Note: Descriptions are shown in the official language in which they were submitted.
CA 02945579 2016-10-17
REMOTE MONITORING FOR HYDRAULIC FRACTURING EQUIPMENT
BACKGROUND OF THE INVENTION
1. Field of Invention
[0001] The present disclosure relates to hydraulic fracturing operations in a
subterranean
formations. In particular, the present disclosure relates to a hydraulic
fracturing system with
imaging devices that are strategically positioned to remotely monitor portions
of the system.
2. Description of Prior Art
[0002] Hydraulic fracturing is a technique used to stimulate production from
some hydrocarbon
producing wells. The technique usually involves injecting fluid into a
wellbore at a pressure
sufficient to generate fissures in the formation surrounding the wellbore.
Typically the
pressurized fluid is injected into a portion of the wellbore that is pressure
isolated from the
remaining length of the wellbore so that fracturing is limited to a designated
portion of the
formation. The fracturing fluid slurry, whose primary component is usually
water, includes
proppant (such as sand or ceramic) that migrate into the fractures with the
fracturing fluid slurry
and remain to prop open the fractures after pressure is no longer applied to
the wellbore. A
primary fluid for the slurry other than water, such as nitrogen, carbon
dioxide, foam (nitrogen
and water), diesel, or other fluids is sometimes used as the primary component
instead of water.
Typically hydraulic fracturing fleets include a data van unit, blender unit,
hydration unit,
chemical additive unit, hydraulic fracturing pump unit, sand equipment, and
other equipment.
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[0003] The process of making the fracturing fluid slurry necessarily includes
combining, such as
in the blender, hydration unit, chemical additive unit, etc., the individual
components of the
slurry. Such operation can be dangerous to operating personnel. For example,
moving proppant
into the blender unit can generate silica dust which, if inhaled by personnel,
can cause permanent
damage to the lungs. Common proppant types include silica sand, resin coated
sand, and ceramic
beads. Ceramic can be very harmful to inhale, and typically consists of very
fine particles that
become airborne and are difficult to filter out. Resin coated sand is the most
dangerous and
harmful to inhale since the resin coating can chip off and become airborne
dust particles. Silica
itself is very harmful to inhale as well.
[0004] Other components, such as chemicals, can be damaging and present
hazards as well. One
dangerous source of chemical contact comes from residue on tankers, trailer
decks, reused hoses
and camlock fittings, or leaky valves. In addition, there is always a risk for
a major hose or
chemical pump failure, or a tank/tote puncture. Some chemicals (such as, for
example the
viscosifier guar gel, and some friction reducers) can be hazardous because of
how slick and
slippery they are. Thus, a small amount on the skin, clothing, ground, or
equipment can cause
personnel to slip and fall, or lose their grip while climbing ladders, leading
to injuries.
[0005] In addition, chemicals such as acids and breakers (for breaking down
viscosifiers) are
extremely corrosive to skin, damaging to inhale, can cause blindness, and
other immediate
hazards. Chemicals such as breakers are also very flammable, which becomes a
hazard if there is
a chance of contact with, for example, diesel fuel or gasoline. On diesel
powered fracturing sites,
it is very common for personnel to have diesel or oil residue on their hands,
boots, or clothes.
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[0006] Furthermore, in fracturing operations, it is also common to use
biocides to kill bacteria
deep in a well, such as to prevent deadly hydrogen sulfide gas build up.
Biocides can be very
damaging to living tissue, especially if ingested or inhaled. Additional
chemicals that are
dangerous if ingested or inhaled include stabilizers, pH buffers, and
inhibitors.
[0007] In addition to the above, hydraulic fracturing operations can be
dangerous for operating
personnel because of high pressure and high voltage equipment. For example,
high pressure
zones are present where the discharge piping leaves the hydraulic fracturing
pumps at pressures
of up to 15,000 pounds per square inch (psi) or more. If the pipes fail, they
can explode, causing
shrapnel to fly. Furthermore, iron pipes can shift and pivot with the pressure
release striking
employees.
[0008] Some voltages in the electric hydraulic fracturing systems can reach up
to 13,800 volts or
more. Dangers in high voltage zones include arc flashes, fires, electrocution,
and explosions.
Hazards can result from breaker or cable coupler failures, or even natural gas
vapors entering the
area. It is desirable, therefore, to design a hydraulic fracturing system to
minimize such
dangerous exposure of operating personnel.
SUMMARY OF THE INVENTION
[0009] The present technology provides a hydraulic fracturing system for
fracturing a
subterranean formation, including a pump in communication via pump components
with a
wellbore that intersects the formation, and that pressurizes fluid in the
wellbore, the fluid
including a fracturing fluid slurry. The system further includes hydraulic
fracturing system
components for making the fracturing fluid slurry, and a monitoring system
that selectively
captures and transmits real time images of at least one of the hydraulic
fracturing system
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components or pump components to enable remote monitoring of the at least one
of the
hydraulic fracturing system components or pump components.
[0010] In some embodiments, the monitoring system can include a camera, a
controller, a
display, a human machine interface, and communication means between the
camera, controller,
human machine interface, and the monitor. In addition, the display can include
a monitor from
which the images are viewed. In some example embodiments, the display can be
disposed within
a passenger compartment mounted to a fluid blender, so that the images can be
viewed by
operations personnel in the passenger compartment.
[0011] According to some embodiments, the hydraulic fracturing components can
be selected
from the group consisting of a chemical tanker, a hydration unit, a hopper, a
blender unit, and
auger associated with a blender unit, a conveyor, and an acid tanker. In
addition, the pump
components can be selected from the group consisting of intake piping,
discharge piping, hoses,
fittings, and valves associated with a hydraulic fracturing pump. Furthermore,
the monitoring
system can include a camera disposed on a trailer, and wherein the hydraulic
fracturing
components or pump components include hose or pipe connections on the trailer.
In alternate
embodiments, the monitoring system can include a camera disposed on a first
trailer, and
wherein the hydraulic fracturing components or pump components include hose or
pipe
connections on a second trailer that is adjacent the first trailer.
[0012] In some example embodiments, the monitoring system can selectively
capture and
transmit real time images of a silica exposure zone, or of an opening to a
vessel, so that a level
within the vessel is discernible in the images. In some embodiments, the
vessel can contain
proppant, acid, or chemicals.
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[0013] Another embodiment of the present technology provides including the
steps of driving a
pump to pressurize fluid in a hydraulic fracturing system containing hydraulic
fracturing
components and pump components, fracturing the formation by directing the
pressurized fluid
into a wellbore that intersects the formation, and monitoring the hydraulic
fracturing system. The
step of monitoring the hydraulic fracturing system includes obtaining images
of hydraulic
fracturing components and pump components of the hydraulic fracturing system,
and viewing
the images remotely.
[0014] In some embodiments, the hydraulic fracturing components and pump
components can be
disposed in areas where there is a greater possibility of personal injury than
where the images are
being viewed. In some embodiments, step of obtaining images can be performed
by a camera
that is disposed adjacent at least one of the hydraulic fracturing components
or the pump
components, and the step of viewing can be performed within an enclosure.
[0015] In certain other embodiments, the method can include selectively
obtaining images of
different hydraulic fracturing components or pump components on a single
monitor.
Furthermore, the hydraulic fracturing components and pump components can
include discharge
piping that is in fluid communication with the pump, and vessel openings, and
the images of the
hydraulic fracturing system can include images of at least one of a silica
exposure zone, hose
connections,a high pressure zone that includes discharge pumps or discharge
pipes or both, a
chemical exposure zone, high voltage zones, and natural gas supply piping.
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BRIEF DESCRIPTION OF DRAWINGS
[0016] Some of the features and benefits of the present invention having been
stated, others will
become apparent as the description proceeds when taken in conjunction with the
accompanying
drawings, in which:
[0017] FIG. 1 is a schematic example of a hydraulic fracturing system for use
in fracturing a
subterranean formation.
[0018] FIG. 2 is a plan schematic view of an alternate example of the system
of FIG. 1, and
which includes examples of visual monitoring equipment.
[0019] FIG. 3 is a perspective view of an example of a visual monitoring
device mounted on a
blender, where the blender is included with the hydraulic fracturing system of
FIG. 1.
[0020] FIGS. 4 and 5 are perspective views of an example of a monitor
displaying images
captured by a visual monitoring device.
[0021] FIGS. 6 and 7 are lower and upper views of an example of a visual
monitoring device
that is mounted on the blender of FIG. 3.
[0022] While the invention will be described in connection with the preferred
embodiments, it
will be understood that it is not intended to limit the invention to that
embodiment. On the
contrary, it is intended to cover all alternatives, modifications, and
equivalents, as may be
included within the spirit and scope of the invention as defined by the
appended claims.
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DETAILED DESCRIPTION OF INVENTION
[0023] The method and system of the present disclosure will now be described
more fully
hereinafter with reference to the accompanying drawings in which embodiments
are shown. The
method and system of the present disclosure may be in many different forms and
should not be
construed as limited to the illustrated embodiments set forth herein; rather,
these embodiments
are provided so that this disclosure will be thorough and complete, and will
fully convey its
scope to those skilled in the art. Like numbers refer to like elements
throughout. In an
embodiment, usage of the term -about" includes +/- 5% of the cited magnitude.
In an
embodiment, usage of the term "substantially" includes +/- 5% of the cited
magnitude.
100241 It is to be further understood that the scope of the present disclosure
is not limited to the
exact details of construction, operation, exact materials, or embodiments
shown and described, as
modifications and equivalents will be apparent to one skilled in the art. In
the drawings and
specification, there have been disclosed illustrative embodiments and,
although specific terms
are employed, they are used in a generic and descriptive sense only and not
for the purpose of
limitation.
[0025] Figure 1 is a schematic example of a hydraulic fracturing system 10
that is used for
pressurizing a wellbore 12 to create fractures 14 in a subterranean formation
16 that surrounds
the wellbore 12. Included with the system 10 is a hydration unit 18 that
receives fluid from a
fluid source 20 via line 22, and also selectively receives additives from an
additive source 24 via
line 26. Additive source 24 can be separate from the hydration unit 18 as a
stand-alone unit, or
can be included as part of the same unit as the hydration unit 18. The fluid,
which in one
example is water, is mixed inside of the hydration unit 18 with the additives.
In an embodiment,
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the fluid and additives are mixed over a period of time, to allow for uniform
distribution of the
additives within the fluid. In the example of Figure 1, the fluid and additive
mixture is
transferred to a blender unit 28 via line 30. A proppant source 32 contains
proppant, which is
delivered to the blender unit 28 as represented by line 34, where line 34 can
be a conveyer.
Inside the blender unit 28, the proppant and fluid/additive mixture are
combined to form a
fracturing slurry, which is then transferred to a fracturing pump system 36
via line 38; thus fluid
in line 38 includes the discharge of blender unit 28 which is the suction (or
boost) for the
fracturing pump system 36.
100261 Blender unit 28 can have an onboard chemical additive system, such as
with chemical
pumps and augers. Optionally, additive source 24 can provide chemicals to
blender unit 28; or a
separate and standalone chemical additive system (not shown) can be provided
for delivering
chemicals to the blender unit 28. In an example, the pressure of the slurry in
line 38 ranges from
around 80 psi to around 100 psi. The pressure of the slurry can be increased
up to around 15,000
psi by pump system 36. A motor 39, which connects to pump system 36 via
connection 40,
drives pump system 36 so that it can pressurize the slurry. In one example,
the motor 39 is
controlled by a variable frequency drive ("VFD-).
100271 After being discharged from pump system 36, slurry is pumped into a
wellhead assembly
41. Discharge piping 42 connects discharge of pump system 36 with wellhead
assembly 41 and
provides a conduit for the slurry between the pump system 36 and the wellhead
assembly 41. In
an alternative, hoses or other connections can be used to provide a conduit
for the slurry between
the pump system 36 and the wellhead assembly 41. Optionally, any type of fluid
can be
pressurized by the fracturing pump system 36 to form injection fracturing
fluid that is then
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pumped into the wellbore 12 for fracturing the formation 14, and is not
limited to fluids having
chemicals or proppant.
[0028] An example of a turbine 44 is provided in the example of Figure 1. The
turbine can be
gas powered, receiving a combustible fuel from a fuel source 46 via a feed
line 48. In one
example, the combustible fuel is natural gas, and the fuel source 46 can be a
container of natural
gas or a well (not shown) proximate the turbine 44. Combustion of the fuel in
the turbine 44 in
turn powers a generator 50 that produces electricity. Shaft 52 connects
generator 50 to turbine
44. The combination of the turbine 44, generator 50, and shaft 52 define a
turbine generator 53.
In another example, gearing can also be used to connect the turbine 44 and
generator 50.
[0029] An example of a micro-grid 54 is further illustrated in Figure 1, and
which distributes
electricity generated by the turbine generator 53. Included with the micro-
grid 54 is a
transformer 56 for stepping down voltage of the electricity generated by the
generator 50 to a
voltage more compatible for use by electrically powered devices in the
hydraulic fracturing
system 10. In another example, the power generated by the turbine generator
and the power
utilized by the electrically powered devices in the hydraulic fracturing
system 10 are of the same
voltage, such as 4160 V, so that main power transformers are not needed. In
one embodiment,
multiple 3500 kVA dry cast coil transformers are utilized. Electricity
generated in generator 50 is
conveyed to transformer 56 via line 58. In one example, transformer 56 steps
the voltage down
from 13.8 kV to around 600 V. Other step down voltages can include 4,160 V,
480 V, or other
voltages.
[0030] The output or low voltage side of the transformer 56 connects to a
power bus 60, lines 62,
64, 66, 68, 70, and 71 connect to power bus 60 and deliver electricity to
electrically powered
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components of the system 10. More specifically, line 62 connects fluid source
20 to bus 60, line
64 connects additive source 24 to bus 60, line 66 connects hydration unit 18
to bus 60, line 68
connects proppant source 32 to bus 60, line 70 connects blender unit 28 to bus
60, and line 71
connects bus 60 to an optional variable frequency drive ("VFD") 72. Line 73
connects VFD 72
to motor 39. In one example, VFD 72 can be used to control operation of motor
39, and thus also
operation of pump 36.
[0031] In an example, additive source 24 contains ten or more chemical pumps
for
supplementing the existing chemical pumps on the hydration unit 18 and blender
unit 28.
Chemicals from the additive source 24 can be delivered via lines 26 to either
the hydration unit
18 and/or the blender unit 28. In one embodiment, the elements of the system
10 are mobile and
can be readily transported to a wellsite adjacent the wellbore 12, such as on
trailers or other
platforms equipped with wheels or tracks.
[0032] Referring now to Figure 2 shown in a plan schematic view is an example
of the hydraulic
fracturing system 10 as arranged at a well site 80. In this example, a series
of cameras 821_13 are
shown strategically located about the system 10 in order to capture real time
images of
designated portions of the hydraulic fracturing system 10. Image zones 841_13
are shown that are
associated with each of the cameras 821_13 and depict an example of objects in
an area or space
whose image is captured by the cameras 821_13. Cameras 821,2 of Figure 2 are
depicted mounted
respectively on chemical tankers 861,2 and are oriented so that their
respective image zones 841,2
encompass rear portions of the chemical tankers 861,2. Thus the image(s)
captured by cameras
821,2 includes images of the rear portions of the chemical tankers 861,2.
Specific hardware imaged
in one example of the image zones 841,2 include hose connections and booster
pumps (not
shown) on the rear of these tankers 861,7. Optionally, the image zones 841,2
may extend to an
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adjacent chemical trailer 88 shown adversely located adjacent tankers 861,2.
Mounted on
hydration unit 18 is camera 823 whose image zone 843 covers a rear portion of
chemical tanker
88; images captured by camera 823 may be analyzed for leaks or failed hose
connections. Trailer
mounted blender units 281,2 are shown disposed on a side of hydration unit 18
and opposite from
chemical trailer 88. Ends of the trailers includes hoppers 901,2 that
selectively contain sand or
proppant that is drawn from the hoppers 901,2 with auger sets 921,2. Cameras
826,7 are mounted
on augers 9212, and wherein the associated image zones 846,7 of the cameras
866,7 includes the
hoppers 901,2. Thus, analyzing information collected by cameras 826,7 can
provide information
indicating a level of sand or proppant within hoppers 901,2, without an
operator approaching the
hoppers 901,2.
[0033] As described above, the sand or proppant drawn from hoppers 901,2 by
augers 941,2 is
deposited within tubs 941,2 where it can be mixed with fluids in order to form
a slurry. Cameras
824,5 are mounted on blender units 281,2 respectively, and have image zones
844,5 that capture the
opening of the hoppers 901,2. Thus analyzing data or images captured by
cameras 824,5 provides
information real time about the level of the slurry mixture within hoppers
9012, again without an
operator approaching the hoppers 901,2.
[0034] Camera 829 is shown mounted on a dust collector 96 which is disposed
adjacent an end of
conveyor 34 that is distal from blender units 281,2. The image zone 849
encompasses an end of
conveyor 34 distal from blender units 281,2. Silos 981_5 or other proppant
dispensers are shown
disposed on alternating sides of conveyor 34 and which can be used to dispense
sand or proppant
onto conveyor 34, which then deposits the sand or proppant into the hoppers
901,2. Camera 828
has a corresponding image zone 848 that captures information along conveyor 34
proximate to
hoppers 901,2 and distal from dust collector 96. Shown having an end proximate
where conveyor
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34 interfaces with hoppers 901,2 is an acid tanker 100 which can optionally be
used to deposit
acidic material into the fluid being deposited into the wellbore 12 (Figure
1). Camera 8211 is
mounted on acid tanker 100 and shown having an image zone 8411 that
encompasses openings on
the acid tanker 100 so that levels of material within acid tanker 100 can be
monitored by viewing
images captured by camera 821 Camera 8211 can be useful to make sure the acid
tanker 100
does not overflow, which condition could be caused by a valve failure and
resultant fluid
backflush. Typically, an operator monitors the acid tanker, and regularly
gives hand signals to
indicate the operating conditions of the acid tanker 100. Hand signals are
preferable to radios
when communicating such information, since the operator near the acid tanker
typically dresses
in protective clothing that can make it difficult to use a radio. Camera 8211
can be used either to
view the acid tanker itself, or also to view the operator displaying hand
signals.
[0035] Arranged in rows and transverse to acid tanker 100 are pump trucks
1021_12, which make
up the pump system 36 for pressurizing the slurry so that it can be injected
into wellhead 41.
Discharge piping 42 is shown extending along a path adjacent each of the pump
trucks 1021_12
and having an end connected to wellhead assembly 41. Cameras 8210,12 are shown
with image
zones 8410,12 that cover hoses, fittings, and an area where discharge leads
from the specific
pumps on the pump trucks 1021,1? interface with discharge piping 42. While a
pair of cameras
8210,12 are illustrated, cameras may be provided for each pair of the pump
trucks 1021,12 or each
one individually. Shown spaced away from the rows of pump trucks 1021_12 is a
data van 104 and
on which camera 8213 is mounted. The corresponding image zone 8413 of camera
8213 is directed
towards wellhead assembly 41 and can observe the wellhead assembly 41 as well
as all discharge
piping 42 and at least some of the leads connecting to piping 42. Thus
situated, camera 8213
allows personnel to stay out of the high pressure zones around the pumps. This
is useful because
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is a pipe fails at high pressure, it can seriously injure personnel with, for
example, flying
shrapnel.
[0036] Shown in an end perspective view in Figure 3 is an example of camera
826,7 mounted on
one of the auger elements that make up auger system 921,2. Here each of the
auger elements
includes a tube and a screw-like member that rotates within the tube in order
to urge the proppant
upward from the hopper 901,2 and into hopper 941,7 (Figure 2). Further
illustrated in Figure 3 is
an example of a hydraulic system 106 for raising and lowering the auger
system, 921,7. As
shown, camera 826,7 is mounted to one of the auger tubes via a bolted
connection.
[0037] Figure 4 illustrates an example of viewing an image of hopper 901,2
within a blender cab
1081,7 that is part of the blender unit 281,2 (Figure 2). A monitor 1101,2 is
mounted within cab
1081,2 that is in communication with camera 826,7. Accordingly, a designated
portion within
system 10 (Figure 2) can be remotely viewed by operations personnel in an
enclosed space and
away from an area that may present hazards to personnel. Alternately, this
camera feed can also
be viewed within the datavan.
[0038] Figure 5 illustrates one example where operations personnel can
selectively change the
image being viewed to that of a separate camera. For example, within cab
1081,2, monitor 1101,2
is displaying an example of mixing tub 941,2. In an example, changing the
display on the monitor
1101,2 to view other images is accomplished by an operator manipulating a
human machine
interface ("HMI") which can be a keyboard, joystick, panel, or any other
device that allows a
user to adjust operation or control of what is being viewed on monitor 1101,2.
Again, the image
of the tub 941,2 is being remotely viewed in an enclosed space that is away
from a potentially
hazardous area.
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[0039] Figure 6 illustrates an example of camera 824,5 mounted on blender unit
281,2 (Figure 2)
and outside of cab 1081,2. Here, the end of the camera 824.5 having a lens is
pointing away from
cab 1081,2 and mounting hardware in brackets are shown suspending camera 824,5
at a
strategically located orientation so that designated portions can be monitored
with camera 824,5.
[0040] Figure 7 shows in a perspective view an example of camera 824,5 taken
from a rear view
and having lead 1124,5 leading from camera 824,5 so that images captured by
camera 824,5 can be
processed and transmitted to a location that is remote to camera 824,5 for
viewing.
[0041] Referring back to Figure 2, a schematic example of monitoring system
114 is shown
which includes cameras 821_13, monitor 110, a communication means 116,
controller 118, and
human machine interface 120. Communication means 116 can be any form of
communicating
data that represents images within system 114, and can be wireless, hard-
wired, or fiber optic
material. Controller 118 can be an information handling system, and may
include a processor,
memory accessible by the processor, non-volatile storage area accessible by
the processor, and
logics for performing each of the steps required for operation of the
controller 118.
[0042] Advantages of the monitoring system 114 described herein are that all
parts of silica
exposure zones, including the silos 981_5, or any other sand storage
container, sand conveyor, and
dust vacuum system, can be monitored without the requirement for operations
personnel to enter
this region, thereby shielding personnel from harmful silica dust. Moreover,
high-pressure zones
where high-pressure fluid is being pumped within piping can be imaged without
requiring
operations personnel to be proximate the piping when high pressure fluid is
within the piping.
Chemical areas can also be monitored remotely and so that operations personnel
are not subject
to exposure to hazardous chemicals. Moreover, areas of the system 10 that
contain cables at a
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high voltage may also be remotely monitored thereby avoiding the need for
personnel to enter
these zones. In addition, cameras can be used to monitor fuel gas lines for
the turbines that power
the electric motors on an electric fleet. In one optional embodiment, mounts
for the cameras 821_
13 are able to pivot on two axes and can be adjusted up down and left and
right. The imaging can
be displayed on video and discernible by operations personnel such that visual
images
reproduced real time. In one alternative, infrared imaging is performed.
100431 The present invention described herein, therefore, is well adapted to
carry out the objects
and attain the ends and advantages mentioned, as well as others inherent
therein. While a
presently preferred embodiment of the invention has been given for purposes of
disclosure,
numerous changes exist in the details of procedures for accomplishing the
desired results. These
and other similar modifications will readily suggest themselves to those
skilled in the art, and are
intended to be encompassed within the spirit of the present invention
disclosed herein and the
scope of the appended claims.
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