Switchgear load sharing for oil field equipment

• US 9,893,500 B2
• Filed: 04/14/2017
• Issued: 02/13/2018
• 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, LLC (ProFrac Holding Corp.)
• Inventors: Oehring, Jared, Hinderliter, Brandon N.
• Primary Examiner(s): Thompson, Kenneth L
• Application Number:
  US15/487,694
• Publication Number:
  US 20170222409A1
• Time in Patent Office: 305 Days
• CPC Class Codes: E21B 43/2607 Surface equipment specially adapted for fracturing operations
• 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 23/04 Combinations of two or more pumps
• CPC Class Codes: F04B 35/04 the means being electric
• 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: H02B 7/06 Distribution substations, e.g. for urban network H02B7/01 takes precedence
• CPC Class Codes: H02J 2310/10 The network having a local or delimited stationary reach
• CPC Class Codes: H02J 2310/40 The network being an on-board power network, i.e. within a vehicle
• CPC Class Codes: H02J 3/0073 for providing alternative feeding paths between load and source when the main path fails, e.g. transformers, busbars

Abstract

A hydraulic fracturing system for fracturing a subterranean formation is disclosed. In an embodiment, the system may include a plurality of electric pumps fluidly connected to a well associated with the subterranean formation and powered by at least one electric motor, and configured to pump fluid into a wellbore associated with the well at a high pressure so that the fluid passes from the wellbore into the subterranean formation and fractures the subterranean formation; at least one generator electrically coupled to the plurality of electric pumps so as to generate electricity for use by the plurality of electric pumps; and at least one switchgear electrically coupled to the at least one generator and configured to distribute an electrical load between the plurality of electric pumps and the at least one generator.

Claims

1. A hydraulic fracturing system for fracturing a subterranean formation comprising:

a plurality of electric pumps fluidly connected to a well associated with the subterranean formation and powered by at least one electric motor, and configured to pump fluid into a wellbore associated with the well at a high pressure so that the fluid passes from the wellbore into the subterranean formation and fractures the subterranean formation;

at least one generator electrically coupled to the plurality of electric pumps so as to generate electricity for use by the plurality of electric pumps;

at least two switchgear units electrically coupled to the at least one generator and configured to distribute an electrical load between the plurality of electric pumps and the at least one generator; and

a tie breaker electrically coupled between each of the at least two switchgear units.

2. The system of claim 1, wherein the system comprising the plurality of electric pumps, the at least one generator, and the at least two switchgear units comprises a single electrical microgrid.

3. The system of claim 2, wherein the system comprising the single electrical microgrid is split into two or more electrical banks, each of the two or more electrical banks comprising:

at least one generator, and

at least one switchgear,

wherein when one or more of the two or more electrical banks is shut down, each of the other active electrical banks is configured to distribute the electrical load between the plurality of electric pumps and the at least one generator associated with each active electrical bank.

4. The system of claim 3, wherein the tie breaker is configured to:

evenly distribute the electrical load between the plurality of electric pumps and the at least one generator when the tie breaker is in a closed position; and

isolate one or more of the plurality of electric pumps, the at least one generator, and the at least two switchgear units when the tie breaker is in an open position.

5. The system of claim 4, wherein:

the tie breaker is in the closed position, and

at least one generator is shut down and at least one other generator is active,

wherein the electrical load is evenly distributed among the at least one other active generators.

6. The system of claim 1, wherein the tie breaker comprises a long distance transmission line.

7. The system of claim 1, wherein the at least two switchgear units are configured to distribute power among any of one or more transformers, auxiliaries, or other switchgear units, or a combination thereof.

8. The system of claim 7, wherein the one or more auxiliaries comprise any of a blender, electric wireline equipment, a water transfer pump, an electric crane, a data van, a work trailer, living quarters, an emergency shower, sand equipment, a turbine inlet chiller, a compressor station, a pumping station, a second fracturing site, a drill rig, or a nitrogen plant, or a combination thereof.

9. The system of claim 1, wherein the at least one generator comprises one of a turbine generator or a diesel generator, or a combination thereof.

10. The system of claim 9, wherein the at least one turbine generator is powered by natural gas.

11. The system of claim 1, wherein each component of the system is modular and movable to different locations on mobile platforms.

12. The system of claim 1, further comprising:

a power connection panel associated with the plurality of electric pumps, wherein the power connection panel comprises;

a plurality of power connections for each of the plurality of electric pumps; and

a system ground connection configured to act as a ground between the plurality of electric pumps and a transformer, wherein the transformer is configured to provide power to the plurality of electric pumps.

13. The system of claim 1, further comprising:

a variable frequency drive connected to the at least one electric motor to control the speed of the at least one electric motor, wherein the variable frequency drive frequently performs electric motor diagnostics to prevent damage to the at least one electric motor.

14. A hydraulic fracturing system for fracturing a subterranean formation comprising:

a plurality of electric pumps fluidly connected to a well associated with the subterranean formation and powered by at least one electric motor, and configured to pump fluid into a wellbore associated with the well at a high pressure so that the fluid passes from the wellbore into the subterranean formation and fractures the subterranean formation;

at least one turbine generator electrically coupled to the plurality of electric pumps so as to generate electricity for use by the plurality of electric pumps;

at least two switchgear units electrically coupled to the at least one turbine generator and configured to distribute an electrical load between the plurality of electric pumps and the at least one turbine generator;

a tie breaker electrically coupled between each of the at least two switchgear units and configured to evenly distribute the electrical load between the plurality of electric pumps and the at least one turbine generator when the tie breaker is in a closed position; and

a variable frequency drive connected to the at least one electric motor to control the speed of the at least one electric motor, wherein the variable frequency drive frequently performs electric motor diagnostics to prevent damage to the at least one electric motor.

15. The system of claim 14, wherein the system comprising the plurality of electric pumps, the at least one turbine generator, the at least two switchgear units, the tie breaker, and the variable frequency drive comprises a single electrical microgrid.

16. The system of claim 15, wherein the system comprising the single electrical microgrid is split into two or more electrical banks, each of the two or more electrical banks comprising:

at least one turbine generator, and

at least one switchgear,

wherein when one or more of the two or more electrical banks is shut down, each of the other active electrical banks is configured to distribute the electrical load between the plurality of electric pumps and the at least one turbine generator associated with each active electrical bank.

17. The system of claim 14, wherein the tie breaker is further configured to:

isolate one or more of the plurality of electric pumps, the at least one turbine generator, and the at least two switchgear units when the tie breaker is in an open position.

18. The system of claim 17, wherein:

the tie breaker is in the closed position, and

at least one turbine generator is shut down and at least one other turbine generator is active,

wherein the electrical load is evenly distributed among the at least one other active turbine generators.

19. The system of claim 14, wherein the at least two switchgear units are configured to distribute power among any of one or more transformers, auxiliaries, or other switchgear units, or a combination thereof.