Methods of powering blenders and pumps in fracturing operations using electricity

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.

Description

Notice: More than one reissue application has been filed for the reissue of U.S. Pat. No. 8,834,012. The reissue applications are U.S. patent application Ser. No. 15/079,027, now U.S. Pat. No. RE46,725, which is a reissue application of U.S. Pat. No. 8,834,012; U.S. patent application Ser. No. 15/853,076, now U.S. Pat. No. RE47,695, which is a divisional reissue application of U.S. patent application Ser. No. 15/079,027, now U.S. Pat. No. RE46,725; U.S. patent application Ser. No. 16/537,070, which is a continuation reissue application of U.S. patent application Ser. No. 15/853,076, now U.S. Pat. No. RE47,695; U.S. patent application Ser. No. 16/537,124, which is a continuation reissue application of U.S. patent application Ser. No. 15/853,076 now U.S. Pat. No. RE47,695; the present U.S. patent application Ser. No. FIG. 7 is a schematic diagram illustrating a pumping system in accordance with an exemplary embodiment of the present invention. FIG. 7 is a schematic diagram illustrating a pumping system in accordance with an exemplary embodiment of the present invention, denoted generally with reference numeral 700. In one exemplary embodiment, shown in FIG. 7, the transfer pump 702 may be powered by a natural gas fired engine or a natural gas fired generator set 714. In another exemplary embodiment, also shown in FIG. 7, the transfer pump may be powered by electricity from a power grid 716. Once the fluid system is mixed and blended with proppant and other fluid modifiers it is boosted to the high horsepower down hole pumps 704. The down hole pumps pump the slurry through the high pressure ground manifold 706 to the well head 708 and down hole. In one embodiment, the down hole pumps 704 may be powered by a natural gas fired engine, a natural gas fired generator set 714 or electricity from a power grid 716. The down hole pumps typically account for over two third of the horsepower on location, thereby reducing the carbon footprint of the overall operations.

In one exemplary embodiment, the natural gas used to power the transfer pumps, the down hole pumps or the other system components may be obtained from the field on which the subterranean operations are being performed 720. In one embodiment, the natural gas may be converted to liquefied natural gas 712 and used to power pumps and other equipment that would typically be powered by diesel fuel. In another embodiment, the natural gas may be used to provide power through generator sets 714. The natural gas from the field may undergo conditioning 710 before being used to provide power to the pumps and other equipment. The conditioning process may include cleaning the natural gas, compressing the natural gas in compressor stations and if necessary, removing any water contained therein.

As would be appreciated by those of ordinary skill in the art, with the benefit of this disclosure, the IMSBS may include a different number of storage units 102, IPBs 106 and/or liquid additive storage modules 110, depending on the system requirements. For instance, in another exemplary embodiment (not shown), the IMSBS may include three storage units, one IPB and one liquid additive storage module.

FIG. 6 depicts an isometric view of IMSBS in accordance with an exemplary embodiment of the present invention, denoted generally with reference numeral 600. As depicted in FIG. 6, each of the storage units 602, each of the liquid additive storage modules 604 and each of the IPBs 606 may be arranged as an individual module. In one embodiment, one or more of the storage units 602, the liquid additive storage modules 604 and the IPBs 606 may include a latch system which is couplable to a truck or trailer which may be used for transporting the module. In one embodiment, the storage units 602 may be a self-erecting storage unit as disclosed in U.S. patent application Ser. No. 12/235,270, assigned to Halliburton Energy Services, Inc., which is incorporated by reference herein in its entirety. Accordingly, the storage units 602 may be specially adapted to connect to a vehicle which may be used to lower, raise and transport the storage unit 602. Once at a jobsite, the storage unit 602 may be erected and filled with a predetermined amount of a desired material. A similar design may be used in conjunction with each of the modules of the IMSBS 600 disclosed herein in order to transport the modules to and from a job site. Once the desired number of storage units 602, the liquid additive storage modules 604 and the IPBs 606 are delivered to a job site, they are erected in their vertical position. Dry materials such as proppants or gel powder may then be filled pneumatically to the desired level and liquid chemicals may be pumped into the various storage tanks. Load sensors (not shown) may be used to monitor the amount of materials added to the storage units 602, the liquid additive storage modules 604 and the IPBs 606 in real time.

As would be appreciated by those of ordinary skill in the art, with the benefit of this disclosure, an IMSBS 600 in accordance with an exemplary embodiment of the present invention which permits accurate, real-time monitoring of the contents of the storage units 602, the liquid additive storage modules 604 and/or the IPBs 606 provides several advantages. For instance, an operator may use the amount of materials remaining in the storage units 602, the liquid additive storage modules 604 and/or the IPBs 606 as a quality control mechanism to ensure that material consumption is in line with the job requirements. Additionally, the accurate, real-time monitoring of material consumption expedites the operator's ability to determine the expenses associated with a job.

As would be appreciated by those of ordinary skill in the art, with the benefit of this disclosure, the different equipment used in an IMSBS in accordance with the present invention may be powered by any suitable power source. For instance, the equipment may be powered by a combustion engine, electric power supply which may be provided by an on-site generator or by a hydraulic power supply.

Therefore, the present invention is well-adapted to carry out the objects and attain the ends and advantages mentioned as well as those which are inherent therein. While the invention has been depicted and described by reference to exemplary embodiments of the invention, such a reference does not imply a limitation on the invention, and no such limitation is to be inferred. The invention is capable of considerable modification, alteration, and equivalents in form and function, as will occur to those ordinarily skilled in the pertinent arts and having the benefit of this disclosure. The depicted and described embodiments of the invention are exemplary only, and are not exhaustive of the scope of the invention. Consequently, the invention is intended to be limited only by the spirit and scope of the appended claims, giving full cognizance to equivalents in all respects. The terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee.

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 method of performing a fracturing operation comprising:

having an amount of electricity sufficient to power one or more pumps that are capable of pumping a fracturing fluid down hole to perform the fracturing operation, wherein the amount of electricity is produced on-site using conditioned field gas; and

pumping the fracturing fluid down hole using the amount of electricity to perform the fracturing operation.

28. The method of claim 27, wherein the fracturing fluid comprises a liquid and a solid component.

29. The method of claim 27, wherein the conditioned field gas is liquefied natural gas, compressed natural gas, or a combination thereof.

30. The method of claim 29, wherein the liquefied natural gas, compressed natural gas, or a combination thereof is derived from natural gas obtained from a field where the fracturing operation is being performed.

31. The method of claim 27, wherein the pumping the fracturing fluid down hole further comprises using an engine powered by liquefied natural gas, compressed natural gas, or a combination thereof.

32. The method of claim 27, wherein the conditioned field gas is used to power one or more generators that produces the amount of electricity to power the one or more pumps.

33. The method of claim 27, wherein the conditioned field gas is derived from natural gas obtained from a field where the fracturing operation is being performed.

34. The method of claim 27, wherein the amount of electricity used to power the one or more pumps powers at least two thirds of total horsepower for the fracturing operation.

35. The method of claim 27, further comprising:

having a liquid additive in a storage unit; and

transferring the liquid additive from the storage unit to a blender using at least gravity.

36. The method of claim 27, further comprising:

having a solid component in a storage unit; and

transferring the solid component from the storage unit to a blender using gravity and without a powered conveyor.

37. The method of claim 27, further comprising:

having a solid component in a storage unit;

transferring the solid component from the storage unit to a blender; and

determining a change in weight, mass and/or volume of the solid component in the storage unit.

38. The method of claim 37, further comprising:

using at least one load sensor wirelessly coupled to an information handling system to determine the change in weight, mass and/or volume of the solid component in the storage unit.

39. The method of claim 27, further comprising:

having a solid component in a storage unit;

transferring the solid component from the storage unit to a blender; and

providing a real-time visual depiction of an amount of the solid component contained in the storage unit.

40. The method of claim 27, further comprising:

having a solid component in a storage unit;

transferring the solid component from the storage unit to a blender; and

using an information handling system to monitor an amount of the solid component in the storage unit.

41. The method of claim 27, further comprising:

having a solid component in a storage unit;

transferring the solid component from the storage unit to a blender; and

providing an alert when the amount of the solid component in the storage unit reaches a threshold level.

42. A method of performing a fracturing operation comprising:

using at least one blender to prepare a fracturing fluid and a plurality of pumps to pump the fracturing fluid down hole to perform the fracturing operation,

wherein the at least one blender and the plurality of pumps are powered using only electricity, and

wherein the electricity powering the plurality of pumps is produced using only conditioned field gas obtained from a field where the fracturing operation is being performed.

43. The method of claim 42, wherein the fracturing fluid comprises sand or proppant delivered to the blender from a storage unit using gravity and without a powered conveyor.

44. The method of claim 42, wherein the fracturing fluid is blended and pumped down hole without using diesel.

45. The method of claim 42, wherein the electricity used to power the plurality of pumps powers at least two thirds of total horsepower for the fracturing operation.

46. The method of claim 42, further comprising monitoring and controlling consumption of a material used in the fracturing operation using an information handling system.

47. The method of claim 46, wherein the information handling system is wirelessly coupled to a sensor.

48. The method of claim 42, further comprising real-time monitoring of material consumption to determine expenses associated with the fracturing operation.

49. A method of performing a fracturing operation comprising:

having an amount of electricity sufficient to power a blender that is capable of preparing a fracturing fluid and one or more pumps that are capable of pumping the fracturing fluid down hole to perform the fracturing operation, wherein the amount of electricity is produced on-site using conditioned field gas;

preparing the fracturing fluid using the blender, wherein the blender is powered using the amount of electricity; and

pumping the fracturing fluid down hole using the one or more pumps, wherein the one or more pumps are powered using the amount of electricity.

50. The method of claim 49, further comprising using the amount of electricity to power a transfer pump.

51. The method of claim 49, further comprising powering the one or more pumps using electricity from a power grid.

52. The method of claim 49, wherein the amount of electricity is produced using liquefied natural gas, compressed natural gas, or a combination thereof.

53. The method of claim 49, wherein the conditioned field gas is derived from natural gas obtained from a field where the fracturing operation is being performed.