The preferred embodiments relate generally to the field of hydrocarbon recovery from the earth and, more specifically, to oilfield pressure pumping systems for fracturing underground formations to enhance recovery of hydrocarbons.
Hydraulically fracturing subterranean formations with oilfield pressure pumping systems to enhance flow in oil and gas wells is known. Hydraulic fracturing increases well productivity by increasing the porosity of, and thus flow rate through, production zones that feed boreholes of the wells that remove underground resources like oil and gas.
Oilfield pressure pumping systems include heavy-duty industrial-type components to create the extreme hydraulic pressures, for example, 10,000 psi or more, which are needed to fracture the subterranean geological formations. Positive displacement, high pressure, plunger pumps are used as fracturing (fracking or frac) pumps to generate the extreme hydraulic pressures that are capable of fracturing subterranean geological formations.
Flow and pressure of frac fluids from frac pumps must be closely regulated at the various fracturing stages in order to adequately control the fracturing process. Accordingly, prime movers that deliver power to the frac pumps are variable speed devices, since driving the frac pumps at variable speeds at least partially provides the flow and pressure control.
Typically, the prime movers are high horsepower stationary diesel engines that deliver power to the frac pumps through multi-speed gearboxes or transmissions. High horsepower stationary diesel engines are expensive and require maintenance and operational attention, such as refueling.
Other attempts have been made to use variable speed electric motors to power frac pumps. Variable speed electric motors are able to vary flow and pressure of the frac pumps through speed-varying motor controls, which facilitates control of the fracturing operation. Variable speed electric motors either directly drive the frac pumps at the motors' variable speeds or with an intervening single-speed gearbox or transmission. Such variable speed electric motors include shunt wound, variable speed, DC (direct current) traction motors and variable speed, for example, variable frequency, AC (alternating current) electric motors. Although variable speed electric motors can require less operational attention than high horsepower stationary diesel engines, they are expensive and require sophisticated motor controls.
Constant speed AC motors are more straightforward than variable speed electric motors but have not been used to deliver power to frac pumps. That is because the fixed speed(s) of constant speed AC motors do not provide the desired amount of flow and pressure control of the frac pumps to allow operators to suitably control the fracturing operation. Typical multi-speed gearboxes are unable to resolve this problem with constant speed AC motors because they are unable to shift under full load and have range ratios that are ill-suited to provide a sufficient variety of output shaft speeds or corresponding frac pump flow and pressure control.
Furthermore, constant speed AC motors of high-enough horsepower ratings to power frac pumps are difficult to start because they require extremely high starting currents as in-rush (locked rotor) currents to begin their rotations.
What is therefore needed is a prime mover for high pressure pumping applications, like powering frac pumps, employing a constant speed AC motor, but without the above-noted drawbacks primarily directed to flow and pressure control.
The preferred embodiments overcome the above-noted drawbacks by providing an electro-hydraulic high-pressure pumping system that incorporates a constant speed AC motor. This can be incorporated as an electro-hydraulic frac pump system for use in an oilfield pressure pumping system.
An electro-hydraulic high-pressure oilfield pumping system includes a fracturing (frac) pump and a primary electric motor as a prime mover that delivers power to the frac pump. The primary electric motor may be a constant speed AC (alternating current) motor. A hydraulic starting motor may rotate a shaft of the primary electric motor to achieve or approximate its fixed rated speed before the primary electric motor is energized. A slow frac hydraulic motor may rotate the shaft of the primary electric motor as a passive torque transmission device that delivers power in a downstream direction through a transmission and to the frac pump.
The system may define multiple modes of operation. In a primary electric motor starting mode, a hydraulic starting motor delivers power through the transmission to rotate the motor shaft of the primary electric motor to its fixed rated speed before being energized, which allows the primary electric motor to be started at essentially its normal running current instead of at a high in-rush starting current. In a slow frac mode, a slow frac hydraulic motor delivers power through the transmission to rotate the motor shaft of the primary electric motor to a speed that is less than the fixed rated speed to the primary electric motor to drive the frac pump at a slower speed and provide high-pressure slow speed fracking. In a frac mode, the primary electric motor is energized and delivers power to the transmission into the frac pump.
According to a first embodiment, an electro-hydraulic high-pressure oilfield pumping system for driving a fracturing (frac) pump is configured to pressurize a frac fluid for delivery into a well that extends into a subterranean geological formation. The system includes a primary electric motor that has a motor shaft and defines a prime mover of the electro-hydraulic high-pressure oilfield pumping system. In addition, the system preferably employs a transmission with multiple ranges that provide multiple drive ratios, the transmission being arranged between and configured to deliver power from primary electric motor to the frac pump. A starting motor selectively delivers power through the transmission to rotate the motor shaft of the primary electric motor.
In another aspect of this embodiment, the primary electric motor is a constant speed AC motor that defines a fixed rated speed, and moreover, the hydraulic starting motor is configured to rotate at a speed that corresponds to the fixed rated speed of the primary electric motor.
According to a further aspect of this embodiment, a slow frac motor is provided to selectively deliver power through the transmission to rotate the motor shaft of the primary electric motor. The primary electric motor is a constant speed AC motor that defines a fixed rated speed, and the slow frac motor is configured to rotate at a speed that is less than the fixed rated speed of the primary electric motor.
In another embodiment, an electro-hydraulic high-pressure oilfield pumping system includes a fracturing (frac) pump configured to pressurize a frac fluid for delivery into a well that extends into a subterranean geological formation, and a primary electric motor that has a motor shaft and defines a prime mover of the electro-hydraulic high-pressure oilfield pumping system. A transmission with multiple ranges provides multiple drive ratios and is arranged between and configured to deliver power from primary electric motor to the frac pump. A hydraulic starting motor selectively delivers power through the transmission to rotate the motor shaft of the primary electric motor, and a slow frac hydraulic motor selectively delivers power through the transmission to rotate the motor shaft of the primary electric motor. Also, a hydraulic power pack is configured to selectively permit or prevent flow of hydraulic fluid to each of the hydraulic starting motor and the slow frac hydraulic motor to activate or deactivate the hydraulic starting motor and the slow frac hydraulic motor.
According to another embodiment, a method of fracking a subterranean formation using a primary electric motor includes the step of driving the primary electric motor with a starting motor and driving a frac pump with an output of the primary electric motor to facilitate fracking the subterranean formation. The method further includes selectively delivering power from the primary electric motor to the frac pump using a transmission.
In another aspect of this embodiment, the method further includes the step of, in a starting mode, energizing the hydraulic motor with a second electric motor, and rotating a motor shaft of the primary electric motor with the hydraulic motor to a first speed that corresponds to a fixed rated speed of the primary electric motor. Preferably, the primary electric motor is a constant speed AC motor. Moreover, the method includes the step of, in a slow frac mode, energizing a slow frac hydraulic motor with a third electric motor. The slow frac hydraulic motor selectively delivers power through the transmission to rotate the motor shaft of the primary electric motor to a second speed that is less than the fixed rated speed of the primary electric motor.
These, and other aspects and objects of the present invention, will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following description, while indicating preferred embodiments of the present invention, is given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the present invention without departing from the spirit thereof, and the invention includes all such modifications.
A clear conception of the advantages and features constituting the present invention, and of the construction and operation of typical embodiments of the present invention, will become more readily apparent by referring to the exemplary and, therefore, non-limiting, embodiments illustrated in the drawings accompanying and forming a part of this specification, wherein like reference numerals designate the same elements in the several views, and in which:
In describing preferred embodiments of the invention, which are illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, it is not intended that the invention be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents, which operate in a similar manner to accomplish a similar purpose. For example, the words “connected”, “attached”, “coupled”, or terms similar thereto are often used. They are not limited to direct connection but include connection through other elements where such connection is recognized as being equivalent by those skilled in the art.
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Electric motor 64 selectively delivers torque to slow frac hydraulic motor 60. Like electric motor 58, electric motor 64 may be a variable speed AC motor that is substantially smaller than primary electric motor 42, with electric motor 64 rated at, for example, about 50 HP. Energizing electric motor 64 activates slow frac hydraulic motor 60, which rotates various gear train or other components of transmission 44 and correspondingly rotates the shaft of primary electric motor 42 when the primary electric motor 42 is de-energized. In this way, the slow frac hydraulic motor 60 can be activated to rotate primary electric motor 42 shaft at slow and precisely controlled speeds to deliver torque through the transmission 44 and correspondingly precisely control the frac pump 16 to provide high-pressure low speed fracking. The rotational speed of slow frac hydraulic motor 60 be between about 800 RPM to 1,100 RPM or at an appropriate speed that can rotate the primary electric motor 42 shaft at between about 800 RPM to 1,000 RPM or other speed, depending on the particular speed required to produce the desired flow rate of frac pump 16 for high pressure low speed fracking. Regardless, the precise slow speed control of slow frac hydraulic motor 60 may be achieved using a closed-loop controller (e.g., proportional integral derivative (PID) controller) within the control system 40 (
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Next, when mode selector valve 70 is at a second position shown as position 74, hydraulic fluid directed to slow frac hydraulic motor 60. This defines a slow frac mode of system 10 in which slow frac hydraulic motor 60 delivers torque to rotate shaft of the de-energized primary electric motor 42. The corresponding motor shaft is used as a passively driven torque-transmitting component to deliver power from the slow frac hydraulic motor 60 through transmission 44 and to the frac pump 16 to achieve high-pressure, slow speed, fracking in the slow frac mode of system 10.
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A method 100 of fracking using the above-described systems of the preferred embodiments is set forth in
If, on the other hand, the primary electric motor is not energized, method 100 determines whether the user wants to engage Slow Frac Mode, in Block 110. If not, Method 100 directs hydraulic fluid to hydraulic starting motor in Block 112, Starting Mode. In Block 114, a second electric motor is employed to energize the hydraulic starting motor. Hydraulic starting motor delivers power to the transmission that selectively delivers power to the primary electric motor to bring it to its rated fixed or synchronous speed, allowing connection to the electrical power source DoL (Direct on Line) in Block 118. Once connected to the DoL, primary electric motor can drive the frac pump(s) of the system in Block 108.
In Slow Frac Mode, a third electric motor is employed to energize a slow frac hydraulic motor in Block 120. A clutch may be provided to selectively deliver power from the slow frac hydraulic motor to a transmission in Block 122. Again, the slow frac hydraulic motor delivers torque through the transmission to the primary electric motor for high pressure low speed fracking applications. More particularly, in Block 124, transmission output is used to drive the prime mover (i.e., primary electric motor) at slow, precisely controlled speeds. Prime mover output is then used to drive one or more frac pumps in Block 108.
Although the best mode contemplated by the inventors of carrying out the present invention is disclosed above, practice of the above invention is not limited thereto. It will be manifest that various additions, modifications, and rearrangements of the features of the present invention may be made without deviating from the spirit and the scope of the underlying inventive concept.
This application claims the benefit of priority under 35 USC § 119(e) to U.S. Provisional Patent Application No. 62/835,348, filed Apr. 17, 2019, the entire contents of which are hereby expressly incorporated by reference into the present application.
Filing Document | Filing Date | Country | Kind |
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PCT/US2020/028725 | 4/17/2020 | WO |
Publishing Document | Publishing Date | Country | Kind |
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WO2020/214934 | 10/22/2020 | WO | A |
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