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

• US 9,121,257 B2
• Filed: 11/14/2014
• Issued: 09/01/2015
• 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:
  US14/541,993
• Publication Number:
  US 20150068724A1
• Time in Patent Office: 291 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 hydraulically fracturing an underground hydrocarbon bearing formation at a wellbore that pumps fluid from the wellbore into the formation, the system comprising:

a plurality of pumps powered by one or more electric motors and fluidly connected to the wellbore, the pumps configured to pump fluid into the wellbore at a pressure sufficient so that the fluid passes from the wellbore into the formation, and fractures the formation, wherein a fracturing module comprises at least one of the pumps;

at least one variable frequency drive connected to the one or more electric motors to control the speed of the motors, the at least one variable frequency drive capable of performing monitoring and controlling of the one or more electric motors; and

one or more generators electrically connected to the plurality of pumps to provide electrical power to the pumps,

wherein the fracturing module is mounted on a trailer 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.

2. The system of claim 1, wherein the at least one variable frequency drive is capable of performing monitoring and controlling of the one or more electric motors by regulating a maximum current available to the one or more electric motors.

3. The system of claim 1, wherein at least some of the one or more generators are powered by a fuel selected from a group consisting of natural gas and liquid fuel.

4. The system of claim 1, wherein at least some of the one or more generators are turbine generators.

5. The system of claim 1, further comprising a control system configured to:

sync one or more pumps of the plurality of pumps with an electric blender; and

provide a single command that automatically compensates the change in flow rate of the electric blender based upon the change in flow rate of the one or more pumps of the plurality of pumps for fracturing operations.

6. The system of claim 1, wherein the plurality of pumps are mounted on the trailer and transportable on the trailer.

7. The system of claim 1, further comprising a plurality of variable frequency drives attached to the one or more electrical motors coupled to the plurality of pumps.

8. A system for fracturing an underground hydrocarbon bearing formation in an oil or gas well by pumping hydraulic fracturing fluid into the wellbore, the system comprising:

at least one pump for pumping the hydraulic fracturing fluid into the wellbore, and then from the wellbore into the formation, the at least one pump mounted on a trailer and capable of pumping the hydraulic fracturing fluid at a pressure sufficient to crack the formation;

an electric motor attached to the at least one pump and configured to drive the at least one pump, wherein a fracturing module comprises the electric motor;

a variable frequency drive connected to the electric motor to control the speed of the motor, the variable frequency drive capable of performing monitoring and controlling of the electric motor; and

a generator connected to the electric motor that provides electric power to the electric motor,

wherein the fracturing module is mounted on the trailer 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.

9. The system of claim 8, wherein the variable frequency drive is capable of performing monitoring and controlling of the electric motor by regulating a maximum current available to the electric motor.

10. The system of claim 8, wherein the at least one pump is a plunger-style fluid pump.

11. The system of claim 8, wherein the at least one pump is a triplex or a quintuplex pump rated up to about 2500 horsepower.

12. The system of claim 8, wherein the electric motor has a power output of up to about 2500 horsepower deliverable to the at least one pump.

13. The system of claim 8, wherein the electric motor has a torque of up to about 20,000 foot per pound (ft/lb) deliverable to the at least one pump.

14. The system of claim 8, wherein the generator is a turbine generator.

15. The system of claim 8, wherein the variable frequency drive is mounted to the trailer.

16. The system of claim 8, wherein the trailer has three axles.

17. The system of claim 8, wherein the trailer has mounts attaching the variable frequency drive to the trailer.

18. The system of claim 8, further comprising a control system configured to:

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

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

19. A system for hydraulically fracturing an underground hydrocarbon bearing formation at a wellbore that permits passage of fluid from the wellbore into the formation, the system comprising:

a trailer;

two or more pumps attached to the trailer and fluidly connected to the well, the pumps configured to pump fluid into the wellbore at a high pressure so that the fluid passes from the wellbore into the formation, and fractures the formation, wherein at least one of the pumps is configured to form a fracturing module;

one or more electric motors attached to the pumps to drive the pumps;

at least one variable frequency drive connected to the electric motors to control the speed of the motors, the at least one variable frequency drive capable of performing monitoring and controlling of the electric motors; and

a generator for connection to the one or more electric motors that provides electric power to the one or more electric motors,

wherein the fracturing module is mounted on the trailer 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.

20. The system of claim 19, wherein the at least one variable frequency drive is capable of performing monitoring and controlling of the one or more electric motors by regulating a maximum current available to the one or more electric motors.

21. The system of claim 19, wherein the one or more electric motors are attached to the trailer.

22. The system of claim 19, further comprising a control system configured to:

sync at least one of the two or more pumps with an electric blender; and

provide a single command that automatically compensates the change in flow rate of the electric blender based upon the change in flow rate of the at least one of the two or more pumps for fracturing operations.