Power sources and transmission networks for auxiliary equipment onboard hydraulic fracturing units and associated methods

Patent metadata

Field	Value
Publication number	US-11236739-B2
Application number	US-202117203002-A
Country	US
Kind code	B2
Filing date	Mar 16, 2021
Priority date	Sep 13, 2019
Publication date	Feb 1, 2022
Grant date	Feb 1, 2022

Abstract

Embodiments of systems and methods disclosed provide a hydraulic fracturing unit that includes a reciprocating plunger pump configured to pump a fracturing fluid and a powertrain configured to power the reciprocating plunger pump. The powertrain includes a prime mover and a drivetrain, the prime mover including a gas turbine engine. The hydraulic fracturing unit also includes auxiliary equipment configured to support operation of the hydraulic fracturing unit including the reciprocating plunger pump and the powertrain. A power system is configured to power the auxiliary equipment. The power system includes a power source and a power network. The power source is configured to generate power for the auxiliary equipment. The power network is coupled to the power source and the auxiliary equipment, and configured to deliver the power generated by the power source to the auxiliary equipment. Associated systems including a plurality of hydraulic fracturing units are also provided.

First claim

What is claimed is:

1. A system for fracturing a well, the system comprising:
a plurality of hydraulic fracturing units, each of the plurality of hydraulic fracturing units comprising:
a chassis;
a reciprocating plunger pump connected to the chassis and configured to pump a fracturing fluid;
a powertrain connected to the chassis and configured to power the reciprocating plunger pump, the powertrain including a direct drive gas turbine engine and a drivetrain, the direct drive gas turbine engine operable using two or more different types of fuel; and
auxiliary equipment located onboard the chassis, the auxiliary equipment driven by electric motors to support operation of the hydraulic fracturing unit including the reciprocating plunger pump and the powertrain;

one or more electric power arrangements configured to power the auxiliary equipment of one or more of the plurality of hydraulic fracturing units, each electric power arrangement of the one or more electric power arrangements comprising an engine-generator set configured to generate electric power;
an electric power network configured to deliver electric power generated by at least one of the one or more electric power arrangements to the auxiliary equipment of the one or more of the plurality of hydraulic fracturing units, the electric power network being coupled to a first engine-generator set of a first hydraulic fracturing unit of the plurality of hydraulic fracturing units and first electric motors of the first hydraulic fracturing unit,
the electric power network being switchably connectable to one or more of a utility power grid, a battery bank, or an engine-generator set of a second hydraulic fracturing unit of the plurality of hydraulic fracturing units, and
the electric power network being configured to deliver electric power generated by the first engine-generator set to the first electric motors to drive first auxiliary equipment of the first hydraulic fracturing unit and to be switchably connected to the one or more of the utility power grid, the battery bank, or the second engine-generator set to deliver power to the first electric motors responsive to a failure or fault of the first engine-generator set; and

a manifold connected to respective reciprocating plunger pumps of the plurality of hydraulic fracturing units, the manifold configured to deliver fracturing fluid from the respective reciprocating plunger pumps to the well;
wherein the electric power network comprises an electric bus affixed to the manifold and connecting the one or more of the plurality of hydraulic fracturing units to the first electric power arrangement to power the one or more of the plurality of hydraulic fracturing units.

2. The system of claim 1 , wherein the first engine-generator set includes a diesel engine and an electric motor generator, the diesel engine configured to drive the electric motor generator to generate the electric power.

3. The system of claim 1 , wherein the first engine-generator set includes a gas turbine engine and an electric generator, the gas turbine engine configured to drive the electric generator to generate the electric power.

4. The system of claim 1 , wherein the first electric power arrangement further comprises a connection to the utility power grid, and the electric power network is configured to switchably connect the utility power grid to the one or more of the plurality of electric motors to deliver power to the first electric motors responsive to the failure or fault of the first engine-generator set.

5. The system of claim 1 , wherein the first electric power arrangement further comprises a battery bank chargeable from power generated by the first engine-generator set, and the electric power network is configured to switchably connect the battery bank to the one or more of the plurality of electric motors to deliver power to the first electric motors responsive to the failure or fault of the first engine-generator set.

6. The system of claim 1 , wherein the first electric power arrangement further comprises a connection to the engine-generator set of the second hydraulic fracturing unit, and the electric power network is configured to switchably connect the engine-generator set of the second hydraulic fracturing unit to the one or more of the plurality of electric motors to deliver power to the first electric motors responsive to the failure or fault of the first engine-generator set.

7. The system of claim 1 , wherein the one or more electric power arrangements include a plurality of electric power arrangements, each of the plurality of electric power arrangements being connected to a chassis of a respective one of the plurality of hydraulic fracturing units.

8. The system of claim 7 , wherein the first electric power arrangement is connected to the engine-generator set of the second hydraulic fracturing unit, and
wherein the electric power network is configured to switchably connect the engine-generator set of the second hydraulic fracturing unit to the one or more of the plurality of electric motors to deliver power to the first electric motors of the first hydraulic fracturing unit responsive to the failure or fault of the first engine-generator set of the first hydraulic fracturing unit.

9. The system of claim 7 , further comprising a battery bank connected to the plurality of electric power arrangements, engine-generator sets of the plurality of electric power arrangements being configured to generate electric power from which the battery bank is chargeable, and
wherein the electric power network is configured to switchably connect the battery bank to the one or more of the plurality of electric motors to deliver power to the one or more of the plurality of electric motors of the first hydraulic fracturing unit responsive to the failure or fault of the first engine-generator set of the first hydraulic fracturing unit.

10. The system of claim 9 , wherein the battery bank is configured to be connected to the utility power grid, and the first electric power arrangement is switchably connectable to the utility power grid via the battery bank.

11. The system of claim 9 , wherein the electric bus connects the plurality of electric power arrangements to the battery bank.

12. The system of claim 1 , further comprising a battery bank connected to the first electric power arrangement, wherein the electric power network is configured to switchably connect the battery bank to the one or more of the plurality of electric motors to deliver power to the one or more of the plurality of electric motors of the first hydraulic fracturing unit responsive to the failure or fault of the first engine-generator set of the first hydraulic fracturing unit.

13. The system of claim 12 , wherein the first electric power arrangement further comprises a connection to the utility power grid, and the electric power network is configured to switchably connect the utility power grid to the one or more of the plurality of electric motors to deliver power to the one or more of the plurality of electric motors of the first hydraulic fracturing unit responsive to the failure or fault of the first engine-generator set of the first hydraulic fracturing unit.

14. A method of fracturing a well, the method comprising:
arranging a plurality of hydraulic fracturing units, each hydraulic fracturing unit comprising:
a chassis;
a reciprocating plunger pump connected to the chassis and configured to pump a fracturing fluid;
a powertrain connected to the chassis and configured to power the reciprocating plunger pump, the powertrain including a direct drive gas turbine engine and a drivetra

Assignees

• Bj Energy Solutions Llc

Inventors

• Yeung Tony
• Rodriguez-Ramon Ricardo
• Foster Joseph
• Tew Nicholas

Classifications

• F04B17/05 Primary

  driven by internal-combustion engines · CPC title

• F04B15/02 Primary

  the fluids being viscous or non-homogeneous · CPC title

• E21B43/2607 Primary

  Surface equipment specially adapted for fracturing operations · CPC title

• H02J7/34

  Parallel operation in networks using both storage and other DC sources, e.g. providing buffering (H02J7/14 takes precedence) · CPC title

• H02J9/066

  characterised by the use of dynamo-electric machines (H02J9/08 takes precedence) · CPC title