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

• US 9,103,193 B2
• Filed: 11/14/2014
• Issued: 08/11/2015
• 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:
  US14/542,000
• Publication Number:
  US 20150068754A1
• Time in Patent Office: 270 Days
• Field of Search: 166/308.1, 166/177.5, 166/75.11
• US Class Current: 1/1
• 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 system for use in delivering pressurized fluid to a wellbore to be fractured in order to stimulate oil and gas production, the system comprising:

at least one gas-turbine generator located on a well site containing the wellbore that is electrically connected to a plurality of electric motors that perform fracturing operations, wherein the at least one gas-turbine generator is configured to generate electricity through the conversion of liquid fuels, natural gas, or both;

an electric fracturing blender electrically powered by the at least one gas-turbine generator to produce fracturing fluid;

a plurality of fracturing pumps that are electrically powered by the at least one gas-turbine generator, wherein the fracturing pumps are driven by the plurality of electric motors, wherein at least one fracturing pump is configured to pump the fracturing fluid received from the electric fracturing blender into the wellbore to fracture a geologic formation; and

a control system that remotely controls and monitors via at least one communication link the power generation of the plurality of fracturing pumps and the electric fracturing blender for fracturing operations at the well site, wherein the control system is configured to;

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

provide a single command that automatically compensates the change in flow rate of the electric fracturing blender based upon the change in flow rate of the fluid pump for fracturing operations.

2. The system of claim 1, wherein at least one of the electric motors is operatively coupled to one or more fracturing pumps to form a fracturing module that is mounted on a trailer, wherein the trailer is connected to a manifold system, and wherein the trailer is configured to isolate the fracturing module from the trailer such that the fracturing module is adapted to be removed from the trailer without disconnecting the trailer from the manifold system for fracturing operations.

3. The system of claim 2, wherein the trailer is further configured to connect a replacement module to the trailer in place of the fracturing module without disconnecting the trailer from the manifold system.

4. The system of claim 1, wherein the electric fracturing blender is a dual configuration electric fracturing blender that comprises a first inlet manifold, a second inlet manifold, a first electrically powered blending unit, a second electrically powered blending unit, a first inlet electric motor and a second inlet electric motor, wherein the dual configuration electric fracturing blender is configured to:

receive an unblended fracturing fluid from one or more fluid sources via the first inlet manifold and the second inlet manifold;

pump with at least the power of the first inlet electric motor, the unblended fracturing fluid received via the first inlet manifold to both the first electrically powered blending unit and the second electrically powered blending unit to produce the fracturing fluid; and

pump with at least the power of the second inlet electric motor, the unblended fracturing fluid received via the second inlet manifold to both the first electrically powered blending unit and the second electrically power blending unit to produce the fracturing fluid.

5. The system of claim 4, wherein the dual configuration electric fracturing blender further comprises a first discharge motor, a first outlet manifold, and a second outlet manifold, wherein the first discharge motor is configured to drive the discharge of the fracturing fluid from the first electrically powered blending unit to both the first outlet manifold and the second outlet manifold.

6. The system of claim 5, wherein the dual configuration electric fracturing blender further comprises a second discharge motor, and wherein the second discharge motor is configured to drive the discharge of the fracturing fluid from the second electrically powered blending unit to both the first outlet manifold and the second outlet manifold.

7. The system of claim 4, wherein the dual configuration electric fracturing blender further comprises a first additive fluid motor and a second additive fluid motor, wherein the first additive fluid motor is configured to power delivery of one or more fluid additives to the first electrically powered blending unit to produce the fracturing fluid, and wherein the second additive fluid motor is configured to power delivery of the one or more fluid additives to the second electrically powered blending unit to produce the fracturing fluid.

8. The system of claim 4, wherein the dual configuration electric fracturing blender is configured to provide a total output capability of about 240 barrels per minute (bbl/min) based upon at least the first inlet electric motor and the second inlet electric motor.

9. The system of claim 1, wherein the at least one gas-turbine generator is further configured to generate electricity of about 13.8 kilovolts for fracturing operations and provide the generated electricity to the electric motors without a transmission of grid power.

10. The system of claim 4, further comprising a plurality of variable frequency drives, wherein a first variable frequency drive of the plurality of variable frequency drives is configured to control the first inlet electric motor, and wherein a second variable frequency drive of the plurality of variable frequency drives is configured to control at least one of the electric motors.

11. The system of claim 10, wherein the second variable frequency drive of the plurality of variable frequency drives is further configured to control the at least one of the electric motors by controlling the at least one of the electric motors to operate within a defined maximum pressure for fracturing operations.

12. A method for providing fracturing fluid to a wellbore for stimulating oil or gas production using an electrically powered fracturing system, the method comprising:

generating, using at least one gas-turbine generator located at a well site, electric power used for fracturing operations that stimulate the release of hydrocarbons in a geologic formation, wherein the electric power is supplied to at least one electric fracturing motor and at least one electric blending motor by converting a source of natural gas, liquid fuels, or both to electricity;

controlling, using a first variable frequency drive, the at least one electric fracturing motor powered by electricity to drive one or more fluid pumps;

controlling, using a second variable frequency drive, the at least one electric blending motor powered by electricity to produce a fracturing fluid from an electric fracturing blender;

syncing the one or more fluid pumps with the electric fracturing blender; and

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

pumping, using the one or more fluid pumps driven by the at least one electric fracturing motor, a blended fracturing fluid down a wellbore located at the well site; and

fracturing the rock formation using the blended fracturing fluid pumped down the wellbore to stimulate the release of hydrocarbons within the geologic formation.

13. The method of claim 12, further comprising removing a fracturing module that comprises the at least one electric fracturing motor coupled to the one or more fluid pumps from a trailer without disconnecting the trailer from a manifold system, wherein the manifold system is used to connect the trailer to fracturing operations at the well site.

14. The method of claim 12, wherein the single command from the central control replaces a plurality of manual commands separately provided to the fluid pumps and the electric fracturing blender for implementing the change of flow rate for the fluid pumps and the change of flow rate for the electric fracturing blender.

15. The method of claim 12, wherein the electric fracturing blender is a dual configuration electric blender, wherein the at least one electric blending motor is a first inlet electric motor, and wherein the method of claim 12 further comprises:

receiving an unblended fracturing fluid from one or more fluid sources via a first inlet manifold of the dual configuration electric blender and a second inlet manifold of the dual configuration electric blender;

delivering, using at least the power of the first inlet electric motor, the unblended fracturing fluid received via the first inlet manifold to a first electrically powered blending tub of the dual configuration electric blender, a second electrically powered blending tub of the dual configuration electric blender, or both; and

delivering, using at least the power of a second inlet electric motor of the dual configuration electric blender, the unblended fracturing fluid received via the second inlet manifold of the dual configuration electric blender to the first electrically powered blending tub of the dual configuration electric blender, the second electrically powered blending tub of the dual configuration electric blender, or both.

16. The method of claim 15, further comprising:

discharging, using a first discharge motor of the dual configuration electric blender, the blended fracturing fluid from the first electrically powered blending tub of the dual configuration electric blender to a first outlet manifold of the dual configuration electric blender, a second outlet manifold of the of the dual configuration electric blender, or both; and

discharging, using a second discharge motor of the dual configuration electric blender, the blended fracturing fluid from the second electrically powered blending tub of the dual configuration electric blender to the first outlet manifold of the dual configuration electric blender, the second outlet manifold of the dual configuration electric blender, or both.

17. The method of claim 16, wherein a plurality of inlet crossings direct the delivery of the unblended fracturing fluid received via the first inlet manifold to both the first electrically powered blending tub of the dual configuration electric blender and the second electrically powered blending tub of the dual configuration electric blender, and wherein an outlet crossing is used to direct the discharge of the blended fracturing fluid from the first electrically powered blending tub of the dual configuration electric blender to both the first outlet manifold of the dual configuration electric blender and the second outlet manifold of the of the dual configuration electric blender.

18. A system for use in delivering pressurized fluid to a wellbore to be fractured in order to stimulate oil and gas production, the system comprising:

at least one gas-turbine generator located on a well site containing the wellbore that is electrically connected to a plurality of electric fracturing motors that perform fracturing operations, wherein the at least one gas-turbine generator is configured to generate electricity through the conversion of liquid fuels, natural gas, or both;

an electric fracturing blender electrically powered by the at least one gas-turbine generator to produce fracturing fluid; and

a plurality of fracturing pumps that are electrically powered by the at least one gas-turbine generator, wherein the fracturing pumps are driven by the plurality of electric fracturing motors, wherein at least one fracturing pump is configured to pump the fracturing fluid received from the electric fracturing blender into the wellbore to fracture a geologic formation,

wherein at least one of the electric fracturing motors is operatively coupled to one or more fracturing pumps to form a fracturing module that is mounted on a trailer, wherein the trailer is connected to a manifold system, and wherein the trailer is configured to isolate the fracturing module from the trailer such that the fracturing module is adapted to be removed from the trailer without disconnecting the trailer from the manifold system for fracturing operations.

19. The system of claim 18, wherein the trailer is further configured to connect a replacement unit to the trailer in place of the fracturing module without disconnecting the trailer from the manifold system.

20. The system of claim 18, further comprising a control system that remotely controls and monitors via at least one communication link the power generation of the plurality of fracturing pumps and the electric fracturing blender for fracturing operations at the well site, wherein the control system is configured to:

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

provide a single command that automatically compensates the change in flow rate of the electric fracturing blender based upon the change in flow rate of the fluid pump for fracturing operations.