Electric or natural gas fired small footprint fracturing fluid blending and pumping equipment

• US RE46,725 E1
• Filed: 03/23/2016
• Issued: 02/20/2018
• Est. Priority Date: 09/11/2009
• Status: Active Grant

• Current Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Original Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Inventors: Case, Leonard R., Hagan, Ed B., Stegemoeller, Calvin L., Hyden, Ron
• Primary Examiner(s): XU, LING X
• Application Number:
  US15/079,027
• Time in Patent Office: 699 Days
• Field of Search: None
• CPC Class Codes: E21B 21/062 by mixing components

Abstract

Methods and systems for integral storage and blending of the materials used in oilfield operations are disclosed. A modular integrated material blending and storage system includes a first module comprising a storage unit, a second module comprising a liquid additive storage unit and a pump for maintaining pressure at an outlet of the liquid additive storage unit. The system further includes a third module comprising a pre-gel blender. An output of each of the first module, the second module and the third module is located above a blender and gravity directs the contents of the first module, the second module and the third module to the blender. The system also includes a pump that directs the output of the blender to a desired down hole location. The pump may be powered by natural gas or electricity.

Claims

1. An integrated material blending and storage system comprising:

a storage unit;

a blender located under the storage unit;

wherein the blender is operable to receive a first input from the storage unit through a hopper;

a liquid additive storage module having a first pump to maintain constant pressure at an outlet of the liquid additive storage module;

wherein the blender is operable to receive a second input from the liquid additive storage module; and

a pre-gel blender, wherein the pre-gel blender comprises at least a pre-gel storage unit resting on a leg, further wherein the pre-gel storage unit comprises a central core and an annular space, wherein the annular space hydrates the contents of the pre-gel blender;

wherein the blender is operable to receive a third input from the pre-gel blender;

wherein gravity directs the contents of the storage unit, the liquid additive storage module and the pre-gel blender to the blender;

a second pump; and

a third pump;

wherein the second pump directs the contents of the blender to the third pump; and

wherein the third pump directs the contents of the blender down hole;

wherein at least one of the second pump and the third pump is powered by one of natural gas and electricity.

2. The system of claim 1, wherein the storage unit comprises a load sensor.

3. The system of claim 1, wherein the pre-gel blender comprises:

a feeder coupling the pre-gel storage unit to a first input of a mixer;

a fourth pump coupled to a second input of the mixer;

wherein the pre-gel storage unit contains a solid component of a well treatment fluid;

wherein the feeder supplies the solid component of the well treatment fluid to the mixer;

wherein the fourth pump supplies a fluid component of the well treatment fluid to the mixer; and

wherein the mixer outputs a well treatment fluid.

4. The system of claim 3, wherein the well treatment fluid is a gelled fracturing fluid.

5. The system of claim 4, wherein the solid component is a gel powder.

6. The system of claim 4, wherein the fluid component is water.

7. The system of claim 3, wherein the central core contains the solid component of the well treatment fluid.

8. The system of claim 3, wherein the well treatment fluid is directed to the annular space.

9. The system of claim 3, wherein the annular space comprises a tubular hydration loop.

10. The system of claim 9, wherein the well treatment fluid is directed from the mixer to the tubular hydration loop.

11. The system of claim 3, wherein the well treatment fluid is selected from the group consisting of a fracturing fluid and a sand control fluid.

12. The system of claim 3, further comprising a power source to power at least one of the feeder, the mixer and the pump.

13. The system of claim 12, wherein the power source is selected from the group consisting of a combustion engine, an electric power supply and a hydraulic power supply.

14. The system of claim 13, wherein one of the combustion engine, the electric power supply and the hydraulic power supply is powered by natural gas.

15. The system of claim 1, further comprising a load sensor coupled to one of the storage unit, the liquid additive storage module or the pre-gel blender.

16. The system of claim 15, further comprising an information handling system communicatively coupled to the load sensor.

17. The system of claim 15, wherein the load sensor is a load cell.

18. The system of claim 15, wherein a reading of the load sensor is used for quality control.

19. The system of claim 1, wherein the electricity is derived from one of a power grid and a natural gas generator set.

20. A modular integrated material blending and storage system comprising:

a first module comprising a storage unit;

a second module comprising a liquid additive storage unit and a first pump for maintaining pressure at an outlet of the liquid additive storage unit; and

a third module comprising a pre-gel blender, wherein the pre-gel blender comprises at least a pre-gel storage unit resting on a leg, further wherein the pre-gel storage unit comprises a central core and an annular space, wherein the annular space hydrates the contents of the pre-gel blender;

wherein an output of each of the first module, the second module and the third module is located above a blender; and

wherein gravity directs the contents of the first module through a hopper, the second module and the third module to the blender;

a second pump;

wherein the second pump directs the output of the blender to a desired down hole location; and

wherein the second pump is powered by one of natural gas and electricity.

21. The system of claim 20, wherein each of the first module, the second module and the third module is a self erecting module.

22. The system of claim 20, wherein the third module comprises:

a feeder coupling the pre-gel storage unit to a first input of a mixer;

a third pump coupled to a second input of the mixer;

wherein the pre-gel storage unit contains a solid component of a well treatment fluid;

wherein the feeder supplies the solid component of the well treatment fluid to the mixer;

wherein the third pump supplies a fluid component of the well treatment fluid to the mixer; and

wherein the mixer outputs a well treatment fluid.

23. The system of claim 22, wherein the well treatment fluid is directed to the blender.

24. The system of claim 20, wherein the blender mixes the output of the first module, the second module and the third module.

25. The system of claim 20, further comprising a fourth pump for pumping an output of the blender down hole.

26. The system of claim 25, wherein the fourth pump is selected from the group consisting of a centrifugal pump, a progressive cavity pump, a gear pump and a peristaltic pump.

27. A system for preparing fluid for use at a well having a wellbore, the system comprising:

at least one storage unit adapted to connect to a vehicle for transportation;

at least one pre-gel blender having a pre-gel storage unit, wherein the pre-gel storage unit comprises a central core and an annular space;

at least one blender coupled to receive a component of a first fluid from the at least one storage unit through a hopper, the at least one blender having inputs from at least the at least one storage unit, and the at least one pre-gel blender;

at least one pump for applying pressure to the first fluid or a second fluid, and the at least one pump coupled to provide an input to the at least one blender; and

an electric power supply, including an electrical generator located on-site, providing electrical power to at least one of the at least one blender and the at least one pump.

28. The system of claim 27 wherein the pre-gel storage unit contains a gel powder.

29. The system of claim 27 wherein the pre-gel storage unit rests on at least one leg.

30. The system of claim 27 wherein the pre-gel storage unit comprises a space in which contents of the pre-gel storage unit are allowed to hydrate.

31. The system of claim 27 wherein contents of the pre-gel storage unit are allowed to hydrate in the annular space.

32. The system of claim 27 wherein the central core contains a gel powder.

33. The system of claim 32 wherein the gel powder from the pre-gel storage unit is allowed to hydrate in the annular space.

34. The system of claim 27 further comprising a liquid additive storage module, wherein the at least one blender further comprises an input from the liquid additive storage module.

35. The system of claim 34 wherein the pre-gel storage unit contains a gel powder.

36. The system of claim 34 wherein the pre-gel storage unit rests on at least one leg.

37. The system of claim 34 wherein the pre-gel storage unit comprises a space in which contents of the pre-gel storage unit are allowed to hydrate.

38. The system of claim 34 wherein contents of the pre-gel storage unit are allowed to hydrate in the annular space.

39. The system of claim 34 wherein the central core contains a gel powder.

40. The system of claim 39 wherein the gel powder from the pre-gel storage unit is allowed to hydrate in the annular space.

41. The system of claim 39 wherein the pre-gel storage unit comprises a tubular hydration loop in which contents of the pre-gel storage unit are allowed to hydrate.

42. The system of claim 41 wherein the tubular hydration loop is located in an annular space of the pre-gel storage unit.

43. The system of claim 27 wherein a combustion engine provides power to the system.

44. The system of claim 27 wherein a hydraulic power supply provides power to the system.

45. A system comprising:

at least one storage unit;

at least one pre-gel blender;

at least one pre-gel storage unit coupled to the at least one pre-gel blender, wherein the at least one pre-gel storage unit comprises a central core and an annular space;

at least one blender coupled to receive a component of a fluid from the at least one storage unit through a hopper, the at least one blender having inputs from at least the at least one storage unit and the at least one pre-gel blender;

at least one pump in fluid communication with a wellbore in a subterranean field; and

a power supply, including a natural gas device, providing power to at least one of the at least one blender and the at least one pump.

46. The system of claim 45 wherein the at least one pre-gel storage unit contains a gel powder.

47. The system of claim 45 wherein the at least one pre-gel storage unit rests on at least one leg.

48. The system of claim 45 wherein the at least one pre-gel storage unit comprises a space in which the contents of the at least one pre-gel storage unit are allowed to hydrate.

49. The system of claim 45 wherein the contents of the at least one pre-gel storage unit are allowed to hydrate in the annular space.

50. The system of claim 45 wherein the central core contains a gel powder.

51. The system of claim 50 wherein the contents of the at least one pre-gel storage unit are allowed to hydrate in the annular space.

52. The system of claim 45 further comprising a liquid additive storage module, wherein the at least one blender further comprises an input from the liquid additive storage module.

53. The system of claim 52 wherein the at least one pre-gel storage unit contains a gel powder.

54. The system of claim 52 wherein the at least one pre-gel storage unit rests on at least one leg.

55. The system of claim 52 wherein the at least one pre-gel storage unit comprises a space in which the contents of the at least one pre-gel storage unit are allowed to hydrate.

56. The system of claim 52 wherein the contents of the at least one pre-gel storage unit are allowed to hydrate in the annular space.

57. The system of claim 52 wherein the central core contains a gel powder.

58. The system of claim 57 wherein the contents of the at least one pre-gel storage unit are allowed to hydrate in the annular space.

59. The system of claim 52 wherein the at least one pre-gel storage unit comprises a tubular hydration loop in which the contents of the at least one pre-gel storage unit are allowed to hydrate.

60. The system of claim 59 wherein the tubular hydration loop is located in an annular space of the at least one pre-gel storage unit.

61. The system of claim 45 wherein the natural gas generator is coupled to receive the at least some natural gas originating in the underground formation after it has been converted to liquefied natural gas.

62. The system of claim 45 wherein the natural gas generator is coupled to receive the at least some natural gas originating in the underground formation after it has been conditioned.

63. The system of claim 62 wherein the natural gas is conditioned by cleaning the natural gas.

64. The system of claim 62 wherein the natural gas is conditioned by compressing the natural gas in compressor stations.

65. The system of claim 62 wherein the natural gas is conditioned by removing water from the natural gas.

66. The system of claim 45 wherein the natural gas device is a natural gas fired generator.

67. The system of claim 45 wherein the natural gas device is a natural gas fired engine.

68. The system of claim 45 wherein the natural gas device is coupled to receive at least some natural gas originating from the subterranean field.

69. A system for preparing fluid for use at a well having a wellbore, the system comprising:

at least one storage unit adapted to connect to a vehicle for transportation;

at least one pre-gel blender having a pre-gel storage unit, wherein the pre-gel storage unit comprises a tubular hydration loop in which contents of the pre-gel storage unit are allowed to hydrate;

at least one blender coupled to receive a component of a first fluid from the at least one storage unit through a hopper, the blender having inputs from at least the at least one storage unit, and the at least one pre-gel blender;

at least one pump for applying pressure to the first fluid or a second fluid, and the at least one pump coupled to provide an input to the at least one blender; and

an electric power supply, including an electrical generator located on-site, providing electrical power to at least one of the at least one blender and the at least one pump.

70. A system of claim 69 wherein the tubular hydration loop is located in an annular space of the pre-gel storage unit.

71. A system of claim 69 wherein the at least one storage unit comprises a load sensor.

72. A system of claim 69 wherein the pre-gel storage unit contains a gel powder.

73. A system of claim 69 wherein the pre-gel storage unit rests on at least one leg.

74. A system of claim 69 wherein a combustion engine provides power to the system.

75. A system of claim 69 wherein a hydraulic power supply provides power to the system.

76. A system comprising:

at least one storage unit;

at least one pre-gel blender;

at least one pre-gel storage unit coupled to the at least one pre-gel blender, wherein the at least one pre-gel storage unit comprises a tubular hydration loop in which the contents of the at least one pre-gel storage unit are allowed to hydrate;

at least one blender coupled to receive the component of a fluid from the at least one storage unit through a hopper, the blender having inputs from at least the at least one storage unit and the at least one pre-gel blender;

at least one pump in fluid communication with a wellbore in a subterranean field; and

a power supply, including a natural gas device, providing power to at least one of the at least one blender and the at least one pump.

77. The system of claim 76 wherein the tubular hydration loop is located in an annular space of the at least one pre-gel storage unit.

78. A system of claim 76 wherein the at least one storage unit comprises a load sensor.

79. A system of claim 76 wherein the at least one pre-gel storage unit contains a gel powder.

80. A system of claim 76 wherein the at least one pre-gel storage unit rests on at least one leg.

81. A system of claim 76 wherein a combustion engine provides power to the system.

82. A system of claim 76 wherein a hydraulic power supply provides power to the system.

83. A system for preparing fluid for use at a well having a wellbore, the system comprising:

at least one storage unit adapted to connect to a vehicle for transportation;

at least one pre-gel blender having a pre-gel storage unit coupled to the at least one pre-gel blender, wherein the pre-gel storage unit comprises a space in which contents of the pre-gel storage unit are allowed to hydrate;

at least one blender coupled to receive a component of a first fluid from the at least one storage unit through a hopper, the at least one blender having inputs from at least the at least one storage unit, and the pre-gel storage unit;

at least one pump for applying pressure to the first fluid or a second fluid, and the at least one pump coupled to provide an input to the at least one blender; and

an electric power supply, including an electrical generator located on-site, providing electrical power to the at least one of the at least one blender and the at least one pump.

84. A system of claim 83 wherein the at least one storage unit comprises a load sensor.

85. A system of claim 83 wherein the pre-gel storage unit contains a gel powder.

86. A system of claim 83 wherein the pre-gel storage unit rests on at least one leg.

87. A system of claim 83 wherein a combustion engine provides power to the system.

88. A system of claim 83 wherein a hydraulic power supply provides power to the system.

89. A system comprising:

at least one storage unit;

at least one pre-gel blender;

at least one pre-gel storage unit coupled to the at least one pre-gel blender and comprising a space in which the contents of the at least one pre-gel storage unit are allowed to hydrate;

at least one blender coupled to receive the component of a fluid from the at least one storage unit through a hopper, the at least one blender having inputs from at least the at least one storage unit and the at least one pre-gel storage unit;

at least one pump in fluid communication with a wellbore in a subterranean field; and

a power supply, including a natural gas device, providing power to at least one of the at least one blender and the at least one pump.

90. A system of claim 89 wherein the at least one storage unit comprises a load sensor.

91. A system of claim 89 wherein the at least one pre-gel storage unit contains a gel powder.

92. A system of claim 89 wherein the at least one pre-gel storage unit rests on at least one leg.

93. A system of claim 89 wherein a combustion engine provides power to the system.

94. A system of claim 89 wherein a hydraulic power supply provides power to the system.