Remote monitoring for hydraulic fracturing equipment

• US 10,107,086 B2
• Filed: 12/11/2017
• Issued: 10/23/2018
• 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): Wang, Wei
• Application Number:
  US15/838,033
• Publication Number:
  US 20180112507A1
• Time in Patent Office: 316 Days
• CPC Class Codes: E21B 43/2607 Surface equipment specially adapted for fracturing operations
• CPC Class Codes: E21B 43/267 reinforcing fractures by propping
• CPC Class Codes: F01D 15/08 Adaptations for driving, or combinations with, pumps
• CPC Class Codes: F01D 15/10 Adaptations for driving, or combinations with, electric generators
• CPC Class Codes: F02C 3/22 the fuel or oxidant being gaseous at standard temperature and pressure F02C3/28 takes precedence
• CPC Class Codes: F04B 15/02 the fluids being viscous or non-homogeneous
• CPC Class Codes: F04B 17/03 driven by electric motors
• CPC Class Codes: F04B 19/22 of reciprocating-piston type
• CPC Class Codes: F04B 47/02 the driving mechanisms being situated at ground level F04B47/12 takes precedence
• CPC Class Codes: F04B 49/06 Control using electricity regulating by means of floats actuating electric switches F04B49/04
• CPC Class Codes: F04B 49/20 by changing the driving speed
• CPC Class Codes: F04B 51/00 Testing machines, pumps, or pumping installations
• CPC Class Codes: H02P 23/00 Arrangements or methods for the control of AC motors characterised by a control method other than vector control
• CPC Class Codes: H04N 7/185 from a mobile camera, e.g. for remote control

Abstract

A hydraulic fracturing system for fracturing a subterranean formation including a pump in communication via pump components with a wellbore that intersects the formation, and that pressurizes fluid in the wellbore, the fluid comprising a fracturing fluid slurry. The system further includes hydraulic fracturing system components for making the fracturing fluid slurry, and a monitoring system that selectively captures and transmits real time images of at least one of the hydraulic fracturing system components or pump components to enable remote monitoring of the at least one of the hydraulic fracturing system components or pump components.

Claims

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

a pump in communication via pump components with a wellbore that intersects the formation, and that pressurizes fluid in the wellbore, the fluid comprising a fracturing fluid slurry;

hydraulic fracturing system components for making the fracturing fluid slurry; and

a monitoring system that selectively captures and transmits real time images of a blender unit to enable remote monitoring of the blender unit;

wherein the monitoring system selectively captures and transmits real time images of a hopper of the blending unit, so that a slurry level within the hopper is discernible in the images.

2. The hydraulic fracturing system of claim 1, wherein the monitoring system comprises:

a camera;

a controller;

a display;

a human machine interface; and

communication means between the camera, controller, human machine interface, and the display.

3. The hydraulic fracturing system of claim 1, wherein the display comprises a monitor from which the images are viewed.

4. The hydraulic fracturing system of claim 3, wherein the display is disposed within a passenger compartment mounted to the blender unit, so that the images can be viewed by operations personnel in the passenger compartment.

5. The hydraulic fracturing system of claim 1, wherein the monitoring system selectively captures and transmits real time images of a silica exposure zone.

6. The hydraulic fracturing system of claim 1, wherein the monitoring system comprises a camera disposed on an auger of the blender unit, the auger transmitting proppant to the hopper.

7. The hydraulic fracturing system of claim 6, wherein an image zone of the camera includes at least the auger and the hopper.

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

a pump in communication via pump components with a wellbore that intersects the formation, and that pressurizes fluid in the wellbore, the fluid comprising a fracturing fluid slurry;

hydraulic fracturing system components for making the fracturing fluid slurry; and

a monitoring system that selectively captures and transmits real time images of discharge piping of the pump to enable remote monitoring of the pump;

wherein the monitoring system selectively captures and transmits real time images of at least one of the discharge piping or leads connected to the discharge piping, so that potential leak points are discernible in the images.

9. The hydraulic fracturing system of claim 8, wherein the monitoring system comprises:

a camera;

a controller;

a display;

a human machine interface; and

communication means between the camera, controller, human machine interface, and the display.

10. The hydraulic fracturing system of claim 9, wherein the display comprises a monitor from which the images are viewed.

11. The hydraulic fracturing system of claim 8, wherein the pump components are selected from the group consisting of intake piping, discharge piping, hoses, fittings, and valves associated with the pump.

12. The hydraulic fracturing system of claim 8, wherein the monitoring system selectively captures and transmits real time images of a high pressure zone around the pumps.

13. The hydraulic fracturing system of claim 8, wherein the monitoring system comprises a camera disposed on at least one of a pump truck or a data van.

14. The hydraulic fracturing system of claim 13, wherein an image zone of the camera includes at least the discharge piping, the leads, and a wellhead assembly.

15. The method of claim 14, wherein the blending unit further comprises an auger, and wherein the images of at least one of the auger or the hopper include a silica exposure zone.

16. A method of fracturing a subterranean formation comprising:

driving a pump to pressurize fluid in a hydraulic fracturing system containing hydraulic fracturing components and pump components;

fracturing the formation by directing the pressurized fluid into a wellbore that intersects the formation; and

monitoring the hydraulic fracturing system with a monitoring system by;

obtaining images of a blender unit of the hydraulic fracturing system; and

viewing the images remotely;

wherein the monitoring system selectively captures and transmits real time images a hopper of the blending unit, so that a slurry level within the hopper is discernible in the images.

17. The method of claim 16, wherein the blender unit is disposed in areas where there is a greater possibility of personal injury than where the images are being viewed.

18. The method of claim 16, wherein the step of obtaining images is performed by a camera that is disposed adjacent or on the blender unit.

19. The method of claim 16, wherein the step of viewing is performed within an enclosure.

20. The method of claim 16, further comprising:

selectively obtaining images of different blending units on a single monitor.