Note: Descriptions are shown in the official language in which they were submitted.
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COMPACT ELECTRIC HYDRAULIC FRACTURING TRAILER
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to and the benefit
of U.S. Patent Application No.
17/088,934, filed November 4, 2020, titled "COMPACT ELECTRIC HYDRAULIC
FRACTURING TRAILER: which claims priority to and the benefit of U.S.
Provisional
Application No. 62/930,418, filed November 4, 2019, titled "COMPACT ELECTRIC
HYDRAULIC FRACTURING TRAILER", the full disclosure of which is incorporated
herein
by reference for all purposes.
Field of Invention
[0002] This invention relates in general to hydraulic
fracturing technology, and more
particularly to systems and methods pertaining to electric hydraulic
fracturing trailers.
Backzround
[0003] Hydraulic fracturing has been used for decades to
stimulate production from
conventional oil and gas wells. The practice consists of pumping fluid into a
wellbore at high
pressure. Inside the wellbore, the fluid is forced into the formation being
produced. When the
fluid enters the formation, it fractures, or creates fissures, in the
formation. Water, as well as
other fluids, and some solid proppants, are then pumped into the fissures to
stimulate the release
of oil and gas from the formation. Fracturing rock in a formation requires
that the fracture fluid
be pumped into the wellbore at very high pressure. This pumping is typically
performed by large
pumps and various other large and heavy equipment. These components are moved
and
positioned on large heavy duty trailers In order to carry all the required
equipment, conventional
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trailers are approximately 50 feet in length. Typically, a fracturing
operation requires many such
trailers to be simultaneously used and located at a job site, thus taking up
quite a large footprint
among other inefficiencies.
Summary of the Invention
100041 In accordance with one or more embodiments, a compact fracturing system
includes a
pump truck having a length of at most 40 feet and an electronic system
positioned on the pump
truck. The electronic system includes a transformer and electronic motor
controls housed
together with the transformer, and a variable-frequency drive (VFD). The pump
trailer further
includes a lubrication system having a plurality of sensors, the lubrication
system compatible
with oil lubrication. In some embodiments, the compact fracturing system
includes at least a
3,000 hydraulic horsepower motor drive. In some embodiments, the compact
fracturing system
includes a quintuplex pump. In some embodiments, the compact fracturing system
includes a
regulated suction stabilizer. In some embodiments, the lubrication system is a
stroke based
packing lubrication system. In some embodiments, the pump truck has a length
of at most 37
feet The electronic system further comprises a housing. The transformer and
electric motor
controls are housed within the housing. In some embodiments, the compact
fracturing system
includes a rear mounted power end tube cooler. In some embodiments, the
compact fracturing
system includes a variable speed cooler motor.
100051 In accordance with another example embodiment, a compact fracturing
system
includes an electronic system providing power, controls, or both to one or
more components of
the compact fracturing system. The electronic system includes a transformer,
electronic motor
controls, and a housing. The electronic motor controls and the transformer are
housed together
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within the housing. In some embodiments, the compact fracturing system further
includes a
regulated suction stabilizer. In some embodiments, the compact fracturing
system further
includes a stroke based lubrication system compatible with oil lubricant. In
some embodiments,
the compact fracturing system further includes a variable speed cooler motor.
In some
embodiments, the compact fracturing system further includes a 3,000 hydraulic
horsepower
motor drive. In some embodiments, the compact fracturing system further
includes a variable
frequency drive (VFD). In some embodiments, the compact fracturing system
further includes a
quintuplex pump. In some embodiments, the compact fracturing system further
includes a rear
mounted power end lube cooler. In some embodiments, the electronic system is
located on a
pump truck have a length of 37 feet or less.
100061 In accordance with another embodiment, a method of hydraulic fracturing
includes
positioning a compact pump trailer at a pump site. The compact pump trailer
has a length below
40 feet. In some embodiments, the pump trailer has a length below 37 feet. The
method further
includes powering a pump via an electronics system, in which the electronics
system includes a
transformer and electronic motor controls housed together. In some
embodiments, the pump
trailer includes a regulated suction stabilizer and a read mounted power end
lube cooler. In some
embodiments, the pump trailer includes a stroke based lubrication system
compatible with oil
lubricant.
Brief Description of the Drawings
100071 FIG. 1 illustrates a compact pump trailer 100 (also
known as a pump truck) that is a
part of a hydraulic fracturing system, in accordance with some embodiments of
the present
disclosure.
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100081 FIG. 2 is a diagram illustrating the electronic
system 104, in accordance with example
embodiments.
100091 FIG. 3 is a diagram illustrating the instrumented
lubrication system 106, in accordance
with example embodiments_
100101 FIG. 4 illustrates a method 400 of hydraulic
fracturing, in accordance with example
embodiments.
Detailed Description of the Invention
100011 Electric powered hydraulic fracturing services are a growing part of
the broader hydraulic
fracturing industry. The ability to power hydraulic fracturing pumps using
electric motors, rather
than diesel engines or other power sources, provides many advantages. One such
advantage is a
reduced footprint at a hydraulic fracturing site, due to the omission of bulky
diesel motors and
other equipment. In fact, some hydraulic fracturing systems can be contained
on trailers of 50
feet or less.
100021 The present technology relates to an electric hydraulic fracturing
system designed to be
more compact than known systems, such that primary components of the system
can be mounted
on a pump trailer of less than 40 feet, and in some cases less than 37 feet
(up to a 23% reduction
in trailer size over other electric hydraulic fracturing trailers).
100031 While a more compact trailer provides many advantages, there are
technological hurdles
to achieving such a reduction in size. For example, pump trailers are used to
carry many pieces
of equipment and thus must be able to fit and support all of the equipment.
Thus, the size of the
pump trailer is at least in part dictated by the size and orientation of the
onboard equipment.
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Embodiments of the present disclosure provide solutions to overcome some of
these
technological challenges.
100041 In some embodiments, the reduction in the length of the pump trailer is
at least in part
achieved by combining the transformer and electric motor controls, such as the
variable
frequency drive (VFD) to be housed together. For example, there may be a
housing in which the
transformer and the electric motor controls are housed. Some embodiments of
the technology can
also include upgrades to the power end, including a more robust construction
to stand up to the
harsh working environments throughout the industry.
100051 Some embodiments of the present technology can also include a packing
lubrication
system that utilizes multiple sensors to lubricate more efficiently. This
system improves packing
life, reduces waste, and increases operational efficiencies In addition, the
technology can include
a design to fit oil lubrication, which reduces the cleanup associated with
grease-based systems.
100061 FIG. 1 illustrates a compact pump trailer 100 (also known as a pump
truck) that is a part
of a hydraulic fracturing system, in accordance with some embodiments of the
present
disclosure. The pump trailer 100 has a shorter length 102 than conventional
pump trailers. In
some embodiments, the length 102 of the pump trailer 100 may be less than 40
feet. In some
embodiments, the length 102 of the pump trailer 100 may be 37 feet. In some
embodiments, the
length 102 of the pump trailer 100 may be 36.9 feet_ The pump trailer 100 also
includes an
electronic system 104 in which a transformer and an electronic motor controls
are housed
together. In some embodiments, the electronic motor controls include a
variable-frequency drive
(VFD). In some embodiments, the pump trailer 100 further includes at least a
3,000 hydraulic
horsepower motor drive 108. In some embodiments, the electronic system 102
includes a
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housing in which the transformer and the electronic motor controls are housed.
In some
embodiments, the housing includes one cable plug-in for transmission of power
and/or
communication signals.
100071 The compact pump trailer 100 also includes a lubrication system 106 The
lubrication
system 106 is instrumented with a plurality of sensors. The plurality of
sensors provides more
detailed data which is used to lubricate more effectively and more
efficiently. In some
embodiments, the lubrication system is compatible with oil lubrication. In
some embodiments,
the lubrication system is a stroke based packing lubrication system.
100081 In some embodiments, the pump trailer 100 further includes a quintuplex
pump 110. In
some embodiments, the pump trailer 100 further includes a regulated suction
stabilizer 112,
which provides smoother flow and reduced vibrations In some embodiments, the
pump trailer
100 further includes a rear mounted power end lube cooler 114. In some
embodiments, the pump
trailer 100 further includes a variable speed cooler motor 116, which
minimizes noise output.
100091 FIG. 2 is a diagram illustrating the electronic system 104, in
accordance with example
embodiments. As mentioned, the electronic system 104 includes a transformer
202 and electronic
motor controls 204 are housed together within a housing 206. In some
embodiments, the
electronic motor controls include a variable-frequency drive (VFD). In some
embodiments, the
housing includes one cable plug-in 208 for transmission of power and/or
communication signals.
100101 FIG. 3 is a diagram illustrating the instrumented lubrication system
106, in accordance
with example embodiments. The lubrication system 106 is instrumented with a
plurality of
sensors 302 The plurality of sensors 302 provides more detailed data which is
used to lubricate
more effectively and more efficiently. In some embodiments, the lubrication
system 106 is
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compatible with oil lubrication. In some embodiments, the lubrication system
is a stroke based
packing lubrication system.
100111 FIG. 4 illustrates a method 400 of hydraulic fracturing, in accordance
with example
embodiments. The method includes positioning (402) a compact pump trailer at a
pump site. The
compact pump trailer has a length below 40 feet. In some embodiments, the pump
trailer has a
length below 37 feet. The method further includes powering (404) a pump via an
electronics
system. The electronics system includes a transformer and electronic motor
controls, in which
the transformer and the electronic motor controls housed together, thereby
requiring a smaller
footprint and allowing the size of the pump trail to be smaller than
conventional pump trailers.
100121 Embodiments may be described in view of the following clauses:
1. A compact fracturing system, comprising:
a pump truck having a length of at most 40 feet;
an electronic system, comprising:
a transformer;
electronic motor controls housed together with the transformer, and
a variable-frequency drive (VFD); and
a lubrication system comprising a plurality of sensors, the lubrication system
compatible with oil lubrication.
2. The compact fracturing system of clause I, further comprising at least a
3,000
hydraulic horsepower motor drive.
3. The compact fracturing system of clause 1, further comprising a
quintuplex pump.
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4. The compact fracturing system of clause 1, further comprising a
regulated suction
stabilizer.
5. The compact fracturing system of clause 1, wherein the lubrication
system is a
stroke based packing lubrication system.
6. The compact fracturing system of clause 1, wherein the pump truck has a
length
of at most 37 feet.
7. The compact fracturing system of clause 1, wherein the electronic system
further
comprises a housing, the transformer and electric motor controls housed within
the housing.
8. The compact fracturing system of clause 1, further comprising a rear
mounted
power end lube cooler.
9. The compact fracturing system of clause 1, further comprising a variable
speed
cooler motor.
10. A compact fracturing system, comprising:
an electronic system providing power, controls, or both to one or more
components of the compact fracturing system, the electronic system comprising:
a transformer;
electronic motor controls; and
a housing, wherein the electronic motor controls and the transformer are
housed
within the housing.
11. The compact fracturing system of clause 10, further comprising a
regulated
suction stabilizer.
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12. The compact fracturing system of clause 10, further comprising a stroke
based
lubrication system compatible with oil lubricant.
13. The compact fracturing system of clause 10, further comprising a
variable speed
cooler motor.
14. The compact fracturing system of clause 10, further comprising a 3,000
hydraulic
horsepower motor drive.
15. The compact fracturing system of clause 10, further comprising a
variable
frequency drive (VIED).
16. The compact fracturing system of clause 10, wherein the electronic
system is
located on a pump truck have a length of 37 feet or less.
17. The compact fracturing system of clause 10, further comprising a
quintuplex
pump.
18. The compact fracturing system of clause 10, further comprising a rear
mounted
power end tube cooler.
19. A method of hydraulic fracturing, comprisingl
positioning a compact frac pump trailer at a pump site, the compact frac pump
trailer having a length below 37 feet; and
powering a pump via an electronics system, the electronics system comprising a
transformer and electronic motor controls, the transformer and the electronic
motor
controls housed together.
20. The method of clause 19, wherein the frac pump trailer further
comprises a
regulated suction stabilizer and a read mounted power end lube cooler.
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21. The method of clause 19, wherein the frac pump
trailer further comprises a stroke
based lubrication system compatible with oil lubricant.
[0013] The present disclosure 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 disclosure 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 disclosure
disclosed herein and the
scope of the appended claims.
to
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