SYSTEM FOR PUMPING HYDRAULIC FRACTURING FLUID USING ELECTRIC PUMPS

• US 20140174717A1
• Filed: 02/26/2014
• Published: 06/26/2014
• 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: Broussard, Joel N., McPherson, Jeff, Kurtz, Robert
• Granted Patent: US 8,789,601 B2
• Time in Patent Office: Days
• US Class Current: 166/66.4
• CPC Class Codes: E21B 43/2607 Surface equipment specially adapted for fracturing operations

Abstract

A system for hydraulically fracturing an underground formation in an oil or gas well to extract oil or gas from the formation, the oil or gas well having a wellbore that permits passage of fluid from the wellbore into the formation. The system includes a plurality of pumps powered by electric induction motors and fluidly connected to the well, the pumps configured to pump fluid into the wellbore at high pressure so that the fluid passes from the wellbore into the, and fractures the formation. The system can also include a plurality of natural gas powered generators electrically connected to the plurality of pumps to provide electrical power to the pumps.

Claims

1. A system for hydraulically fracturing an underground formation in an oil or gas well to extract oil or gas from the formation, the oil or gas well having a wellbore that permits passage of fluid from the wellbore into the formation, the system comprising:

a plurality of pumps powered by electric induction motors and fluidly connected to the well, the pumps configured to pump fluid into the wellbore at high pressure so that the fluid passes from the wellbore into the formation, and fractures the formation; and

a plurality of generators electrically connected to the plurality of pumps to provide electrical power to the pumps.

2. The system of claim 1, wherein at least some of the plurality of generators are powered by a fuel selected from the group consisting of natural gas, liquefied natural gas, and diesel.

3. The system of claim 1, wherein at least some of the plurality of generators are turbine generators.

4. The system of claim 1, further comprising:

an A/C console and a variable frequency drive that controls the speed of at least one of the plurality of pumps.

5. The system of claim 1, wherein the plurality of pumps are mounted on trailers, and can be ported from one well to another.

6. The system of claim 5, wherein the generators are mounted on trailers, and can be ported from one well to another.

7. The system of claim 1, further comprising a plurality of variable frequency drives attached to the plurality of pumps, wherein each variable frequency drive discretely controls a single pump.

8. A system for fracturing a rock formation in an oil or gas well by pumping hydraulic fracturing fluid into the well, the system comprising:

a pump for pumping the hydraulic fracturing fluid into the well, and then from the well into the formation, the pump capable of pumping the hydraulic fracturing fluid at high pressure to crack the formation;

an electric induction motor having a high-strength steel or steel alloy drive shaft attached to the pump and configured to drive the pump;

a variable frequency drive connected to the electric motor to control the speed of the motor; and

a generator connected to the electric motor that provides electric power to the electric motor.

9. The system of claim 8, wherein the pump is a triplex or a quintuplex pump rated at about 2250 horsepower or more.

10. The system of claim 9, wherein the pump has 4.5 inch diameter plungers with an eight inch stroke.

11. The system of claim 8, wherein the electric motor has a maximum continuous power output of about 1500 horsepower or more.

12. The system of claim 11, wherein the electric motor has a maximum continuous torque of about 8750 ft-lb or more.

13. The system of claim 12, wherein the electric motor has a high temperature rating of about 1100 degrees C. or more.

14. The system of claim 13, wherein the drive shaft of the electric motor is composed of 4340 alloy steel.

15. The system of claim 8, wherein the variable frequency drive frequently performs electric motor diagnostics to prevent damage to the electric motor if it becomes grounded or shorted.

16. The system of claim 15, wherein the generator is a turbine generator.

17. The system of claim 8, wherein the variable frequency drive includes power semiconductor heat sinks having one or more thermal sensors monitored by a microprocessor to prevent semiconductor damage caused by excessive heat.

18. A system for hydraulically fracturing an underground formation in an oil or gas well to extract oil or gas from the formation, the oil or gas well having a wellbore that permits passage of fluid from the wellbore into the formation, the system comprising:

a trailer;

two or more pumps attached to the trailer without a skid and fluidly connected to the well, the pumps configured to pump fluid into the wellbore at high pressure so that the fluid passes from the wellbore into the formation, and fractures the formation;

one or more electric induction motors attached to the pumps to drive the pumps, the electric motors attached to the trailer without a skid; and

a generator for connection to the electric induction motor that provides electric power to the electric induction motor.

19. The system of claim 18, further comprising:

a variable frequency drive attached to the trailer and connected to the electric induction motor to control the speed of the motor.