Turbine chilling for oil field power generation

• US 9,995,218 B2
• Filed: 04/13/2017
• Issued: 06/12/2018
• 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:
  US15/486,970
• Publication Number:
  US 20170218843A1
• Time in Patent Office: 425 Days
• Field of Search: 60912, 290 52
• CPC Class Codes: E21B 43/2607 Surface equipment specially adapted for fracturing operations
• CPC Class Codes: F01D 15/08 Adaptations for driving, or combinations with, pumps
• CPC Class Codes: F01D 15/10 Adaptations for driving, or combinations with, electric generators
• CPC Class Codes: F02C 7/143 before or between the compressor stages
• CPC Class Codes: F02C 7/16 characterised by cooling medium
• CPC Class Codes: F04B 17/03 driven by electric motors
• CPC Class Codes: F04B 19/22 of reciprocating-piston type
• CPC Class Codes: F04B 23/04 Combinations of two or more pumps
• CPC Class Codes: F04B 35/04 the means being electric
• CPC Class Codes: F04B 47/00 Pumps or pumping installations specially adapted for raising fluids from great depths, e.g. well pumps by using positive or negative pressurised fluid medium acting directly on the liquid to be pumped F04F1/00
• 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: F05D 2220/76 an electrical generator
• CPC Class Codes: F05D 2260/213 by the provision of a heat exchanger within the cooling circuit
• CPC Class Codes: H02K 7/1823 structurally associated with turbines or similar engines

Abstract

A hydraulic fracturing system for fracturing a subterranean formation is disclosed. In an embodiment, the system may include a plurality of electric pumps configured to pump fluid into a wellbore associated with a well at a high pressure; 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, each turbine generator having at least one air intake channel; and an air chiller system associated with the at least one turbine generator, the air chiller system comprising: a chiller unit configured to chill a fluid; and at least one coil in fluid communication with the chiller unit and positioned adjacent to the at least one air intake channel, wherein the air chiller system is configured to increase a power output of the at least one turbine 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 turbine generator electrically coupled to the plurality of electric pumps so as to generate electricity for use by the plurality of electric pumps, each turbine generator having at least one air intake channel;

a transformer having a high voltage input in electrical communication with an electrical output of the turbine generator, and a low voltage output;

a step down transformer having an input that is in electrical communication with the low voltage output of the transformer; and

an air chiller system associated with the at least one turbine generator, the air chiller system comprising;

a chiller unit configured to chill a fluid; and

at least one coil in fluid communication with the chiller unit and positioned adjacent to the at least one air intake channel,

wherein the air chiller system is configured to increase a power output of the at least one turbine generator.

2. The system of claim 1, wherein the system comprising the plurality of electric pumps, the at least one turbine generator, and the air chiller system comprises a single electrical micro-grid.

3. The system of claim 1, wherein the step down transformer has an output that is in electrical communication with the air chiller system so as to provide electricity for use by the air chiller system.

4. The system of claim 1, wherein the chilled fluid is circulated from the chiller unit through the at least one coil, and wherein ambient air is passed from the at least one air intake channel along an outer surface of the at least one coil and into the at least one turbine generator, such that the air is chilled by the chilled fluid.

5. The system of claim 4, wherein the chilled air is taken in by the at least one turbine generator so as to increase the power output of the at least one turbine generator.

6. The system of claim 4, wherein the fluid is returned to the chiller unit after passing through the at least one coil.

7. The system of claim 4, further comprising a condensation tank, wherein condensation formed on the outer surface of the at least one coil after the chilled fluid is circulated from the chiller unit through the at least one coil is contained in the condensation tank.

8. The system of claim 1, wherein the at least one turbine generator is powered by natural gas.

9. The system of claim 1, wherein the fluid comprises any of water, ammonia, Freon, or a combination thereof.

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

11. 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.

12. 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;

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;

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, each turbine generator having at least one air intake channel; and

an air chiller system associated with the at least one turbine generator, the air chiller system comprising;

a chiller unit configured to chill a fluid; and

at least one coil in fluid communication with the chiller unit and positioned adjacent to the at least one air intake channel,

wherein the air chiller system is configured to increase a power output of the at least one turbine generator.

13. The system of claim 12, wherein the system comprising the plurality of electric pumps, the variable frequency drive, the at least one turbine generator, and the air chiller system comprises a single electrical micro-grid.

14. The system of claim 13, further comprising:

a transformer having a high voltage input in electrical communication with an electrical output of the turbine generator, and a low voltage output; and

a step down transformer having an input that is in electrical communication with the low voltage output of the transformer.

15. The system of claim 14, wherein the step down transformer has an output that is in electrical communication with the air chiller system so as to provide electricity for use by the air chiller system.

16. The system of claim 12, wherein the chilled fluid is circulated from the chiller unit through the at least one coil, and wherein ambient air is passed from the at least one air intake channel along an outer surface of the at least one coil and into the at least one turbine generator, such that the air is chilled by the chilled fluid.

17. The system of claim 16, wherein the chilled air is taken in by the at least one turbine generator so as to increase the power output of the at least one turbine generator.

18. The system of claim 16, wherein the fluid is returned to the chiller unit after passing through the at least one coil.

19. The system of claim 16, further comprising a condensation tank, wherein condensation formed on the outer surface of the at least one coil after the chilled fluid is circulated from the chiller unit through the at least one coil is contained in the condensation tank.