Mobile, modular, electrically powered system for use in fracturing underground formations using liquid petroleum gas

• US 9,140,110 B2
• Filed: 03/14/2013
• Issued: 09/22/2015
• Est. Priority Date: 10/05/2012
• Status: Active Grant

• Current Assignee: Typhon Technology Solutions, LLC
• Original Assignee: Evolution Well Services, LLC
• Inventors: Coli, Todd, Schelske, Eldon
• Primary Examiner(s): Buck, Matthew
• Assistant Examiner(s): LEMBO, AARON LLOYD
• Application Number:
  US13/804,906
• Publication Number:
  US 20140096974A1
• Time in Patent Office: 922 Days
• Field of Search: 166/352, 166/358, 166/268, 166/263, 166/308.1, 166/90.1
• US Class Current: 1/1
• CPC Class Codes: B01F 2101/49 Mixing drilled material or ingredients for well-drilling, earth-drilling or deep-drilling compositions with liquids to obtain slurries
• CPC Class Codes: B01F 23/43 using driven stirrers
• CPC Class Codes: B01F 27/05 Stirrers
• CPC Class Codes: B01F 35/3204 Motor driven, i.e. by means of an electric or IC motor
• CPC Class Codes: B01F 35/71 Feed mechanisms with proportioning B01F35/80
• CPC Class Codes: B01F 35/712 for feeding fluids
• CPC Class Codes: B01F 35/71731 using a hopper
• CPC Class Codes: B01F 35/718 using vacuum, under pressure in a closed receptacle or circuit system
• CPC Class Codes: B01F 35/75465 using suction, vacuum, e.g. with a pipette
• CPC Class Codes: E21B 43/2607 Surface equipment specially adapted for fracturing operations
• CPC Class Codes: F01D 15/10 Adaptations for driving, or combinations with, electric generators
• CPC Class Codes: F04B 1/16 having two or more sets of cylinders or pistons
• CPC Class Codes: F04B 17/03 driven by electric motors
• CPC Class Codes: F05D 2240/24 for turbines

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. The treatment fluid can comprise a water-based fracturing fluid or a waterless liquefied petroleum gas (LPG) fracturing fluid.

Claims

1. A method of delivering fracturing fluid to a wellbore, the method comprising the steps of:

providing a dedicated source of electric power for fracturing operations at a well site that contains a wellbore to be fractured, wherein the dedicated source of electrical power is a turbine generator located at the well site that receives a source of natural gas and generates an electrical power from the received source of natural gas;

pressurizing the fracturing fluid using one or more electric fracturing modules at the well site, wherein each of the electric fracturing modules comprise an electric motor coupled to at least one fluid pump, wherein the dedicated source of electric power provides the electric power to the electric motor; and

operating the one or more electric fracturing modules using electric power from the dedicated source of electric power to pump the fracturing fluid into the wellbore.

2. The method of claim 1, further comprising the steps of blending, using an electric blender, a fluid received from a first fluid source manifold of the electric blender and a second fluid source manifold of the electric blender with a fluid additive from at least one fluid additive source to produce the fracturing fluid, wherein the electric blender comprises at least one electric blender motor that obtains electric power from the dedicated source of electric power.

3. The method of claim 2, further comprising the steps of:

syncing the at least one fluid pump with the electric blender; and

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

4. The method of claim 2, wherein the electric blender is a dual configuration electric blender that further comprises a plurality of blending tubs, and wherein the method further comprising the steps of:

driving, using a first electric blender motor of the at least one electric blender motor, the fluid received in the first fluid source manifold of the electric blender into the plurality of blending tubs; and

driving, using the second electric blender motor of the at least one electric blender motor, the fluid received in the second fluid source manifold of the at least one fluid source manifold into the plurality of blending tubs.

5. The method of claim 1, further comprising the steps of monitoring and controlling, using a variable frequency drive, the electric motor for driving the at least one fluid pump adapted to pump the fracturing fluid down the wellbore.

6. The method of claim 5, wherein the monitoring and controlling, using the variable frequency drive, of the electric motor for driving the at least one fluid pump adapted to pump the fracturing fluid down the wellbore comprises regulating a maximum current available to the electric motor.

7. The method of claim 1, further comprising the steps of removing the one or more electric fracturing modules 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.

8. The method of claim 1, further comprising the steps of:

controlling, using a first variable frequency drive, at least one of the electric motors powered by electricity to drive the at least one fluid pump; and

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

9. The method of claim 8, wherein the first variable frequency drive is adapted to control the electric motor by controlling the electric motor within a maximum pressure for fracturing operations.

10. A method of delivering fracturing fluid to a wellbore, the method comprising:

providing a dedicated source of electric power for fracturing operations at a well site that contains a wellbore to be fractured, wherein the dedicated source of electricity generates electric power by converting a source of natural gas to electricity, wherein the dedicated source of electric power supplies electric power to at least one fracturing module and an electric blender;

blending, using the electric blender, a fluid received from at least one fluid source manifold with a fluid additive received from at least one fluid additive source to produce the fracturing fluid, wherein the electric blender comprises the at least one fluid source manifold, the at least one fluid additive source, and a plurality of blending tubs for blending the fluid and fluid additive;

providing the at least one fracturing module at the well site, wherein the at least one fracturing module comprises an electric motor and at least one fluid pump coupled to the electric motor;

providing the fracturing fluid for pressurized delivery to the wellbore using the at least one fracturing module; and

fracturing a rock formation using the fracturing fluid pumped down the wellbore.

11. A method of providing electric power to at least one fracturing module at a wellbore, the method comprising the steps of:

providing a turbine generator located within a well site that contains a wellbore to be fractured, wherein the turbine generator provides a dedicated source of electric power for fracturing operations at the well site by receiving a source of natural gas and converting the source of natural gas to electric power, wherein the turbine generator supplies the electric power to one or more fracturing modules and a dual configuration electric blender;

receiving an unblended fracturing fluid from a first inlet manifold of the dual configuration electric blender;

receiving an unblended fracturing fluid from a second inlet manifold of the dual configuration electric blender;

driving, using a first electric blender motor of the dual configuration electric blender, the unblended fracturing fluid from the first inlet manifold of the dual configuration electric blender to a first blending tub of the dual configuration electric blender, a second blending tub of the dual configuration electric blender, or both to form a blended fracturing fluid;

driving, using a second electric blender motor of the dual configuration electric blender, the unblended fracturing fluid from the first inlet manifold of the dual configuration electric blender to the first blending tub of the dual configuration electric blender, the second blending tub of the dual configuration electric blender, or both to form the blended fracturing fluid;

pressurizing the blended fracturing fluid using a fracturing fluid via the one or more fracturing modules for pressurized delivery within the wellbore, wherein each of the fracturing modules comprise an electric motor and a coupled fluid pump, wherein the gas turbine generator provides the electric power to the electric motor; and

operating the one or more fracturing modules using the electric power generated from the turbine generator located within the well site in order to pump the fracturing fluid into the wellbore.

12. A system for use in delivering pressurized fluid to a wellbore, the system comprising:

a dedicated source of electricity for fracturing operations located at a well site that comprises a wellbore to be fractured, wherein the dedicated source of electricity is adapted to generate electric power by converting a source of natural gas to electricity, wherein the dedicated source of electricity provides electric power to an electrically powered fracturing module and an electrically powered blender;

an electrically powered fracturing module operatively associated with the dedicated source of electricity, wherein the electrically powered fracturing module comprises an electric motor and at least one fluid pump coupled to the electric motor;

an electrically powered blender operatively associated with the dedicated source of electricity and adapted to provide treatment fluid to the fluid pump for delivery to the wellbore, wherein the electrically powered blender module comprises at least one electric blending motor that is powered by the dedicated source of electricity; and

a control system configured to control the electrically powered fracturing module to drive one or more fluid pumps and the at least one electric blending motor to produce the treatment fluid from the electrically powered blender.

13. A system for use in delivering pressurized fluid to a wellbore, the system comprising:

a dedicated source of electricity for fracturing operations located at a well site that comprises a wellbore to be fractured, wherein the dedicated source of electricity is adapted to generate electric power by converting a source of natural gas to electricity, wherein the dedicated source of electricity provides electric power to an electrically powered fracturing module; and

an electrically powered fracturing module operatively associated with the dedicated source of electricity, wherein the electrically powered fracturing module comprises an electric motor and at least one fluid pump coupled to the electric motor, wherein the electrically powered fracturing module is adapted to pump fracturing fluid using the electric power from the dedicated source of electricity into the wellbore.

14. The system of claim 13, further comprising:

an electrically powered blender module operatively associated with the dedicated source of electricity and adapted to provide fracturing fluid to the fluid pump for delivery to the wellbore, wherein the electrically powered blender module comprises at least one electric blending motor that is powered by the dedicated source of electricity; and

a central control adapted to prevent overflow of the electrically powered blender module and cavitation of the fluid pump by implementing a change of flow rate for the fluid pump and a change of flow rate for the electrically powered blender module using a single command.

15. The system of claim 14, wherein the single command from the central control replaces a plurality of manual commands separately provided to the fluid pump and the electrically powered blender module for implementing the change of flow rate for the fluid pump and the change of flow rate for the electrically powered blender module.

16. The system of claim 13, further comprising a fracturing trailer at the well site for mounting the electrically powered fracturing module, wherein the fracturing trailer is connected to a manifold system for fracturing operations, and wherein the fracturing trailer is adapted to isolate the electrically powered fracturing module from the fracturing trailer such that the electrically powered fracturing module is adapted to be removed from the fracturing trailer without disconnecting the fracturing trailer from the manifold system.

17. The system of claim 16, further comprising a replacement pumping module comprising at least one pump and an electric motor, wherein the replacement pumping module is adapted to connect to the fracturing trailer in place of the electrically powered fracturing module without disconnecting the fracturing trailer from the manifold system.

18. The system of claim 13, further comprising a variable frequency drive adapted to monitor and control the electric motor for driving the at least one fluid pump adapted to pump the fracturing fluid down the wellbore.

19. The system of claim 18, wherein the variable frequency drive is adapted to monitor and control the electric motor by regulating a maximum current available to the electric motor.

20. The system of claim 13, further comprising:

an electrically powered blender module operatively associated with the dedicated source of electricity and adapted to provide fracturing fluid to the at least one fluid pump for delivery to thewellbore, wherein the electrically powered blender module comprises at least one electric blending motor; and

a central control system adapted to prevent overflow of the electrically powered blender module and cavitation of the fluid pump by implementing a change of flow rate for the fluid pump and a change of flow rate for the electrically powered blender module using a single command.

21. The system of claim 20, further comprising a variable frequency drive adapted to control the at least one electric blending motor used to produce fracturing fluid from the electrically powered fracturing module.

22. The system of claim 20, wherein the central control system is configured to:

sync the at least one fluid pump with the electrically powered blender module; and

automatically compensate the change in flow rate of the electrically powered blender module based upon the change in flow rate of the at least one fluid pump instructed by the single command.

23. The system of claim 13, further comprising an electrically powered blender module operatively associated with the dedicated source of electricity and adapted to provide fracturing fluid to the fluid pump for delivery to the wellbore, wherein the electrically powered blender module is a dual configuration electric blender that further comprises a plurality of blending tubs, and wherein the dual configuration electric blender is configured to:

drive, using a first electric blender motor, the fluid received in a first fluid source manifold of the electrically powered blender module into the plurality of blending tubs to produce the fracturing fluid; and

drive, using a second electric blender motor, the fluid received in a second fluid source manifold of the electrically powered blender module into the plurality of blending tubs to produce the fracturing fluid.

24. The system of claim 13, wherein the dedicated source of electricity is further adapted to generate electricity of 13.8 kilovolts for fracturing operations and provide the generated electricity to the electric motor without a transmission of grid power.

25. A system for use in delivering pressurized fluid to a wellbore, the system comprising:

a dedicated source of electricity for fracturing operations located at a well site that comprises a wellbore, wherein the dedicated source of electricity is adapted to generate a source of electric power by converting a source of natural gas to electricity, wherein the dedicated source of electricity provides electric power to an electrically powered fracturing module and an electrically powered blender module;

an electrically powered fracturing module operatively associated with the dedicated source of electricity, wherein the electrically powered fracturing module comprising an electric motor and at least one fluid pump coupled to the electric motor, wherein the at least one fluid pump adapted to pump the treatment fluid down the wellbore;

an electrically powered blender module operatively associated with the dedicated source of electricity and adapted to provide treatment fluid to the fluid pump for delivery to the wellbore, wherein the electrically powered blender module comprises at least one electric blending motor; and

a central control system adapted to prevent overflow of the electrically powered blender module and cavitation of the fluid pump by implementing a change of flow rate for the fluid pump and a change of flow rate for the electrically powered blender module using a single command.

26. The system of claim 25, wherein the electrically powered blender module is a dual configuration electric fracturing blender that comprises a first inlet manifold, a second inlet manifold, a first blending unit, a second blending unit, a first inlet electric motor and a second inlet electric motor, and wherein the electrically powered blender module is adapted to:

receive an unblended fracturing fluid from the first inlet manifold and the second manifold;

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

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

27. The system of claim 25, wherein the dual configuration electric fracturing blender further comprises a first discharge motor, a first outlet manifold, and a second outlet manifold, and wherein the first discharge motor is adapted to drive the discharge of the fracturing fluid from the first blending unit to the first outlet manifold and the second outlet manifold.

28. The system of claim 25, wherein the central control system is adapted to remotely control and monitor via at least one communication link the power generation of the electrically powered fracturing module and the electrically powered blender module for fracturing operations at the well site.

29. A method of delivering fracturing fluid to a wellbore, the method comprising the steps of:

providing a dedicated source of electric power for fracturing operations at a well site that contains a wellbore to be fractured, wherein the dedicated source of electrical power is a turbine generator located at the well site and adapted to receive a source of natural gas and produce an electrical power from the received source of natural gas, wherein the dedicated source of electric power supplies electric power to one or more electric fracturing modules and an electric blender;

blending, using the electric blender located at the well site, a fluid received from at least one fluid source manifold of the electric blender with a fluid additive from at least one fluid additive source of the electric blender to produce the fracturing fluid;

pressurizing the fracturing fluid using the one or more electric fracturing modules at the well site, wherein each of the electric fracturing modules comprise an electric motor and a coupled fluid pump, wherein the dedicated source of electric power provides the electrical power to the electric motor;

operating the one or more electric fracturing modules using electric power from the dedicated source to pump the fracturing fluid into the wellbore; and

preventing overflow of the electric blender and cavitation of the fluid pumps for fracturing operations by implementing a change of flow rate for the one or more electric fracturing modules and a change of flow rate for the electric blender using a single command from a central control.

30. A system for use in delivering pressurized fluid to a wellbore, the system comprising:

a dedicated source of electricity for fracturing operations located at a well site that comprises a wellbore, wherein the dedicated source of electricity is adapted to generate a source of electric power by converting a source of natural gas to electricity;

an electrically powered fracturing module operatively associated with the dedicated source of electricity, wherein the electrically powered fracturing module comprises an electric motor and at least one fluid pump coupled to the electric motor, wherein the at least one fluid pump adapted to pump the treatment fluid down the wellbore;

an electrically powered blender module operatively associated with the dedicated source of electricity and adapted to provide treatment fluid to the fluid pump for delivery to the wellbore, wherein the electrically powered blender module comprises at least one electric blending motor;

a variable frequency drive adapted to control the electric motor for driving the at least one fluid pump adapted to pump the treatment fluid down the wellbore;

a second variable frequency drive adapted to control the at least one electric blending motor used to produce treatment fluid from the electrically powered fracturing module; and

a central control adapted to prevent overflow of the electrically powered blender module and cavitation of the fluid pump by implementing a change of flow rate for the fluid pump and a change of flow rate for the electrically powered blender module using a single command,

wherein the dedicated source of electricity provides electric power to the electrically powered fracturing module and the electrically powered blender module.