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

• US 9,366,114 B2
• Filed: 04/06/2012
• Issued: 06/14/2016
• 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:
  US13/441,334
• Publication Number:
  US 20120255734A1
• Time in Patent Office: 1,530 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 method of delivering fracturing fluid to a wellbore, the method comprising the steps of:

providing a dedicated source of electric power at a site containing a wellbore to be fractured, wherein the dedicated source of electrical power is a turbine generator;

providing a source of natural gas, wherein the natural gas is used to drive the turbine generator in the production of electrical power;

providing one or more electric fracturing modules at the site, the electric fracturing modules comprising an electric motor and a coupled fluid pump, the electric motor operatively associated with the dedicated source of electric power;

providing the fracturing fluid for pressurized delivery to a wellbore;

operating the fracturing modules using electric power from the dedicated source to pump the fracturing fluid to the wellbore;

providing an electric blender module, the electric blender module comprising;

a fluid source, a fluid additive source, and a blender tub;

providing a fracturing trailer at the site for housing the one or more fracturing modules and the electric blender module; and

supplying electric power from the dedicated source to the electric blender module to affect blending of a fluid from the fluid source with a fluid additive from the fluid additive source to generate the fracturing fluid.

2. The method of claim 1, wherein the electric motor is an alternating current (AC) permanent magnet motor capable of operation in the range of up to 1500 revolutions per minute (rpm) and up to 20,000 foot per pounds (ft/lbs) of torque.

3. The method of claim 1, wherein the pump is a quintiplex plunger-style fluid pump.

4. The method of claim 1, wherein the pump is a triplex plunger-style fluid pump.

5. The method of claim 1, wherein the dedicated source of electric power is disposed at a remote location from the one or more electric fracturing modules.

6. The method of claim 1, wherein the site is an onshore site.

7. The method of claim 1, wherein the site is an offshore site.

8. The method of claim 1, wherein the fluid from the fluid source is blended with the fluid additive from the fluid additive source in the blender tub.

9. The method of claim 1, wherein the electric blender module further comprises at least one electric motor that is operatively associated with the dedicated source of electric power and that affects blending of the fluid from the fluid source with the fluid additive from the fluid additive source.

10. The method of claim 1, wherein the electric blender module further comprises a first electric motor and a second electric motor, both operatively associated with the dedicated source of electric power, and wherein the first electric motor affects delivery of the fluid from the fluid source to the blender tub and the second electric motor affects blending of the fluid from the fluid source with the fluid additive from the fluid additive source in the blender tub.

11. The method of claim 10, wherein the electric blender module further comprises a third electric motor operatively associated with the dedicated source of electric power, and wherein the third electric motor affects delivery of the fluid additive from the fluid additive source to the blender tub.

12. The method of claim 1, wherein the electric blender module comprises a first blender unit and a second blender unit each disposed thereon, and wherein the first blender unit and the second blender unit each comprise the fluid source, the fluid additive source, and the blender tub.

13. The method of claim 12, wherein the first blender unit and the second blender unit each comprise at least one electric motor that is operatively associated with the dedicated source of electric power and that affects blending of the fluid from the fluid source with the fluid additive from the fluid additive source.

14. The method of claim 12, wherein the first blender unit and the second blender unit each comprise a first electric motor and a second electric motor, both operatively associated with the dedicated source of electric power, and wherein the first electric motor affects delivery of the fluid from the fluid source to the blender tub and the second electric motor affects blending of the fluid from the fluid source with the fluid additive from the fluid additive source in the blender tub.

15. The method of claim 14, wherein the first blender unit and the second blender unit each further comprise a third electric motor operatively associated with the dedicated source of electric power, and wherein the third electric motor affects delivery of the fluid additive from the fluid additive source to the blender tub.

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

a well site comprising a wellbore and a dedicated source of electricity;

an electrically powered fracturing module operatively associated with the dedicated source of electricity, the electrically powered fracturing module comprising an electric motor and a fluid pump coupled to the electric motor;

an electrically powered blender module operatively associated with the dedicated source of electricity and capable of providing treatment fluid to the fluid pump for delivery to the wellbore;

a control system for regulating the fracturing module in delivery of treatment fluid from the electrically powered blender module to the fluid pump for delivery to the wellbore; and

a fracturing trailer at the well site for housing the electrically powered fracturing module and the electrically powered blender module.

17. The system of claim 16, further wherein the fracturing trailer houses a plurality of fracturing modules.

18. The system of claim 16, wherein the dedicated source of electricity is disposed at a remote location from the electrically powered fracturing module.

19. The system of claim 16, wherein the well site is an onshore site.

20. The system of claim 16, wherein the well site is an offshore site and the dedicated source of electricity and the electrically powered fracturing module are located on an offshore vessel.

21. The system of claim 16 wherein the electrically powered blender module comprises:

a first electrically driven blender unit;

a first inlet manifold coupled to the first electrically driven blender unit and capable of delivering an unblended fracturing fluid thereto;

a first outlet manifold coupled to the first electrically driven blender unit and capable of delivering the blended fracturing fluid away therefrom;

a second electrically driven blender unit;

a second inlet manifold coupled to the second electrically driven blender unit and capable of delivering the unblended fracturing fluid thereto;

a second outlet manifold coupled to the second electrically driven blender unit and capable of delivering the blended fracturing fluid away therefrom;

an inlet crossing line coupled to the first inlet manifold and the second inlet manifold and capable of delivering the unblended fracturing fluid there between; and

an outlet crossing line coupled to the first outlet manifold and the second outlet manifold and capable of delivering the blended fracturing fluid there between.