System for fueling electric powered hydraulic fracturing equipment with multiple fuel sources

• US 10,020,711 B2
• Filed: 04/14/2017
• Issued: 07/10/2018
• Est. Priority Date: 11/16/2012
• Status: Active Grant

• Current Assignee: U.S. Well Services, LLC (ProFrac Holding Corp.)
• Original Assignee: U.S. Well Services, LLC (ProFrac Holding Corp.)
• Inventors: Oehring, Jared, Hinderliter, Brandon N.
• Primary Examiner(s): Thompson, Kenneth L
• Application Number:
  US15/487,656
• Publication Number:
  US 20170218727A1
• Time in Patent Office: 452 Days
• Field of Search: 60912, 417 52
• CPC Class Codes: E21B 43/2607 Surface equipment specially adapted for fracturing operations
• CPC Class Codes: F02B 2043/103 Natural gas, e.g. methane or LNG used as a fuel
• CPC Class Codes: F02B 43/08 Plants characterised by the engines using gaseous fuel generated in the plant from solid fuel, e.g. wood
• CPC Class Codes: F02B 43/10 Engines or plants characterised by use of other specific gases, e.g. acetylene, oxyhydrogen
• CPC Class Codes: F02B 63/04 for electric generators
• CPC Class Codes: F02M 37/32 characterised by filters or filter arrangements
• CPC Class Codes: F04B 17/03 driven by electric motors
• CPC Class Codes: F04B 35/04 the means being electric
• CPC Class Codes: F04B 47/02 the driving mechanisms being situated at ground level F04B47/12 takes precedence
• CPC Class Codes: F04B 49/20 by changing the driving speed
• CPC Class Codes: H02K 7/1815 structurally associated with reciprocating piston engines general aspects of generating sets, e.g. housing, F02B63/04
• CPC Class Codes: H02K 7/1823 structurally associated with turbines or similar engines
• CPC Class Codes: H02P 21/00 Arrangements or methods for the control of electric machines by vector control, e.g. by control of field orientation
• CPC Class Codes: H02P 29/0241 the fault being an overvoltage

Abstract

A hydraulic fracturing system for fracturing a subterranean formation is disclosed. In an embodiment, the system can include a plurality of electric pumps fluidly connected to a well associated with the subterranean formation and powered by at least one electric motor, and configured to pump fluid into a wellbore associated with the well at a high pressure; at least one generator electrically coupled to the plurality of electric pumps so as to generate electricity for use by the plurality of electric pumps; a gas compression system fluidly coupled to the at least one generator so as to provide fuel for use by the at least one generator; and a combustible fuel vaporization system gaseously coupled to the gas compression system so as to provide at least one of vaporized fuel or gasified fuel, or a combination thereof, to the gas compression system.

Claims

1. A hydraulic fracturing system for fracturing a subterranean formation comprising:

a plurality of electric pumps fluidly connected to a well associated with the subterranean formation and powered by at least one electric motor, 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;

at least one generator electrically coupled to the plurality of electric pumps so as to generate electricity for use by the plurality of electric pumps;

a gas compression system fluidly coupled to the at least one generator so as to provide fuel for use by the at least one generator;

an inert gas source providing an inert gas to regulate the fuel provided to the at least one generator; and

a combustible fuel vaporization system gaseously coupled to the gas compression system so as to provide at least one of vaporized fuel or gasified fuel, or a combination thereof, to the gas compression system.

2. The system of claim 1, further comprising at least one of:

a liquid fuel source;

or

a solid fuel source,

wherein each of the liquid fuel source and the solid fuel source are configured to supply fuel to the combustible fuel vaporization system.

3. The system of claim 2, wherein each of the liquid fuel source and the solid fuel source comprise at least one of a hydrogen-based, hydrocarbon-based, or alcohol-based fuel source, or any combination thereof.

4. The system of claim 3, wherein the liquid fuel source comprises any of a kerosene, methanol, No. 2 fuel oil, hydrogen, liquefied natural gas (LNG), substitute natural gas (SNG), liquid hydrocarbon, or ammonia fuel source, or any combination thereof.

5. The system of claim 3, wherein the solid fuel source comprises any of a wood gas or coal gas fuel source, or a combination thereof.

6. The system of claim 2, wherein the inert gas is provided to regulate the liquid fuel source or the solid fuel source prior to providing fuel for use by the at least one generator.

7. The system of claim 6, wherein the inert gas source comprises at least one of an oxygen-lean or a nitrogen-rich inert gas source, or a combination thereof.

8. The system of claim 2, further comprising:

at least one filter configured to filter at least one of particulates, water, or condensate, or a combination thereof, from at least one of the liquid fuel source and the solid fuel source.

9. The system of claim 1, further comprising:

a vaporized gas heating system in gaseous communication with the combustible fuel vaporization system so as to prevent the vaporized gas from cooling to below a condensation point associated with the vaporized gas.

10. The system of claim 9, wherein the vaporized gas heating system is powered by the at least one generator.

11. The system of claim 1, further comprising:

a variable frequency drive connected to the at least one electric motor to control the speed of the at least one electric motor, wherein the variable frequency drive frequently performs electric motor diagnostics to prevent damage to the at least one electric motor.

12. The system of claim 1, wherein the at least one generator comprises one of a turbine generator or a reciprocating engine generator, or a combination thereof.

13. A hydraulic fracturing system for fracturing a subterranean formation comprising:

a plurality of electric pumps fluidly connected to a well associated with the subterranean formation and powered by at least one electric motor, 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;

at least one turbine generator electrically coupled to the plurality of electric pumps so as to generate electricity for use by the plurality of electric pumps;

a gas compression system fluidly coupled to the at least one turbine generator so as to provide fuel for use by the at least one turbine generator;

a combustible fuel vaporization system gaseously coupled to the gas compression system so as to provide at least one of vaporized fuel or gasified fuel, or a combination thereof, to the gas compression system; and

a variable frequency drive connected to the at least one electric motor to control the speed of the at least one electric motor, wherein the variable frequency drive frequently performs electric motor diagnostics to prevent damage to the at least one electric motor.

14. The system of claim 13, further comprising at least one of:

a liquid fuel source;

or

a solid fuel source,

wherein each of the liquid fuel source and the solid fuel source are configured to supply fuel to the combustible fuel vaporization system.

15. The system of claim 14, wherein each of the liquid fuel source and the solid fuel source comprise at least one of a hydrogen-based, hydrocarbon-based, or alcohol-based fuel source, or any combination thereof.

16. The system of claim 15, wherein the liquid fuel source comprises any of a kerosene, methanol, No. 2 fuel oil, hydrogen, liquefied natural gas (LNG), substitute natural gas (SNG), liquid hydrocarbon, or ammonia fuel source, or any combination thereof.

17. The system of claim 15, wherein the solid fuel source comprises any of a wood gas or coal gas fuel source, or a combination thereof.

18. The system of claim 14, further comprising an inert gas source, wherein an inert gas is provided to regulate the liquid fuel source or the solid fuel source prior to providing fuel for use by the at least one turbine generator.

19. The system of claim 18, wherein the inert gas source comprises at least one of an oxygen-lean or a nitrogen-rich inert gas source, or a combination thereof.

20. The system of claim 14, further comprising:

at least one filter configured to filter at least one of particulates, water, or condensate, or a combination thereof, from at least one of the liquid fuel source and the solid fuel source.