System and method for dedicated electric source for use in fracturing underground formations using liquid petroleum gas

• US 10,107,084 B2
• Filed: 10/24/2016
• Issued: 10/23/2018
• Est. Priority Date: 10/05/2012
• Status: Active Grant

• Current Assignee: Typhon Technology Solutions, LLC
• Original Assignee: Evolution Well Services, LLC
• Inventors: Coli, Todd, Schelske, Eldon
• Primary Examiner(s): Buck, Matthew R
• Assistant Examiner(s): LEMBO, AARON LLOYD
• Application Number:
  US15/332,709
• Publication Number:
  US 20170037718A1
• Time in Patent Office: 729 Days
• CPC Class Codes: B01F 2101/49 Mixing drilled material or ingredients for well-drilling, earth-drilling or deep-drilling compositions with liquids to obtain slurries
• CPC Class Codes: B01F 23/43 using driven stirrers
• CPC Class Codes: B01F 27/05 Stirrers
• CPC Class Codes: B01F 35/3204 Motor driven, i.e. by means of an electric or IC motor
• CPC Class Codes: B01F 35/712 for feeding fluids
• CPC Class Codes: B01F 35/71731 using a hopper
• CPC Class Codes: B01F 35/718 using vacuum, under pressure in a closed receptacle or circuit system
• CPC Class Codes: B01F 35/75465 using suction, vacuum, e.g. with a pipette
• CPC Class Codes: E21B 43/2607 Surface equipment specially adapted for fracturing operations
• CPC Class Codes: F01D 15/10 Adaptations for driving, or combinations with, electric generators
• CPC Class Codes: F04B 1/16 having two or more sets of cylinders or pistons
• CPC Class Codes: F04B 17/03 driven by electric motors
• CPC Class Codes: F05D 2240/24 for turbines

Abstract

The present invention provides a method and system for providing on-site electrical power to a fracturing operation, and an electrically powered fracturing system. Natural gas can be used to drive a turbine generator in the production of electrical power. A scalable, electrically powered fracturing fleet is provided to pump fluids for the fracturing operation, obviating the need for a constant supply of diesel fuel to the site and reducing the site footprint and infrastructure required for the fracturing operation, when compared with conventional systems. The treatment fluid can comprise a water-based fracturing fluid or a waterless liquefied petroleum gas (LPG) fracturing fluid.

Claims

1. A system for hydraulic fracturing, comprising:

at least one pump adapted to pressurize and pump fracturing fluid into a wellbore at a well site;

at least one electric motor operatively coupled to the at least one pump such that the at least one electric motor is adapted to power the at least one pump;

a variable frequency drive connected to the at least one electric motor; and

at least one dedicated source of electricity for fracturing operations on the well site, wherein the at least one dedicated source of electricity comprises a turbine generator, and wherein the at least one dedicated source of electricity is operatively coupled to the at least one electric motor such that the dedicated source of electricity is adapted to supply electricity to the at least one electric motor for driving the at least one pump.

2. The system of claim 1, wherein the fracturing fluid comprises a liquefied petroleum gas.

3. The system of claim 2, wherein the liquefied petroleum gas is waterless.

4. The system of claim 1, wherein the turbine generator is adapted to:

receive a hydrocarbon fuel source that comprises at least one of the following;

natural gas, liquid fuel, and condensate; and

convert the hydrocarbon fuel source into the electricity.

5. The system of claim 1 further comprising at least one electric blender operatively coupled to the dedicated source of electricity such that the dedicated source of electricity is adapted to supply electricity to at least one electric blender for producing fracturing fluid.

6. The system of claim 5, wherein the at least one electric blender further comprises a first inlet manifold operatively coupled to the first inlet electric motor and a second inlet manifold operatively coupled to a second inlet electric motor.

7. The system of claim 6, wherein the at least one electric blender further comprises a first blending tub operatively coupled to a first tub electric motor and a second blending tub operatively coupled to a second tub electric motor.

8. The system of claim 5, further comprising a central control system adapted to prevent overflow of the at least one electric blender and cavitation of the at least one pump by implementing a change of flow rate for the at least one pump and a change of flow rate for the at least one electric blender.

9. The system of claim 1, wherein the dedicated source of electricity is adapted to generate electricity for fracturing operations.

10. The system of claim 5, further comprising a central control system adapted to:

sync the at least one pump with the at least one electric blender; and

automatically compensate the change in flow rate of the at least one electric blender based upon the change in flow rate of the at least one pump instructed by a single command.

11. A method for hydraulic fracturing, comprising:

providing at least one dedicated source of electric power for fracturing operations on a well site that comprises a wellbore to be fractured, wherein the dedicated source of electrical power is a turbine generator that converts a source of hydrocarbon fuel to electricity;

pressurizing a fracturing fluid using at least one pump driven by at least one electric motor at the well site, wherein the dedicated source of electric power provides electric power to the at least one electric motor that is operatively controlled with a variable frequency drive;

operating the at least one pump and the at least one electric motor using electric power from the at least one dedicated source of electric power to pump the fracturing fluid into the wellbore.

12. The method of claim 11, wherein the fracturing fluid comprises one or more fluids from the group of linear gelled water, gelled water, gelled oil, slick water, slick oil, poly emulsion, foam/emulsion, liquid CO.sub.2, N.sub.2, binary fluid and acid.

13. The method of claim 11, further comprising blending, using an electric blender, a fluid received from a first fluid source manifold of the electric blender and a second fluid source manifold of the electric blender with a fluid additive from at least one fluid additive source to produce the fracturing fluid, wherein the at least one dedicated source of electric power provides the electric power to the electric blender.

14. The method of claim 13, wherein blending, using the at least one electric blender, the fluid received from the first fluid source manifold of the at least one electric blender and the second fluid source manifold of the at least one electric blender with the fluid additive from the at least one fluid additive source to produce the fracturing fluid comprises driving the fluid received from the first fluid source manifold and the second fluid source manifold into a first blending tub of the at least one electric blender and a second blending tub of the at least one electric blender using a first inlet electric motor of the at least one electric blender and a second inlet electric motor of the at least one electric blender.

15. The method of claim 13, further comprising:

controlling, using a first variable frequency drive, the at least one of the electric motors powered by electricity to drive the at least one pump; and

controlling, using a second variable frequency drive, at least one electric blender motor of the at least one electric blender, wherein the at least one electric blender motor is powered by electricity to produce the fracturing fluid from the at least one electric blender.

16. The method of claim 13, further comprising:

syncing the at least one pump with the electric blender; and

automatically compensating the change in flow rate of the electric blender based upon the change in flow rate of the at least one pump instructed by a single command from a central control for fracturing operations.

17. The method of claim 11, wherein the dedicated source of electric power provides electric power to the electric motor by generating electricity for fracturing operations, and wherein the source of hydrocarbon fuel comprises natural gas.

18. A system for hydraulically fracturing, comprising:

at least one dedicated source of electricity for fracturing operations on the well site, wherein the at least one dedicated source of electricity comprises a turbine generator;

at least one electric motor connected to the at least one dedicated source of electricity such that the dedicated source of electricity is capable of providing electric power to the at least one electric motor, the electric motor operatively controlled with a variable frequency drive;

at least one pump attached to the at least one electric motor such that the at least one electric motor is capable of driving the at least one pump to pressurize and pump fracturing fluid into a wellbore at a well site; and

wherein the fracturing fluid comprises liquid petroleum gas.

19. The system of claim 18, wherein the gas turbine generator is capable of converting a source of natural gas into electric power.

20. The system of claim 18, further comprising an electric blender that comprises a first inlet electric motor, a second inlet electric motor, a first blending tub electric motor, and a second blending tub electric motor.