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Patent · US10280724B2 · B2 · US

Hydraulic fracturing equipment with non-hydraulic power

(11) Publication number
US10280724B2
(21) Application number
15/644,487
(22) Filing date
2017-07-07
(30) Priority date
2017-07-07
(43) Publication date
2019-05-07
(45) Date of grant
2019-05-07
(51) IPC
E21B 43/26; F04B 49/20; F04B 51/00; H02P 27/06
(52) CPC
  • E21B Earth or rock drilling; obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells: 43/2607, 43/26
  • F04B Positive-displacement machines for liquids; pumps: 17/03, 49/06, 49/20, 51/00
  • H02P Control or regulation of electric motors, electric generators or dynamo-electric converters; controlling transformers, reactors or choke coils: 27/047, 27/06, 5/74
(73) Assignee
US Well Services LLC
(72) Inventors
Brandon N. Hinderliter
(54) Title
Hydraulic fracturing equipment with non-hydraulic power
(57) Abstract

The present disclosure is directed to a hydraulic fracturing system for fracturing a subterranean formation. In an embodiment, the system can include an electric pump fluidly connected to a well associated with the formation, and configured to pump fluid into a wellbore associated with the well at a high pressure so that the fluid passes from the wellbore into the formation and fractures the formation. The system can further include one or more ancillary units associated with the fluid pumped into the wellbore. The system can further include a first motor electrically coupled to the electric pump to operate the electric pump, and one or more second motors, each of the second motors electrically coupled to each of the ancillary units to operate the one or more ancillary units.

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Claims (17)

  1. A hydraulic fracturing system for fracturing a subterranean formation comprising: an electric pump fluidly connected to a well associated with the subterranean formation, and configured to pump fluid into a wellbore associated with the well at a high pressure so that the fluid passes from the wellbore into the subterranean formation and fractures the subterranean formation; one or more ancillary units associated with the fluid pumped into the wellbore, the one or more ancillary units comprising a blender, the blender being positioned on a trailer and fluidly connected to an auger, wherein one or more second motors are positioned any of proximate a top elevation of the auger or proximate a bottom elevation of the auger, or a combination thereof, such that the one or more second motors provide power to drive the auger; a first motor electrically coupled to the electric pump to operate the electric pump; the one or more second motors comprising one or more electric motors, each of the one or more second motors electrically coupled to at least one of the one or more ancillary units to operate the at least one of the one or more ancillary units; and a plurality of variable-frequency drives (VFD), each VFD connected to at least one of the first motor or the one or more second motors to control the speed of the first motor or the one or more second motors.
  2. The system of claim 1, wherein the first motor is selected from the group consisting of any of an electric motor, a diesel motor, a natural gas motor, a gasoline motor, and a hydraulic motor, or a combination thereof.
  3. The system of claim 1, further comprising: an electric generator, wherein the first motor is electrically coupled to the electric pump via the electric generator to generate electricity for use by the electric pump.
  4. The system of claim 1, wherein the electric motor is selected from the group consisting of any of a single-phase AC motor, a three-phase motor, and a DC motor.
  5. The system of claim 1, wherein each VFD frequently performs electric motor diagnostics to prevent damage to the first motor or the one or more second motors.
  6. The system of claim 1, further comprising: one or more trailer, wherein the one or more ancillary units are positioned on the one or more trailer, and wherein each VFD is positioned on the one or more trailer proximate each of the one or more ancillary units.
  7. The system of claim 6, wherein the one or more second motors are each positioned on the one or more trailers proximate each of the one or more ancillary units.
  8. The system of claim 1, wherein additional of the one or more ancillary units are selected from the group consisting of any of a blender, a hydration unit, a chemical additive unit, a small pump, a chemical pump, a water pump, a valve actuator, a cooling fan, an auger, a mixing paddle, a conveyor belt, and a blower, or any combination thereof.
  9. The system of claim 1, wherein the one or more ancillary units comprise the hydration unit, the hydration unit being positioned on a trailer, the trailer further comprising a VFD, wherein the one or more second motors are positioned any of between the hydration unit and the VFD, or below the VFD, or a combination thereof, and wherein the one or more second motors provide power to the hydration unit via the VFD.
  10. A hydraulic fracturing system for fracturing a subterranean formation comprising: an electric pump fluidly connected to a well associated with the subterranean formation, and configured to pump fluid into a wellbore associated with the well at a high pressure so that the fluid passes from the wellbore into the subterranean formation and fractures the subterranean formation; one or more ancillary units associated with the fluid pumped into the wellbore, the one or more ancillary units comprising a blender, the blender being positioned on a trailer and fluidly connected to an auger, wherein one or more second motors are positioned any of proximate a top elevation of the auger or proximate a bottom elevation of the auger, or a combination thereof, such that the one or more second motors provide power to drive the auger; a first motor electrically coupled to the electric pump to operate the electric pump; the one or more second motors comprising an electric motor, and each of the one or more second motors electrically coupled to at least one of the one or more ancillary units to operate the at least one of the one or more ancillary units; and a plurality of variable-frequency drives (VFD), each VFD connected to at least one of the first motor or the one or more second motors to control the speed of the first motor or the one or more second motors.
  11. The system of claim 10, wherein the first motor is selected from the group consisting of any of an electric motor, a diesel motor, a natural gas motor, a gasoline motor, and a hydraulic motor, or a combination thereof.
  12. The system of claim 10, wherein the electric motor is selected from the group consisting of any of a single-phase AC motor, a three-phase motor, and a DC motor.
  13. The system of claim 10, wherein each VFD frequently performs electric motor diagnostics to prevent damage to the first motor or the one or more second motors.
  14. The system of claim 10, further comprising: one or more trailer, wherein the one or more ancillary units are positioned on the one or more trailer, and wherein each VFD is positioned on the one or more trailer proximate each of the one or more ancillary units.
  15. The system of claim 10, wherein the one or more second motors are each positioned on the one or more trailers proximate each of the one or more ancillary units.
  16. The system of claim 10, wherein additional of the one or more ancillary units are selected from the group consisting of any of a blender, a hydration unit, a chemical additive unit, a small pump, a chemical pump, a water pump, a valve actuator, a cooling fan, an auger, a mixing paddle, a conveyor belt, and a blower, or any combination thereof.
  17. A method for powering one or more ancillary units associated with a hydraulic fracturing system, the method comprising: fluidly connecting an electric pump to a well associated with a subterranean formation, the electric pump configured to pump fluid into a wellbore associated with the well at a high pressure so that the fluid passes from the wellbore into the subterranean formation and fractures the subterranean formation; fluidly connecting the one or more ancillary units with the fluid pumped into the wellbore, the one or more ancillary units comprising a blender, the blender being positioned on a trailer and fluidly connected to an auger, wherein one or more second motors are positioned any of proximate a top elevation of the auger or proximate a bottom elevation of the auger, or a combination thereof, such that the one or more second motors provide power to drive the auger; electrically coupling a first motor to the electric pump to operate the electric pump; electrically coupling the one or more second motors to each of the one or more ancillary units to operate the one or more ancillary units, the one or more second motors comprising an electric motor; and connecting each of a plurality of variable-frequency drives (VFD) to at least one of the first motor or the one or more second motors to control the speed of the first motor or the one or more second motors.

Description

This disclosure relates generally to hydraulic fracturing and more particularly to systems and methods for ancillary components of hydraulic fracturing equipment powered by non-hydraulic electric motors.

With advancements in technology over the past few decades, the ability to reach unconventional sources of hydrocarbons has tremendously increased. Horizontal drilling and hydraulic fracturing are two such ways that new developments in technology have led to hydrocarbon production from previously unreachable shale formations. Hydraulic fracturing operations typically require powering numerous components in order to recover oil and gas resources from the ground. For example, hydraulic fracturing usually includes pumps that inject fracturing fluid down the wellbore, blenders that mix proppant into the fluid, cranes, wireline units, and many other components that all must perform different functions to carry out fracturing operations.

Historically, large diesel motors have been used for drive power in hydraulic fracturing systems, while a system of hydraulics is typically used to drive smaller ancillary devices such as augers, chemical pumps, mixing paddles, water pumps, and cooling fans. For example, hydraulic power can include use of pressure and flow of hydraulic oil as a power source for turning valves, rotating fans and blowers, or spinning pumps to displace fracturing slurry, proppant, or chemicals onboard individual pieces of ancillary equipment. The use of hydraulics to power such ancillary elements of the hydraulic fracturing system includes several disadvantages, however.

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Record as JSON 
{
  "publication_number": "US10280724B2",
  "country": "US",
  "kind": "B2",
  "title": "Hydraulic fracturing equipment with non-hydraulic power",
  "abstract": "The present disclosure is directed to a hydraulic fracturing system for fracturing a subterranean formation. In an embodiment, the system can include an electric pump fluidly connected to a well associated with the formation, and configured to pump fluid into a wellbore associated with the well at a high pressure so that the fluid passes from the wellbore into the formation and fractures the formation. The system can further include one or more ancillary units associated with the fluid pumped into the wellbore. The system can further include a first motor electrically coupled to the electric pump to operate the electric pump, and one or more second motors, each of the second motors electrically coupled to each of the ancillary units to operate the one or more ancillary units.",
  "claims": [
    "1. A hydraulic fracturing system for fracturing a subterranean formation comprising: an electric pump fluidly connected to a well associated with the subterranean formation, and configured to pump fluid into a wellbore associated with the well at a high pressure so that the fluid passes from the wellbore into the subterranean formation and fractures the subterranean formation; one or more ancillary units associated with the fluid pumped into the wellbore, the one or more ancillary units comprising a blender, the blender being positioned on a trailer and fluidly connected to an auger, wherein one or more second motors are positioned any of proximate a top elevation of the auger or proximate a bottom elevation of the auger, or a combination thereof, such that the one or more second motors provide power to drive the auger; a first motor electrically coupled to the electric pump to operate the electric pump; the one or more second motors comprising one or more electric motors, each of the one or more second motors electrically coupled to at least one of the one or more ancillary units to operate the at least one of the one or more ancillary units; and a plurality of variable-frequency drives (VFD), each VFD connected to at least one of the first motor or the one or more second motors to control the speed of the first motor or the one or more second motors.",
    "2. The system of claim 1, wherein the first motor is selected from the group consisting of any of an electric motor, a diesel motor, a natural gas motor, a gasoline motor, and a hydraulic motor, or a combination thereof.",
    "3. The system of claim 1, further comprising: an electric generator, wherein the first motor is electrically coupled to the electric pump via the electric generator to generate electricity for use by the electric pump.",
    "4. The system of claim 1, wherein the electric motor is selected from the group consisting of any of a single-phase AC motor, a three-phase motor, and a DC motor.",
    "5. The system of claim 1, wherein each VFD frequently performs electric motor diagnostics to prevent damage to the first motor or the one or more second motors.",
    "6. The system of claim 1, further comprising: one or more trailer, wherein the one or more ancillary units are positioned on the one or more trailer, and wherein each VFD is positioned on the one or more trailer proximate each of the one or more ancillary units.",
    "7. The system of claim 6, wherein the one or more second motors are each positioned on the one or more trailers proximate each of the one or more ancillary units.",
    "8. The system of claim 1, wherein additional of the one or more ancillary units are selected from the group consisting of any of a blender, a hydration unit, a chemical additive unit, a small pump, a chemical pump, a water pump, a valve actuator, a cooling fan, an auger, a mixing paddle, a conveyor belt, and a blower, or any combination thereof.",
    "9. The system of claim 1, wherein the one or more ancillary units comprise the hydration unit, the hydration unit being positioned on a trailer, the trailer further comprising a VFD, wherein the one or more second motors are positioned any of between the hydration unit and the VFD, or below the VFD, or a combination thereof, and wherein the one or more second motors provide power to the hydration unit via the VFD.",
    "10. A hydraulic fracturing system for fracturing a subterranean formation comprising: an electric pump fluidly connected to a well associated with the subterranean formation, and configured to pump fluid into a wellbore associated with the well at a high pressure so that the fluid passes from the wellbore into the subterranean formation and fractures the subterranean formation; one or more ancillary units associated with the fluid pumped into the wellbore, the one or more ancillary units comprising a blender, the blender being positioned on a trailer and fluidly connected to an auger, wherein one or more second motors are positioned any of proximate a top elevation of the auger or proximate a bottom elevation of the auger, or a combination thereof, such that the one or more second motors provide power to drive the auger; a first motor electrically coupled to the electric pump to operate the electric pump; the one or more second motors comprising an electric motor, and each of the one or more second motors electrically coupled to at least one of the one or more ancillary units to operate the at least one of the one or more ancillary units; and a plurality of variable-frequency drives (VFD), each VFD connected to at least one of the first motor or the one or more second motors to control the speed of the first motor or the one or more second motors.",
    "11. The system of claim 10, wherein the first motor is selected from the group consisting of any of an electric motor, a diesel motor, a natural gas motor, a gasoline motor, and a hydraulic motor, or a combination thereof.",
    "12. The system of claim 10, wherein the electric motor is selected from the group consisting of any of a single-phase AC motor, a three-phase motor, and a DC motor.",
    "13. The system of claim 10, wherein each VFD frequently performs electric motor diagnostics to prevent damage to the first motor or the one or more second motors.",
    "14. The system of claim 10, further comprising: one or more trailer, wherein the one or more ancillary units are positioned on the one or more trailer, and wherein each VFD is positioned on the one or more trailer proximate each of the one or more ancillary units.",
    "15. The system of claim 10, wherein the one or more second motors are each positioned on the one or more trailers proximate each of the one or more ancillary units.",
    "16. The system of claim 10, wherein additional of the one or more ancillary units are selected from the group consisting of any of a blender, a hydration unit, a chemical additive unit, a small pump, a chemical pump, a water pump, a valve actuator, a cooling fan, an auger, a mixing paddle, a conveyor belt, and a blower, or any combination thereof.",
    "17. A method for powering one or more ancillary units associated with a hydraulic fracturing system, the method comprising: fluidly connecting an electric pump to a well associated with a subterranean formation, the electric pump configured to pump fluid into a wellbore associated with the well at a high pressure so that the fluid passes from the wellbore into the subterranean formation and fractures the subterranean formation; fluidly connecting the one or more ancillary units with the fluid pumped into the wellbore, the one or more ancillary units comprising a blender, the blender being positioned on a trailer and fluidly connected to an auger, wherein one or more second motors are positioned any of proximate a top elevation of the auger or proximate a bottom elevation of the auger, or a combination thereof, such that the one or more second motors provide power to drive the auger; electrically coupling a first motor to the electric pump to operate the electric pump; electrically coupling the one or more second motors to each of the one or more ancillary units to operate the one or more ancillary units, the one or more second motors comprising an electric motor; and connecting each of a plurality of variable-frequency drives (VFD) to at least one of the first motor or the one or more second motors to control the speed of the first motor or the one or more second motors."
  ],
  "description_excerpt": "This disclosure relates generally to hydraulic fracturing and more particularly to systems and methods for ancillary components of hydraulic fracturing equipment powered by non-hydraulic electric motors.\n\nWith advancements in technology over the past few decades, the ability to reach unconventional sources of hydrocarbons has tremendously increased. Horizontal drilling and hydraulic fracturing are two such ways that new developments in technology have led to hydrocarbon production from previously unreachable shale formations. Hydraulic fracturing operations typically require powering numerous components in order to recover oil and gas resources from the ground. For example, hydraulic fracturing usually includes pumps that inject fracturing fluid down the wellbore, blenders that mix proppant into the fluid, cranes, wireline units, and many other components that all must perform different functions to carry out fracturing operations.\n\nHistorically, large diesel motors have been used for drive power in hydraulic fracturing systems, while a system of hydraulics is typically used to drive smaller ancillary devices such as augers, chemical pumps, mixing paddles, water pumps, and cooling fans. For example, hydraulic power can include use of pressure and flow of hydraulic oil as a power source for turning valves, rotating fans and blowers, or spinning pumps to displace fracturing slurry, proppant, or chemicals onboard individual pieces of ancillary equipment. The use of hydraulics to power such ancillary elements of the hydraulic fracturing system includes several disadvantages, however.",
  "cpc": [
    "E21B 43/2607",
    "E21B 43/26",
    "F04B 17/03",
    "F04B 49/06",
    "F04B 49/20",
    "F04B 51/00",
    "H02P 27/047",
    "H02P 27/06",
    "H02P 5/74"
  ],
  "ipc": [
    "E21B 43/26",
    "F04B 49/20",
    "F04B 51/00",
    "H02P 27/06"
  ],
  "assignees": [
    "US Well Services LLC"
  ],
  "inventors": [
    "Brandon N. Hinderliter"
  ],
  "filing_date": "2017-07-07",
  "publication_date": "2019-05-07",
  "grant_date": "2019-05-07",
  "priority_date": "2017-07-07",
  "application_number": "US-201715644487-A",
  "family_id": "64902600",
  "cited_by_count": 248,
  "citations": [
    "US1671436A",
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    "US2183364A",
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    "US2753940A",
    "US3061039A",
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