Note: Descriptions are shown in the official language in which they were submitted.
WELL SITE ADAPTIVE POWER MANAGEMENT SYSTEM
Cross-Reference to Related Application
[0001] This application is a non-provisional application which claims priority
from U.S.
provisional application number 62/987,681, filed March 10, 2020, which is
incorporated by
reference herein in its entirety.
Technical Field/Field of the Disclosure
[0002] The present disclosure relates generally to power systems for
electrical equipment and
specifically to power supplies for frac equipment.
Background of the Disclosure
[0003] During frac operations, multiple pieces of frac equipment may be in
continuous use.
Such equipment may include, for example, one or more blenders, hydrators,
pumps, CAS, and
belt loader systems as well as control systems for operating the equipment and
infrastructure
such as light plants for night operation. Typically, the frac equipment is
powered using diesel
engines or electric motors with one or more generators. However, the
requirement to
continuously supply electrical power to frac equipment, which may require
continuous
operation of the generators, may result in high operation costs due to fuel
consumption and
maintenance requirements on the generators as well as producing noise and
emissions.
Summary
[0004] The present disclosure provides for a method. The method may include
providing a frac
system. The frac system may include one or more pieces of frac equipment;
power generation
equipment; a power storage device; and a power controller. The method may
include measuring,
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with the power controller, a charge status for the power storage device;
measuring, with the
power controller, an electrical power load being used by the frac equipment;
and engaging or
disengaging the power generation equipment based on the measured charge status
and electrical
power load.
[0005] The present disclosure also provides for a frac system. The frac system
may include one
or more pieces of frac equipment; a generator or gas turbine; a power storage
device; and a
power controller. The power controller may be adapted to selectively operate
the generator or
gas turbine, determine whether to power the frac equipment from the generator
or gas turbine
or the power storage device, and determine whether to charge the power storage
device from
the generator or gas turbine.
[0006] The present disclosure provides for a frac system. The frac system may
include one or
more pieces of frac equipment, power distribution equipment in electrical
communication with
the frac equipment; and power generation equipment in electrical communication
with the
power distribution equipment.
Brief Description of the Drawings
[0007] The present disclosure is best understood from the following detailed
description when
read with the accompanying figures. It is emphasized that, in accordance with
the standard
practice in the industry, various features are not drawn to scale. In fact,
the dimensions of the
various features may be arbitrarily increased or reduced for clarity of
discussion.
[0008] FIG. 1 depicts a block diagram of a frac system consistent with at
least one embodiment
of the present disclosure.
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[0009] FIG. 2 depicts a process flow diagram of a frac system consistent with
at least one
embodiment of the present disclosure.
[0010] FIG. 3 depicts a block diagram of a frac system consistent with at
least one embodiment
of the present disclosure.
[0011] FIG. 4 depicts a process flow diagram of a frac system consistent with
at least one
embodiment of the present disclosure.
[0012] FIG. 5 depicts a block diagram of a frac system consistent with at
least one embodiment
of the present disclosure.
[0013] FIG. 6 depicts a block diagram of a frac system consistent with at
least one embodiment
of the present disclosure.
[0014] FIG. 7 depicts a block diagram of a frac system consistent with at
least one embodiment
of the present disclosure.
[0015] FIG. 8 depicts a block diagram of a frac system consistent with at
least one embodiment
of the present disclosure.
[0016] FIG. 9 depicts a block diagram of a frac system consistent with at
least one embodiment
of the present disclosure.
[0017] FIG. 10 depicts a block diagram of a frac system consistent with at
least one embodiment
of the present disclosure.
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[0018] FIG. 11 depicts a block diagram of a frac system consistent with at
least one embodiment
of the present disclosure.
Detailed Description
[0019] It is to be understood that the following disclosure provides many
different
embodiments, or examples, for implementing different features of various
embodiments.
Specific examples of components and arrangements are described below to
simplify the present
disclosure. These are, of course, merely examples and are not intended to be
limiting. In
addition, the present disclosure may repeat reference numerals and/or letters
in the various
examples. This repetition is for the purpose of simplicity and clarity and
does not in itself dictate
a relationship between the various embodiments and/or configurations
discussed.
[0020] FIG. 1 depicts a block diagram of frac system 100 consistent with at
least one
embodiment of the present disclosure. Frac system 100 may be positioned at
wellsite 10. In
some embodiments, frac system 100 may include frac equipment 101. Frac
equipment 101 may
include, for example and without limitation, one or more blenders, hydrators,
CAS, belt loaders,
acidizing units, chemical additive units, frac pumps, light plants, and
control systems such as a
data van. One or more elements of frac equipment 101 may be powered by
electricity.
[0021] In some embodiments, frac system 100 includes generator 111. Generator
111 may be
positioned on-site at wellsite 10. In some embodiments, generator 111 may be a
diesel generator.
In some embodiments, generator 111 may be a natural-gas powered generator. In
some
embodiments, frac system 100 may include two or more generators 111.
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[0022] In some embodiments, frac system 100 may include power storage device
121. Power
storage device 121 may be used to store electric power, such as power
generated by generators
111. In some embodiments, power storage device 121 may include, for example
and without
limitation, one or more batteries, capacitors, electromechanical power storage
devices, or other
power storage devices known in the art. In certain embodiments, power storage
device 121 may
be omitted.
[0023] As depicted schematically in FIG. 1, frac equipment 101 may be
electrically coupled to
generator 111 by one or more power lines, depicted as generator supply line
113, and may be
electrically coupled to power storage device 121 by one or more power lines,
depicted as storage
supply line 123. Power storage device 121 may be electrically coupled to
generator 111 by one
or more power lines, depicted as charge line 125. Electrical coupling between
elements of frac
system 100 may be accomplished by power distribution equipment as described
below. Power
distribution equipment includes, but is not limited to, switchgear,
transformers, breakers, and
relays.
[0024] In some embodiments, frac system 100 may include power controller 131.
Power
controller 131 may, in some embodiments, control the operation of the power
supply of frac
system 100. In some embodiments, for example and without limitation, power
controller 131
may control the electrical connections provided by generator supply line 113,
storage supply
line 123, and charge line 125 as further discussed herein below. Control over
these connections
may be accomplished by a power distribution system indicated by switches 103a-
c. In some
embodiments, power controller 131 may include a processor adapted to perform
computer
program instructions stored on tangible, non-transitory computer memory media.
In some
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embodiments, the processor may be, for example and without limitation, a
microprocessor,
microcontroller, digital signal processor, ASIC, FPGA, or CPLD.
[0025] In some embodiments, power controller 131 may include one or more
sensors used to
measure one or more states of components of frac system 100. For example, in
some
embodiments, power controller 131 may include charge sensor 133 used to
determine the charge
state of power storage device 121. In some embodiments, power controller 131
may include
load sensor 135 used to determine the electrical power load being used by frac
equipment 101.
[0026] In some embodiments, power controller 131 may be adapted to control the
operation of
generator 111. In such embodiments, power controller 131, through control line
137 as shown
.. schematically in FIG. 1, may control operation of generator 111 by one or
more of selectively
turning on generator 111, turning off generator 111, or controlling the power
output of generator
111.
[0027] In some embodiments, power controller 131 may use information
determined from
charge sensor 133 and load sensor 135 to select an operational state for frac
system 100. In such
.. an embodiment, power controller 131 may select among states, including, but
not limited to,
states in which frac equipment 101 is powered by generator 111 alone, by power
storage device
121 alone, or by a combination of generator 111 and power storage device 121.
Power controller
131 may, in a state when a combination of generator 111 and power storage
device 121 are both
operating, determine the power from generator 111 and the power from power
storage device
.. 121. In some embodiments, power controller 131 may further determine
whether generator 111
is to be enabled. In some embodiments, power controller 131 may determine
whether power
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storage device 121 is to be charged during operation of generator 111. In
certain embodiments,
a gas turbine, such as described below with respect to FIG. 10 may be used in
place of generator
111.
[0028] FIG. 2 depicts a nonlimiting example of a process flow diagram for the
operation [200]
of frac system 100 consistent with at least one embodiment of the present
disclosure. In some
embodiments, power controller 131 may initially determine the charge status
[201] of power
storage device 121 using charge sensor 133. Where power storage device 121 is
sufficiently
charged to allow for a desired period of operation of frac equipment 101
without need for
operation of generator 111 as determined by load sensor 135 or by one or more
user inputs,
power controller 131 may turn off generator 111 if generator 111 is in
operation [203], and may
selectively electrically connect power storage device 121 to frac equipment
101 such that frac
equipment 101 is operated on power from power storage device 121 [205]. In
such an
embodiment, generator 111 is off, reducing wear, fuel expenditure, noise, and
emissions as
compared to a system in which generator 111 is otherwise in continuous
operation.
[0029] In some cases, while operating using power from power storage device
121 alone, power
controller 131 may continue to monitor the charge state of power storage
device 121 using
charge sensor 133 [207]. If power controller 131 determines that the charge
state of power
storage device 121 falls below a threshold charge state, power controller 131
may turn on
generator 111 [209]. In some embodiments, power from generator 111 may be used
to provide
power to frac equipment 101 [211]. In some embodiments, power from generator
111 may be
used to charge power storage device 121. In some embodiments, power controller
131 may
determine whether to power frac equipment 101 from both generator 111 and
power storage
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device 121 once generator 111 is turned on [213] depending, for example and
without limitation,
on the charge state of power storage device 121 as measured by charge sensor
133 and the power
load of frac equipment 101 as measured by load sensor 135.
[0030] In some embodiments, power from generator 111 may be used to both power
frac
equipment 101 and charge power storage device 121 [215]. Such an operating
state may be used
when, for example and without limitation, the power load from frac equipment
101 is
sufficiently below the power output of generator 111 to allow excess power to
be used to charge
power storage device 121 without affecting operation of frac equipment 101 or
when frac
equipment 101 is not in operation and it is desired to charge power storage
device 121.
[0031] In other cases, where power storage device 121 is determined to not be
sufficiently
charged to allow for the desired period of operation of frac equipment 101
without need for
operation of generator 111 as determined by load sensor 135 or by one or more
user inputs
[201], power controller 131 may turn on generator 111 [209] if generator 111
is not on and may
determine whether to power frac support equipment 201 from generator 111 alone
[211] or from
generator 111 and power storage device 121 [213] as well as whether to charge
power storage
device 121 [215].
[0032] In some embodiments such as discussed with respect to FIG. 1, power
supplied to frac
system 100 may be limited to only that provided by generator 111. In other
embodiments as
depicted schematically in FIG. 3, power from a utility depicted as grid power
351 may be
available at least part of the time to frac system 300. FIG. 3 depicts a block
diagram of frac
system 300 consistent with at least one embodiment of the present disclosure.
Frac system 300
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may be positioned at wellsite 10. In some embodiments, frac system 300 may
include frac
equipment 301. One or more elements of frac equipment 301 may be powered by
electricity.
[0033] In some embodiments, frac system 300 includes generator 311. Generator
311 may be
positioned on-site at wellsite 10. In some embodiments, generator 311 may be a
diesel generator.
In some embodiments, generator 311 may be a natural-gas powered generator. In
some
embodiments, frac system 300 may include two or more generators 311.
[0034] In some embodiments, frac system 300 may include power storage device
321. Power
storage device 321 may be used to store electric power, such as power
generated by generators
311. In some embodiments, power storage device 321 may include, for example
and without
limitation, one or more batteries, capacitors, electromechanical power storage
devices, or other
power storage devices known in the art. In certain embodiments, power storage
device 321 may
be omitted.
[0035] As depicted schematically in FIG. 3, frac equipment 301 may be
electrically coupled to
generator 311 by one or more power lines, depicted as generator supply line
313, and may be
electrically coupled to power storage device 321 by one or more power lines,
depicted as storage
supply line 323. Power storage device 321 may be electrically coupled to
generator 311 by one
or more power lines, depicted as charge line 325.
[0036] In some embodiments, frac system 300 may include power controller 331.
Power
controller 331 may, in some embodiments, control the operation of the power
supply of frac
system 300. In some embodiments, for example and without limitation, power
controller 331
may control the electrical connections provided by generator supply line 313,
storage supply
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line 323, and charge line 325 as further discussed herein below. Control over
these connections
may be accomplished by a power distribution system indicated by switches 303a-
e.
[0037] In some embodiments, power controller 331 may include one or more
sensors used to
measure one or more states of components of frac system 300. For example, in
some
embodiments, power controller 331 may include charge sensor 333 used to
determine the charge
state of power storage device 321. In some embodiments, power controller 331
may include
load sensor 335 used to determine the electrical power load being used by frac
equipment 301.
[0038] In some embodiments, power controller 331 may be adapted to control the
operation of
generator 311. In such embodiments, power controller 331, through control line
337 as shown
schematically in FIG. 3, may control operation of generator 311 by one or more
of selectively
turning on generator 311, turning off generator 311, or controlling the power
output of generator
311.
[0039] In some embodiments, grid power 351 may be available to frac system 300
and may be
used to power frac equipment 301 and/or charge power storage device 321. In
some cases,
availability of grid power 351 may be dependent on several factors including,
for example and
without limitation, whether the utility company providing grid power 351
allows the power draw
required by frac system 300 and whether grid power 351 is cost effective
compared to power
from generator 311. In some embodiments, grid power 351 may be electrically
coupled to frac
equipment 301 by one or more power lines, depicted as grid supply line 353,
and may be
electrically coupled to power storage device 321 by one or more power lines,
depicted as grid
charge line 355.
Date Recue/Date Received 2020-10-08
[0040] In some embodiments, power controller 331 may use information
determined from
charge sensor 333 and load sensor 335 to select an operational state for frac
system 300. In such
an embodiment, power controller 331 may select among states in which frac
equipment 301 is
powered by generator 311 alone, by power storage device 321 alone, by grid
power 351 alone,
.. or by a combination of one or more of generator 311, power storage device
321, and grid power
351. In some embodiments, power controller 331 may further determine whether
generator 311
is to be enabled. In some embodiments, power controller 331 may determine
whether power
storage device 321 is to be charged during operation of generator 311 or while
grid power 351
is available. In some embodiments, power controller 311 may determine to
charge power storage
device 321 from generator 311 or grid power 351.
[0041] FIG. 4 depicts a nonlimiting example of a process flow diagram for the
operation [400]
of frac system 300 consistent with at least one embodiment of the present
disclosure. In some
embodiments, power controller 331 may initially determine the charge status
[401] of power
storage device 321 using charge sensor 333. Where power storage device 321 is
sufficiently
.. charged to allow for a desired period of operation of frac equipment 301
without need for
operation of generator 311 as determined by load sensor 335 or by one or more
user inputs,
power controller 331 may turn off generator 311 if generator 311 is in
operation [403], and may
selectively electrically connect power storage device 321 to frac equipment
301 such that frac
equipment 301 is operated on power from power storage device 321 [405]. In
such an
embodiment, generator 311 is off, reducing wear, fuel expenditure, noise, and
emissions as
compared to a system in which generator 311 is otherwise in continuous
operation.
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[0042] In some cases, while operating using power from power storage device
321 alone, power
controller 331 may continue to monitor the charge state of power storage
device 321 using
charge sensor 333 [407]. If power controller 331 determines that the charge
state of power
storage device 321 falls below a threshold charge state, power controller 331
may turn on
generator 311 [409]. In some embodiments, power from generator 311 may be used
to provide
power to frac equipment 301 [411]. In some embodiments, power from generator
311 may be
used to charge power storage device 321. In some embodiments, power controller
331 may
determine whether to power frac equipment 301 from both generator 311 and
power storage
device 321 once generator 311 is turned on [413] depending, for example and
without limitation,
on the charge state of power storage device 321 as measured by charge sensor
333 and the power
load of frac equipment 301 as measured by load sensor 335.
[0043] In some embodiments, power from generator 311 may be used to both power
frac
equipment 301 and charge power storage device 321 [415]. Such an operating
state may be used
when, for example and without limitation, the power load from frac equipment
301 is
sufficiently below the power output of generator 311 to allow excess power to
be used to charge
power storage device 321 without affecting operation of frac equipment 301 or
when frac
equipment 301 is not in operation and it is desired to charge power storage
device 321.
[0044] In other cases, where power storage device 321 is determined to not be
sufficiently
charged to allow for the desired period of operation of frac equipment 301
without need for
operation of generator 311 as determined by load sensor 335 or by one or more
user inputs
[401], power controller 331 may turn on generator 311 [409] if generator 311
is not on and may
determine whether to power frac support equipment 101 from generator 311 alone
[411] or from
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generator 311 and power storage device 321 [413] as well as whether to charge
power storage
device 321 [415].
[0045] In some cases where it is determined that grid power is available to be
used by frac
system 300 [417], power controller 331 may determine whether to charge power
storage device
321 [415] and/or operate frac equipment 301 from grid power [419]. Power
controller 331 may
also determine whether to turn off generator 311 [403] when grid power is
available.
[0046] FIGS. 5-11 depict additional embodiments of frac systems consistent
with embodiments
of the present disclosure. FIG.5 is an overview block diagram of frac system
500 of an
exemplary embodiment. FIG. 5 includes frac equipment 501. In a non-limiting
embodiment,
frac equipment may include data van 501a, blender 501b, hydrator 501c, CAS
501d, and other
equipment 501e, which can include, but is not limited to belt loaders,
acidizing units, chemical
additive units, frac pumps, and light plants. Frac system 500 may also include
power
distribution equipment 120 in electrical communication with frac equipment
501. Frac system
500 further includes power controller 531. In addition, frac system 500
includes power
generation equipment 530. Power generation equipment 530 may include, for
example,
generator 511, gas turbine 532, grid power 551, power storage device 521, and
combinations
thereof. Generators 511 may be diesel, natural gas, or may use other types of
fuel.
[0047] In the embodiment shown in FIG. 6, generator 511 is in electrical
connection with power
distribution equipment 120, which is in electrical connection with frac
equipment 501. In the
embodiment shown in FIG. 6, power controller 531 is omitted.
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[0048] In the embodiment shown in FIG. 7, gas turbine 532 is in electrical
connection with
power distribution equipment 120, which is in electrical connection with frac
equipment 501.
In the embodiment shown in FIG. 7, power controller 531 is omitted.
[0049] In the embodiment shown in FIG. 8, grid power 551 is in electrical
connection with
power distribution equipment 120, which is in electrical connection with frac
equipment 501.
In the embodiment shown in FIG. 8, power controller 531 is omitted.
[0050] In the embodiment shown in FIG. 9, generator 511 and power storage
device 521 are in
electrical connection. Generator 511 and power storage device 521 are in data
connection with
power controller 531 and in electrical connection with power distribution
equipment 120.
Power distribution equipment 120 is in electrical connection with frac
equipment 501. Power
controller 531 operates as described above with respect to power controller
131.
[0051] In the embodiment shown in FIG. 10, gas turbine 532 and power storage
device 521 are
in electrical connection. Gas turbine 532 and power storage device 521 are in
data connection
with power controller 531 and in electrical connection with power distribution
equipment 120.
Power distribution equipment 120 is in electrical connection with frac
equipment 501. Power
controller 531 operates as described above with respect to power controller
131.
[0052] In the embodiment shown in FIG. 11, grid power 551 and power storage
device 521 are
in electrical connection. Grid power 551 and power storage device 521 are in
data connection
with power controller 531 and in electrical connection with power distribution
equipment 120.
Power distribution equipment 120 is in electrical connection with frac
equipment 501. Power
controller 531 operates as described above with respect to power controller
131.
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[0053] The foregoing outlines features of several embodiments so that a person
of ordinary skill
in the art may better understand the aspects of the present disclosure. Such
features may be
replaced by any one of numerous equivalent alternatives, only some of which
are disclosed
herein. One of ordinary skill in the art should appreciate that they may
readily use the present
disclosure as a basis for designing or modifying other processes and
structures for carrying out
the same purposes and/or achieving the same advantages of the embodiments
introduced herein.
One of ordinary skill in the art should also realize that such equivalent
constructions do not
depart from the spirit and scope of the present disclosure and that they may
make various
changes, substitutions, and alterations herein without departing from the
spirit and scope of the
present disclosure.
Date Recue/Date Received 2020-10-08
