System for pumping hydraulic fracturing fluid using electric pumps

• US 10,337,308 B2
• Filed: 07/05/2016
• Issued: 07/02/2019
• 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: Broussard, Joel N., McPherson, Jeff, Kurtz, Robert
• Primary Examiner(s): Thompson, Kenneth L
• Application Number:
  US15/202,085
• Publication Number:
  US 20160326854A1
• Time in Patent Office: 1,092 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 17/03 driven by electric motors
• CPC Class Codes: F04B 19/22 of reciprocating-piston type
• CPC Class Codes: F04B 49/20 by changing the driving speed
• CPC Class Codes: F05D 2220/32 in gas turbines
• CPC Class Codes: H02P 23/00 Arrangements or methods for the control of AC motors characterised by a control method other than vector control

Abstract

A system for hydraulically fracturing an underground formation in an oil or gas well to extract oil or gas from the formation, the oil or gas well having a wellbore that permits passage of fluid from the wellbore into the formation. The system includes a plurality of electric pumps fluidly connected to the well, and configured to pump fluid into the wellbore at high pressure so that the fluid passes from the wellbore into the, and fractures the formation. The system can also include a plurality of natural gas powered generators electrically connected to the plurality of electric pumps to provide electrical power to the pumps.

Claims

1. A system for hydraulically fracturing an underground formation in an oil or gas well to extract oil or gas from the formation, the oil or gas well having a wellbore that permits passage of fluid from the wellbore into the formation, the system comprising:

a pump fluidly connected to the well; and

an electric motor to power the pump;

the pump configured to pump fluid into the wellbore at high pressure so that the fluid passes from the wellbore into the formation, and fractures the formation, wherein the pump is a triplex or a quinteplex pump rated at about 2250 hydraulic horsepower or more.

2. The system of claim 1, wherein the electric motor has a maximum continuous power output of about 1750 brake horsepower or more.

3. The system of claim 1, wherein the electric motor has a maximum continuous torque of about 8750 lb-ft or more.

4. The system of claim 1, wherein the electric pump is mounted on a vehicle, and can be ported from one well to another.

5. The system of claim 1, further comprising:

a variable frequency drive connected to the electric motor to control the speed of the motor.

6. The system of claim 5, wherein the variable frequency drive has one or more power semiconductor heat sinks having thermal sensors monitored by a microprocessor to prevent damage caused by excessive heat.

7. The system of claim 1, further comprising:

a generator electrically connected to the electric motor to provide electric power to the motor.

8. The system of claim 7, wherein the generator is fueled by natural gas.

9. The system of claim 7, wherein the generator is a turbine generator.

10. The system of claim 7, wherein the pump, electric motor, and generator are mounted on a vehicle, and can be ported from one well to another.

11. The system of claim 10, wherein the vehicle is a truck having at least five axles.