Automated fracturing system and method

An automated hydraulic fracturing system, including a pump system, a blender configured to form the fracturing fluid, a proppant storage and delivery system, a hydration unit configured to mix an additive into a fluid to form the fluid mixture and provide the fluid mixture to the blender, a fluid storage and delivery system, and an additive storage and delivery system, and an automated control system including a plurality of sensing devices and a plurality of control devices integrated into the pump system, the blender system, the proppant storage and delivery system, the fluid storage and delivery system, and the additive storage and delivery system, the automated control system configured to monitor parameters of the automated hydraulic fracturing system via the plurality of sensing devices and transmit control instructions for one or more of the plurality of control devices to control an aspect of the automated hydraulic fracturing system.

BACKGROUND

With advancements in technology over the past few decades, the ability to reach unconventional sources of hydrocarbons has tremendously increased. Horizontal drilling and hydraulic fracturing are two such ways that new developments in technology have led to hydrocarbon production from previously unreachable shale formations. Hydraulic fracturing (fracturing) operations typically require powering numerous components in order to recover oil and gas resources from the ground. For example, hydraulic fracturing usually includes pumps that inject fracturing fluid down the wellbore, blenders that mix proppant into the fluid, cranes, wireline units, and many other components that all must perform different functions to carry out fracturing operations.

Conventionally, these components or systems of components are generally independent systems that are individually controlled by operators. Furthermore, in some cases, operators are also responsible for taking measurements, interpreting raw data, making calculations, and the like. Thus, a large amount of operator intervention to diagnose, interpret, respond to, adjust, and otherwise control operating conditions of the various components.

SUMMARY

Applicant recognized the problems noted above herein and conceived and developed embodiments of systems and methods, according to the present disclosure, for assessing flow rates in hydraulic fracturing systems.

In an embodiment, an automated hydraulic fracturing system includes a pump system fluidly coupled to a wellhead to pump a fracturing fluid into the wellhead, wherein the pump is instrumented with a pump sensor and a pump controller. The hydraulic fracturing system further includes a blender system fluidly coupled to the pump, the blender mixing together one or more materials to form the fracturing fluid, wherein the blender is instrumented with a blender sensor and a blender controller, and a source system for providing at least one of the one or more materials to the blender, wherein the source is instrumented with a source sensor and a source controller. The hydraulic fracturing system also includes another component, the component instrumented with at least one of a component sensor and a component controller. At least one of the pump controller, blender controller, the source controller, or the component controller controls a respective aspect of the automated hydraulic fracturing system based at least in part on automated instructions, the automated instructions generated based on measurements received from at least one of the pump sensor, the blender sensor, the source sensor, or the component sensor.

In an embodiment, an automated hydraulic fracturing system includes a pump system fluidly coupled to a wellhead at a wellsite to pump a fracturing fluid into the wellhead, a blender configured to mix together proppant and a fluid mixture to form the fracturing fluid, a proppant storage and delivery system configured to provide the proppant for the blender, a hydration unit configured to mix an additive into a fluid to form the fluid mixture and provide the fluid mixture to the blender, a fluid storage and delivery system configured to provide the fluid for the hydration unit, an additive storage and delivery system configured to provide the additive to the hydration unit, and an automated control system including a plurality of sensing devices and a plurality of control devices integrated into the pump system, the blender system, the proppant storage and delivery system, the fluid storage and delivery system, and the additive storage and delivery system, the automated control system configured to monitor one or more parameters of the automated hydraulic fracturing system via the plurality of sensing devices and transmit control instructions for one or more of the plurality of control devices to control an aspect of the automated hydraulic fracturing system.

In an embodiment, an automated hydraulic fracturing method includes initiating a hydraulic fracturing operation using an automated hydraulic fracturing system, providing a first material for a fracturing fluid from a first source to a blender, the first source including a source sensor for measuring one or more parameters associated with the first source and a source controller for controlling one or more functions of the first source, providing a second material for the fracturing fluid from a second source to the blender, mixing the first material and the second material at the blender to form the fracturing fluid, the blender including a blender sensor for measuring one or more parameters associated with the blender and a blender controller for controlling one or more functions of the bender, providing the fracturing fluid from the blender to a pump, the pump including a pump sensor for measuring one or more parameters associated with the pump and a pump controller for controlling one or more functions of the pump, injecting the fracturing fluid from the pump into a wellhead coupled to a well, monitoring the one or more parameters via the source sensor, the blender sensor, and the pump sensor, generating automated instructions for at least one of the source controller, the blender controller, or the pump controller based at last in part on the one or more parameters, and controlling at least one of the one or more functions of the first source, the blender, or the pump via the source controller, the blender controller, or the pump controller, respectively, based at least in part on the automated instructions.

DETAILED DESCRIPTION

The foregoing aspects, features, and advantages of the present disclosure will be further appreciated when considered with reference to the following description of embodiments and accompanying drawings. In describing the embodiments of the disclosure illustrated in the appended drawings, specific terminology will be used for the sake of clarity. However, the disclosure is not intended to be limited to the specific terms used, and it is to be understood that each specific term includes equivalents that operate in a similar manner to accomplish a similar purpose.

When introducing elements of various embodiments of the present disclosure, the articles “a”, “an”, “the”, and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including”, and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Any examples of operating parameters and/or environmental conditions are not exclusive of other parameters/conditions of the disclosed embodiments. Additionally, it should be understood that references to “one embodiment”, “an embodiment”, “certain embodiments”, or “other embodiments” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Furthermore, reference to terms such as “above”, “below”, “upper”, “lower”, “side”, “front”, “back”, or other terms regarding orientation or direction are made with reference to the illustrated embodiments and are not intended to be limiting or exclude other orientations or directions. Additionally, recitations of steps of a method should be understood as being capable of being performed in any order unless specifically stated otherwise. Furthermore, the steps may be performed in series or in parallel unless specifically stated otherwise.

FIG. 1is a schematic representation of an embodiment of a hydraulic fracturing system10positioned at a well site12. In the illustrated embodiment, pump trucks14, which make up a pumping system16, are used to pressurize a fracturing fluid solution for injection into a wellhead18. A hydration unit20receives fluid from a fluid source22via a line, such as a tubular, and also receives additives from an additive source24. In an embodiment, the fluid is water and the additives are mixed together and transferred to a blender unit26where proppant from a proppant source28may be added to form the fracturing fluid solution (e.g., fracturing fluid) which is transferred to the pumping system16. The pump trucks14may receive the fracturing fluid solution at a first pressure (e.g., 80 psi to 100 psi) and boost the pressure to around 15,000 psi for injection into the wellhead18. In certain embodiments, the pump trucks14are powered by electric motors.

After being discharged from the pump system16, a distribution system30, such as a missile, receives the fracturing fluid solution for injection into the wellhead18. The distribution system30consolidates the fracturing fluid solution from each of the pump trucks14(for example, via common manifold for distribution of fluid to the pumps) and includes discharge piping32(which may be a series of discharge lines or a single discharge line) coupled to the wellhead18. In this manner, pressurized solution for hydraulic fracturing may be injected into the wellhead18. In the illustrated embodiment, one or more sensors34,36are arranged throughout the hydraulic fracturing system10. In embodiments, the sensors34transmit flow data to a data van38for collection and analysis, among other things.

FIG. 2is a detailed schematic representation of an automated hydraulic fracturing system40, that can be used for pressurizing a wellbore42to create fractures44in a subterranean formation46that surrounds the wellbore42. Included with the system40is a hydration unit48that receives fluid from a fluid source50via line52, and also selectively receives additives from an additive source54via line56. Additive source54can be separate from the hydration unit48as a stand-alone unit, or can be included as part of the same unit as the hydration unit48. The fluid, which in one example is water, is mixed inside of the hydration unit48with the additives. In an embodiment, the fluid and additives are mixed over a period of time, to allow for uniform distribution of the additives within the fluid. In the example ofFIG. 2, the fluid and additive mixture is transferred to a blender unit58via line60. A proppant source62contains proppant, which is delivered to the blender unit58as represented by line64, where line64can be a conveyer. Inside the blender unit58, the proppant and fluid/additive mixture are combined to form a fracturing fluid, which is then transferred to a fracturing pump system66via line68; thus fluid in line68includes the discharge of blender unit58which is the suction (or boost) for the fracturing pump system66.

Blender unit58can have an onboard chemical additive system, such as with chemical pumps and augers. Optionally, additive source54can provide chemicals to blender unit58; or a separate and standalone chemical additive system (not shown) can be provided for delivering chemicals to the blender unit58. In an example, the pressure of the fracturing fluid in line68ranges from around 80 psi to around 100 psi. The pressure of the fracturing fluid can be increased up to around 15,000 psi by pump system66. A motor69, which connects to pump system66via connection40, drives pump system66so that it can pressurize the fracturing fluid. In one example, the motor69is controlled by a variable frequency drive (“VFD”).

After being discharged from pump system66, fracturing fluid is pumped into a wellhead assembly71. Discharge piping42connects discharge of pump system66with wellhead assembly71and provides a conduit for the fracturing fluid between the pump system66and the wellhead assembly71. In an alternative, hoses or other connections can be used to provide a conduit for the fracturing fluid between the pump system66and the wellhead assembly71. Optionally, any type of fluid can be pressurized by the fracturing pump system66to form injection fracturing fluid that is then pumped into the wellbore42for fracturing the formation44, and is not limited to fluids having chemicals or proppant.

An example of a turbine74is provided in the example ofFIG. 1. The turbine74can be gas powered, receiving a combustible fuel from a fuel source76via a feed line78. In one example, the combustible fuel is natural gas, and the fuel source76can be a container of natural gas or a well (not shown) proximate the turbine74. Combustion of the fuel in the turbine74in turn powers a generator80that produces electricity. Shaft82connects generator80to turbine74. The combination of the turbine74, generator80, and shaft82define a turbine generator83. In another example, gearing can also be used to connect the turbine74and generator80.

An example of a micro-grid84is further illustrated inFIG. 2, and which distributes electricity generated by the turbine generator83. Included with the micro-grid84is a transformer86for stepping down voltage of the electricity generated by the generator80to a voltage more compatible for use by electrically powered devices in the hydraulic fracturing system40. In another example, the power generated by the turbine generator and the power utilized by the electrically powered devices in the hydraulic fracturing system10are of the same voltage, such as 4160 V, so that main power transformers are not needed. In one embodiment, multiple 3500 kVA dry cast coil transformers are utilized. Electricity generated in generator80is conveyed to transformer86via line88. In one example, transformer86steps the voltage down from 13.8 kV to around 600 V. Other step down voltages can include 4,160 V, 480 V, or other voltages.

The output or low voltage side of the transformer56connects to a power bus90, lines92,94,96,98,100, and101connect to power bus90and deliver electricity to electrically powered components of the system40. More specifically, line92connects fluid source20to bus90, line94connects additive source24to bus90, line96connects hydration unit18to bus90, line98connects proppant source62to bus90, line100connects blender unit28to bus90, and line101connects bus90to an optional variable frequency drive (“VFD”)102. Line103connects VFD102to motor69. In one example, VFD102can be used to control operation of motor69, and thus also operation of pump66.

In an example, additive source54contains ten or more chemical pumps for supplementing the existing chemical pumps on the hydration unit48and blender unit58. Chemicals from the additive source54can be delivered via lines56to either the hydration unit48and/or the blender unit58. In one embodiment, the elements of the system40are mobile and can be readily transported to a wellsite adjacent the wellbore42, such as on trailers or other platforms equipped with wheels or tracks.

In the illustrated embodiment, one or more instrumentation devices104such as various types of sensors106and controllers108are arranged throughout the hydraulic fracturing system40and coupled to one or more of the aforementioned components, including any of the wellhead assembly71, pump66, blender unit58, proppant source62, hydration unit48, additive source54, fluid source50, generator80, turbine74, fuel source76, any deliveries lines, and various other equipment used in the hydraulic fracturing system40, not all of which are explicitly described herein for sake of brevity. The instrumentation104may include various sensors, actuators, and/or controllers, which may be different for different components. For example, the instrumentation devices104may include hardware features such as, low pressure transducer (low and high frequency), high pressure transducers (low and high frequency), low frequency accelerometers, high frequency accelerometers, temperature sensors, external mounted flow meters such as doppler and sonar sensors, magnetic flow meters, turbine flow meters, proximity probes and sensors, speed sensors, tachometers, capacitive, doppler, inductive, optical, radar, ultrasonic, fiber optic, and hall effect sensors, transmitters and receivers, stroke counters, GPS location monitoring, fuel consumption, load cells, PLCs, and timers. In some embodiments, the instrumentation devices may be installed on the components and dispersed in various locations.

The components may also include communication means that enable all the sensor packages, actuation devices, and equipment components to communicate with each other allowing for real time conditional monitoring. This would allow equipment to adjust rates, pressure, operating conditions such as engine, transmission, power ends RPMs, sand storage compartment gates, valves, and actuators, sand delivery belts and shoots, water storage compartments gates, valves, and actuators, water delivery lines and hoses, individual fracture pump's rates as well as collective system rates, blender hydraulics such as chemical pumps, liquid and dry, fan motors for cooling packages, blender discharge pumps, electric and variable frequency powered chemical pumps and auger screws, suction and discharge manifold meters, valves, and actuators. Equipment can prevent failures, reduce continual damage, and control when it is allowed and not allowed to continue to operate based on live and continuous data readings. Each component may be able to provide troubleshooting codes and alerts that more specifically narrow down the potential causes of issues. This allows technicians to more effectively service equipment, or for troubleshooting or other processes to be initialized automatically. Conditional monitoring will identify changes in system components and will be able to direct, divert, and manage all components so that each is performing its job the most efficiently

In some embodiments, the sensors may transmit data to a data van38for collection and analysis, among other things. In some embodiment, the sensors may transmit data to other components, to the central processing unit, or to devices and control units remote from the site. The communications between components, sensors, and control devices may be wired, wireless, or a combination of both. Communication means may include fiber optics, electrical cables, WiFi, Bluetooth, radio frequency, and other cellular, nearfield, Internet-based, or other networked communication means.

The features of the present disclosure may allow for remote monitoring and control from diverse location, not solely the data van68. Fracturing control may be integrated in with the sensor and monitoring packages104to allow for automated action to be taken when/if needed. Equipment may be able to determine issues or failures on its own, then relay that message with a specified code and alarm. Equipment may also be in control to shut itself down to prevent failures from occurring. Equipment may monitor itself as well as communicate with the system as a whole. This may allow whole system to control equipment and processes so that each and every component is running at its highest efficiency, sand, water, chemical, blenders, pumps, and low and high pressure flow lines. Features of the present disclosure may capture, display, and store data, which may be visible locally and remotely. The data may be accessible live during the data collection and historical data may also be available. Each component to this system can be tested individually with simulation as well as physical function testing.

Operating efficiencies for each individual component and the system40may be greatly improved. For example, sand storage and delivery to the blender can be monitored with load cells, sonar sensors and tachometers to determine storage amounts, hopper levels, auger delivery to the tub. Pump efficiencies may be monitored with flow sensors, accelerometers, pressure transducer and tachometers to optimize boost and rate while minimizing harmful conditions such as cavitation or over rating. Failure modes such as wash outs, cutting, valve and/or seat failures, packing issues and supply blockage can be captured and then prevented. Flow lines, both suction supply and discharge can be monitored with flow meters to distribute and optimize flow rates and velocities while preventing over pumping scenarios. Feedback loops of readings from blender to supply manifolds and to pumps can work with each other to optimize pressure and flow. Dropping out of an individual pump may occur preventing further failures, when this occurs the system as a whole may automatically select the best pumps to make up that needed rate. These changes and abilities solve equipment issues and prevent down time as well as provide a means to deliver a consistent job.

In some embodiments, instrumentation devices104(any of the above described, among others) can be imbedded, mounted, located in various locations such as in line with flow vessels like hoses, piping, manifolds, placed one pump components such as fluid ends, power ends, transmission, engines, and any component within these individual pieces, mounted external to piping and flow vessels, mounted on under or above sand and water storage containers. Blender hoppers could be duel equipped with hopper proximity level sensors as well as a load cell to determine amount of sand in the hopper at any given time.

FIG. 3includes a diagram110illustrating a connected automated fracturing system, in accordance with various embodiments. In this example, one or more components42of a fracturing system, such as a pump112, blender114, hydration unit116, fluid source118, proppant source120, additive source122, and one or more other components124, may include communication devices for transmitting and receiving data with each other over a communication network126. In some embodiments, at least some of the components include processors that analyze the data received from one or more of the other components and automatically controls one or more aspects of that component. The communication network110may include various types of wired or wireless communication protocols, or a combination of wired and wireless communications. In some embodiments, the connected automated fracturing system further includes one or more of a plurality of components including a manifold, a manifold trailer, a discharge piping, flow lines, conveyance devices, a turbine, a motor, a variable frequency drive, a generator, or a fuel source. Sensors and control devices may be integrated into the one or more of these components, allowing these components to communicate with the rest of the system.

FIG. 4includes a diagram130illustrating a communications network of the automated fracturing system, in accordance with various embodiments. In this example, one or more hydraulic fracturing components138, such as, and not limited to, any of those mentioned above, may be communicative with each other via a communication network140such as described above with respect toFIG. 3. The components138may also be communicative with a control center132over the communication network140. The control center132may be instrumented into the hydraulic fracturing system or a component. The control center132may be onsite, in a data van, or located remotely. The control center132may receive data from any of the components138, analyze the received data, and generate control instructions for one or more of the components based at least in part on the data. For example, the control center132may control an aspect of one component based on a condition of another component. In some embodiments, the control center140may also include a user interface, including a display for displaying data and conditions of the hydraulic fracturing system. The user interface may also enable an operator to input control instructions for the components134. The control center140may also transmit data to other locations and generate alerts and notification at the control center140or to be received at user device remote from the control center140.

FIG. 5is a flow chart of an embodiment of an automated hydraulic fracturing method140, in accordance with example embodiments. It should be noted that the method may include additional steps, fewer steps, and differently ordered steps than illustrated in this example. In this example, a hydraulic fracturing operation is initiated142using an automated hydraulic fracturing system. A first material for a fracturing fluid is provided144from a first source to a blender. The first source includes a sensor for measuring one or more parameters associated with the first source and a controller for controlling one or more functions of the first source. A second material for the fracturing fluid is provided from a second source to the blender. The second source may also be instrumented with a sensor and a controller. The first material and the second material is mixed146at the blender to form the fracturing fluid. The blender may also be include a sensor for measuring one or more parameters associated with the blender and a controller for controlling one or more functions of the bender. The fracturing fluid is provided from the blender to a pump, and the pump includes a sensor for measuring one or more parameters associated with the pump and a controller for controlling one or more functions of the pump. The fracturing fluid is then injected150from the pump into a wellhead coupled to a well. The one or more parameters are monitored152via the sensors on the first source, second source, blender, pump, and various other sensors in the hydraulic fracturing system. Automated instructions can then be generated154for at least one of the source controller, the blender controller, or the pump controller based at last in part on the one or more parameters.

At least one of the one or more functions of the first source, the blender, the pump, or other component of the hydraulic fracturing system may be controlled156via the respective controller based on the automated control instructions. In some embodiments, the instructions may cause one or more of the control devices to automatically adjust one or more of a flow rate, a pressure, power, motor speed, gates, valve, actuators, delivery lines and conveyance devices, pump rates, or cooling systems. For example, a pump system may include comprises a motor controlled by the pump controller based at least in part on the automated instructions. In some embodiments, the blender includes at least one of a chemical pump, a cooling system, an auger, a blender discharge pump, a valve, or an actuator, any of which may be controlled by the blender controller based at least in part on the automated instructions. In some embodiments, the first or second source may include at least one of a gate, a valve, an actuator, a delivery belt, a delivery line, or a chemical pump, any one of which may controlled by a source controller based at least in part on the automated instructions. For example, the rate of delivery of a material may be automatically started, stopped, or adjusted based on the automated instructions. The pressure or rate at which the fracturing fluid is injected into the wellhead may be controlled based on the automated instructions.

The hydraulic fracturing system may include other components, such as a turbine, a generator, a hydration unit, a distribution system, a fuel source, or a wellhead, among others. These components may also be instrumented with sensors that measures at least one parameter associated with the turbine, the generator, the hydration unit, the distribution system, the fuel source, or the wellhead. These components may also include controllers, which control at least one aspect of the turbine, the generator, the hydration unit, the distribution system, the fuel source, or the wellhead, based at least in part on the automated instructions. In some embodiments, the hydraulic fracturing system includes a plurality of pumps and a distribution system, in which fracturing fluid is provided from the blender to the plurality of pumps, the fracturing fluid is provided from the plurality of pumps to the distribution system, and the fracturing fluid is injected from the distribution system into the wellbore. The individual pressure at each pump may be automatically adjusted based on the automated instructions. The combined or overall pump rate of the plurality of pumps may also be controlled, and the rate at the distribution system may also be controlled via the automated instructions.

In some embodiments, the method140may include detecting that at least one of the one or more parameters is outside of an acceptable threshold and automatically stopping or adjusting one or more functions of the hydraulic fracturing system in response to the detection. In some embodiments, the method140may include detecting substandard performance in one or more areas of the automated hydraulic fracturing system, automatically troubleshooting the automated hydraulic fracturing system based on live data from a plurality of sensors or previous data collected by the sensors, determining one or more causes or suspected causes of the substandard performance, and automatically adjusting one or more components of the automated hydraulic fracturing system to resolve the substandard performance. In some embodiments, the system may provide troubleshooting codes or alerts indicative of one or more sources of a performance issue.

FIG. 6illustrates a method160of controlling an automated fracturing system, in accordance with various embodiments. In this embodiment, the method160includes receiving162data from one or more components of an automated fracturing system, such as those described above. The method160further includes determining164a condition of the system based on the received data. The method further includes controlling166one or more aspects of the system based on the determined condition.

FIG. 7is a block diagram of an embodiment of a control system170for receiving, analyzing, and storing information from the well site. As described above, sensors178are arranged at the well site and may transmit data to a control unit176for evaluation and potential adjustments to operating parameters of equipment at the well site. The control unit176may be communicatively coupled to a network172, such as the Internet, that can access a data store174, such as a cloud storage server. Accordingly, in embodiments, data from the sensors178is transmitted to the control unit176(which may be located on a component, within a data van, or remotely) and is stored locally. However, the control unit176may upload the data from the sensors178along with other data, to the data store174via the network172. Accordingly, data from previous pumping operations or different sensors may be utilized to adjust various aspects of the hydraulic fracturing operation as needed. For example, the flow data from the sensor178may be coupled with information from the sensors178(such as the vibration sensor, gear sensors, RPM sensors, pressure sensors, etc.) to provide diagnostics with information from the data store174. For example, previous data may be used as training data for a machine learning model for predicting various control parameters of a present operation. In embodiments, the data store174includes information of the equipment used at the well site. It should be appreciated that, in various embodiments, information from the data store174may be stored in local storage, for example in storage within a data can, and as a result, communication over the network172to the remote data store174may not be used. For example, in various embodiments, drilling operations may be conducted at remote locations where Internet data transmission may be slow or unreliable. As a result, information from the data store174may be downloaded and stored locally at the data van before the operation, thereby providing access to the information for evaluation of operation conditions at the well site.

The foregoing disclosure and description of the disclosed embodiments is illustrative and explanatory of the embodiments of the invention. Various changes in the details of the illustrated embodiments can be made within the scope of the appended claims without departing from the true spirit of the disclosure. The embodiments of the present disclosure should only be limited by the following claims and their legal equivalents.