APPARATUS FOR EXPANDABLE STORAGE AND METERING

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

REFERENCE TO A MICROFICHE APPENDIX

Not applicable.

FIELD OF THE INVENTION

The present invention relates generally to apparatus and methods for expandable storage and metering. More particularly, the present invention relates to various embodiments of an expandable storage and metering device that is transported in an empty, collapsed state to a site where it is expanded to increase its internal storage volume. Still more particularly, the present invention relates to apparatus and method of storing and metering materials for well services such as fracturing, cementing, and drilling operations.

BACKGROUND

Hydraulic fracturing is a means of stimulating flow from a subterranean formation into a drilled wellbore. After a well is drilled into reservoir rock containing oil, natural gas, or water, a fracturing fluid is injected at high pressure down the wellbore and against the formation, causing it to crack and the cracks to propagate. The fracturing fluid contains a propping agent, usually sand, which prevents the cracks or fractures from closing when pumping of the fracturing fluid into the wellbore is discontinued. The cracks, propped open by the propping agent, provide a path for recoverable fluid, such as oil, natural gas, or water, from the formation into the wellbore, thereby increasing the rate of well production.

Typically hydraulic fracturing fluids are prepared at the surface before being pumped into the wellbore and comprise a thickened or gelled aqueous solution formed by metering and combining large volumes of fluids in a large mixing apparatus and then blending them with a proppant. One common method of preparing a fracturing fluid involves combining a fracture fluid and liquid additives in a mixing device and then blending into that mixture a proppant (e.g., dry sand) transferred from a storage device, such as a truck, by a conveyor belt. The mixing device discharges the mixture of proppant, fracture fluid, and liquid additives to one or more pumps that transfer this fracturing fluid down the wellbore.

Although effective, this method of producing a fracturing fluid can be very resource intensive, and therefore costly. At the well site, the proppant, fracture fluid, and liquid additives require their own storage and metering devices. Depending on the size of the fracturing job, multiple storage and metering devices for each component may be necessary. For example, multiple truckloads of sand, a typical proppant, may be required. Additionally, all such devices must be transported to the well site, which may be at a remote location or even offshore. Equipment, transportation, and labor costs alone suggest utilizing the largest storage and metering devices possible. However, legal road height and width restrictions impose limitations on the size of those devices and costly permits and/or escort vehicles for devices exceeding those restrictions may be financially prohibitive. Moreover, the well site footprint may be too small to permit maneuverability of large devices.

Thus, there is a need for an expandable storage and metering device which is transportable in a collapsed condition, thereby meeting standard size restrictions, but expandable to increase its internal storage volume at a well site so that fewer devices are needed for a given wellbore servicing job and associated equipment, transportation, and labor costs are reduced.

SUMMARY OF THE INVENTION

Apparatus and methods for expandable storage and metering are disclosed. In some embodiments, the expandable storage and metering device comprises a body with a storage cavity therein, a chassis upon which the body is mounted, and a plurality of ports in communication with the storage cavity, wherein the body is expandable and collapsible to change the internal volume of the storage cavity.

Some method embodiments for operating the expandable storage and metering device comprise expanding the device, wherein said expanding comprises actuating one or more hydraulic struts to raise the roof of the device and raising the walls of the device by means of their attachment to the roof, and collapsing the device, wherein said collapsing comprises actuating the one or more hydraulic struts to retract the roof and lowering the walls by means of their attachment to the roof.

Other method embodiments for operating the expandable storage and metering device comprise expanding the device, wherein said expanding comprises disconnecting the roof of the device, removing the roof, positioning at least one stackable module on top of the device, and securing the at least one stackable module to the device, and collapsing the device, wherein said collapsing comprises disconnecting the at least one stackable module from the device, removing the at least one stackable module from the device, replacing the roof, and securing the roof to the device.

Some method embodiments for operating an expandable storage and metering device in wellbore servicing comprise positioning an expandable storage and metering device at a well site, expanding the device, storing one or more materials in the device, and metering the one or materials from the device, wherein said metering is performed at a rate that can be changed during wellbore service.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more detailed description of the present invention, reference will now be made to the accompanying drawings, wherein:

FIG. 1 depicts a perspective side view of one representative expandable storage and metering device, referred to herein as the “pop-up” concept, in an expanded configuration;

FIG. 2 depicts the “pop-up” concept illustrated by FIG. 1 in a collapsed configuration;

FIGS. 3A and 3B depict a side view and an end view, respectively, of another representative expandable storage and metering device referred to herein as the “stackable modular” concept;

FIGS. 4A and 4B depict a side view and an end view, respectively, of the “slide-out” concept;

FIGS. 5A and 5B depict a side view and an end view, respectively, of the “combination” concept; and

FIG. 6 illustrates a typical well fracturing operation wherein one representative expandable storage and metering device is utilized.

NOTATION AND NOMENCLATURE

Certain terms are used throughout the following description and claims to refer to particular assembly components. This document does not intend to distinguish between components that differ in name but not function. In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . ”.

DETAILED DESCRIPTION

Various embodiments of an expandable storage and metering device transportable in a collapsed state, but operable to expand at a job site, thereby increasing its internal storage volume, will now be described with reference to the accompanying drawings, wherein like reference numerals are used for like features throughout the several views. There are shown in the drawings, and herein will be described in detail, specific embodiments of the expandable storage and metering device with the understanding that this disclosure is representative only and is not intended to limit the invention to those embodiments illustrated and described herein. The embodiments of the expandable storage and metering device and methods disclosed herein may be used in any type of application, operation, or process, on land or on water, including well fracturing, cementing, and drilling operations, for which it is desired to provide material at a specific rate. Such material may include solid bulk material such as sand, cement, proppant, clay, etc.; liquid material such as water or other liquid additives; pumpable slurries such as cement, drilling fluids, or fracturing fluids; or any other material for use in servicing a wellbore that requires large volumes typically stored in a non-pressurized or near atmospheric container. It is to be fully recognized that the different teachings of the embodiments disclosed herein may be employed separately or in any suitable combination to produce desired results.

FIG. 1 depicts a perspective side view of one representative expandable storage and metering device 100, referred to herein as the “pop-up” concept, comprising a rectangular-shaped body 105 attached to a conventional chassis 110, landing legs 115 connected to and extending downward from the base 120 of the rectangular body 105, a primary conveyor 125 suspended beneath the body base 120 by vertical supports 130, an elevating conveyor 135 connected to one end of the primary conveyor 125, and a hydraulic power pack 140 supported by a frame 145 attached to the body base 120. The chassis 110 includes support structure 153 and two pairs of wheels 150. The rectangular-shaped body 105 further comprises a front end wall 155, a back end wall 160, two side walls 165, 170, and a roof 175, which is extendable and retractable by one or more actuators 180 located along the side walls 165, 170. The actuators 180 may be hydraulic, pneumatic, mechanical, electrical, or a combination thereof. The rectangular body 105 may be compartmentalized by dividers 195 positioned along the length of the body 105 to create multiple bins 200, as illustrated by FIG. 1. In the absence of dividers 195, a single bin 200 is created by the front end wall 155, back end wall 160, two side walls 165, 170, base 120, and roof 175.

The side walls 165, 170, front end wall 155, and back end wall 160 each comprise a lower wall portion 185 attached to the body base 120 and an upper wall portion 190 attached to the roof 175. The upper wall portion 190 retracts and extends with the roof 175 by virtue of its attachment to the roof 175. The lower wall portion 185 and the upper wall portion 190 are connected such that when the roof 175 is retracted, the upper wall portion 190 slides downward relative to the lower wall portion 185, which does not move. In some embodiments, the upper wall portion 190 slides downward along the outer surface of the lower wall portion 185 to be stored externally adjacent to the lower wall portion 185 during transport of the storage and metering device 100 in a collapsed state. In other embodiments, the upper wall portion 190 slides downward along the inner surface of the lower wall portion 185 to be stored internally adjacent to the lower wall portion 185 during transport.

The dividers 195, if present, each share the same construction as the side walls 165, 170, front end wall 155, and back end wall 160. The dividers 195 comprise a lower divider portion 205 attached to the body base 120 and an upper divider portion 210 attached to the roof 175. The upper divider portion 210 retracts and extends with the roof 175 by virtue of its attachment to the roof 175. The lower divider portion 205 and the upper divider portion 210 are connected such that when the roof 175 is retracted, the upper divider portion 210 slides downward relative to the lower divider portion 205, which does not move. In some embodiments, the upper divider portion 210 slides downward along surface 212 of the lower divider portion 205 to be stored adjacent to surface 212 during transport of the storage and metering device 100. In other embodiments, the upper divider portion 210 slides downward along surface 214 of the lower divider portion 205 to be stored adjacent to surface 214 during transport, wherein surfaces 212 and 214 are opposite sides of the lower divider portion 205.

The bins 200 are one or more sealed storage compartments for materials, both solid and liquid, including but not limited to proppants, such as sand and sintered bauxite, and water for well fracturing, cementing, and drilling operations. These bins 200 are be designed to have internal storage volumes which increase from their minimum capacities when the roof 175 and upper wall portion 190 and the upper divider portion 210 are fully retracted to their maximum capacities when the roof 175 and upper wall portion 190 and the upper divider portion 210 are fully extended, where the maximum capacity of each bin 200 may be as much as double its minimum capacity. Dividers 195, if present, provide multiple independent bins 200 which allow for the storage and use of multiple grades or types of materials within the same storage and metering device 100 while preventing any cross-contamination of one grade or type of material to another.

The lower wall portion 185, lower divider portion 205, upper wall portion 190, and upper divider portion 210 may be constructed or formed out of any suitable material that may be flexible, elastic, inflexible, inelastic, or a combination thereof. To withstand the forces resulting from the weight of materials stored in the bins 200, the lower wall portion 185 and lower divider portion 205 are constructed of any suitable strength material known in the art, such as but not limited to, carbon steel, plastics, composites, aluminum, and thermosets. In some embodiments, these components 185, 205 may be constructed of 3/16″ thick carbon steel. Due to the distribution of materials contained within the bins 200, the upper wall portion 190 and upper divider portion 210 experience lower loads than the lower wall portion 185 and lower divider portion 205 and therefore need not be constructed of similar strength material. At the same time, it is desirable that these components 190, 210 be as light as possible to minimize the burden on the actuators 180 and transportation costs. Given these considerations, the upper wall portion 190 and upper divider portion 210 are constructed of any suitable material known in the art, such as but not limited to plastics, composites, material weaves such as metal weaves, fiberglass weaves, teflon-coated fiberglass weaves, thermoset weaves, polyester weaves, and PVC-coated polyester weaves.

FIG. 1 illustrates the expandable storage and metering device 100 with the roof 175 extended by virtue of the actuators 180, while FIG. 2 illustrates the same device 100 but with the roof 175 retracted. When the roof 175 is extended, the upper wall portion 190 and upper divider portion 210 also extend by virtue of their attachment to the roof 175, as illustrated in FIG. 1. In this configuration, the internal storage volume of the bins 200 is maximized. To provide stability for the expandable storage and metering device 100 in this condition, the landing legs 115 are extended downward from the body base 120 to contact the ground or other rigid surface. When the roof 175 is retracted, the upper wall portion 190 and upper divider portion 210 typically also retract and may be stored within the body 105 of the device 100, as illustrated by FIG. 2. In this configuration, the internal storage volume of the bins 200 is minimized. This is the configuration assumed by the expandable storage and metering device 100 during transportation. As such, additional support provided by the landing legs 115 is not needed and the legs 115 are retracted.

The ability to transport the storage and metering device 100 in a collapsed condition, as illustrated by FIG. 2, to a job site where the device 100 is expanded to increase its internal storage volume, as illustrated by FIG. 1, allows the device 100 to be maneuvered into and out of job sites it may not have been able to ingress and egress if the device 100 were a non-collapsible structure. Moreover, by expanding the storage capacity of the devices 100 after positioning them at a job site, fewer devices 100 are required for a job. The ability to increase the internal storage volume of the device 100 may also permit the device 100 to store all materials required for the job prior to initiation of, for example, a fracturing process or cementing operation. In the event that more materials are required, the devices 100 have the ability to be refilled during the course of a fracturing or cementing job, again for example only. For instance, the expandable well servicing storage and metering device may be configured with one or more openings to accept the insertion or delivery of well servicing materials for storage and metering. This opening may be located or positioned on any portion of the structure whereby loading or delivery of well servicing materials into the expandable storage and metering device may be performed. Preferably, this opening will be located on an upper portion of the expandable storage and metering device, i.e., the roof, or upper wall portion. The opening may be configured with a structure or component to facilitate the separation of the external space surrounding the storage and metering device from the internal space configured to house the well servicing materials. This structure or component can be fashioned in the form of a door, lid, plate, or other configuration and fixably connected to the storage and metering device by any commonly recognized securing mechanism or component such as a bolt, screw, locking pin, or combinations thereof.

Materials stored within the bins 200 are released through dispersal ports 108 located in the body base 105 and dumped onto the primary conveyor 125 positioned directly beneath the ports 108. The volumetric rate at which the material stored within the bins 200 is released is a function of the speed of the primary conveyor 125. Sensors 109 may be associated with the expandable storage and metering device, such as proximate to the load path between the support structure 153 and the landing legs 115, to monitor real time material inventory. These sensors 109 may be configured to provide various types of information relating to the mass of materials stored in the bins 200. Using the sensors 109, the amount of materials metered out as well as the rate at which the materials are supplied to a job process can be determined and monitored. The ability to monitor and vary the rate at which materials are supplied to a fracturing process, for example, is advantageous because the volumetric requirements for materials often change during the course of a fracturing job.

The hydraulic power pack 140 provides power to operate the primary conveyor 125 and the elevating conveyor 135. When both are operational, the materials are transported by the primary conveyor 125 to the elevating conveyor 135 and from the elevating conveyor 135 to equipment attached or proximately located to the expandable storage and metering device 100, for example, a gathering conveyor in a well fracturing operation. The hydraulic power pack 140 may also provide power to extend and retract the landing legs 115 and the roof 175 if the actuators 180 employed are hydraulic in nature.

In the embodiments illustrated by FIGS. 1 and 2, the actuators 180 extend and retract the roof 175. Hence, these embodiments of the expandable storage and metering device 100 are referred to herein as the “pop-up” concept. Another embodiment of the “pop-up” concept, drawing on the previous description, includes the expandable storage and metering device's walls having the ability to concentrically collapse so that the profile of the unexpanded state of the device would be significantly less than that of the expanded profile due to the walls ability to expand from a concentrically stored position, in a manner similar to the extension of a Chinese paper yo-yo. In other embodiments of the expandable storage and metering device 100, the roof 175 is not extended or retracted but rather it is removed on site using a crane or other similar means and replaced with one or more stackable modules 220. Although similar in many respects to the previously described embodiments, the “stackable modular” concept differs in the way the expandable storage and metering device 100 expands to maximize its internal storage volume and collapses to a transportable configuration.

FIGS. 3A and 3B illustrate embodiments of the “stackable modular” concept wherein the roof 175 is removed and replaced by a single stackable module 220, comprising a roof 225 and four walls 230, using a crane or other similar means. The module 220, which extends the full length of the expandable storage and metering device 100, is stacked directly on top of the lower rigid walls 185 to create a single bin 200. The module 220 may be subdivided by one or more dividers 235 secured to its roof 225 and walls 230. If present, the dividers 235 are aligned with dividers 195, which subdivide the volume created by the rigid lower walls 185 and base 120, to create two or more bins 200. By way of example only, five bins 200 are depicted in FIG. 3A. Once positioned, the stackable module 220 is secured to the lower wall portion 185 using any suitable fasteners known in the art, such as but not limited to screws, bolts and locking pins. Dividers 235, if present, are similarly secured to dividers 195.

Due to the distribution of materials contained within the bins 200, the walls 230 and dividers 235 may experience lower loads than the lower wall portion 185 and dividers 195. Therefore, the walls 230 and dividers 235 need not be constructed of the same or similar strength material used in the lower wall portion 185 and dividers 185. At the same time, it is desirable that the walls 230 and dividers 235 be as light as possible to minimize transportation costs. Given these considerations, the walls 230, dividers 235, and roof 220 are constructed of any suitable material known in the art, such as but not limited to, fiberglass.

In other embodiments of the “stackable modular” concept, the roof 175 may be removed and replaced by multiple modules 220, each comprising a roof 225 and four walls 230, using a crane or other similar means. The stackable modules 220 are stacked directly on top of the lower wall portion 185 and positioned such that the walls 230 of each module 220 are aligned with the lower wall portion 185 and dividers 195 to create one or more bins 200. In these embodiments, multiple bins 200 may be created to span the full length of the expandable storage and metering device 100. Alternatively, one or more bins 200 may be created which span less than the full length of the device 100. For example, a single bin 200 may be created which is similar in length to the bin 237 shown in FIG. 3A. Once positioned, the walls 230 of the one or more stackable modules 220 are secured to the lower wall portion 185 and dividers 195 using any suitable fasteners known in the art, such as but not limited to screws, bolts, and locking pins.

To collapse embodiments of the “stackable modular” concept, the walls 230 and dividers 235, if present, of the one or more stackable modules 220 are disconnected from the lower wall portion 185 and dividers 195 of the body 105. The modules 220 are then removed and the roof 175 replaced, again using a crane or similar means. After the roof 175 is secured, the expandable storage and metering device 100 is in a collapsed condition ready for transport.

The “pop-up” and “stackable modular” concepts are embodiments of the expandable storage and metering device 100 that expand vertically to increase the internal storage volume of the device 100. In other embodiments, the storage and metering device 100 may expand in a horizontal direction. FIGS. 4A and 4B illustrate embodiments of the expandable storage and metering device 100, referred to herein as the “slide-out” concept, wherein in the side walls 240, front end wall 245, and back end wall 250 slide out in a horizontal direction to increase the internal storage volume of the device 100. Actuators slide the walls 240, 245, 250 outward to expand the device 100 and retract the walls 240, 245, 250 to collapse the device 100. Due to the weight distribution of material when the device 100 assumes its expanded configuration, the support substructure 153 of the device 100 is designed to provide additional stability for the device 100 in this configuration beyond that provided the landing legs 115. Another embodiment of the “slide-out” concept, drawing on the previous description, includes the expandable storage and metering device's walls having the ability to concentrically collapse so that the profile of the unexpanded state of the device would be significantly less than that of the expanded profile due to the walls ability to expand from a concentrically stored position, in a manner similar to the extension of a Chinese paper yo-yo.

FIGS. 5A and 5B illustrate embodiments of the expandable storage and metering device 100 wherein the device 100 expands both horizontally and vertically. Hence, they are referred to herein as the “combination” concept. In some embodiments, the side walls 240, the front end wall 245, and the back end wall 245 first slide outward in a horizontal direction and then upward in a vertical direction to increase the internal storage volume of the device 100. Alternatively, the walls 240, front end wall 245, and back end wall 250 may first slide upward in a vertical direction and then outward in a horizontal direction to increase the internal storage volume of the device 100. Actuators slide the walls 240, 245, 250 outward and upward, or vice versa, to expand the device 100 and retract the walls 240, 245, 250 to collapse the device 100. Due to the weight distribution of material when the device 100 assumes its expanded configuration, the support substructure 153 of the device 100 is designed to provide additional stability for the device 100 in this configuration beyond that provided the landing legs 115.

The embodiments of the expandable storage and metering device 100 disclosed herein may be used in any type of application, operation, or process, including well fracturing, cementing, and drilling operations, for which it is desired to provide material at a specific rate. As one illustrative example, FIG. 6 schematically depicts a well fracturing operation 600 wherein one representative expandable storage and metering device 100 is used to provide sand 605 at a desired rate to produce a fracture fluid 630. The device 100, which may be any one of the previously described embodiments, is positioned at a well fracturing job site, expanded to maximize its internal volume, and then loaded with enough sand 605 to complete the fracturing job or to capacity if the amount of sand 605 required for the job exceeds the storage capacity of the device 100. In the latter scenario, the device 100 may be refilled one or more times during the fracturing process until the process is completed.

At the well site, the expandable storage and metering device 100 is attached to or positioned proximately to a gathering conveyor 610. Sand 605, stored in bins 200 of the device 100, is metered out at a desired rate onto the primary conveyor 125. The sand 605 is then transported first by the primary conveyor 125 and then by the elevating conveyor 135 to the gathering conveyor 610. The gathering conveyor 610 transports the sand 605 to the blending system 615. Sand 605 is dumped from the gathering conveyor 610 into the blending system 615 where it is combined with frac fluid 620 and liquid additives 625 provided to the blending system 615 by pumps 635 and 640, respectively. Although not shown in FIG. 6, the frac fluid 620 and liquid additives 625, like the sand 605, may also be stored and metered out by one or more expandable storage and metering devices 100. The blending system 615 combines the sand 605, frac fluid 620, and liquid additives 625 to produce a fracture fluid 630 which is then injected into a wellbore 650 by pump 645 for use in the well fracturing process.

The foregoing descriptions of specific embodiments of expandable storage and metering devices and their methods of use have been presented for purposes of illustration and description and are not intended to be exhaustive or to limit the invention to the precise forms disclosed. Obviously many other modifications and variations of these embodiments are possible. In some embodiments, the expandable storage and metering device may be an E-Mover manufactured and sold by Halliburton. Also, methods of operation may vary. For example, an expandable storage and metering device may be used to store a single type or grade of material or multiple such materials, each within its own independent bin. Although a method of using an expandable storage and metering device to provide sand to a well fracturing process was disclosed and described herein, multiple such devices may be used to provide sand to the process. Alternatively or additionally, multiple such devices may store and meter out other materials or fluids needed for the well fracturing process. Moreover, similar expandable storage and metering devices may be used in other types of applications, processes, and operations, including cementing and drilling operations. These applications, processes, and operations may be land-based or offshore.

While various embodiments of an expandable storage and metering device and methods of utilizing those devices have been shown and described herein, modifications may be made by one skilled in the art without departing from the spirit and the teachings of the invention. The embodiments described are representative only, and are not intended to be limiting. Many variations, combinations, and modifications of the applications disclosed herein are possible and are within the scope of the invention. Accordingly, the scope of protection is not limited by the description set out above, but is defined by the claims which follow, that scope including all equivalents of the subject matter of the claims.

APPARATUS FOR EXPANDABLE STORAGE AND METERING

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