Monitoring and control of proppant storage from a datavan

• US 10,254,732 B2
• Filed: 08/12/2016
• Issued: 04/09/2019
• 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, Inc.
• Inventors: Oehring, Jared, Hinderliter, Brandon Neil, Baron, Arthur
• Primary Examiner(s): Thompson, Kenneth L
• Application Number:
  US15/235,716
• Publication Number:
  US 20160349728A1
• Time in Patent Office: 970 Days
• CPC Class Codes: E21B 43/267 reinforcing fractures by propping
• CPC Class Codes: G05B 19/0428 Safety, monitoring G05B19/0423 takes precedence
• CPC Class Codes: G05B 19/46 hydraulic
• CPC Class Codes: G05B 2219/37303 Two measurements, speed of motor and speed of load
• CPC Class Codes: G05B 2219/45004 Mining
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A system and method that remotely monitors and controls proppant usage in a fracturing operation. The system and method allow operators to wirelessly monitor and control proppant storage units from inside a datavan through sensors and control mechanisms that interface with fracturing software to schedule the flow of the proppant. A sensor monitors the weight, container level, or volume of the proppant being used to keep the induced hydraulic fracture open. A serial to Ethernet converter converts this information and sends it wirelessly to a datavan. A user at the datavan controls the proppant usage through a display in the datavan of the storage units with the appropriate weight. The container monitoring software links with the fracturing software, providing real-time information about proppant usage so that the user can properly schedule proppant flow to the well through valves, conveyor belts, and other control mechanisms.

Claims

1. A system for use with a fracturing operation comprising:

a plurality of electric-powered pumps fluidly connected to a well and powered by at least one electric motor, and configured to pump fluid into the well at high pressure so that the fluid passes from the well into the formation, and fractures the formation; and

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

a weight monitoring system in selective cooperation with a proppant container that selectively contains proppant used in fracturing;

an information handling system in communication with the weight monitoring system; and

a proppant dispensing system coupled with the proppant container and that is in communication with and selectively activated by the information handling system.

2. The system of claim 1, further including a serial to Ethernet converter for sending and receiving Ethernet data to and from the information handling system, and for sending and receiving serial data to and from the proppant container.

3. The system of claim 1, wherein the information handling system selectively sends commands to actuate a valve coupled with the proppant container to provide a designated amount of proppant for use by a fracturing operation.

4. The system of claim 1, where the information handling system alerts a user if an amount of proppant in the proppant container is below a threshold level, and where the information handling system estimates the amount of proppant in the proppant container based on a signal received from the weight monitoring system.

5. The system of claim 1, where the weight monitoring system comprises a sensor for measuring one or more of a weight of the proppant container, a level of proppant in the proppant container, and a volume of proppant in the proppant container, and wherein the sensor comprises a measuring device selected from the group consisting of gamma ray gauges, radar gauges, laser gauges, weight measuring load cells, pressure sensors, ultrasonic gauges, and combinations thereof.

6. The system of claim 1 where control by the variable frequency drive is either wired or wireless.

7. The system of claim 1, where the proppant storage containers include one of silos or trailer mounted containers.

8. A method for conducting a fracturing operation comprising:

pumping fluid with a plurality of electric-powered pumps into a wellbore at high pressure so that the fluid passes from the wellbore into the formation, and fractures the formation;

controlling the speed of an electric motor powered the electric-powered pumps with a variable frequency drive, wherein the variable frequency drive frequently performs electric motor diagnostics to prevent damage to the electric motor;

sensing an amount of proppant contained in at least one proppant storage container;

comparing the amount of proppant sensed in the proppant storage container with a designated amount of proppant; and

regulating a flow of proppant from the proppant storage container based on the step of comparing the amount of proppant sensed and the designated amount of proppant.

9. The method of claim 8, further comprising a scheduling step that includes interfacing with a fracturing system that can actuate valves and other control mechanisms to provide proppant to fracturing operations on conveyor belts.

10. The method of claim 8, further comprising directing an amount of proppant toward a well through the use of conveyor belts that are controlled by a user at a datavan.

11. The method of claim 8, further comprising generating an alert if proppant in the proppant storage container goes below a threshold level.

12. The method of claim 8, where the sensing the amount of proppant in the proppant storage container comprises using a device that is selected from the group consisting of gamma ray gauges, radar gauges, laser gauges, weight measuring load cells, pressure sensors, ultrasonic gauges.

13. The method of claim 8, where the proppant storage containers include one of silos or trailer mounted containers.