Mobile, modular, electrically powered system for use in fracturing underground formations

• US 10,227,855 B2
• Filed: 03/31/2016
• Issued: 03/12/2019
• Est. Priority Date: 04/07/2011
• Status: Active Grant

• Current Assignee: Typhon Technology Solutions, LLC
• Original Assignee: Evolution Well Services, LLC
• Inventors: Coli, Todd, Schelske, Eldon
• Primary Examiner(s): Harcourt, Brad
• Application Number:
  US15/086,806
• Publication Number:
  US 20160208593A1
• Time in Patent Office: 1,076 Days
• CPC Class Codes: B01F 35/3204 Motor driven, i.e. by means of an electric or IC motor
• CPC Class Codes: B62D 63/06 Trailers vehicles comprising living accommodation for people, e.g. caravans, camping or like vehicles B60P3/32
• CPC Class Codes: E21B 41/0085 Adaptations of electric power generating means for use in boreholes
• CPC Class Codes: E21B 43/00 Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells applicable only to water E03B
• 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: F04B 17/03 driven by electric motors
• CPC Class Codes: F04B 19/22 of reciprocating-piston type
• CPC Class Codes: F04B 23/06 the pumps being all of reciprocating positive-displacement type
• 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 7/1823 structurally associated with turbines or similar engines

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.

Claims

1. A method of delivering pressurized fluid to a wellbore to be fractured, the method comprising the steps of:

providing a gas-powered turbine generator that generates electric power at a site containing the wellbore;

providing an electric motor electrically connected to the turbine generator;

providing a first electric blender unit for blending a first fluid received from a first fluid source manifold with a first fluid additive from a first fluid additive source to produce a first fracturing fluid that is discharged to a first outlet manifold;

providing a second electric blender unit for blending a second fluid received from a second fluid source manifold with a second fluid additive from a second fluid additive source to produce a second fracturing fluid that is discharged to a second outlet manifold; and

providing a fracturing fluid pump configured to be driven by the electric motor and to pump the first fracturing fluid and the second fracturing fluid into a conduit in communication with the wellbore, wherein the first and second electric blender units are configured to operate simultaneously, and the electric motor, the fracturing fluid pump, the first electric blender unit, and the second electric blender unit are located on a trailer to be transported to the well site.

2. The method of claim 1 wherein the turbine generator provides electric power to the first and second electric blender units.

3. The method of claim 1, further comprising providing a first inlet crossing line coupled to the first fluid source manifold and the second fluid source manifold such that unblended fracturing fluid that enters the first fluid source manifold and the second fluid source manifold is capable of being delivered to both the first electric blender unit and the second electric blender unit;

and a first outlet crossing line coupled to the first outlet manifold and the second outlet manifold such that the first fracturing fluid and the second fracturing fluid are capable of being delivered to both the first outlet manifold and the second outlet manifold.

4. The method of claim 3, further comprising providing a second inlet crossing line coupled to a fluid inlet of the first electric blender unit and a fluid outlet of the first electric blender unit, wherein the unblended first fluid can bypass the first electric blender unit and be fed into the fluid outlet of the first blender unit.

5. The method of claim 1, wherein the first fluid received from the first fluid source manifold is configured to provide a separate fluid stream to the first electric blender unit and separate fluid stream to the second electric blender unit.

6. The method of claim 1, wherein the second fluid received from the second fluid source manifold is configured to provide a separate fluid stream to the first electric blender unit and separate fluid stream to the second electric blender unit.

7. The method of claim 1, further comprising providing a variable frequency drive electrically coupled to the electric motor, wherein the variable frequency drive is configured to control a speed of the electric motor.

8. The method of claim 7, wherein the variable frequency drive is further configured to control the electric motor by controlling the electric motor to operate within a defined maximum pressure for fracturing operations.

9. The method of claim 1, wherein the turbine generator is powered by natural gas.

10. The method of claim 1, wherein the turbine generator is powered by condensate liquid fuel.

11. The method of claim 1, wherein the turbine generator provides a dedicated source of electrical power for fracturing operations at the wellbore.

12. The method of claim 1, wherein the fracturing fluid pump is a quintiplex plunger-style fluid pump.

13. The method of claim 1, wherein the fracturing fluid pump is a triplex plunger-style fluid pump.

14. A method of delivering pressurized fluid to a wellbore to be fractured, the method comprising the steps of:

providing a gas-powered turbine generator that generates electric power at a site containing the wellbore;

providing an electric fracturing motor electrically connected to the turbine generator;

providing a first electric blender unit electrically connected to the turbine generator, the first electric blender unit comprising;

a first blender tub;

a first electric motor for delivering a first fluid received from a first fluid source manifold to the first blender tub;

a second electric motor for delivering a fluid additive from a fluid additive source to the first blender tub, wherein when the fluid additive is sand, the second electric motor can deliver approximately 15 t/min of sand to the first blender tub; and

a third electric motor for blending the first fluid with the fluid additive in the first blender tub to produce a fracturing fluid; and

providing a fracturing fluid pump configured to be driven by the electric fracturing motor and to pump the fracturing fluid into a conduit in communication with the wellbore.

15. The method of claim 14, further comprising:

providing a second electric blender unit electrically connected to the turbine generator, the second electric blender unit comprising;

a second blender tub;

a fourth electric motor for delivering a second fluid received from a second fluid source manifold to the second blender tub;

a fifth electric motor for delivering the fluid additive to the second blender tub, wherein when the fluid additive is sand, the second electric motor can deliver approximately 15 t/min of sand to the second blender tub; and

a sixth electric motor for blending the second fluid with the fluid additive in the second blender tub to produce the fracturing fluid;

wherein the first blender unit is configured to receive the second fluid from the second fluid source manifold and deliver the second fluid to the first blender tub, and the second blender unit is configured to receive the first fluid from the first fluid source manifold and deliver the first fluid to the second blender tub.

16. The method of claim 15, wherein the electric fracturing motor, the fracturing fluid pump, the first electric blender unit, and the second electric blender unit are located on a trailer to be transported to the well site.

17. A method of delivering pressurized fluid to a wellbore to be fractured, the method comprising the steps of:

providing a gas-powered turbine generator that generates electric power at a site containing the wellbore;

providing an electric motor electrically connected to the turbine generator;

providing a first electric blender unit for blending a first fluid received from a first fluid source manifold with a first fluid additive from a first fluid additive source to produce a first fracturing fluid that is discharged to a first outlet manifold;

providing a second electric blender unit for blending a second fluid received from a second fluid source manifold with a second fluid additive from a second fluid additive source to produce a second fracturing fluid that is discharged to a second outlet manifold;

providing a first inlet crossing line coupled to the first fluid source manifold and the second fluid source manifold such that unblended fracturing fluid that enters the first fluid source manifold and the second fluid source manifold is capable of being delivered to both the first electric blender unit and the second electric blender unit; and

a first outlet crossing line coupled to the first outlet manifold and the second outlet manifold such that the first fracturing fluid and the second fracturing fluid are capable of being delivered to both the first outlet manifold and the second outlet manifold; and

providing a fracturing fluid pump configured to be driven by the electric motor and to pump the first fracturing fluid and the second fracturing fluid into a conduit in communication with the wellbore, wherein the first and second electric blender units are configured to operate simultaneously.

18. The method of claim 17, further comprising providing a second inlet crossing line coupled to a fluid inlet of the first electric blender unit and a fluid outlet of the first electric blender unit, wherein the unblended first fluid can bypass the first electric blender unit and be fed into the fluid outlet of the first blender unit.

19. The method of claim 17, further comprising providing a variable frequency drive electrically coupled to the electric motor, wherein the variable frequency drive is configured to control a speed of the electric motor.

20. A method of delivering pressurized fluid to a wellbore to be fractured, the method comprising the steps of:

providing a gas-powered turbine generator that generates electric power at a site containing the wellbore;

providing an electric motor electrically connected to the turbine generator;

providing a first electric blender unit for blending a first fluid received from a first fluid source manifold with a first fluid additive from a first fluid additive source to produce a first fracturing fluid that is discharged to a first outlet manifold;

providing a second electric blender unit for blending a second fluid received from a second fluid source manifold with a second fluid additive from a second fluid additive source to produce a second fracturing fluid that is discharged to a second outlet manifold, wherein the first fluid received from the first fluid source manifold is configured to provide a separate fluid stream to the first electric blender unit and separate fluid stream to the second electric blender unit; and

providing a fracturing fluid pump configured to be driven by the electric motor and to pump the first fracturing fluid and the second fracturing fluid into a conduit in communication with the wellbore, wherein the first and second electric blender units are configured to operate simultaneously.

21. The method of claim 20, wherein the second fluid received from the second fluid source manifold is configured to provide a separate fluid stream to the first electric blender unit and separate fluid stream to the second electric blender unit.