Methods and systems for operating a fleet of pumps

• US 10,815,764 B1
• Filed: 06/05/2020
• Issued: 10/27/2020
• Est. Priority Date: 09/13/2019
• Status: Active Grant

• Current Assignee: BJ Energy Solutions, LLC
• Original Assignee: BJ Energy Solutions, LLC
• Inventors: Yeung, Tony, Rodriguez-Ramon, Ricardo, Fu, Diankui, Zemlak, Warren, Seth, Samir Nath, Foster, Joseph
• Primary Examiner(s): Sayre, James G
• Application Number:
  US16/946,082
• Time in Patent Office: 144 Days
• CPC Class Codes: E21B 43/26 by forming crevices or fractures
• CPC Class Codes: E21B 43/2607 Surface equipment specially adapted for fracturing operations
• CPC Class Codes: F04B 17/05 driven by internal-combustion engines
• CPC Class Codes: F04B 2201/1203 Power on the axis
• CPC Class Codes: F04B 2203/11 of a gas turbine
• CPC Class Codes: F04B 23/04 Combinations of two or more pumps
• CPC Class Codes: F04B 23/06 the pumps being all of reciprocating positive-displacement type
• CPC Class Codes: F04B 49/007 Installations or systems with two or more pumps or pump cylinders, wherein the flow-path through the stages can be changed, e.g. from series to parallel centrifugal pumps F04D15/0072
• CPC Class Codes: F04B 49/02 Stopping, starting, unloading or idling control
• CPC Class Codes: F04B 49/065 and making use of computers
• CPC Class Codes: F04B 49/10 Other safety measures
• CPC Class Codes: F04B 49/20 by changing the driving speed
• CPC Class Codes: F04B 51/00 Testing machines, pumps, or pumping installations
• CPC Class Codes: F04B 9/02 the means being mechanical

Abstract

A system and method for operating a fleet of pumps for a turbine driven fracturing pump system used in hydraulic fracturing is disclosed. In an embodiment, a method of operating a fleet of pumps associated with a hydraulic fracturing system includes receiving a demand Hydraulic Horse Power (HHP) signal. The demand HHP signal may include the Horse Power (HP) required for the hydraulic fracturing system to operate and may include consideration for frictional and other losses. The method further includes operating all available pump units at a percentage of rating below Maximum Continuous Power (MCP) level, based at least in part on the demand HHP signal. Furthermore, the method may include receiving a signal for loss of power from one or more pump units. The method further includes operating one or more units at MCP level and operating one or more units at Maximum Intermittent Power (MIP) level to meet the demand HHP signal.

Claims

1. A method of operating a plurality of pump units associated with a high-pressure, high-power hydraulic fracturing assembly, each of the pump units including a turbine engine, a driveshaft, a gearbox connected to the turbine engine and driveshaft for driving the driveshaft, and a pump connected to the driveshaft, the method comprising:

receiving a demand hydraulic horse power (HHP) signal for operation of the hydraulic fracturing assembly;

based at least in part on the demand HHP signal, operating all available pump units of the plurality of pump units at a first output power to achieve the demand HHP;

receiving a loss of power signal for at least one pump unit of the plurality of pump units during operation of the plurality of pump units;

after receiving the loss of power signal, designating the at least one pump unit as a reduced power pump unit (RPPU) and the remaining pump units as operating pump units (OPU); and

operating at least one of the OPUs at a second output power to meet the demand HHP signal for operation of the hydraulic fracturing assembly,

the first output power being in the range of approximately 70% to 100% of a maximum continuous power (MCP) level of the plurality of pump units, the second output power being greater than the first output power and being in the range of approximately 70% of the MCP level to approximately a maximum intermittent power (MIP) level of the plurality of pump units.

2. The method of claim 1, further comprising operating at least one of the OPUs at a third output power, the third output power being in the range of approximately 70% to approximately the MIP level.

3. The method of claim 2, wherein the third output power is greater than the first output power.

4. The method of claim 2, wherein the third output power is approximately equal to the first output power.

5. The method of claim 1, wherein the at least one RPPU comprises one pump unit, and wherein the OPUs operating at the second output power comprise one or more less pump units than the plurality of pump units.

6. The method of claim 1, wherein the at least one pump unit of the OPUs comprises all of the OPUs, and wherein the second output power comprises the MIP level.

7. The method of claim 1, wherein the first output power is 100% of the MCP level.

8. The method of claim 1, wherein the first output power is 90% of the MCP level.

9. The method of claim 8, wherein the second output power is 107% of the MCP level.

10. The method of claim 9, wherein the second output power is the MIP level.

11. The method of claim 1, wherein the at least one pump unit of the OPUs comprises at least two pump units, and wherein the second output power comprises the MIP level.

12. The method of claim 1, further comprising operating the at least one RPPU at a reduced output power below the first output power.

13. The method of claim 12, wherein the reduced output power of the RRPU is approximately 20% less than the first output power.

14. The method of claim 1, further comprising shutting down the at least one RPPU, and wherein the second output power is approximately the MIP level.

15. A system to control operation of a plurality of pump units associated with a hydraulic fracturing assembly, each of the pump units including a turbine engine, connected to a gearbox for driving a driveshaft, and a pump connected to the drive shaft, the system comprising:

a controller in communication with the plurality of pump units, the controller including one or more processors and memory having computer-readable instructions stored therein and operable by the processor to;

receive a demand hydraulic horse power (HHP) signal for the hydraulic fracturing assembly,

based at least in part on the demand HHP signal, operate all available pump units of the plurality of pump units at a first output power to achieve the demand HHP;

receive a loss of power signal from at least one pump unit of the plurality of pump units,

after receiving the loss of power signal, designate the at least one pump unit as a reduced power pump unit (RPPU), and

designate the remaining pump units as operating pump units (OPU), and operate one or more of the OPUs at a second output power to meet the demand HHP signal of the hydraulic fracturing system,

the first output power being in the range of approximately 70% to 100% of a maximum continuous power (MCP) level of the plurality of pump units, the second output power being greater than the first output power and being in the range of approximately 70% of MCP level to approximately a maximum intermittent power (MIP) level of the plurality of pump units.

16. The system of claim 15, wherein after receiving the loss of power signal, the computer readable instructions are operable to operate at least one of the OPUs at a third output power, the third output power being in the range of approximately 70% to approximately the MIP level.

17. The system of claim 16, wherein the third output power is greater than the first output power.

18. The system of claim 16, wherein the third output power is approximately equal to the first output power.

19. The system of claim 16, wherein the at least one RPPU comprises one pump unit, and wherein the OPUs comprise one less pump unit than the plurality of pump units.

20. The system of claim 16, wherein the at least one pump unit of the OPUs comprises all of the OPUs, and wherein the second output power comprises the MIP level.

21. The system of claim 16, wherein the first output power is 100% of the MCP.

22. The system of claim 21, wherein the second output power 107% of the MCP level.

23. The system of claim 22, wherein the second output power is the MIP level.

24. The system of claim 16, wherein the first output power is 90% of the MCP level.

25. The system of claim 16, wherein the at least one pump unit of the OPUs comprises at least two pump units, and wherein the second output power comprises the MIP level.

26. The system of claim 16, wherein after receiving the loss of power signal, the computer readable instructions are operable to operate the at least one RPPU at a reduced output power below the first output power.

27. The system of claim 26, wherein the reduced output power of the RRPU is approximately 20% less than the first output power.

28. The system of claim 16, wherein after receiving the loss of power signal, the computer readable instructions are operable to shut down the at least one RRPU, and the second output power is approximately the MIP level.