupy valuable space at the
job site. Additionally, the transfer of dry materials and chemicals
to the blender consumes a significant amount of energy as well as
other system resources and contributes to the carbon foot print of
the job site. Moreover, in typical "on land" operations the entire
equipment spread including the high horsepower pumping units are
powered by diesel fired engines and the bulk material metering,
conveying and pumping is done with diesel fired hydraulic systems.
Emissions from the equipment that is powered by diesel fuel
contributes to the overall carbon footprint and adversely affects
the environment.
FIGURES
Some specific example embodiments of the disclosure may be
understood by referring, in part, to the following description and
the accompanying drawings.
FIG. 1 is a top view of an Integrated Material Storage and Blending
System in accordance with an exemplary embodiment of the present
invention.
FIG. 2 is a cross sectional view of an Integrated Pre-gel Blender
in accordance with a first exemplary embodiment of the present
invention.
FIG. 3 is a cross sectional view of an Integrated Pre-gel Blender
in accordance with a second exemplary embodiment of the present
invention.
FIG. 4 is a cross sectional view of an Integrated Pre-gel Blender
in accordance with a third exemplary embodiment of the present
invention.
FIG. 5 depicts a close up view of the interface between the storage
units and a blender in an Integrated Material Storage and Blending
System in accordance with an exemplary embodiment of the present
invention.
FIG. 6 is an isometric view of an Integrated Material Storage and
Blending System in accordance with an exemplary embodiment of the
present invention.
.Iadd.FIG. 7 is a diagram illustrating a pumping system in
accordance with an exemplary embodiment of the present invention.
.Iaddend.
While embodiments of this disclosure have been depicted and
described and are defined by reference to example embodiments of
the disclosure, such references do not imply a limitation on the
disclosure, and no such limitation is to be inferred. The subject
matter disclosed is capable of considerable modification,
alteration, and equivalents in form and function, as will occur to
those skilled in the pertinent art and having the benefit of this
disclosure. The depicted and described embodiments of this
disclosure are examples only, and not exhaustive of the scope of
the disclosure.
SUMMARY
The present invention relates generally to oilfield operations, and
more particularly, to methods and systems for integral storage and
blending of the materials used in oilfield operations.
In one embodiment, the present invention is directed to an
integrated material blending and storage system comprising: a
storage unit; a blender located under the storage unit; wherein the
blender is operable to receive a first input from the storage unit;
a liquid additive storage module having a pump to maintain constant
pressure at an outlet of the liquid additive storage module;
wherein the blender is operable to receive a second input from the
liquid additive storage module; and a pre-gel blender; wherein the
blender is operable to receive a third input from the pre-gel
blender; wherein gravity directs the contents of the storage unit,
the liquid additive storage module and the pre-gel blender to the
blender; a first pump; and a second pump; wherein the first pump
directs the contents of the blender to the second pump; and wherein
the second pump directs the contents of the blender down hole;
wherein at least one of the first pump and the second pump is
powered by one of natural gas and electricity.
In another exemplary embodiment, the present invention is directed
to a modular integrated material blending and storage system
comprising: a first module comprising a storage unit; a second
module comprising a liquid additive storage unit and a pump for
maintaining pressure at an outlet of the liquid additive storage
unit; and a third module comprising a pre-gel blender; wherein an
output of each of the first module, the second module and the third
module is located above a blender; and wherein gravity directs the
contents of the first module, the second module and the third
module to the blender; a pump; wherein the pump directs the output
of the blender to a desired down hole location; and wherein the
pump is powered by one of natural gas and electricity.
The features and advantages of the present disclosure will be
readily apparent to those skilled in the art upon a reading of the
description of exemplary embodiments, which follows.
DESCRIPTION
The present invention relates generally to oilfield operations, and
more particularly, to methods and systems for integral storage and
blending of the materials used in oilfield operations.
Turning now to FIG. 1, an Integrated Material Storage and Blending
System (IMSBS) in accordance with an exemplary embodiment of the
present invention is depicted generally with reference numeral 100.
The IMSBS 100 includes a number of storage units 102. The storage
units 102 may contain sand, proppants or other solid materials used
to prepare a desired well treatment fluid.
In one exemplary embodiment, the storage units 102 may be connected
to load sensors (not shown) to monitor the reaction forces at the
legs of the storage units 102. The load sensor readings may then be
used to monitor the change in weight, mass and/or volume of
materials in the storage units 102. The change in weight, mass or
volume can be used to control the metering of material from the
storage units 102 during well treatment operations. As a result,
the load sensors may be used to ensure the availability of
materials during oilfield operations. In one exemplary embodiment,
load cells may be used as load sensors. Electronic load cells are
preferred for their accuracy and are well known in the art, but
other types of force-measuring devices may be used. As will be
apparent to one skilled in the art, however, any type of
load-sensing device can be used in place of or in conjunction with
a load cell. Examples of suitable load-measuring devices include
weight-, mass-, pressure- or force-measuring devices such as
hydraulic load cells, scales, load pins, dual sheer beam load
cells, strain gauges and pressure transducers. Standard load cells
are available in various ranges such as 0-5000 pounds, 0-10000
pounds, etc.
In one exemplary embodiment the load sensors may be communicatively
coupled to an information handling system 104 which may process the
load sensor readings. While FIG. 1 depicts a separate information
handling system 104 for each storage unit 102, as would be
appreciated by those of ordinary skill in the art, with the benefit
of this disclosure, a single information handling system may be
used for all or any combination of the storage units 102. Although
FIG. 1 depicts a personal computer as the information handling
system 104, as would be apparent to those of ordinary skill in the
art, with the benefit of this disclosure, the information handling
system 104 may include any instrumentality or aggregate of
instrumentalities operable to compute, classify, process, transmit,
receive, retrieve, originate, switch, store, display, manifest,
detect, record, reproduce, handle, or utilize any form of
information, intelligence, or data for business, scientific,
control, or other purposes. For example, the information handling
system 104 may be a network storage device, or any other suitable
device and may vary in size, shape, performance, functionality, and
price. For instance, in one exemplary embodiment, the information
handling system 104 may be used to monitor the amount of materials
in the storage units 102 over time and/or alert a user when the
contents of a storage unit 102 reaches a threshold level. The user
may designate a desired sampling interval at which the information
handling system 104 may take a reading of the load sensors.
The information handling system 104 may then compare the load
sensor readings to the threshold value to determine if the
threshold value is reached. If the threshold value is reached, the
information handling system 104 may alert the user. In one
embodiment, the information handling system 104 may provide a
real-time visual depiction of the amount of materials contained in
the storage units 102. Moreover, as would be appreciated by those
of ordinary skill in the art, with the benefit of this disclosure,
the load sensors may be coupled to the information handling system
104 through a wired or wireless (not shown) connection.
As depicted in FIG. 1, the IMSBS 100 may also include one or more
Integrated Pre-gel Blenders (IPB) 106. The IPB 106 may be used for
preparing any desirable well treatment fluids such as a fracturing
fluid, a sand control fluid or any other fluid requiring hydration
time.
FIG. 2 depicts an IPB 200 in accordance with an exemplary
embodiment of the present invention. The IPB 200 comprises a
pre-gel storage unit 202 resting on legs 204. As would be
appreciated by those of ordinary skill in the art, the pre-gel
storage unit 202 may be a storage bin, a tank, or any other
desirable storage unit. The pre-gel storage unit 202 may contain
the gel powder used for preparing the gelled fracturing fluid. As
would be appreciated by those of ordinary skill in the art, with
the benefit of this disclosure, the gel powder may comprise a dry
polymer. Specifically, the dry polymer may be any agent used to
enhance fluid properties, including, but not limited to, wg18,
wg35, wg36 (available from Halliburton Energy Services of Duncan,
Okla.) or any other guar or modified guar gelling agents. The
materials from the pre-gel storage unit 202 may be directed to a
mixer 206 as a first input through a feeder 208. As would be
appreciated by those of ordinary skill in the art, with the benefit
of this disclosure, in one embodiment, the mixer 206 may be a
growler mixer and the feeder 208 may be a screw feeder which may be
used to provide a volumetric metering of the materials directed to
the mixer 206. A water pump 210 may be used to supply water to the
mixer 206 as a second input. A variety of different pumps may be
used as the water pump 210 depending on the user preferences. For
instance, the water pump 210 may be a centrifugal pump, a
progressive cavity pump, a gear pump or a peristaltic pump. The
mixer 206 mixes the gel powder from the pre-gel storage unit 202
with the water from the water pump 210 at the desired concentration
and the finished gel is discharged from the mixer 206 and may be
directed to a storage unit, such as an external frac tank (not
shown), for hydration. The finished gel may then be directed to a
blender 108 in the IMSBS 100.
In one exemplary embodiment, the legs 204 of the pre-gel storage
unit 202 are attached to load sensors 212 to monitor the reaction
forces at the legs 204. The load sensor 212 readings may then be
used to monitor the change in weight, mass and/or volume of
materials in the pre-gel storage unit 202. The change in weight,
mass or volume can be used to control the metering of material from
the pre-gel storage unit 202 at a given set point. As a result, the
load sensors 212 may be used to ensure the availability of
materials during oilfield operations. In one exemplary embodiment,
load cells may be used as load sensors 212. Electronic load cells
are preferred for their accuracy and are well known in the art, but
other types of force-measuring devices may be used. As will be
apparent to one skilled in the art, however, any type of
load-sensing device can be used in place of or in conjunction with
a load cell. Examples of suitable load-measuring devices include
weight-, mass-, pressure- or force-measuring devices such as
hydraulic load cells, scales, load pins, dual sheer beam load
cells, strain gauges and pressure transducers. Standard load cells
are available in various ranges such as 0-5000 pounds, 0-10000
pounds, etc.
In one exemplary embodiment the load sensors 212 may be
communicatively coupled to an information handling system 214 which
may process the load sensor readings. Although FIG. 2 depicts a
personal computer as the information handling system 214, as would
be apparent to those of ordinary skill in the art, with the benefit
of this disclosure, the information handling system 214 may include
any instrumentality or aggregate of instrumentalities operable to
compute, classify, process, transmit, receive, retrieve, originate,
switch, store, display, manifest, detect, record, reproduce,
handle, or utilize any form of information, intelligence, or data
for business, scientific, control, or other purposes. For example,
the information handling system 214 may be a network storage
device, or any other suitable device and may vary in size, shape,
performance, functionality, and price. For instance, in one
exemplary embodiment, the information handling system 214 may be
used to monitor the amount of materials in the pre-gel storage unit
202 over time and/or alert a user when the contents of the pre-gel
storage unit 202 reaches a threshold level. The user may designate
a desired sampling interval at which the information handling
system 214 may take a reading of the load sensors 212. The
information handling system 214 may then compare the load sensor
readings to the threshold value to determine if the threshold value
is reached. If the threshold value is reached, the information
handling system 214 may alert the user. In one embodiment, the
information handling system 214 may provide a real-time visual
depiction of the amount of materials contained in the pre-gel
storage unit 202.
Moreover, as would be appreciated by those of ordinary skill in the
art, with the benefit of this disclosure, the load sensors 212 may
be coupled to the information handling system 214 through a wired
or wireless (not shown) connection. As would be appreciated by
those of ordinary skill in the art, with the benefit of this
disclosure, in one exemplary embodiment, the dry polymer material
may be replaced with a Liquid Gel Concentrate ("LGC") material that
consists of the dry polymer mixed in a carrier fluid. In this
exemplary embodiment, the feeder and mixer mechanisms would be
replaced with a metering pump of suitable construction to inject
the LGC into the water stream, thus initiating the hydration
process.
FIG. 3 depicts an IPB in accordance with a second exemplary
embodiment of the present invention, denoted generally by reference
numeral 300. The IPB 300 comprises a pre-gel storage unit 302
resting on legs 308. The pre-gel storage unit 302 in this
embodiment may include a central core 304 for storage and handling
of materials. In one embodiment, the central core 304 may be used
to store a dry gel powder for making gelled fracturing fluids. The
pre-gel storage unit 302 may further comprise an annular space 306
for hydration volume. As would be appreciated by those of ordinary
skill in the art, with the benefit of this disclosure, the gel
powder may comprise a dry polymer. Specifically, the dry polymer
may comprise a number of different materials, including, but not
limited to, wg18, wg35, wg36 (available from Halliburton Energy
Services of Duncan, Okla.) or any other guar or modified guar
gelling agents.
The materials from the central core 304 of the pre-gel storage unit
302 may be directed to a mixer 310 as a first input through a
feeder 312. As would be appreciated by those of ordinary skill in
the art, with the benefit of this disclosure, in one embodiment,
the mixer 310 may be a growler mixer and the feeder 312 may be a
screw feeder which may be used to provide a volumetric metering of
the materials directed to the mixer 310. A water pump 314 may be
used to supply water to the mixer 310 as a second input. A variety
of different pumps may be used as the water pump 314 depending on
the user preferences. For instance, the water pump 314 may be a
centrifugal pump, a progressive cavity pump, a gear pump or a
peristaltic pump. The mixer 310 mixes the gel powder from the
pre-gel storage unit 302 with the water from the water pump 314 at
the desired concentration and the finished gel is discharged from
the mixer 310. As discussed above with reference to the storage
units 102, the pre-gel storage unit 302 may rest on load sensors
316 which may be used for monitoring the amount of materials in the
pre-gel storage unit 302. The change in weight, mass or volume can
be used to control the metering of material from the pre-gel
storage unit 302 at a given set point.
In this embodiment, once the gel having the desired concentration
is discharged from the mixer 310, it is directed to the annular
space 306. The gel mixture is maintained in the annular space 306
for hydration. Once sufficient time has passed and the gel is
hydrated, it is discharged from the annular space 306 through the
discharge line 318.
FIG. 4 depicts a cross sectional view of a storage unit in an IPB
400 in accordance with a third exemplary embodiment of the present
invention. The IPB 400 comprises a pre-gel storage unit 402 resting
on legs 404. The pre-gel storage unit 402 in this embodiment may
include a central core 406 for storage and handling of materials.
In one embodiment, the central core 406 may be used to store a dry
gel powder for making gelled fracturing fluids. As would be
appreciated by those of ordinary skill in the art, with the benefit
of this disclosure, the gel powder may comprise a dry polymer.
Specifically, the dry polymer may be any agent used to enhance
fluid properties, including, but not limited to, wg18, wg35, wg36
(available from Halliburton Energy Services of Duncan, Okla.) or
any other guar or modified guar gelling agents. The pre-gel storage
unit 402 may further comprise an annular space 408 which may be
used as a hydration volume. In this embodiment, the annular space
408 contains a tubular hydration loop 410.
The materials from the central core 406 of the pre-gel storage unit
402 may be directed to a mixer 412 as a first input through a
feeder 414. As would be appreciated by those of ordinary skill in
the art, with the benefit of this disclosure, in one embodiment,
the mixer 412 may be a growler mixer and the feeder 414 may be a
screw feeder which may be used to provide a volumetric metering of
the materials directed to the mixer 412. A water pump 416 may be
used to supply water to the mixer 412 as a second input. A variety
of different pumps may be used as the water pump 416 depending on
the user preferences. For instance, the water pump 416 may be a
centrifugal pump, a progressive cavity pump, a gear pump or a
peristaltic pump. The mixer 412 mixes the gel powder from the
pre-gel storage unit 402 with the water from the water pump 416 at
the desired concentration and the finished gel is discharged from
the mixer 412. As discussed above with reference to FIG. 1, the
pre-gel storage unit 402 may rest on load sensors 418 which may be
used for monitoring the amount of materials in the pre-gel storage
unit 402. The change in weight, mass or volume can be used to
control the metering of material from the pre-gel storage unit 402
at a given set point.
In this embodiment, once the gel having the desired concentration
is discharged from the mixer 412, it is directed to the annular
space 408 where it enters the tubular hydration loop 410. As would
be appreciated by those of ordinary skill in the art, with the
benefit of this disclosure, the portions of the gel mixture are
discharged from the mixer 412 at different points in time, and
accordingly, will be hydrated at different times. Specifically, a
portion of the gel mixture discharged from the mixer 412 into the
annular space 408 at a first point in time, t1, will be
sufficiently hydrated before a portion of the gel mixture which is
discharged into the annular space 408 at a second point in time,
t2. Accordingly, it is desirable to ensure that the gel mixture is
transferred through the annular space 408 in a First-In-First-Out
(FIFO) mode. To that end, in the third exemplary embodiment, a
tubular hydration loop 410 is inserted in the annular space 408 to
direct the flow of the gel as it is being hydrated.
As would be appreciated by those of ordinary skill in the art, with
the benefit of this disclosure, in order to achieve optimal
performance, the tubular hydration loop 410 may need to be cleaned
during a job or between jobs. In one embodiment, the tubular
hydration loop 410 may be cleaned by passing a fluid such as water
through it. In another exemplary embodiment, a pigging device may
be used to clean the tubular hydration loop 410.
Returning to FIG. 1, the IMSBS 100 may include one or more blenders
108 located at the bottom of the storage units 102. In one
embodiment, multiple storage units 102 may be positioned above a
blender 108 and be operable to deliver solid materials to the
blender 108. FIG. 5 depicts a close up view of the interface
between the storage units 102 and the blender 108. As depicted in
FIG. 5, gravity directs the solid materials from the storage units
102 to the blender 108 through the hopper 502, obviating the need
for a conveyer system.
Returning to FIG. 1, the IMSBS 100 may also include one or more
liquid additive storage modules 110. The liquid additive storage
modules 110 may contain a fluid used in preparing the desired well
treatment fluid. As would be appreciated by those of ordinary skill
in the art, with the benefit of this disclosure, depending on the
well treatment fluid being prepared, a number of different fluids
may be stored in the liquid additive storage modules 110. Such
fluids may include, but are not limited to, surfactants, acids,
cross-linkers, breakers, or any other desirable chemical additives.
As discussed in detail with respect to storage units 102, load
sensors (not shown) may be used to monitor the amount of fluid in
the liquid additive storage modules 110 in real time and meter the
amount of fluids delivered to the blender 108. As would be
appreciated by those of ordinary skill in the art, with the benefit
of this disclosure, a pump may be used to circulate the contents
and maintain constant pressure at the head of the liquid additive
storage modules 110. Because the pressure of the fluid at the
outlet of the liquid additive storage modules 110 is kept constant
and the blender 108 is located beneath the liquid additive storage
modules 110, gravity assists in directing the fluid from the liquid
additive storage modules 110 to the blender 108, thereby obviating
the need for a pump or other conveyor systems to transfer the
fluid.
As depicted in more detail in FIG. 5, the blender 108 includes a
fluid inlet 112 and an optional water inlet 504. Once the desired
materials are mixed in the blender 108, the materials exit the
blender 108 through the outlet 114.
In one embodiment, when preparing a well treatment fluid, a base
gel is prepared in the IPB 106. In one embodiment, the gel prepared
in the IPB may be directed to an annular space 406 for hydration.
In another exemplary embodiment, the annular space may further
include a hydration loop 410. In one exemplary embodiment, the
resulting gel from the IPB 106 may be pumped to the centrally
located blender 108. Each of the base gel, the fluid modifying
agents and the solid components used in preparing a desired well
treatment fluid may be metered out from the IPB 106, the liquid
additive storage module 110 and the storage unit 102, respectively.
The blender 108 mixes the base gel with other fluid modifying
agents from the liquid additive storage modules 110 and the solid
component(s) from the storage units 102. As would be appreciated by
those of ordinary skill in the art, with the benefit of this
disclosure, when preparing a fracturing fluid the solid component
may be a dry proppant. In one exemplary embodiment, the dry
proppant may be gravity fed into the blending tub through metering
gates. Once the blender 108 mixes the base gel, the fluid modifying
agent and the solid component(s), the resulting well treatment
fluid may be directed to a down hole pump (not shown) through the
outlet 114. A variety of different pumps may be used to pump the
output of the IMSBS down hole. For instance, the pump used may be a
centrifugal pump, a progressive cavity pump, a gear pump or a
peristaltic pump. In one exemplary embodiment, chemicals from the
liquid additive storage modules 110 may be injected in the
manifolds leading to and exiting the blender 108 in order to bring
them closer to the centrifugal pumps and away from other chemicals
when there are compatibility or reaction issues.
As would be appreciated by those of ordinary skill in the art, with
the benefit of this disclosure, the mixing and blending process may
be accomplished at the required rate dictated by the job
parameters. As a result, pumps that transfer the final slurry to
the down hole pumps typically have a high horsepower requirement.
.Iadd.FIG. 7 depicts a pumping system in accordance with an
exemplary embodiment of the present invention, denoted generally
with reference numeral 700. .Iaddend.In one exemplary embodiment,
.Iadd.shown in FIG. 7, .Iaddend.the transfer pump .Iadd.702
.Iaddend.may be powered by a natural gas fired engine or a natural
gas fired generator set .Iadd.714.Iaddend.. In another exemplary
embodiment, the transfer pump may be powered by electricity from a
power grid. Once the fluid system is mixed and blended with
proppant and other fluid modifiers it is boosted to the high
horsepower down hole pumps .Iadd.704.Iaddend.. The down hole pumps
pump the slurry through the high pressure ground manifold .Iadd.706
.Iaddend.to the well head .Iadd.708 .Iaddend.and down hole. In one
embodiment, the down hole pumps .Iadd.704 .Iaddend.may be powered
by a natural gas fired engine, a natural gas fired generator set
.Iadd.714 .Iaddend.or electricity from a power grid. The down hole
pumps typically account for over two third of the horsepower on
location, thereby reducing the carbon footprint of the overall
operations.
In one exemplary embodiment, the natural gas used to power the
transfer pumps, the down hole pumps or the other system components
may be obtained from the field on which the subterranean operations
are being performed .Iadd.720.Iaddend.. In one embodiment, the
natural gas may be converted to liquefied natural gas .Iadd.712
.Iaddend.and used to power pumps and other equipment that would
typically be powered by diesel fuel. In another embodiment, the
natural gas may be used to provide power through generator sets
.Iadd.714.Iaddend.. The natural gas from the field may undergo
conditioning .Iadd.710 .Iaddend.before being used to provide power
to the pumps and other equipment. The conditioning process may
include cleaning the natural gas, compressing the natural gas in
compressor stations and if necessary, removing any water contained
therein.
As would be appreciated by those of ordinary skill in the art, with
the benefit of this disclosure, the IMSBS may include a different
number of storage units 102, IPBs 106 and/or liquid additive
storage modules 110, depending on the system requirements. For
instance, in another exemplary embodiment (not shown), the IMSBS
may include three storage units, one IPB and one liquid additive
storage module.
FIG. 6 depicts an isometric view of IMSBS in accordance with an
exemplary embodiment of the present invention, denoted generally
with reference numeral 600. As depicted in FIG. 6, each of the
storage units 602, each of the liquid additive storage modules 604
and each of the IPBs 606 may be arranged as an individual module.
In one embodiment, one or more of the storage units 602, the liquid
additive storage modules 604 and the IPBs 606 may include a latch
system which is couplable to a truck or trailer which may be used
for transporting the module. In one embodiment, the storage units
602 may be a self-erecting storage unit as disclosed in U.S. patent
application Ser. No. 12/235,270, assigned to Halliburton Energy
Services, Inc., which is incorporated by reference herein in its
entirety. Accordingly, the storage units 602 may be specially
adapted to connect to a vehicle which may be used to lower, raise
and transport the storage unit 602. Once at a jobsite, the storage
unit 602 may be erected and filled with a predetermined amount of a
desired material. A similar design may be used in conjunction with
each of the modules of the IMSBS 600 disclosed herein in order to
transport the modules to and from a job site. Once the desired
number of storage units 602, the liquid additive storage modules
604 and the IPBs 606 are delivered to a job site, they are erected
in their vertical position. Dry materials such as proppants or gel
powder may then be filled pneumatically to the desired level and
liquid chemicals may be pumped into the various storage tanks. Load
sensors (not shown) may be used to monitor the amount of materials
added to the storage units 602, the liquid additive storage modules
604 and the IPBs 606 in real time.
As would be appreciated by those of ordinary skill in the art, with
the benefit of this disclosure, an IMSBS 600 in accordance with an
exemplary embodiment of the present invention which permits
accurate, real-time monitoring of the contents of the storage units
602, the liquid additive storage modules 604 and/or the IPBs 606
provides several advantages. For instance, an operator may use the
amount of materials remaining in the storage units 602, the liquid
additive storage modules 604 and/or the IPBs 606 as a quality
control mechanism to ensure that material consumption is in line
with the job requirements. Additionally, the accurate, real-time
monitoring of material consumption expedites the operator's ability
to determine the expenses associated with a job.
As would be appreciated by those of ordinary skill in the art, with
the benefit of this disclosure, the different equipment used in an
IMSBS in accordance with the present invention may be powered by
any suitable power source. For instance, the equipment may be
powered by a combustion engine, electric power supply which may be
provided by an on-site generator or by a hydraulic power
supply.
Therefore, the present invention is well-adapted to carry out the
objects and attain the ends and advantages mentioned as well as
those which are inherent therein. While the invention has been
depicted and described by reference to exemplary embodiments of the
invention, such a reference does not imply a limitation on the
invention, and no such limitation is to be inferred. The invention
is capable of considerable modification, alteration, and
equivalents in form and function, as will occur to those ordinarily
skilled in the pertinent arts and having the benefit of this
disclosure. The depicted and described embodiments of the invention
are exemplary only, and are not exhaustive of the scope of the
invention. Consequently, the invention is intended to be limited
only by the spirit and scope of the appended claims, giving full
cognizance to equivalents in all respects. The terms in the claims
have their plain, ordinary meaning unless otherwise explicitly and
clearly defined by the patentee.
* * * * *
References