Automated fracturing system and method

• US 10,408,031 B2
• Filed: 10/15/2018
• Issued: 09/10/2019
• Est. Priority Date: 10/13/2017
• 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., Christinzio, Alexander James
• Primary Examiner(s): Thompson, Kenneth L
• Application Number:
  US16/160,708
• Publication Number:
  US 20190112910A1
• Time in Patent Office: 330 Days
• CPC Class Codes: E21B 21/062 by mixing components
• CPC Class Codes: E21B 41/00 Equipment or details not covered by groups E21B15/00 - E21B40/00
• CPC Class Codes: E21B 43/26 by forming crevices or fractures
• CPC Class Codes: E21B 43/2607 Surface equipment specially adapted for fracturing operations

Abstract

An automated hydraulic fracturing system, including a pump system, a blender configured to form the fracturing fluid, a proppant storage and delivery system, a hydration unit configured to mix an additive into a fluid to form the fluid mixture and provide the fluid mixture to the blender, a fluid storage and delivery system, and an additive storage and delivery system, and an automated control system including a plurality of sensing devices and a plurality of control devices integrated into the pump system, the blender system, the proppant storage and delivery system, the fluid storage and delivery system, and the additive storage and delivery system, the automated control system configured to monitor parameters of the automated hydraulic fracturing system via the plurality of sensing devices and transmit control instructions for one or more of the plurality of control devices to control an aspect of the automated hydraulic fracturing system.

Claims

1. An automated hydraulic fracturing method, comprising:

initiating a hydraulic fracturing operation using an automated hydraulic fracturing system;

delivering a fluid from a fluid storage system to a hydration unit;

delivering an additive from an additive storage system to the hydration unit;

mixing the fluid and the additive at the hydration unit to form a fluid mixture;

delivering the fluid mixture from the hydration unit to a blender;

delivering proppant from a proppant storage system to the blender;

mixing the fluid mixture and the proppant at the blender to form a fracturing fluid, the blender comprising a blender sensor for measuring one or more parameters associated with the blender and a blender controller for controlling one or more functions of the bender;

providing the fracturing fluid from the blender to a pump, the pump comprising a pump sensor for measuring one or more parameters associated with the pump and a pump controller for controlling one or more functions of the pump;

injecting the fracturing fluid from the pump into a wellhead coupled to a well;

monitoring one or more parameters of the hydraulic fracturing operation via a plurality of sensing devices integrated into the proppant storage system, the fluid storage system, the additive storage system, the hydration unit, the blender, and the pump;

generating automated instructions for at least one of the sensing and control devices based at last in part on the one or more parameters; and

controlling one or more functions of the hydraulic fracturing operation via a plurality of control devices integrated into the proppant storage system, the fluid storage system, the additive storage system, the hydration unit, the blender, and the pump based at least in part on the automated instructions.

2. The method of claim 1, further comprising:

detecting that at least one of the one or more parameters is outside of an acceptable threshold; and

automatically stopping or adjusting at least one of the one or more functions in response to the detection.

3. The method of claim 1, further comprising:

detecting substandard performance in one or more areas of the automated hydraulic fracturing system;

automatically troubleshooting the automated hydraulic fracturing system based on live or previously collected data from the sensing devices;

determining one or more causes or suspected causes of the substandard performance; and

automatically adjusting one or more components of the automated hydraulic fracturing system to resolve the substandard performance.

4. The method of claim 1, further comprising:

detecting that at least one performance issue of the automated hydraulic fracturing system; and

providing troubleshooting codes or alerts indicative of one or more sources of the performance issue.

5. The method of claim 1, further comprising:

transmitting information derived from the one or more parameters to a remote control center;

receiving control instructions from the remote control center; and

automatically controlling at least one aspect of the hydraulic fracturing system based at least in part on the received control instructions.

6. The method of claim 1, further comprising:

automatically starting, stopping, or adjusting the rate of delivery of the proppant or fluid mixture to the blender based at least in part on the automated instructions.

7. The method of claim 1, further comprising:

controlling a pressure or rate at which the fracturing fluid is injected into the wellhead based on the automated instructions.

8. The method of claim 1, further comprising:

providing the fracturing fluid from the blender to a plurality of pumps;

providing the fracturing fluid from the plurality of pumps to a distribution system;

injecting the fracturing fluid from the distribution system into the wellbore; and

automatically adjusting individual pressures or pump rates of the plurality of pumps and/or a pressure or pump rate of the distribution system based on the automated instructions.