Patent Application
20240295167
The present disclosure relates generally to wellbore operations, and more particularly, to the use of a packing lubrication system to supply lubricant to multiple hydraulic fracturing pumping units from a single remotely located lubricant reservoir.
In many hydraulic fracturing operations, it may be desirable to drill multiple wells on a single pad, to perform wellbore operations continuously, and/or to drill deeper or longer wells. These and other intense fracturing operations may result in increased equipment use and consequently, increased equipment wear. This is especially true of hydraulic fracturing pumps, which are the most important and consequential piece of equipment for a hydraulic fracturing operation. Hydraulic fracturing pumps may use proppant-laden fluids, which can be abrasive to the equipment and these fluids are typically pumped under high pressures and high-flow rates. A hydraulic fracture pump may use a lubrication system to improve pump efficiency and to increase the useful life of the pump. The lubrication system may reduce component wear by lubricating pump components thereby reducing the grinding of components against one another. The lubrication system may also cool these pump components by absorbing and transferring heat from the pump components. In some cases, the lubricant may be used to remove unwanted particulates from the pumping system thereby reducing the damage these particulates can have on pump components.
The lubrication system is an important part of a hydraulic fracturing pump. The present invention provides improved apparatus and methods for lubricating a hydraulic fracturing pump.
Illustrative examples of the present disclosure are described in detail below with reference to the attached drawing figures, which are incorporated by reference herein, and wherein:
The illustrated figures are only exemplary and are not intended to assert or imply any limitation with regard to the environment, architecture, design, or process in which different examples may be implemented.
The present disclosure relates generally to wellbore operations, and more particularly, to the use of a packing lubrication system to supply lubricant to multiple hydraulic fracturing pumping units from a single remotely located lubricant reservoir.
In the following detailed description of several illustrative examples, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific examples that may be practiced. These examples are described in sufficient detail to enable those skilled in the art to practice them, and it is to be understood that other examples may be utilized, and that logical structural, mechanical, electrical, and chemical changes may be made without departing from the spirit or scope of the disclosed examples. To avoid detail not necessary to enable those skilled in the art to practice the examples described herein, the description may omit certain information known to those skilled in the art. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the illustrative examples are defined only by the appended claims.
Unless otherwise indicated, all numbers expressing quantities of ingredients, properties such as molecular weight, reaction conditions, and so forth used in the present specification and associated claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained by the examples of the present invention. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claim, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. It should be noted that when “about” is at the beginning of a numerical list, “about” modifies each number of the numerical list. Further, in some numerical listings of ranges some lower limits listed may be greater than some upper limits listed. One skilled in the art will recognize that the selected subset will require the selection of an upper limit in excess of the selected lower limit.
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.” Unless otherwise indicated, as used throughout this document, “or” does not require mutual exclusivity.
The terms uphole and downhole may be used to refer to the location of various components relative to the bottom or end of a well. For example, a first component described as uphole from a second component may be further away from the end of the well than the second component. Similarly, a first component described as being downhole from a second component may be located closer to the end of the well than the second component.
The present disclosure relates generally to wellbore operations, and more particularly, to the use of a packing lubrication system to supply lubricant to multiple hydraulic fracturing pumping units from a single remotely located lubricant reservoir. One advantage of the packing lubrication system is that the lubrication system is configured to supply a steady, controlled, and measured flow of lubricant to multiple pumping units from a single lubricant reservoir. As the lubricant flow is supplied from a single reservoir, multiple fluid reservoirs for each hydraulic fracturing pump unit are not needed. This change provides several benefits for wellbore operators. One benefit, is that there is no need to refill the individual lubricant reservoirs. Typically, the individual reservoirs for each hydraulic fracturing pump unit are smaller as they only supply lubricant to one hydraulic fracturing pump unit. As the reservoirs are smaller, they require more frequent refilling. Refilling the hydraulic fracturing pump units increases the use of labor resources, increases downtime, and in some instances may be impossible as some wellbore operations restrict access to the individual reservoirs until the wellbore operations are completed. In contrast, a single large lubricant reservoir can supply lubricant to multiple hydraulic fracturing pump units with less overall refilling time. Likewise, the single lubricant reservoir can be placed in a remote location from the hydraulic fracturing pump units so that its access is not limited by certain wellbore operations. An additional advantage is the incorporation of a feedback control system which may be used to monitor the individual feeds of the lubricant flow to the fluid ends of the hydraulic fracturing pump units. The control system coordinates and monitors the lubricant flow and can provide updates to a wellbore operator if the actual cycle count of lubricant flow differs from the desired cycle count of lubricant flow. The control system can function automatically if desired and can regulate the lubricant flow to each hydraulic fracturing pump unit through the control of a regulating valve (e.g., a solenoid valve) configured to regulate the outbound lubricant flow. In some examples, the packing lubrication system can be controlled remotely through remote operation of the control system. If adjustments need to be made, the automatic control system can be adjusted and provided with new parameters. Likewise, should there be an issue with one of the hydraulic fracturing pump units, the regulating valve and lubricant supply to just that individual unit can be shut off while maintenance or repairs are made. This operation can occur without needing to impede lubricant flow to the remaining hydraulic fracturing pump units.
The packing lubrication system comprises a single lubricant reservoir. The lubricant reservoir is of sufficient size to supply a steady flow of lubricant to multiple hydraulic fracturing pump units. The lubricant reservoir may be located remotely from the multiple hydraulic fracturing pump units and may be accessible for refilling or maintenance even if access to the individual hydraulic fracturing pump units is restricted, for example, due to specific wellbore operations that can be hazardous to personnel within specific areas.
The single lubricant reservoir is fluidically coupled to a single lubricant pump configured to steadily and continuously pump a large volume of filtered lubricant to multiple individual hydraulic fracturing pump units. The lubricant reservoir is coupled to the lubricant pump with a hose or other conduit. Any lubricant pump is sufficient for use provided it can maintain the desired output and pressure to all hydraulic fracturing pump units. As an example, if an individual hydraulic fracturing pump unit has a lubricant consumption rate of 0.20 cubic inches per minute and there are twenty-four hydraulic fracturing pump units, the total volume of lubricant consumed would be 4.8 cubic inches per minute (or 0.17 pounds of lubricant per minute). A lubricant pump configured to supply greater than 4.8 cubic inches per minute (or 0.17 pounds per minute) of lubricant while maintaining a sufficient pump pressure would be sufficient for supplying lubricant to twenty-four pumping units under these conditions. The lubricant pump may be located remotely from the hydraulic fracturing pump unit. The lubricant pump may be operated remotely, and because it is remote, it may be accessible even when access to the hydraulic fracturing pump unit is impossible because of an ongoing wellbore operation.
The single lubricant pump is fluidically coupled to a plurality of regulating valves with hoses or other conduits. Each hydraulic fracturing pump unit is regulated by one regulating valve. The regulating valve may be any valve capable of closing sufficiently to shut down the flow of lubricant. Additionally, the regulating valve should be configurable to be controlled by a control system which may be remotely located from the regulating valve. Examples of a regulating valve include, but are not limited to, solenoid valves, electric motor valves, or diaphragm valves. Any species of these valve classes may be used, for example, solenoid poppet valves, pilot operated solenoid valves, etc. The regulating valve is fluidically coupled between a divider block and the single lubricant pump. The regulating valve is electrically coupled to a control system which may be used to remotely open and close the valve as desired by sending an electrical signal to the regulating valve to actuate the regulating valve. The regulating valve may be opened when it is desired to flow lubricant to a hydraulic fracturing pump unit such as when the hydraulic fracturing pump is to be used to perform a hydraulic fracturing operation. The regulating valve may be closed when it is not desired to flow lubricant to the hydraulic fracturing pump unit, for example, when the hydraulic fracturing operation is completed or if the hydraulic fracturing pump unit or other system component requires maintenance or repair.
The regulating valve is fluidically coupled to a divider block via a hose or other conduit. The divider block is fluidically coupled between the regulating valve and the hydraulic fracturing pump unit with hoses or other conduits. The divider block receives the flow of lubricant through the regulating valve and then divides and positively meters the received lubricant equally to each of the packing sets of the fluid end of the hydraulic fracturing pump unit. Any type of divider block may be used so long as it is compatible with the hydraulic fracturing pump unit and regulating valve chosen, for example the divider block should be capable of dividing the fluid equally to the number of packing sets of the hydraulic fracturing pump unit. Additionally, the divider block may be capable of being electrically connected to the control system.
In some optional examples, the divider block may be connected to a contact switch which may be optionally mounted to the divider block. The contact switch may count each cycle of the divider block's lubrication output. The contact switch is connectable to the control system. The control system may be used to track the cycle counts of the divider block taken by the contact switch.
A control system is electrically connected to the regulating valve. In some optional examples the control system is electrically connected to the divider block. The control system is configurable to remotely operate the regulating valve. In the examples, where the control system is electrically connected to the divider block, the control system may be used to track the lubricant cycles of the divider block provided by a contact switch or other cycle counting mechanism. In some optional examples, the control system may be programmable to operate the regulating valve automatically without operator input. In some optional examples, the control system operates the regulating valve, either automatically via its programming or with operator input, to achieve a desired cycle count per minute from the divider block. In these optional examples, the contact switch or other counting mechanism may be used to provide a count of the divider block cycles to the control system and these cycle counts may be tracked by the control system. Further, the control system may compare the actual cycle count that it tracks to the desired cycle count provided to the control system previously. Should the actual cycle count differ from the desired cycle count, the control system may flag the specific divider block and provide a notification capable of being received by a wellbore operator. For example, the notification may comprise an email, a text, a system message on a screen of the control system, or any other such notification. The wellbore operator may then elect to close lubricant flow to the specific divider block by closing the regulating valve coupled to the specific divider block. The divider block or other system components are then available for inspection, maintenance, or repair. Alternatively, the control system may be programmed to automatically shut off the regulating valve if the actual cycle count differs from the desired cycle count, or if a specific differential threshold between the cycle counts is reached. The control system may also be configured to display a general health status of the packing lubrication system. For example, the control system may be electrically connected to the lubricant reservoir and may provide a status of the lubricant level within the reservoir. The control system may also be electrically connected to the lubricant pump and may display issues with the lubricant pump such as a blockage or pump lock. Likewise, the control system may also be electrically connected to the hydraulic fracturing pump unit and may display issues with the hydraulic fracturing pump unit such as a blockage, pump lock, or a drop in lubricant below a desired threshold.
The control system is configurable to selectively operate the regulating valves independently of each other. For example, the control system may close some of the regulating valves and open others thereby only allowing lubricant to flow to the hydraulic fracturing pump units that are in use. The control system may then actuate the regulating valves to close those regulating valves whose respective hydraulic fracturing pump units are finishing their operations and may open any regulating valves whose respective hydraulic fracturing pump units are beginning their operations. In some examples, the control system may be programmable to open and close the regulating valves on a schedule. In some examples, the control system may be operated remotely to adjust the opening and closing of the individual regulating valves from a remote device such as a mobile phone or a computer.
The packing lubrication system provides lubricant to a plurality of hydraulic fracturing pump units. The hydraulic fracturing pump unit is fluidically coupled at its fluid end to the divider block via a hose or other conduit. Each hydraulic fracturing pump unit is fluidically coupled to one divider block which is fluidically coupled to one regulating valve as discussed above. Any hydraulic fracturing pump unit may be used provided it is sufficient for use with the desired wellbore operation. In some examples, multiple hydraulic fracturing pump units may be used on a single pad. In some examples, the hydraulic fracturing pump unit may be electrically connected to the control system. The control system may display warnings or issues with the status of the hydraulic fracturing pump unit.
The packing lubrication system uses lubricant to lubricate a plurality of hydraulic fracturing pump units. The lubricant selected may be any lubricant sufficient for use with the hydraulic fracturing pump units. Generally, the lubricant is an oil-based lubricant. In some examples, the lubricant may be synthetic.
In some optional examples, the packing lubrication system may comprise a rate control orifice, which is also known as a flow control orifice. The rate control orifice may be fluidically coupled between the lubricant pump and the regulating valve with hoses or any other sufficient conduits. The rate control orifice may decrease the lubricant flow from the lubricant pump to the regulating valve by bottlenecking and reducing the flow path for the lubricant. The diameter of the rate control orifice provides a constant flow rate through the orifice. In some examples, the diameter of the rate control orifice may be adjusted to provide a desired flow rate of the lubricant to the regulating valve.
The packing lubrication systems and associated system components disclosed herein may directly or indirectly affect one or more components or pieces of equipment associated with or which may come into contact with the packing lubrication systems and associated system components such as, but not limited to, wellbore casing, wellbore liner, completion string, insert strings, drill string, coiled tubing, slickline, wireline, drill pipe, drill collars, mud motors, downhole motors and/or pumps, cement pumps, surface-mounted motors and/or pumps, centralizers, turbolizers, scratchers, floats (e.g., shoes, collars, valves, etc.), logging tools and related telemetry equipment, actuators (e.g., electromechanical devices, hydromechanical devices, etc.), sliding sleeves, production sleeves, plugs, screens, filters, flow control devices (e.g., inflow control devices, autonomous inflow control devices, outflow control devices, etc.), couplings (e.g., electro-hydraulic wet connect, dry connect, inductive coupler, etc.), control lines (e.g., electrical, fiber optic, hydraulic, etc.), surveillance lines, drill bits and reamers, sensors or distributed sensors, downhole heat exchangers, valves and corresponding actuation devices, tool seals, packers, cement plugs, bridge plugs, and other wellbore isolation devices, or components, and the like.
Provided are automatic packing lubrication systems for lubricating a hydraulic fracturing pump unit in accordance with the disclosure and the illustrated FIGs. An example system comprises a single lubricant reservoir, a single lubricant pump fluidically coupled to the lubricant reservoir, at least two regulating valves fluidically coupled to the lubricant pump, at least two divider blocks, wherein one divider block is individually fluidically coupled to one regulating valve, wherein for every divider block there is a regulating valve fluidically coupled between the divider block and the single lubricant pump, and a control system connected to and configured to control the regulating valve.
Additionally or alternatively, the system may include one or more of the following features individually or in combination. The control system may also connect to each of the divider blocks. The system may further comprise a contact switch for each divider block; wherein there is a contact switch coupled to each of the divider blocks and the individual contact switches are configured to count a pumping cycle of their respective divider blocks. The control system may be configured to track the pumping cycles of the divider blocks based on the counts of the contact switches. The control system may be configured to compare the tracked pumping cycles of the divider blocks to a desired pumping cycle count for each of the divider blocks and if the tracked divider block cycle count differs from the desired divider block cycle count, the control system is configured to flag the specific divider block and provide a notification capable of being received by a wellbore operator. The may further comprise a rate control orifice fluidically coupled between the single lubricant pump and the regulating valve. Each of the regulating valves may be selected from the group consisting of solenoid valves, electric motor valves, diaphragm valves, or any combination thereof. The lubricant may be an oil-based lubricant. The system may further comprise a hydraulic fracturing pump unit for each divider block; wherein one hydraulic fracturing pump unit is fluidically coupled to each divider block. The control system may be programmable to control the regulating valve automatically and without the control of a wellbore operator. The control system may be configured to control each regulating valve independently of the other regulating valves.
Provided are methods for lubricating a hydraulic fracturing pump unit in accordance with the disclosure and the illustrated FIGs. An example method comprises pumping a lubricant from a single reservoir to at least two regulating valves with a single lubricant pump, pumping the lubricant from each regulating valve to a divider block; wherein each regulating valve is fluidically coupled to a single divider block, and then pumping the lubricant to a hydraulic fracturing pump unit from the divider block; wherein each divider block is fluidically coupled to a single hydraulic fracturing pump unit.
Additionally or alternatively, the method may include one or more of the following features individually or in combination. The method may further comprise controlling the flow of the lubricant through the regulating valve by opening or closing the regulating valve with a control system. The method may further comprise counting a pumping cycle of each divider block with a contact switch. The method may further comprise tracking the pumping cycle count of each divider block with a control system. The method may further comprise comparing the tracked pumping cycles of the divider blocks to a desired pumping cycle count for each of the divider blocks and if the tracked divider block cycle count differs from the desired divider block cycle count, the control system flags the specific divider block and provides a notification capable of being received by a wellbore operator. A control system may control the regulating valve automatically and without the control of a wellbore operator. A control system may be configured to control each regulating valve independently of the other regulating valves. The method may further comprise reducing the flow rate of the lubricant to the regulating valves with a rate control orifice fluidically coupled between the single lubricant pump and the regulating valves, wherein there is one rate control orifice for each regulating valve. The regulating valves may be selected from the group consisting of wherein each of the regulating valves are selected from the group consisting of solenoid valves, electric motor valves, diaphragm valves, or any combination thereof. The control system may also connect to each of the divider blocks. The system may further comprise a contact switch for each divider block; wherein there is a contact switch coupled to each of the divider blocks and the individual contact switches are configured to count a pumping cycle of their respective divider blocks. The control system may be configured to track the pumping cycles of the divider blocks based on the counts of the contact switches. The control system may be configured to compare the tracked pumping cycles of the divider blocks to a desired pumping cycle count for each of the divider blocks and if the tracked divider block cycle count differs from the desired divider block cycle count, the control system is configured to flag the specific divider block and provide a notification capable of being received by a wellbore operator. The may further comprise a rate control orifice fluidically coupled between the single lubricant pump and the regulating valve. Each of the regulating valves may be selected from the group consisting of solenoid valves, electric motor valves, diaphragm valves, or any combination thereof. The lubricant may be an oil-based lubricant. The system may further comprise a hydraulic fracturing pump unit for each divider block; wherein one hydraulic fracturing pump unit is fluidically coupled to each divider block. The control system may be programmable to control the regulating valve automatically and without the control of a wellbore operator. The control system may be configured to control each regulating valve independently of the other regulating valves.
The preceding description provides various examples of the systems and methods of use disclosed herein which may contain different method steps and alternative combinations of components. It should be understood that, although individual examples may be discussed herein, the present disclosure covers all combinations of the disclosed examples, including, without limitation, the different component combinations, method step combinations, and properties of the system. It should be understood that the compositions and methods are described in terms of “comprising,” “containing,” or “including” various components or steps. The systems and methods can also “consist essentially of or “consist of the various components and steps. Moreover, the indefinite articles “a” or “an,” as used in the claims, are defined herein to mean one or more than one of the element that it introduces.
For the sake of brevity, only certain ranges are explicitly disclosed herein. However, ranges from any lower limit may be combined with any upper limit to recite a range not explicitly recited, as well as ranges from any lower limit may be combined with any other lower limit to recite a range not explicitly recited. In the same way, ranges from any upper limit may be combined with any other upper limit to recite a range not explicitly recited. Additionally, whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range are specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values even if not explicitly recited. Thus, every point or individual value may serve as its own lower or upper limit combined with any other point or individual value or any other lower or upper limit, to recite a range not explicitly recited.
One or more illustrative examples incorporating the examples disclosed herein are presented. Not all features of a physical implementation are described or shown in this application for the sake of clarity. Therefore, the disclosed systems and methods are well adapted to attain the ends and advantages mentioned, as well as those that are inherent therein. The particular examples disclosed above are illustrative only, as the teachings of the present disclosure may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown other than as described in the claims below. It is therefore evident that the particular illustrative examples disclosed above may be altered, combined, or modified, and all such variations are considered within the scope of the present disclosure. The systems and methods illustratively disclosed herein may suitably be practiced in the absence of any element that is not specifically disclosed herein and/or any optional element disclosed herein.
Although the present disclosure and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the disclosure as defined by the following claims.
